description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to active solid state devices, and more specifically to a flat heat pipe for cooling an integrated circuit chip.
[0002] As integrated circuit chips decrease in size and increase in power, the required heat sinks and heat spreaders have grown to be larger than the chips. Heat sinks are most effective when there is a uniform heat flux applied over the entire heat input surface. When a heat sink with a large heat input surface is attached to a heat source of much smaller contact area, there is significant resistance to the flow of heat along the heat input surface of the heat sink to the other portions of the heat sink surface which are not in direct contact with the contact area of the integrated circuit chip. Higher power and smaller heat sources, or heat sources which are off center from the heat sink, increase the resistance to heat flow to the balance of the heat sink. This phenomenon can cause great differences in the effectiveness of heat transfer from various parts of a heat sink. The effect of this unbalanced heat transfer is reduced performance of the integrated circuit chip and decreased reliability due to high operating temperatures.
[0003] The brute force approach to overcoming the resistance to heat flow within heat sinks which are larger than the device being cooled is to increase the size of the heat sink, increase the thickness of the heat sink surface which contacts the device to be cooled, increase the air flow which cools the heat sink, or reduce the temperature of the cooling air. However, these approaches increase weight, noise, system complexity, and expense.
[0004] It would be a great advantage to have a simple, light weight heat spreader for an integrated circuit chip which furnishes an essentially isothermal surface even though only a part of that surface is in contact with the chip and also includes a simple means for assuring a direct heat transfer path between the chip and a heat sink which dissipates the heat.
SUMMARY OF THE INVENTION
[0005] The present invention is an inexpensive heat pipe heat spreader for integrated circuit chips which is of simple, light weight construction. It is easily manufactured, requires little additional space, and provides additional surface area for cooling the integrated circuit and for attachment to heat transfer devices such as cooling fins for disposing of the heat from the integrated circuit chip. Furthermore, the heat pipe heat spreader of the invention is constructed to maximize heat transfer from the integrated circuit chip to the heat sink.
[0006] The internal structure of the heat pipe is an evacuated vapor chamber with a limited amount of liquid. In the preferred embodiment of the invention two plates form the casing of the heat pipe vapor chamber, thus forming an essentially flat heat pipe. Capillary wick material covers the inside surfaces of at least one plate, the evaporator surface of the heat pipe casing, which is in contact with the integrated circuit chip.
[0007] However, because the heat input area at the integrated circuit chip on the evaporator surface of such a flat heat pipe is usually much smaller than the fin or other heat removal structure attached to the opposite surface, a considerable amount of the heat must first be transferred thrughout the thin plate of the casing before it can be used to evaporate the liquid from the capillary wick which is attached to the thin plate.
[0008] Although a heat pipe transfers heat with less temperature difference than a solid metal conductor, the insertion of the small cross section path along the casing sides to get to the majority of the heat pipe evaporator loses some of this benefit. The present invention therefore adds a parallel heat transfer path which is a solid metal structure spanning the space within the heat pipe between the integrated circuit contact area and the center portion of the fin structure.
[0009] As with any other parallel path, the heat conductive structure reduces the heat flow resistance, even though its heat transfer impedance is not quite as effective as would be a heat pipe of the same dimensions. However, the structure does have a very low thermal impedance because it has a very short length of thermal path, only the small internal height of the heat pipe, and a relatively large cross section. Furthermore, since the sides of the heat conductive structure are covered with capillary wick material, there is very little reduction in the effective area of the evaporator wick.
[0010] The conductive structure also serves other important purposes. It supports the flat plates and prevents them from deflecting inward and distorting to deform the flat surface that is in contact with the integrated circuit chip. This feature is very important for good heat transfer between the heat spreader and the integrated circuit chip. The structure also serves as critical support for the portions of the capillary wick which cover its sides and span the internal space between the plates. The capillary wick on the sides of the structure, along with capillary wick covering the inside surfaces of both of the plates, provides a gravity independent characteristic to the heat spreader, and the structure around which the wick is located assures that the capillary wick on its sides is not subjected to destructive compression forces.
[0011] The present invention thereby provides a heat pipe with heat transfer characteristics superior to those of either a single solid plate or a simple flat heat pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The FIGURE is a perspective view of the preferred embodiment of the flat heat pipe of the invention with part of one plate of the envelope removed to view the interior.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The FIGURE is a perspective view of the preferred embodiment of flat heat pipe 10 of the invention with part of one plate 12 of the envelope removed to view the interior.
[0014] Heat pipe 10 is constructed with a casing formed by sealing together two formed plates, contact plate 14 and cover plate 12 . Contact plate 14 and cover plate 12 are formed as shallow pans so that there is a space between their interior surfaces when they are joined together at seal 16 on their peripheral lips by conventional means, such as soldering or brazing, to form heat pipe 10 . Heat pipe 10 is then evacuated to remove all non-condensible gases and a suitable quantity of heat transfer fluid is placed within it. This is the conventional method of constructing a heat pipe, and is well understood in the art of heat pipes.
[0015] The interior of heat pipe 10 is, however, constructed unconventionally in that solid structure 18 made of a heat conductive material such as copper spans the interior space between contact plate 14 and cover plate 12 and is attached to each plate with a heat conductive bond. Such bonds are typically either soldered or brazed. The location and size of solid structure 18 is determined by the location and size of the integrated circuit chip or other heat source from which heat pipe 10 is spreading heat. Ideally, solid structure 18 is constructed so that it is aligned with the heat source being cooled, is of the same cross section as the size of the contact area of the heat source, and is located on the opposite surface of contact plate 14 from the heat source.
[0016] Heat pipe 10 also includes internal sintered metal capillary wick 20 which covers the entire inside surfaces 11 of cover plate 12 and 13 of contact plate 14 , including their sides. As is well understood in the art of heat pipes, a capillary wick provides the mechanism by which liquid condensed at the cooler condenser of a heat pipe is transported back to the hotter evaporator where it is evaporated. The vapor produced at the evaporator then moves to the condenser where it again condenses. The two changes of state, evaporation at the hotter locale and condensation at the cooler site, are what transport heat from the evaporator to the condenser. In a well designed heat pipe this transfer of heat occurs with virtually the same temperature at the evaporator as at the condenser.
[0017] It should be appreciated that in typical use contact plate 14 is held in thermally conductive contact with a heat source such as an integrated circuit chip (not shown), and cover plate 12 is attached to a cooling device such an assembly of cooling fins (not shown). Thus, the function of heat pipe 10 is to spread the heat generated at the small area of an integrated circuit chip, from which it is more difficult to dissipate any significant quantity of heat, to a much larger surface area such as an assembly of cooling fins. The larger area facilitates heat removal without requiring an unreasonably high temperature.
[0018] It is also worth recognizing that when capillary wick 20 is attached to the inside surface of both contact plate 14 and cover plate 12 , heat pipe 10 actually operates independent of orientation, and it does not matter whether the heat input is at contact plate 14 or cover plate 12 .
[0019] In the preferred embodiment of the present invention, heat pipe 10 also has capillary wick on sides 22 of solid structure 18 , and that wick is in contact with capillary wick 20 on the inside surfaces of plates 12 and 14 . The wick on sides 22 of structure 18 thereby interconnects wick 11 of cover plate 12 and wick 13 of contact plate 14 with continuous capillary wick. This geometry assures that, even if heat pipe 10 is oriented so that the condenser is lower than the evaporator, liquid condensed upon the inner surface of either plate will still be in contact with capillary wick on sides 22 of solid structure 18 . The liquid will therefore be moved by capillary force back to the hotter surface which functions as the evaporator. Solid structure 18 also prevents the structurally weaker capillary wick wrapped around it from suffering any damage.
[0020] However, another important function of the wick on sides 22 of solid structure 18 is its function as additional evaporator surface. At the same time as solid structure 18 is conducting heat directly between contact plate 14 and cover plate 12 , heat within solid structure 18 is also evaporating liquid from the wick on sides 22 of solid structure 18 to add to the heat transfer capability of heat pipe 10 .
[0021] The preferred embodiment of the invention has been constructed as heat pipe 10 shown in the FIGURE. This heat pipe is approximately 3.0 inches by 3.5 inches with a total thickness of 0.200 inch. Cover plate 12 and contact plate 14 are constructed of OFHC copper 0.035 inch thick, and solid structure 18 spans the 0.130 inch height of the internal volume of heat pipe 10 . Capillary wick 22 is constructed of sintered copper powder, averages 0.040 inch thick, and covers essentially all the surfaces inside heat pipe 10 , including sides 24 . Solid structure 18 is also constructed of OFHC copper and is 0.80 inch by 0.80 inch and 0.130 inch thick.
[0022] The thermal conductivity of solid structure provides additional heat conduction between plates 12 and 14 , and thereby reduces the temperature difference within heat pipe 10 between the heat source and the heat sink. This reduction of temperature difference directly affects the operation of heat pipe 10 , and essentially results in a similar reduction in the operating temperature of any heat source such as an integrated circuit chip.
[0023] The invention thereby furnishes an efficient means for cooling an integrated circuit and does so without the need for larger heat spreaders which not only add weight but also do not transfer heat away from the integrated circuit as efficiently as does the heat pipe of the invention.
[0024] It is to be understood that the form of this invention as shown is merely a preferred embodiment. Various changes may be made in the function and arrangement of parts; equivalent means may be substituted for those illustrated and described; and certain features may be used independently from others without departing from the spirit and scope of the invention as defined in the following claims. For example, the heat conductive solid structure could be constructed of materials other than copper, and although it is pictured as a rectangular prism, it could be constructed as any other shape. | The invention is a flat heat pipe heat spreader with the addition of a solid heat conductive structure spanning the internal space in the heat pipe only at the region of contact with the heat source. Capillary wick is also bonded to the sides of the solid heat conductive structure. Thus, the solid structure provides both direct heat conduction from the heat source to a heat sink mounted atop the heat spreader and also acts as an extended evaporator surface within the heat pipe. The combination furnishes a decrease in the thermal resistance compared to a heat pipe without the solid structure. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to fluid driven motors and has particular reference to motors driven by combined pressurized air and vacuum or partial vacuum, or increased and decreased densities of air molecules.
2. Description of the Prior Art
Motors operated by compressed air or by an increase in the density of air molecules have been used heretofore in which case air under a pressure greater than that of atmospheric pressure is applied at appropriate times against one side of one or more drive pistons or their equivalents while the opposite side is subjected to normal atmospheric pressure to drive the motor. Other motors have been used in which air under atmospheric pressure is applied to one side of a piston or the like and the other side is subjected to air pressure below atmospheric pressure or a reduction in the density of air molecules to produce a net driving force.
On the other hand, attempts have been made to increase the efficiency of air driven motors, such as small windshield wiper motors or the like by subjecting a drive piston thereof, on one side, to air pressure greater than atmospheric pressure and, on the other side thereof, to a negative air pressure less than atmospheric pressure. The U.S. Pat. Nos. to Oishei 1,694,279 and O'Shei 2,345,213 disclose such motors. These motors have not proved satisfactory, however, because they derive motive power, at least partly, from suction or air pressure below atmospheric pressure which is developed in the intake manifold of an internal combustion engine in which the air pressure varies in accordance with certain operating conditions of the engine, such as varying load conditions. Therefore, such engines cannot produce constant power even though they were developed in an attempt to obtain such constant power. Also, such motors utilize relatively low air pressure or increase in air molecules and a low degree of vaccum or reduction of air molecules.
SUMMARY OF THE INVENTION
A principal object of the present invention is to provide a fluid driven motor having greatly increased efficiency and power.
Another object is to provide a gas driven motor utilizing as its power source, gas at pressures substantially above atmospheric pressure and gas at pressures substantially below atmospheric pressure.
Another object is to provide a gas driven motor capable of producing a large amount of power for a given size motor.
Another object is to provide a gas driven motor with means driven by the motor to apply air pressure and vaccum to the motor.
Another object is to provide a motor capable of driving itself.
Applicant has discovered that a substantial increase in efficiency and output power can be obtained in an air or other gas driven motor by applying a constant air pressure of several atmospheres or increase in density of air molecules to one side of a piston or its equivalent and a constant vacuum or reduction in density of air molecules in the neighborhood of 15 inches or less of mercury to the opposite side. This is particularly noticeable when the amount of vacuum is increased, as the power output is found to increase in other than a straight line relationship relative to the differential of the positive and negative air pressures applied to the piston. It is believed that this phenomenon is at least partly due to the reduction of resistance and friction within the motor.
Accordingly, the present invention comprises one or more cylinders or motor chambers with pistons, diaphragms or other air operated drive members operable therein which are subjected to air pressure on one side and vacuum on the opposite side, with valve means operable by the motor to alternate the pressurized air and vacuum when each piston or the like reaches the end of its stroke, thereby providing a continuous and smooth mechanical power output. It will be noted that this results in power being applied to both sides of each piston during both forward and reverse strokes thereof. Thus, air molecules are continuously added to one side of each piston and removed from the other and vice versa.
The pressurized air and vacuum can be derived from sources independent of the motor but this can be supplemented or even supplanted by a source, such as a vacuum and/or air pump, driven by the motor itself so that the air molecules are transferred from one side to the other of each piston.
The motor may be made in different forms. For example, three embodiments are disclosed, one showing a motor as being of a reciprocal piston driven type, another as a diaphragm driven type and a third as a combined internal combustion engine and pressurized air-vacuum motor.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner in which the above and other objects of the invention are accomplished will be readily understood on reference to the following specification when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a sectional plan view through a piston driven motor embodying a preferred form of the present invention, and is taken substantially along line 1--1 of FIG. 2.
FIG. 2 is a sectional elevation view taken substantially along the line 2--2 of FIG. 1.
FIG. 3 is a fragmentary sectional view showing certain of the valves for one of the cylinders and is taken along the line 3--3 of FIG. 2.
FIG. 4 is a bottom plan view taken in the direction of the arrow 4 in FIG. 2.
FIG. 5 is a sectional view taken along the line 5--5 of FIG. 1.
FIG. 6 is a sectional view showing one form of the pressurized air and vacuum source and is taken along the line 6--6 of FIG. 4.
FIG. 7 is a sectional view, similar to that of FIG. 6, but showing a modified form of pressurized air and vacuum source.
FIG. 8 is diagramatic view showing the relation between the timing of the various pressurized air and vacuum controlling valves.
FIG. 9 is a sectional view through a modified form of the invention embodying a diaphragm driven motor.
FIG. 10 is a sectional view through another modified form of the invention in which the motor of the present invention is provided with an internal combustion feature.
FIG. 11 is a diagrammatic view showing the timing of the various valves in the motor shown in FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in particular to FIGS. 1 to 8, the embodiment shown therein comprises an opposed cylinder type motor including a combined cylinder and crankcase block 11 which is divided into two halves 12 and 13 hermetically sealed together and having adjacent surrounding flanges 14 secured together by bolts 15. Both cylinder block halves have bearings 16, 17 and 18 fitted within semicircular openings to rotatably support a crankshaft 20. Two pair of axially aligned cylinders 21, 22 and 23, 24 are formed in the block 11. Such pairs of cylinders are coextensive with respective intermediate crankcase sections 25 and 26.
Pistons 27, 28, 29 and 30 are slidably mounted in respective ones of the cylinders 21 to 24. Such pistons are provided with piston rings 31 and pivotally connected at 32 to the outer edges of connecting rods 33 journalled at their opposite ends on associated crank pins 34 formed on the offset portions of the crankshaft 20.
It will be noted that the crank pins 34 of the crankshaft 20 which are operatively associated with the aligned pistons 27 and 28, are located 180° apart and that the crank pins operatively associated with the pistons 29 and 30 are also arranged 180° apart but are offset at 90° with the first set of crank pins. Thus, as shown in FIGS. 1 and 2, the pistons 27 and 28 are depicted at top dead center, i.e. at the outer extremes of their respective strokes, while the pistons 29 and 30 are depicted half way through their respective strokes.
It will be further noted that the aligned cylinders, i.e. 21, 22 and 23, 24 of each pair are in alignment with each other but, along with their respective crankcase sections are hermetically sealed from the cylinders of the other pair.
Each of the cylinder block halves 12 and 13 has an integral head portion comprising two spaced head walls 36 and 37 with side walls, i.e. 38, FIG. 5, and a labyrinth wall 40 dividing the space therebetween to form a pressure chamber 41 to receive pressurized air from an inlet 42 and a vacuum chamber 43 connected to a vacuum connection 44.
A pair of outer valves are provided for each cylinder, such valves, i.e. 45, 46 for cylinder 21, valves 47, 48 for cylinder 22, valves 50, 51 for cylinder 23 and valves 52, 53 for cylinder 24 are of the poppet type, each having a stem 54 slidable endwise in a bearing 55 formed in the outer head wall 37 and having a head movable into and out of engagement with a valve seat 56 surrounding a port 57 formed in the inner head wall 36. Each valve stem has a cam follower cap 58 secured to the outer end thereof and a compression spring 60 is interposed between the cap and outer wall 37 to yieldably hold the cam follower against a cam 61. The cams 61 for the valves 45, 46, 50 and 51 of the right hand bank are formed on a cam shaft 62. The latter is journalled in bearings, i.e. 63, formed in brackets 64 integral with respective cylinder block halves 12 and 13. A cam cover 65 is secured to the outer head wall 37 by screws 66. The similar cams for the valves 47, 48, 52 and 53 of the left hand bank are formed on a second cam shaft 69.
As shown particularly in FIG. 5, the ports 57 of valves 45 and 50 associated with cylinders 21 and 23, respectively, open into the pressure chamber 41 and the ports of the valves 46 and 51 associated with cylinders 21 and 23, respectively, open into the vacuum chamber 43.
Referring to FIGS. 2, 3 and 4, an additional pair of valves 67 and 68 are provided for the crankcase section 25, common to cylinders 21 and 22, and another pair of valves 70 and 71 are provided for the crankcase section 26, common to the cylinders 23 and 24. Such valves 67, 68 and 70, 71 are mounted in a manner similar to that described above for the valves 45, 46, etc., and for this purpose, a wall 73 is spaced downwardly from the wall 74 forming the underside of the cylinder block halves 12 and 13. A surrounding wall 75, and an inner labyrinth wall 76 divide the space between the walls 73 and 74 into a pressure chamber 78 and a vacuum chamber 79. The port, i.e. 80, of valve 67 and a similar port of valve 70 open into the pressure chamber 78 while the ports of valves 68 and 71 open into the vacuum chamber 79. Pressure chamber 78 communicates with the pressure chamber 41 through a passage 81 and vacuum chamber 79 communicates with the vacuum chamber 43 of the left bank of cylinders through a passage 82.
The valves 67, 68, 70 and 71 are controlled by cams 83 formed on a cam shaft 84 rotatably mounted in bearings 85.
All three cam shafts 62, 69 and 84 are driven in synchronism with the crank shaft 20 by an endless chain 87 which is engaged around sprockets, i.e. 88, of the same diameter and fastened to the crank shaft 20 and the cam shafts 62, 69 and 84.
Describing first the embodiment shown in FIG. 6, the pressure outlet connection 42 of the right hand bank of cylinders and the similar pressure outlet connection 90 of the left hand bank of cylinders are connected together by a conduit 92 and to a suitable source, not shown, of pressurized air through a shut-off valve 93. On the other hand, the vacuum connection 43 of the right hand bank of cylinders and the similar vacuum connection 91 of the left hand bank of cylinders are connected together by conduit 94 and to a suitable source, not shown, of vacuum through a shut-off valve 95. Accordingly, when the valves 93 and 95 are open, pressurized air will be applied to the valves 45, 47, 50, 52, 67 and 70 while vacuum will be applied to the remaining valves 46, 48, 51, 68 and 71.
Timing of the various valves in relation to rotation of the crankshaft 20 is shown in FIG. 8 wherein it will be noted that each piston is constantly driven during both forward and return strokes thereof by both vacuum and pressurized air. For example, from 0° to 90°, valves 45, 47, 50 and 52 are open, applying pressurized air to the outer ends of all of the pistons 27, 28, 29 and 30, respectively. Concurrently, valves 68 and 71 are open, applying a vacuum to the inner ends of the various pistons. At 90°, as the pistons 29 and 30 reach their inner dead center positions, the valves 51 and 53 open to apply vacuum to the outer ends of pistons 29 and 30. At this time, valve 70 opens to apply pressurized air to the inner ends of such pistons to cooperate with vacuum applied to the outer ends of these pistons to return the same outwardly. A similar procedure occurs when the pistons 27 and 28 reach their inner dead center positions, and a reverse of such procedure occurs when each pair of pistons reach their outer dead center positions.
Describing now the embodiment shown in FIG. 7, the latter retains the conduits 92 and 94 connecting the pressurized air and vacuum connections of the right and left hand cylinder banks. However, an air pump 96 is provided which is driven by the crank shaft 20 and has a vacuum inlet 97 connected to conduit 94 and an air pressure outlet 98 connected to conduit 92. Thus, the pump 96 applies air pressure to conduit 92 and vacuum to conduit 94. Accordingly, the pump 96 may be employed to supplement the air pressure and vacuum obtained from outside sources through the valves 93 and 95, respectively, or the valves 93 and 95 may be shut-off completely, enabling the pump 96 to supply the necessary pressurized air and vacuum to drive the motor.
FIG. 9 illustrates the invention embodied in a diaphragm type air motor comprising banked hemispheroidal chamber walls 100 and 101. A flexible diaphragm 102 is clamped between the walls 101 and 102 by bolts 103 to form a series of diaphragm sections. A drive rod 104 is attached to each operating portion of the diaphragm 102. The rod 104 is slidably mounted in a bearing 105 formed in the lower wall 101 and is operatively connected in a manner not shown to a suitable crankshaft. Poppet valves 106 and 107 are slidably mounted in bearings formed in the wall 101 to open and close ports 108 and 109 communicating each lower diaphragm chamber 110 with a pressurized air conduit 111 and with a vacuum conduit 112, respectively.
Similarly, poppet valves 113 and 114 are provided in the wall 100 of each upper diaphragm chamber 115 to open and close ports 116 and 117 communicating the upper diaphragm chamber 115 with a vacuum conduit 118 and a pressurized air conduit 120, respectively. The various valves 106, 107, 116 and 117 are actuated in the manner similar to the valves of FIG. 1 and the timing thereof is similar to that shown in FIG. 8 in which pressurized air is applied to the underside of the diaphragm 102 and vacuum is concurrently applied to the upperside, the timing being such that as the diaphragm reaches the lower end of its stroke, the relationships of the valves will be reversed to concurrently apply pressurized air to the upperside and vacuum to the underside.
FIG. 10 illustrates the invention embodied in an internal combustion engine of the four stroke cycle type which comprises one or more cylinders 122. A piston 123 is slidable in the cylinder 122 and is pivotally connected to a connecting rod 124 journalled on an offset crank pin 125 of a crankshaft 126.
A poppet valve 127 is provided to open and close a port 128 opening into an intake manifold 130 into which an explosive gas mixture is admitted. An exhaust valve 131 is also provided to open and close a port 132 opening into an exhaust manifold 133. An ignition system including a spark plug 134 is provided in the cylinder to explode the mixture after it has been compressed by the piston 123. Obviously, the engine could be modified to incorporate a diesel operating principle.
The engine operates through four strokes during each cycle in which firing occurs during each second excursion of the piston 123 or revolution of the crankshaft. That is, as seen in FIG. 11, the intake valve 127 is open during the intake phase from approximately 0° to 180° to intake the explosive mixture while the exhaust valve 131 remains closed. During the compression phase, from 180° to 360°, compression of the explosive mixture takes place with both valves closed. Thereafter, the valves remain closed during the firing phase from 360° to 540°, after which, during the exhaust phase from 540° to 720°, the exhaust valve 131 is opened and the intake valve 127 is closed until the end of the cycle.
According to the present invention, a crankcase section 134 defined by a crankcase 135 and wall partitions 136 between the cylinders (if more than one cylinder is employed) hermetically seal the cylinders from each other. Poppet valves 137 and 138 are provided in the crankcase section 134 to open and close ports 140 and 141 communicating with a source of vacuum and a source of pressurized air, respectively. These may be external sources as described heretofore in connection with FIG. 6 or they may be derived from the motor itself as described in connection with FIG. 7. The valves 137 and 138 are operated in a manner similar to the valves 67 and 68 of FIG. 3 and according to the timing chart shown in FIG. 11. Thus, vacuum is applied to the underside of the piston 123, during each inward stroke (intake or firing) thereof and pressurized air is applied to the underside of the piston as it moves outwardly in its outward (compression or exhaust) stroke.
It will be obvious to those skilled in the art that many variations may be made in the exact construction shown herein without departing from the spirit of this invention. For example, the number of cylinders may be increased or decreased as desired. Also, in the claims appended hereto, the term "cylinder" is intended to include a diaphragm chamber and the term "piston means" is intended to include a diaphragm. Further, the term "vacuum" is intended to mean reduced atmospheric pressure or a reduction in the density of gas or air molecules and the term "fluid under pressure", "gas under pressure," or the like is intended to mean increased fluid or the like pressure or an increase in the density of fluid or the like molecules. | A motor is provided of the piston or diaphragm type in which vacuum is constantly applied to one side of a piston or the like and air under pressure is constantly applied to the opposite side to drive the piston through a stroke. The vacuum and pressurized air may be obtained from sources outside the motor. A valve mechanism driven by the motor reverses the application of vacuum and air pressure when the piston reaches each end of its stroke so that power is continuously applied to both sides of the piston during both forward and reverse movement thereof. Different pistons are arranged out of phase with one another to provide a smooth flow of mechanical power. In one version, the motor drives an air pump having a vacuum inlet and an air pressure outlet, and by connecting such inlet and outlet to the valve mechanism, the motor will drive a load as well as itself. In another version, the motor has an internal combustion apparatus incorporated therewith. | 5 |
This is a continuation of application Ser. No. 07/190,661 filed on May 5, 1988, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to non-invasive oximetry of the pulse type in which light, which has irradiated a volume of arterial blood within a subject, is sensed in order to determine oxygen saturation of the subject's blood. The light which contacts the subject, depending on its spectral content, is variously absorbed, reflected, scattered and transmitted by the blood and other tissue of the subject, before detection. The intensity and the change of intensity of either the reflected, scattered, or the transmitted light are used to determine oxygen saturation of the subject's blood. Such change is essentially due to the arterial pulse, which causes the volume of irradiated blood to vary in accordance with the arterial pulse.
2. Statement of the Prior Art
U.S. Pat. No. 3,847,483, issued Nov. 12, 1974 to Shaw et al, describes and claims an invasive oximetry method and apparatus wherein blood optical density is determined from measures of reflected intensity of red and infrared light transmitted to and from the blood. Both time and frequency multiplexing are used to separate red intensity from infrared intensity.
U.S. Pat. No. 4,086,915, issued May 2, 1978 to Kofsky et al, describes and claims a non-invasive oximetry method and apparatus wherein change of blood optical density, due to the arterial pulse, is determined from measures of change in transmitted or reflected intensity of red and infrared light incident on ear or other blood-perfused tissue of a living subject. Time multiplexing is used for separating change in red intensity from change in infrared intensity.
In the same vein are Hamaguri U.S. Pat. No. 4,266,554, May 12, 1981; Wilber U.S. Pat. No. 4,407,290, Oct. 4, 1983; New et al U.S. Pat. No. 4,653,498, Mar. 31, 1987; Edgar et al, U.S. Pat. No. 4,714,080, Dec. 22, 1987; and Aoyagi et al, laid-open Japanese Patent Application No. Sho 50/1975-128387. These disclose various circuit realizations and oximetric mathematical exegeses differing in detail from those which Kofsky, et al, supra apply to non-invasive, pulse oximetry.
Again, frequency multiplexing in oximetry is referred to in Yee et al, "A Proposed Miniature Red/Infrared Oximeter Suitable for Mounting on a Catheter Tip", IEEE Trans. Biomed. Eng., Vol. 24, pp. 195-197, March, 1977, who describe invasive and non-invasive oximetric probes, and, as well, Schibli et al, "An Electronic Circuit for Red/Infrared Oximeters", IEEE Trans. Biomed Eng., Vol. BME-25, No. 1, pp. 94-96, January, 1978, describe in vitro oximetry wherein blood optical density is determined from measures of reflected intensity of red and infrared light transmitted to and from extracorporeal blood using a probe of Yee et al, supra. V. M. Krishnan, in a Jun. 6, 1973 thesis for the Master of Science degree in Electrical Engineering, University of Washington, describes details of circuitry relating to frequency multiplexing, which Yee et al include by reference in their paper.
Lastly, Huch et al "LIMITATIONS OF PULSE OXIMETRY", The Lancet, Feb. 13, 1988, pp. 357, 358, presents one recent view of the character of results obtained by current pulse oximetric methods and apparatus.
It is the main object of the present invention to provide an oximeter wherein oxygen saturation measurement is based on non-invasively obtained, frequency-multiplexed, arterial-pulse modulated information contained in red and infrared radiation from blood-perfused tissue.
A particular object of the invention is to provide such oximeter wherein the red and infrared information is obtained from red and infrared light reflected from and scattered in the blood-perfused tissue.
SUMMARY OF THE PRESENT INVENTION
In the present invention, light from red and infrared sources irradiates a portion of a subject's finger, earlobe, or other blood-perfused tissue, and a photosensor senses such of said light as is returned from said portion, and produces therefrom a corresponding electrical signal. The sources are energized by pulse trains of differing, fixed frequencies, but constant in amplitudes, so that the light therefrom is also in two components, each having a different spectral content, and each varying in amplitude at a different frequency. The spectral content of the red component is chosen so that the absorption thereof by oxygenated blood is different from the absorption thereof by deoxygenated blood. The spectral content of the infrared component is chosen so that absorption thereof by oxygenated blood is about the same as for deoxygenated blood. However, the subject's arterial pulse varies the volume of blood in the irradiated portion of tissue, and thereby amplitude modulates each light component in accordance with the arterial pulse induced variations of blood volume in the tissue. Accordingly, the electrical signal produced by the photosensor also has two components. One component's amplitude varies at the frequency of energization of the red light source, and is proportional to absorption of the red light by the tissue. The other component's amplitude varies at the frequency of energization of the infrared light source, and is also proportional to absorption of the infrared light by the tissue.
The photosensor's electrical signal is processed by electrical circuitry which separates AC components thereof in accordance with the frequency of energization of said sources, and removes any out of band component which may be present in the photosensor's electrical signal.
In other words, all the information of interest contained in the radiation from the blood-perfused tissue has been frequency-multiplexed, so to speak, so that it is carried by a single signal, in a single channel, until the signal reaches a point where one desires to extract from it information which is at a single, or more accurately, in a narrow band of frequencies. In the present invention, when such point is reached by the frequency-multiplexed signal from the photosensor, the above said two components are obtained simultaneously, i.e., demultiplexed, by means of filter circuitry.
Further processing includes detecting the amplitude modulation of the AC components and measuring it, and using the resulting measures in computing percent oxygen saturation of the blood in the irradiated tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a box diagram of the invention, and
FIGS. 2A through 2G show the signal waveforms found in the invention considered in the light of FIG. 1.
FIGS. 3A and 3B show a detailed circuit schematic of an actual embodiment of the invention, FIG. 3 indicating the orientation of FIGS. 3A and 3B with respect to one another.
DESCRIPTION OF PREFERRED EMBODIMENT
In FIG. 1, switches 1 and 2 intermittently connect red LED 3 and infrared LED 4, respectively, to a source of electricity (not shown). Switch 1 makes and breaks at the frequency of 4f, whereas switch 2 makes and breaks at the frequency f, where f is a frequency roughly an order of magnitude or more larger than about 60 Hz. The light of the LEDs irradiates a portion of a living subject's finger 5, and a photodiode 6 senses such of that light as is returned from said portion, an amplifier 7 being provided for producing an output voltage proportional to the current through said diode which current in turn is proportional to the radiation it receives from finger 5.
The voltage output of amplifier 7 is coupled by a capacitor 8 to a voltage amplifier 9, which in turn is coupled via an automatic gain control 10 to a voltage amplifier 11. The output voltage of amplifier 11 is coupled via capacitors 12 and 13 to respective filters 14 and 15.
Filter 14 passes a narrow band of frequencies containing frequency f whereas filter 15 passes a narrow band of frequencies containing frequency 4f. Filters 14 and 15 are connected to respective AM detectors 16 and 17, which remove the carriers. Detector 16 produces a slowly varying voltage which contains information as to the effect on the red light of the irradiated portion of finger 5, whereas detector 17 produces a slowly varying voltage which contains information as to the effect on the infrared light of the irradiated portion of finger 5. Substantially all other information originally contained in the output voltage of amplifier 7 has been processed out by the circuitry coupled to amplifier 7 via capacitor 8. Thus, capacitor 8 eliminates DC or slowly-varying components, whereas the filters 14 and 15 eliminate any signal outside their respective f and 4f bands.
As is known in the prior art, the light picked up by photodiode 6 is a measure of the optical density of the tissue from which it comes, with respect to the spectral content of the red and infrared light irradiating such tissue. Hence, the output voltages of the AM detectors 16 and 17 are measures of red and infrared optical density, respectively. These voltages, after amplification by voltage amplifiers 18 and 19, are coupled by capacitors 20 and 21, respectively, to bandpass filters 22 and 23 the output voltages of which are amplified by voltage amplifiers 28 and 29, whose output voltages appear at terminals 30 and 31 respectively. The AM detector output voltages are also directly coupled via low pass filters 24 and 25, respectively, to offsets 26 and 27, which have voltage output terminals 32 and 33, respectively.
Despite the presence of filters 22 through 25, offsets 26 and 27, and amplifiers 28 and 29, in FIG. 1 the voltages dVred, dVir, Vred, and Vir at output terminals 30 through 33 represent, respectively, change of red optical density of the blood in the irradiated portion of tissue, change of infrared optical density thereof, red optical density thereof, and infrared optical density thereof.
The terminals 30 through 33 are connected to an analog to digital converter (ADC) 34 in order to convert the analog voltages at those terminals to digital signals which it applies to a microprocessor 35, and which are suitable for processing by microprocessor 35, which last, as indicated by connection lines 36, 37, and 38, also controls AGC 10 and offsets 26 and 27. Microprocessor 35 examines the magnitudes of the signals it receives from ADC 34 and adjusts AGC 10 as necessary to keep the analog signals at terminals 30 through 33 within a range appropriate to the capabilities of ADC 10. Similarly, the offsets 26 and 27 are caused by microprocessor 35 to set the levels of the DC signals at terminals 30 and 33. Ultimately, the signal processing by the microprocessor produces a number representing percent oxygen saturation, which number will be displayed, recorded or otherwise rendered in a form perceptible to medical or other personnel.
FIGS. 2A, B, C, D, E, F and G show the signal wave forms at various points in FIG. 1, beginning with either one of the LEDs 3 and 4. Taking the vertical as amplitude or intensity, and the horizontal as time, then at 2A the LED output is in the form of constant amplitude light pulses, due to pulses of current through the LED.
At 2B, the output of amplifier 7, the LED's light pulses, modulated by the tissue and blood of the subject, have been converted into DC voltage pulses whose envelope represents AC arterial blood pulses superimposed on a DC component which is due to blood and tissue, among other things. The pulse train of 2B next encounters capacitor coupling which removes DC component, so that the pulse train becomes a two-sided signal as shown in 2C, which represents modulation of an AC-only carrier.
The pulse trains in 2B, and 2C, of course, would be more complex than shown since there are two LEDs irradiating the finger, not one, so that the spectral content of the photodiode output contains both f and 4f pulse components. However, when the mixture of these components passes through the filters 14 and 15, the f and 4f information is separated from each other into two trains each like that shown in 2D, which is much like 2C, except for rounding of the heretofore squarish peaks, by the filters.
Next, the 2D pulse trains encounter the AM detectors 16 and 17, which remove the f and 4f carriers, and thereby produce 2E signals whose amplitudes represent the combined effect of blood, tissue and arterial pulse in the portion of finger irradiated by the red and infrared light pulses.
The 2E signals then provide signals 2F, as a result of passing through capacitors 20 and 21, and bandpass filters 22 and 23, and, simultaneously, signals 2G, as a result of passing through LP filters 24 and 25, and offsets 26 and 27.
The signals 2G vary little in amplitude since the arterial pulse component has been much attenuated (FIG. 2G exaggerates their variation), and so represent the respective effects of a fixed portion of blood and tissue on the red and infrared light irradiating those portions, whereas signal 2F represents the variation of those effects by the arterial pulse in said portion.
Signals 2F and 2G, of which there are, of course, two sets of each type, namely, a first set of 2F and 2G signals corresponding to the red light, and a second set of 2F and 2G signals corresponding to the infrared light, provide information which may be used, for example only, for obtaining the approximate derivatives utilized for determining percent oxygen saturation by Kofsky et al, supra, in conjunction with various coefficients (which may be, but need not necessarily be the pseudo coefficients of Kofsky et al).
Turning to FIGS. 3, 3A and 3B, and beginning with FIG. 3A, a photodiode 46, corresponding to diode 6 of FIG. 1, is illuminated by red and infrared light from perfused tissue of an earlobe, finger, or the like, irradiated by LEDs (not shown in FIG. 3, but such as 3 and 4 of FIG. 1, and pulse energized as disclosed in connection therewith). The photodiode current which is a mixture of two sets of pulses, as shown in FIG. 2B, and at frequencies f and 4f, is amplified by amplifier 47 whose output voltage is coupled via capacitor 48 to amplifier 49, of which the output traverses a resistive voltage divider 50, corresponding to AGC 10.
Amplifier 47 is fitted out as a voltage amplifier which converts the photodiode current to voltage at a higher signal level by means of the illustrated circuitry which will be recognized as conventional by one of ordinary skill in the art, and so will not be described further herein. Similarly, the remaining amplifiers 49, 51, 71, 76, 77, 66 and 67 are amplifiers fitted out as voltage amplifiers by the illustrated circuitry of conventional design. For the most part, the amplifiers serve to maintain adequate signal levels and/or buffering, as is conventional. In FIG. 1, which is very much idealized, bandpass filters 14 and 15 would function ideally, that is, filter 14 would stop all frequencies but f and filter 15 would stop all frequencies but 4f. In actual fact, however, as shown in FIG. 3A, the input voltage to amplifier 51 is applied also to an amplifier 71. The output voltages of amplifiers 51 and 71 in turn are applied to passive notch filters 74 and 75 which notch out, respectively, a narrow band of frequencies including 4f, and a narrow band of frequencies including f. Ideally, all frequencies but 4f would get to filter 54, and all frequencies but f would get to filter 55. The filters 74 and 75 connect to capacitors 52 and 53 via respective voltage amplifiers 76 and 77 which make up for the voltage attenuation due to the filters 74 and 75, which are typical third order passive RC filters.
Capacitors 52 and 53 correspond to FIG. 1's capacitors 12 and 13, and like them, couple the red and infrared components of signal voltage to active bandpass filters 54 and 55 and to the counterparts of FIG. 1's LP filters 24 and 25. The latter filters are provided by circuitry (not shown) internal to the chips 68 and 69, to which the detector output voltages are connected via capacitors 60 and 61 (each with series resistor), corresponding to capacitors 20 and 21, FIG. 1. These capacitors with series resistor stop very low frequencies, so that these, with the two chips, provide bandpass filters 62 and 63.
The offset amplifiers 66 and 67 are shown to be conventional differential amplifiers each receiving on one input terminal an AM detector output voltage, but on the other terminal the same offset voltage which may be established either automatically (as by a processor, corresponding to the processor 35 in FIG. 1), or as in FIG. 3B, by manually setting a resistive potentiometer 65 to provide the same predetermined portion of the system supply voltage to each of the offset amplifiers' said other terminals.
As shown in FIG. 3B, the terminals 30 through 33 are provided by a connector 70, which also provides, as indicated by the labels for other connector terminals, system supply voltage (+5 v.), high frequency control (HFC), low frequency control (LFC), and a clock voltage CLK, typically a fraction of a megaHz frequency of a clock in, say, a processor corresponding to the processor 35.
As shown in FIG. 3B, each of filters 54 and 55 is constituted by a commercially available LTC 1060 chip, each of which is a switched capacitor bandpass filter, and is fitted out with the illustrated circuitry, which is of conventional nature, calculated to make the filter pass a narrow band of frequencies, in the one case centered on the frequency f, and in the other, 4f.
Each of AM detectors 56 and 57, which correspond to detector 16 and 17, FIG. 1, is a conventional half-wave rectifier whose DC output voltage is smoothed by an RC filter before passing to pins 1 of the switched capacitor bandpass filters 62 and 63 provided by commercially available MF6 CN100 chips 68 or 69, and capacitors 60 and 61. A buffer amplifier (not shown) inside each chip presents the detected voltage on each chip pin 2 for applying it to an offset amplifiers 66 or 67.
The HFC terminal of the connector 70 proper is shown as connecting to an unmarked terminal external to connector 70. The chip of filter 54, in turn has a similar external terminal marked HFC, connected to its pins 10 and 11. This is merely for drafting convenience, and symbolizes an interconnecting line between those pins and terminal HFC of the connector. An actual connection is shown between the LFC terminal and the pins 10 and 11 of filter 55's chip.
The CLK signal, which may come from a processor corresponding to the processor 35, connects to pins 9 of chips 68 and 69, whereby to provide for setting filter center frequencies.
In the circuit of FIG. 3, f is 1.1 kHz and 4f is 4.4 kHz. The spectral content of ambient light, power line effects, etc., is well below these frequencies, and is largely filtered out by the high pass filter effect due to the circuitry of amplifier 49. After this, the composite signal applied to amplifiers 51 and 71 consists essentially of a band of frequencies including f and a band of frequencies including 4f, each band being substantially free of undesired spectral components. The frequencies within the pass bands, and on either side of the center frequencies, are the so-called side-band frequencies. The f and 4f bands do overlap enough that elimination of the overlapping spectral components in the bandpass filters 54 and 55 would demand more stringent frequency selectivity of filters 54 and 55 than is desirable from some design points of view. The notch filters 74 and 75 minimize the need for excessive bandpass filter selectivity simply by removing f and 4f bands before the respective 4f and f signals are applied to respective filters 55 and 54.
The bandpass filters provided by the internal low pass filter of the MF6 CN100's and external capacitors 60 and 61 with their series resistors, function not only to remove the DC component of the AM detector outputs, namely, Vred and Vir, but also stabilize the remaining AC components corresponding to dVred and dVir, by removing detector noise. In this case, the bandpass is (0.1-10)Hz. This filtering is done to avoid jitter. Thus, if the AC components are subjected by the processor to detection of peaks as represented by the voltage swings at terminals 30 and 31, jitter may look like peaks to the microprocessor.
Insofar as the DC components are concerned, it will be noted that the offset amplifiers 66 and 67 are fitted out as low pass elements which attenuate the arterial pulse components of the AM detector outputs.
The radiation picked up by the photosensor 46 (or 6, FIG. 1) is that which is returned from an area of skin contacting the receptive surface of the photosensor. The returning radiation is what remains after the radiation emitted by the LED's interacts with the corneal, epidermal and dermal layers, and is commonly thought to be a measure of how much of the incident radiation has been absorbed by the hemoglobin, regardless of whether it is being "returned" as a result of having been scattered from the erythrocytes, or is being "returned" as a result of having been transmitted through the tissue. In other words, it is an empirical fact that the desired measured value, namely, how much radiation has been absorbed by the hemoglobin can be measured by measuring either how much radiation is scattered from the blood, or how much gets through the blood, and this is why substantially the same circuitry can be used for both reflective and transmissive optoplethysmographic SaO 2 determination.
Ideally, the red and infrared radiation would be isobestic with respect to all the components of tissue with which they interact, except with respect to oxygenation of the hemoglobin. However, this is not the case, so the ultimate (for the two wave length case) empirical expression relating to the degree of oxygenation to the four voltages at terminals 31 through 33 is:
SaO2=(A+R)/(B+CR). (1)
In equation (1), A, B and C are constants, whereas R is approximately (I'red/Ired)/(I'ir/Iir), wherein I represents original intensity, and I' the time derivative of original intensity with Vred, Vir, dVred and dVir being practical measures of intensities and intensity time derivatives (that is, the peak to peak values of the dVs, i.e., dVred and dVir, are usable as a measure of derivatives, namely, I'red and I'ir).
The foregoing is in accordance with the teachings of Kofsky et al, supra, wherein it is taught the time derivative of a medium's optical density D for a given wavelength is a fraction of the time derivative of optical path length in the medium, concentrations of various components of the medium, and attenuation coefficients of such components, so that, supposing that:
D'=I'/I, (2)
then measurements of the voltages at terminals 30 through 33, for known values of SaO 2 , can be used as a basis for determining suitable values for A, B and C in Equation (1), or for constants in some other empirically-determined expression for SaO 2 .
Were ideal isobestic conditions to obtain, equation (1) would reduce to (A'+B'R), essentially the same thing except that C is eliminated, i.e., A' is A/B and B' is 1/B.
Kofsky et al, supra, teach evaluating four attenuation coefficients of a system of equations involving Vred, Vir, dVred and dVir. In the practice of the present invention, equation (1) represents a linear approximation to the Kofsky et al approach. In the present invention, we use a 880 nanometer LED for the infrared wavelength. This wavelength is close enough to being isobestic that using the isobestic form of equation (1) in the practice of our invention provides satisfactory accuracy. For respectively brief and lengthy studies of optoplethysmography as applied to measurement of hemoglobin oxygenation, see J. A. Nijboer et al, "Photoelectric Plethysmography-Some Fundamental Aspects of the Reflection and Transmission Method", Clin. Phys. Physiol. Meas., 1981, Vol. 2, No. 3, pp 205-215, and Y. Mendelson, "Theory And Development Of A Transcutaneous Reflectance Oximeter System For Noninvasive Measurements Of Arterial Oxygen Saturation", pp i-xxii, and 1-254. The Mendelson item is a Ph. D. thesis submitted to Case Western Reserve University, May 25, 1983, and is available from University Microfilms International, 300 N. Zeeb Road, Ann Arbor, Mich. 48106.
Finally, see also Rolfe (Ed.), Non-Invasive Physiological Measurements, Vol, 1, Academic Press Inc., 111 Fifth Avenue, New York, N.Y. 10003; 1979, Chapter 6, pp. 125-151, Photoelectric Plethysmography For Estimating Cutaneous Blood Flow (A. V. J. Challoner).
The LED's 3 and 4 were 660 nm and 880 nm, respectively, the former being operated at 40 ma peak current, and with a 33% duty cycle and 76 mw peak electrical power. The LED 4 was operated at 6 ma peak current, and with a 50% duty cycle and 7.2 mw peak electrical power. The photosensor 46 (or 6, FIG. 1) was a PIN photodiode, wired to the amplifier 47 (or 7, FIG. 1) by twisted pair in grounded external shield cabling, in order to avoid noise pick-up (e.g. RF), a desideratum which can also be fulfilled by a fiber optic link conducting light from the finger to photosensor 46 (or 6, FIG. 1) which can be close coupled to amplifier 47 (or 7, FIG. 1) so as to make it easier to avoid noise pick-up.
The circuit of FIGS. 3A, and 3B, is shown as using the reflective mode to pick-up returning finger radiation. However, it may also be used with a transmission type pick-up, i.e., where the sensor 46 (or 6, FIG. 1) is located on the other side of the finger, earlobe, or the like, from the LED's.
While the mode or modes of light/tissue interaction are rather complex (see Nijboer et al, above-cited, for example), it appears that the teachings of Kofsky et al are equally applicable to reflective and transmissive LED/photosensor pick-ups, hence only empirical parameters (mainly gains and calibration constants) might vary from those given in FIGS. 3A and 3B.
The circuit values, tolerances, voltage levels, etc., of the FIG. 3A/3B circuit, being shown thereon, nothing need be said here about these. However, it is to be noted that except for electrolytics (which have polarity indicated) the capacitors are either Mylar or ceramic, (the feedback capacitor of amplifier 47 is NPO), and their values are in microfarad units. The chips were as follows:
LM358: generic
4042; generic
LTC 1060: Linear Technology
MF6 CN100: National Semiconductor
The contact between LEDs, photosensor and tissue should be a light-tight as possible, yet exert approximately no deforming pressure on the t issue.
The FIG. 1 LED-photosensor-finger arrangement is roughly that of an actual example of the invention. However, in practice, the LED's are as close together as possible, so that, as FIG. 1 suggests, their illumination patterns overlap considerably. However, the photosensor has a 10.08 mm 2 effective sensing area whose center line, at the skin surface, is about 0.4 in. from the center of the LED-illuminated patch of skin surface. Being supported in a probe surface having a curvature which will fit the average finger without significantly deforming its soft tissue, the angle between the effective direction of LED illumination of finger 5, and the effective direction of radiation from the finger to the photosensor is about 56°. As compared to LED-to-photosensor lesser or greater spacings, the 0.4 in. spacing gives optimum signal to noise ratio of the photodiode current.
In the foregoing, we have described our invention in great detail. Such detail is subject to modification. All the prior art references cited herein, we hereby incorporate herein, in toto, by reference, and commend them, and their like, insofar as applicable, to those skilled in the art, for further elaboration of the art of oximetry, as now known. | Non-invasive oximetry wherein red and infrared light from light sources energized at different frequencies is applied to arterial blood-containing tissue of a living subject. The red and infrared light coming from this tissue is sensed in order to obtain frequency-muliplexed information as to the absorption of said light by said tissue, the information being processed in order to derive therefrom a measure of percent oxygen saturation of said blood. The processing includes filtering for separating information represented by red light absorption from information represented by infrared light absorption. In particular, both notch and bandpass filters are used, and AM detectors provide for further separating such information into DC and AC components. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a liquid crystal display apparatus and a method of restoring a defected pixel, in particular to a liquid crystal display apparatus in which the defected pixel caused by operation failure of thin film active elements can be restored, and a method of restoring the defected pixel.
[0003] 2. Description of the Background Art
[0004] The method of manufacturing a liquid crystal display apparatus including a general thin film transistor (hereinafter referred to as TFT) is as follows. First, gate lines and gate electrodes are formed on a glass substrate (transparent insulating substrate), and an insulating film is formed thereon. An amorphous silicon (a-Si) film which is a semiconductor active film is formed on the insulating film. Source lines, source electrodes and drain electrodes are formed on the amorphous silicon film, an insulating film is stacked thereon, and pixel electrodes are ultimately formed. Contact holes are formed to electrically connect the drain electrodes and the pixel electrodes on the upper most layer. A counter substrate formed with a color filter and the like is manufactured apart from an array substrate manufactured through the above steps. The liquid crystal display apparatus is formed by laminating the array substrate and the counter substrate, injecting liquid crystal material and arranging driver circuit and the like.
[0005] If the TFT of the liquid crystal display apparatus formed as above has an operation failure, normal voltage is not applied to the pixel electrode, and a bright pixel defect is visually recognized. A case of N/W (normally white) in which light passes when voltage is not applied between the pixel electrode and the counter electrode is assumed for the liquid crystal display apparatus.
[0006] Conventionally, if the bright pixel defect caused by operation failure of TFT occurs, the method of restoring the defected pixel disclosed in Japanese Patent Application Laid-Open No. 5-210111 is performed. In the Japanese Patent Application Laid-Open No. 5-210111, the gate electrode and the drain line are connected using a laser repair device, and the gate voltage is applied to the pixel electrode connected to the drain electrode by way of the contact hole. The bright pixel defect caused by operation failure of the TFT is thereby indicated as dark pixel in the N/W liquid crystal display apparatus.
[0007] Since the visibility of a dark pixel defect is low compared to the bright pixel detect, the bright pixel defect is preferably indicated as dark pixel through repairing in terms of quality of the liquid crystal display apparatus, and the yield can also be enhanced.
SUMMARY OF THE INVENTION
[0008] A method of irradiating laser light from the surface (front surface) formed with the TFT and a method of irradiating laser light from the back of the surface formed with the TFT, that is, the glass substrate side (back surface) are adopted when repairing to dark pixel described in Description of the Background Art. The repair from the front surface is possible if the presence of the operation failure of the TFT can be checked in the array substrate state. However, the repair to dark pixel is generally performed by checking the operation failure of the TFT with the array substrate and the counter substrate laminated. Thus, the repair performed after the array substrate and the counter substrate are laminated must inevitably be performed from the glass substrate side of the back surface due to the influence of light shielding film formed on the counter substrate.
[0009] However, since the gate electrode is formed on the lower most layer (layer closest to the glass substrate), the portion overlapping the drain electrode may not be visibly checked when performing the repair to dark pixel from the glass substrate side. Thus, the irradiating position of the laser light becomes the gate line rim at where the gate electrode and the drain electrode overlap. The length of the gate line rim has only a few locations to be irradiated with laser light since it is restricted by the width of the drain electrode. If the irradiating location is few, the connection may be disengaged, thereby returning to the bright pixel after the laser irradiation.
[0010] The irradiating energy must be intensified compared to when irradiating the laser light to the array substrate before lamination in order to connect the gate electrode and the drain electrode with the array substrate and the counter substrate laminated. If the irradiating energy of the laser light is intensified, the effect on the insulating film and the drain electrodes formed on the gate electrodes becomes significant in addition to forming a hole in the gate electrode. Specifically, the metal of the gate electrode may lift up due to the irradiating energy of the laser light, and the metal of the drain electrode may scatter as a block and float in the liquid crystal.
[0011] The cell gap (distance between the array substrate and the counter substrate) of when the array substrate and the counter substrate are laminated is about 4 μm. Thus, lifting of the electrically conductive metal and floating of electrically conductive metal block may cause short circuit between the pixel electrode etc. and the counter electrode, thereby causing bright pixel or line defect.
[0012] The present invention aims to provide a liquid crystal display apparatus in which the irradiating position of the laser light is clear, the gate electrode or the drain electrode has a shape capable of being reliably repaired, and lifting of the electrically conductive metal and scattering of the metal block can be suppressed, and a method of restoring the defected pixel.
[0013] The present invention relates to a liquid crystal display apparatus including a plurality of gate lines formed on a substrate; a plurality of source lines formed so as to be substantially orthogonal to the gate lines; pixel electrodes formed in a matrix form at each intersecting part of the gate line and the source line; and a thin film active element, including a gate electrode connected to the gate line, a source electrode connected to the source line, and a drain electrode connected to the pixel electrode, formed in accordance with each pixel electrode. The thin film active element includes a hole in at least one of either the gate electrode or the drain electrode at a position the gate electrode and the drain electrode overlap in plan view.
[0014] The irradiating position of the laser light is clear, repair can be reliably performed, and lifting of the electrically conductive metal and scattering of the metal block can be suppressed in the liquid crystal display apparatus according to the present invention since the thin film active element includes a hole in at least one of either the gate electrode or the drain electrode at the position the gate electrode and the drain electrode overlap in plan view.
[0015] The present invention relates to a liquid crystal display apparatus including a plurality of gate lines formed on a substrate; a plurality of source lines formed so as to be substantially orthogonal to the gate lines; pixel electrodes formed in a matrix form at each intersecting part of the gate line and the source line; and a thin film active element, including a gate electrode connected to the gate line, a source electrode connected to the source line, and a drain electrode connected to the pixel electrode, formed in accordance with each pixel electrode. The thin film active element includes at least one opening of horseshoe shape in at least one of either the gate electrode or the drain electrode at a position the gate electrode and the drain electrode overlap in plan view.
[0016] The irradiating position of the laser light is clear, repair can be reliably performed, and lifting of the electrically conductive metal or scattering of the metal block can be suppressed in the liquid crystal display apparatus according to the present invention since the thin film active element includes at least one opening of horseshoe shape in at least one of either the gate electrode or the drain electrode at a position the gate electrode and the drain electrode overlap in plan view.
[0017] These and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1A and 1B are plan view and cross sectional view, respectively, showing a liquid crystal display apparatus according to a first embodiment of the present invention;
[0019] FIG. 2 is an enlarged plan view showing a TFT of the liquid crystal display apparatus according to the first embodiment of the present invention;
[0020] FIG. 3 is an enlarged plan view showing a TFT of a liquid crystal display apparatus according to a second embodiment of the present invention;
[0021] FIG. 4 is an enlarged plan view showing a TFT of a liquid crystal display apparatus according to a fourth embodiment of the present invention; and
[0022] FIG. 5 is an enlarged plan view showing a TFT of a liquid crystal display apparatus according to a fifth embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
[0023] FIGS. 1A and 1B show plan view and cross sectional view, respectively, of a liquid crystal display apparatus according to the present embodiment. FIG. 1A shows a plan view of one pixel of the array substrate, and FIG. 1B shows a cross sectional view taken along line A-A′ of FIG. 1A . The liquid crystal display apparatus according to the present embodiment has a configuration in which the pixels are arranged in a matrix form, and each pixel is driven by a thin film transistor (TFT) which is a thin film active element.
[0024] The liquid crystal display apparatus according to the present embodiment has a gate line 1 and a gate electrode 2 arranged on a glass substrate 8 (transparent insulating substrate) as a first layer, an insulating film 9 arranged as a second layer, and an amorphous silicon (a-Si) film 10 which is a semiconductor active film arranged as a third layer, as shown in FIGS. 1A and 1B . The liquid crystal display apparatus according to the present embodiment further has a source line 3 , a source electrode 4 and a drain electrode 5 arranged as a fourth layer, the insulating film 9 as a fifth layer, and finally a pixel electrode 11 as a sixth layer. A contact hole is formed in the insulating film 9 to electrically contact the drain electrode 5 and the pixel electrode 6 .
[0025] A Cs (storage capacitor) line 7 is further arranged in the liquid crystal display apparatus according to the present embodiment, as shown in FIG. 1A . The Cs line 7 is formed in the same layer as the gate line 1 etc., and forms a storage capacitor between the pixel electrode 6 . In FIG. 1A , the amorphous silicon film 10 is used to enhance the insulation at the intersecting part of the gate line 1 and the source line 3 , and the intersecting part of the Cs line 7 and the source line 3 .
[0026] The liquid crystal display apparatus according to the present embodiment further has a counter substrate arranged at the position opposing the array substrate formed with the TFT, as shown in FIG. 1B . The counter substrate has a counter electrode 13 arranged on the glass substrate 8 . Although not shown, color filter, light shielding film and the like are sometimes arranged on the counter substrate. The liquid crystal material 12 is sandwiched by the array substrate and the counter substrate.
[0027] An enlarged view of region B of FIG. 1A is shown in FIG. 2 . FIG. 2 shows an enlarged view of the TFT of the liquid crystal display apparatus according to the present embodiment. In FIG. 2 , a hole 15 is formed in the gate electrode 2 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view. The hole 15 to be formed may be of any shape, and only needs to be at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view.
[0028] The location of the hole 15 can be checked from the glass substrate side (back surface) by opening the hole 15 in the gate electrode 2 . Thus, when the bright pixel defect caused by the operation failure of the TFT is produced and the repair to the dark pixel is to be performed, the laser light 14 is irradiated from the glass substrate side (back surface), as shown in FIG. 1B , and the gate electrode 2 and the drain electrode 5 are connected using the hole 15 of the gate electrode 2 . That is, the laser light 14 is reliably irradiated to the overlapping portion of the gate electrode 2 and the drain electrode 5 by irradiating the laser light 14 to the peripheral edge of the hole 15 of the gate electrode 2 .
[0029] Furthermore, the overlapping portion of the gate electrode 2 and the drain electrode 5 that can be recognized from the glass substrate side (back surface) and that can be irradiated with the laser light 14 is only one side of the gate electrode 2 in the prior art. However, the overlapping portion of the gate electrode 2 and the drain electrode 5 that can be recognized from the glass substrate side (back surface) and that can be irradiated with the laser light 14 increases to four sides of the peripheral edge of the hole 15 by forming the hole 15 in the gate electrode 2 . Therefore, the location for connecting the gate electrode 2 and the drain electrode 5 increases by using the hole 15 of the gate electrode 2 in the liquid crystal display apparatus of the present embodiment.
[0030] In the liquid crystal display apparatus according to the present embodiment, the hole 15 is formed in the gate electrode 2 , and the gate electrode 2 and the drain electrode 5 are connected at the peripheral edge of the hole 15 , and thus the gate electrode 2 and the drain electrode 5 can be processed with an energy weaker than the energy of the conventional laser light used in connecting the gate electrode 2 and the drain electrode 5 . The lifting of the metal of the drain electrode 5 and the scattering of the metal block can be thus reduced by using the laser light of weak energy in the liquid crystal display apparatus according to the present embodiment.
[0031] Therefore, the irradiating position of the laser light 14 is clear, repair can be reliably performed, and lifting of the electrically conductive metal or scattering of the metal block can be suppressed in the liquid crystal display apparatus according to the present embodiment since the hole 15 is formed in the gate electrode 2 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view.
[0032] The method of restoring the defected pixel of the liquid crystal display apparatus according to the present embodiment includes a step of specifying the defected pixel caused by operation failure of the TFT through lighting test etc., and a step of irradiating a predetermined laser light 14 to the peripheral edge of the hole 15 formed in the TFT of the specified defected pixel to connect the gate electrode 2 and the drain electrode 5 , whereby lifting of the electrically conductive metal and scattering of the metal block can be suppressed and repair can be reliably performed.
[0033] One hole 15 is formed in the gate electrode 2 in the liquid crystal display apparatus according to the present embodiment, but the present invention is not limited thereto. The irradiating position of the laser light 14 can be checked from the glass substrate side (back surface), and repair can be reliably performed, similar to the present embodiment, even if a plurality of holes 15 are formed in the gate electrode 2 in a mesh form at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view. Therefore, the present invention can have advantages of suppressing lifting of the electrically conductive metal and scattering of the metal block even if the plurality of holes 15 are formed in the same gate electrode 2 .
Second Embodiment
[0034] FIG. 3 shows an enlarged view of the TFT of the liquid crystal display apparatus according to the present embodiment. In FIG. 3 , a hole 16 is formed in the drain electrode 5 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view. The hole 16 to be formed may be of any shape, and only needs to be at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view. The hole 15 is not formed in the gate electrode 2 in the present embodiment.
[0035] In the present embodiment, the location of the hole 16 formed in the drain electrode 5 cannot be checked from the glass substrate side since the hole 15 is not formed in the gate electrode 2 . Thus, the irradiating position of the laser light 14 cannot be specified using the hole 16 when the bright pixel defect caused by the operation failure of the TFT is produced and the laser light 14 is irradiated from the glass substrate side (back surface) as shown in FIG. 1B to connect the gate electrode 2 and the drain electrode 5 .
[0036] However, scattering of the electrically conductive metal block can be suppressed since the hole 16 is formed in the drain electrode 5 in the present embodiment, compared to when irradiating the laser light 14 to connect the gate electrode 2 and the drain electrode 5 without forming the hole 16 in the drain electrode 5 . That is, the amount of metal at the portion of connecting the gate electrode 2 and the drain electrode 5 can be reduced by forming the hole 16 in the drain electrode 5 , and thus the amount of metal that scatters when the laser light 14 is irradiated can be suppressed in the liquid crystal display apparatus according to the present embodiment. Thus, the electrically conductive metal block produced when the laser light 14 is irradiated is prevented from becoming a size of a degree of short circuiting the pixel electrode 6 etc. and the counter electrode 13 in the present embodiment.
[0037] One hole 16 is formed in the drain electrode 5 in the liquid crystal display apparatus according to the present embodiment, but the present invention is not limited thereto. Effects similar to the present embodiment are obtained even if a plurality of holes 16 are formed in a mesh form in the drain electrode 5 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view.
Third Embodiment
[0038] The hole 15 is formed in the gate electrode 2 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view in the liquid crystal display apparatus according to the first embodiment, as shown in FIG. 2 . On the other hand, the hole 16 is formed in the drain electrode 5 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view in the liquid crystal display apparatus according to the second embodiment, as shown in FIG. 3 .
[0039] First and second embodiments are combined in the liquid crystal display apparatus according to the present embodiment. That is, the hole 15 is formed in the gate electrode 2 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view, and the hole 16 is formed in the drain electrode 5 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view in the liquid crystal display apparatus of the present embodiment. The figure of the liquid crystal display apparatus according to the present embodiment is a combination of FIGS. 2 and 3 , and thus the figure will be omitted.
[0040] Therefore, the irradiating position of the laser light is clear, repair can be reliably performed, and lifting of the electrically conductive metal and scattering of the metal block can be suppressed since the hole 15 is formed in the gate electrode 2 and the hole 16 is formed in the drain electrode 5 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view in the liquid crystal display apparatus according to the present embodiment.
[0041] The shape, position and size of the hole 15 and the hole 16 do not need to be the same in the liquid crystal display apparatus according to the present embodiment, and may be of different shape, position and size. The positions of the hole 15 and the hole 16 are limited, however, within the range the gate electrode 2 and the drain electrode 5 overlap in plan view.
[0042] One hole 15 is formed in the gate electrode 2 and one hole 16 is formed in the drain electrode 5 in the liquid crystal display apparatus according to the present embodiment, but the present invention is not limited thereto. Effects similar to the present embodiment are obtained even if a plurality of holes 16 are formed in mesh form in the gate electrode 2 and in the drain electrode 5 at positions where the gate electrode 2 and the drain electrode 5 overlap in plan view.
Fourth Embodiment
[0043] FIG. 4 shows an enlarged view of the TFT of the liquid crystal display apparatus according to the present embodiment. In FIG. 4 , an opening 17 of a horseshoe shape is formed in the gate electrode 2 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view. The opening 17 to be formed may be of any size as long as it is formed at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view.
[0044] The location of the opening 17 can be checked from the glass substrate side by forming the opening 17 in the gate electrode 2 . Thus, the opening 17 of the gate electrode 2 can be used when bright pixel defect caused by operation failure of the TFT is produced, and the laser light 14 is irradiated from the glass substrate side (back surface), as shown in FIG. 1B to connect the gate electrode 2 and the drain electrode 5 . That is, the laser light 14 can be reliably irradiated to the overlapping portion of the gate electrode 2 and the drain electrode 5 by irradiating the laser light 14 to the peripheral edge of the opening 17 of the gate electrode 2 .
[0045] Only one side of the gate electrode 2 of the overlapping portion of the gate electrode 2 and the drain electrode 5 is the location of irradiating the laser light 14 in the prior art, but three sides of the peripheral edge of the opening 17 act as the locations of irradiating the laser light 14 by forming the opening 17 . Thus, the location for connecting the gate electrode 2 and the drain electrode 5 increases by using the opening 17 of the gate electrode 2 in the liquid crystal display apparatus according to the present embodiment.
[0046] The opening 17 is formed in the gate electrode 2 , and the gate electrode 2 and the drain electrode 5 are connected at the peripheral edge in the liquid crystal display apparatus according to the present embodiment, and thus the gate electrode 2 and the drain electrode 5 can be processed with an energy weaker than the energy of the conventional laser light used in connecting the gate electrode 2 and the drain electrode 5 . Thus, lifting of the metal of the drain electrode 5 and scattering of the metal block can be reduced by using the laser light of weak energy in the liquid crystal display apparatus according to the present embodiment
[0047] In the example shown in FIG. 4 , the opening 17 of horseshoe shape is formed in the gate electrode 2 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view, but the present invention is not limited thereto, and the opening of horseshoe shape may be formed in the drain electrode 5 or an opening of horseshoe shape may be formed in both the gate electrode 2 and the drain electrode 5 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view.
[0048] However, the irradiating position of the laser light 14 cannot be specified using the opening, but the amount of metal that scatters when the laser light 14 is irradiated can be suppressed when the opening of horseshoe shape is formed only in the drain electrode 5 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view.
[0049] Therefore, the irradiating position is clear, repair can be reliably performed, and lifting of the electrically conductive metal and scattering of the metal block can be suppressed since the opening of horseshoe shape is formed in at least one of the gate electrode or the drain electrode at the position where the gate electrode and the drain electrode overlap in plan view in the liquid crystal display apparatus according to the present embodiment.
Fifth Embodiment
[0050] FIG. 5 shows an enlarged view of the TFT of the liquid crystal display apparatus according to the present embodiment. In FIG. 5 , a plurality of openings 17 of horseshoe shape is formed in the drain electrode 5 at positions where the gate electrode 2 and the drain electrode 5 overlap in plan view. That is, the drain electrode 5 according to the present embodiment has a comb shape. The number and size of each opening 17 to be formed are not limited as long as it is formed at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view.
[0051] When including the drain electrode 5 of a shape shown in FIG. 5 , the opening 17 cannot be visibly recognized by the gate electrode 2 from the glass substrate side (back surface), and the irradiating position of the laser light 14 cannot be specified using the opening 17 , but the amount of metal that scatters when the laser light 14 is irradiated can be suppressed.
[0052] Therefore, the metal of the drain electrode 5 that scatters when laser light 14 is irradiated can be smaller, and the production of defects caused by scattered metal can be prevented since a plurality of openings 17 are formed in the drain electrode 5 in the liquid crystal display apparatus according to the present embodiment.
[0053] In the example shown in FIG. 5 , the opening 17 of horseshoe shape is formed in plurals in the drain electrode 5 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view, but the present invention is not limited thereto, and the opening of horseshoe shape may be formed in plurals in the gate electrode 2 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view, or the opening of horseshoe shape may be formed in plurals in both the gate electrode 2 and the drain electrode 5 .
[0054] The location of the opening 17 can be checked from the glass substrate side if the opening of horseshoe shape is formed in plurals in the gate electrode 2 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view. Thus, the opening 17 of the gate electrode 2 can be used when bright pixel defect caused by operation failure of the TFT is produced, and the laser light 14 is irradiated from the glass substrate side (back surface) as shown in FIG. 1B to connect the gate electrode 2 and the drain electrode 5 . That is, the laser light 14 can be reliably irradiated to the overlapping portion of the gate electrode 2 and the drain electrode 5 by irradiating the laser light 14 to the peripheral edge of the opening 17 of the gate electrode 2 .
[0055] In the liquid crystal display apparatus according to the present invention, a hole or an opening shown in one of the first embodiment to the fifth embodiment can be combined to a configuration in which a hole or an opening is formed in the gate electrode 2 and the drain electrode 5 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view. For example, a combination in which the hole shown in the first embodiment is formed in the gate electrode 2 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view, and a plurality of openings shown in the fifth embodiment is formed in the drain electrode 5 at the position where the gate electrode 2 and the drain electrode 5 overlap in plan view is considered.
[0056] While the invention has been shown and described in detail, the foregoing description is in all aspects illustrative and not restrictive. It is therefore understood that numerous modifications and variations can be devised without departing from the scope of the invention. | The present invention relates to a liquid crystal display apparatus including a plurality of gate lines; a plurality of source lines formed so as to be substantially orthogonal to the gate lines; pixel electrodes formed in a matrix form at each intersecting part of the gate line and the source line; and a TFT, including a gate electrode connected to the gate line, a source electrode connected to the source line, and a drain electrode connected to the pixel electrode, formed in accordance with each pixel electrode. The TFT according to the present invention includes a hole in at least one of either the gate electrode or the drain electrode at a position where the gate electrode and the drain electrode overlap in plan view. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application claims the benefit of priority to U.S. provisional patent application Ser. No. 61/109,869 entitled “COMPOSITIONS AND METHOD FOR PROTECTION OF HAIR FROM TREATED POOL WATER” filed on Oct. 30, 2008, the subject matter of which is incorporated herein in its entirety.
FIELD OF THE INVENTION
The present invention is directed to compositions for treating hair. The present invention is further directed to methods of making and using compositions for treating hair.
BACKGROUND OF THE INVENTION
The use of chlorine, and to a lesser degree, bromine, and saline, to disinfect both indoor and outdoor swimming pools has been used for some time in order to reduce micro-organism populations. Halogen-containing compounds are used as a result of their rapid in vivo microbiocidal activity due to their strong oxidizing potential in the presence of organic residues, which is essential for rapid reduction of pathogens, which can promote the induction and spread of disease. Chlorine is by far the most widely used disinfectant due primarily to its cost effectiveness and acceptable safety profile. The chlorine compounds most effectively employed consist of sodium hypochlorite, calcium hypochlorite and chlorinated isocyanurates. Sodium hypochlorite is preferred as a result of its lower cost water solubility and ease of dispersion together with easier control of pH requirements for optimal microbiocidal activity. To this effect sodium hypochlorite dissociates in water into hypochlorous acid together with sodium and hypochlorite ions depending upon the pH of the water.
HOCl
H
+
OCl
-
Hypochlorous
increasing
pH
--
->
Hydrogen
+
Hypochlorite
Acid
<
-
decreasing
pH
Ion
Ion
The hypochlorous acid (HA) is the species, which is the oxidant and micro biocide, and therefore, based on the above reaction, exhibits a maximum concentration at neutral pH or in actuality 7.2 to 7.8, These ranges are critical as at 7.2, 66% exists as HA compared to 33% at 7.8, At acidic pH, the chlorine is rapidly lost and at high pH the HA rapidly falls as the equilibrium favors the inactive ionic dissociation as shown above. Based on the foregoing, the advantages of using a halogen and particularly chlorine are obvious, however, the potent oxidizing potential presents deleterious effects to hair. This is evident to both short and long term exposure as oxidants of this type exhibit a rapid electrophilic attack (i.e., draw electrons) from any organic substance, such as hair, lowering its tensile strength, which promotes cuticle damage. This exposes the interior hair morphology to further electrophilic attack leading to free radical induced cellular damage within the cortex. In summary, the least of these problems are also cosmetic, leaving healthy hair damaged, dry/stiff, and subject to breakage in addition to snarling and tangling.
Hair treatment products have been designed for consumer use to rectify and, or mitigate the foregoing consisting of post-treatment with shampoo and conditioners containing antioxidants or reducing agents to remove residual chlorine from hair after swimming. However, these products have been, for the most part, ineffective mainly as a result of the rapid oxidation effects to hair as described above. As a result, the post-treatments described above do not address the irreversible problem of deleterious effects encountered while swimming.
There exists a need in the art for a pre-treatment of hair and scalp prior to immersion in the treated pool arena.
SUMMARY OF THE INVENTION
The present invention addresses the need in the art of compositions and methods of pre-treatment for hair prior to oxidation exposure such as encountered in treated pools (e.g., a chlorinated swimming pool). Thus it is an object of the present invention to provide compositions for pre-treatment of hair prior to exposure to deleterious oxidants. It is also an object of the present invention to provide a method for protecting hair from oxidants and harmful residues encountered in a treated pool environment. It is still further an object of this invention to provide cosmetically acceptable products, which are safe, cost-effective, and consumer friendly, and which after use in a treated pool, leave hair healthy and manageable.
The use of an effective pre-treatment regimen has numerous advantages. Effective protection via the disclosed pre-treating does not permit exposure of treated hair to deleterious chemical agents, such as oxidants. Thus, the instantaneous damage to the exterior and interior of hair are nonexistent when pre-treated according to the present invention. This includes both cosmetic homeostatic and structural damage, such as depletion of the cuticle and cellular damage within the cortex. The hair maintains its natural oil composition (sebum) (i.e., while swimming) as opposed to oxidization leading to the generation of free radicals in sebum lipids, which can become comedogenic to surrounding skin mucosa, i.e. scalp and forehead. Thus as opposed to post-treatment with compositions containing reducing agents, pre-treatment prevents the damage from happening, thereby eliminating or reducing the need for ineffective extensive post remedies.
Accordingly, the present invention is directed to hair pre-treatment compositions suitable for protection of hair from exposure to Oxidizing agents. In one exemplary embodiment, the hair pre-treatment composition of the present invention comprises at least one hydrophilic cationic polymer; at least one lipophilic nonionic polymer; one or more water-soluble antioxidants or reducing agents; and one or more oil-soluble antioxidants or reducing agents. In some exemplary embodiments, the hair pre-treatment composition comprises at least one hydrophilic cationic polymer in the form of a guar hydroxypropyltrimonium chloride (GHPTC); at least one lipophilic nonionic polymer in the form of (i) a polyvinyl stearyl ether, (ii) a vinylpyrrolidone-eicosene copolymer, or (iii) a combination of (i) and (ii); one or more water-soluble antioxidants or reducing agents in the form of cysteine, methionine, BHT, BHA, a polyphenol of plant origin, or any mixture thereof; and one or more oil-soluble antioxidants or reducing agents in the form of a tocopherol, a tocotrienol, beta carotene, or any mixture thereof.
In another exemplary embodiment, the hair pre-treatment composition of the present invention comprises at least one lipophilic nonionic polymer comprising (i) a polyvinyl stearyl ether, (ii) a vinylpyrrolidone-eicosene copolymer, or (iii) a combination of (i) and (ii). The exemplary hair pre-treatment composition may further comprise one or more of (i) at least one hydrophilic cationic polymer comprising guar hydroxypropyltrimonium chloride (GHPTC), a cationic cellulosic polymer, a diallyl dimethyl ammonium chloride/acrylamide copolymer, or any combination thereof; (ii) one or more water-soluble antioxidants or reducing agents comprising cysteine, methionine, BHT, BHA, a polyphenol of plant origin, or any mixture thereof; (iii) one or more oil-soluble antioxidants or reducing agents comprising a tocopherol, a tocotrienol, beta carotene, or any mixture thereof; and (iv) one or more optional cosmetic base materials such as a humectant, a fragrance, a pH control agent, a buffer, or a combination thereof.
In yet another exemplary embodiment, the hair pre-treatment composition of the present invention comprises at least one hydrophilic cationic polymer, wherein the at least one hydrophilic cationic polymer comprises guar hydroxypropyltrimonium chloride (GHPTC); at least one lipophilic nonionic polymer, wherein the at least one lipophilic nonionic polymer comprises (i) a polyvinyl stearyl ether, (ii) a vinylpyrrolidone-eicosene copolymer, or (iii) a combination of (i) and (ii); one or more water-soluble antioxidants or reducing agents, wherein the one or more water-soluble antioxidants or reducing agents comprises cysteine, methionine, or any mixture thereof; and one or more oil-soluble antioxidants or reducing agents, wherein the one or more oil-soluble antioxidants or reducing agents comprises a tocopherol, a tocotrienol, beta carotene, or any mixture thereof.
The present invention is also directed to methods of making and using hair pre-treatment compositions suitable for protecting hair from exposure to oxidizing agents. In one exemplary embodiment, the method of making a hair pre-treatment composition of the present invention comprises mixing (i) at least one hydrophilic cationic polymer; (ii) at least one lipophilic nonionic polymer; (iii) one or more water-soluble antioxidants or reducing agents; and (iv) one or more oil-soluble antioxidants or reducing agents. In some exemplary embodiments, the method of making a hair pre-treatment composition comprises mixing (1) at least one hydrophilic cationic polymer in the form of a guar hydroxypropyltrimonium chloride (GHPTC); (2) at least one lipophilic nonionic polymer in the form of (i) a polyvinyl stearyl ether, (ii) a vinylpyrrolidone-eicosene copolymer, or (iii) a combination of (i) and (ii); (3) one or more water-soluble antioxidants or reducing agents in the form of cysteine, methionine, BHT, BHA, a polyphenol of plant origin, or any mixture thereof; and (4) one or more oil-soluble antioxidants or reducing agents in the form of a tocopherol, a tocotrienol, beta carotene, or any mixture thereof.
In other exemplary embodiments, the method of making a hair pre-treatment composition comprises forming a hair pre-treatment composition comprising at least one lipophilic nonionic polymer comprising (i) a polyvinyl stearyl ether, (ii) a vinylpyrrolidone-eicosene copolymer, or (iii) a combination of (i) and (ii). In this exemplary method, the method of making a hair pre-treatment composition may further comprise incorporating one or more of the following components into the lipophilic nonionic polymer-containing composition: (i) at least one hydrophilic cationic polymer comprising guar hydroxypropyltrimonium chloride (GHPTC), a cationic cellulosic polymer, a diallyl dimethyl ammonium chloride/acrylamide copolymer, or any combination thereof; (ii) one or more water-soluble antioxidants or reducing agents comprising cysteine, methionine, BHT, BHA, a polyphenol of plant origin, or any mixture thereof; (iii) one or more oil-soluble antioxidants or reducing agents comprising a tocopherol, a tocotrienol, beta carotene, or any mixture thereof; and (iv) one or more optional cosmetic base materials such as a humectant, a fragrance, a pH control agent, a buffer, or a combination thereof.
In yet other exemplary embodiments, the method of making a hair pre-treatment composition comprises forming a hair pre-treatment composition comprising at least one hydrophilic cationic polymer, wherein the at least one hydrophilic cationic polymer comprises guar hydroxypropyltrimonium chloride (GHPTC); at least one lipophilic nonionic polymer, wherein the at least one lipophilic nonionic polymer comprises (i) a polyvinyl stearyl ether, (ii) a vinylpyrrolidone-eicosene copolymer, or (iii) a combination of (i) and (ii); one or more water-soluble antioxidants or reducing agents, wherein the one or more water-soluble antioxidants or reducing agents comprises cysteine, methionine, or any mixture thereof; and one or more oil-soluble antioxidants or reducing agents, wherein the one or more oil-soluble antioxidants or reducing agents comprises a tocopherol, a tocotrienol, beta carotene, or any mixture thereof.
Methods of using the disclosed hair pre-treatment compositions comprise applying a given hair pre-treatment composition to hair prior to exposing the hair to an oxidizing environment, such as a chlorinated swimming pool. In one exemplary embodiment, the method of using a hair pre-treatment composition comprises applying a hair pre-treatment composition to hair, wherein the hair pre-treatment composition comprises one or more of the following components: (i) at least one hydrophilic cationic polymer; (ii) at least one lipophilic nonionic polymer; (iii) one or more water-soluble antioxidants or reducing agents; (iv) one or more oil-soluble antioxidants or reducing agents; and (v) one or more optional cosmetic base materials such as a dye, a fragrance, etc. Exemplary methods of using a disclosed hair pre-treatment composition may further comprise one or more additional steps such as exposing the treated hair to an oxidizing environment (e.g., a chlorinated swimming pool); rinsing the treated hair prior to and/or after exposure to the oxidizing environment; shampooing the treated hair to remove at least a portion of the hair pre-treatment composition; conditioning the hair following or during the shampooing step; and drying the hair.
The present invention is further directed to treated hair comprising hair coated with any of the hair pre-treatment compositions of the present invention.
The present invention is even further directed to method of doing business, wherein the method of doing business comprises offering for sale any of the hair pre-treatment compositions of the present invention. Exemplary methods of doing business may comprise offering for sale a given the hair pre-treatment composition of the present invention alone or in a hair treatment kit containing other hair treatment products such as a shampoo, a conditioner, or a combination thereof.
These and other features and advantages of the present invention will become apparent after a review of the following detailed description of the disclosed embodiments and the appended claims.
DETAILED DESCRIPTION
The present invention is directed to a variety of hair pre-treatment compositions. In some embodiments, the hair pre-treatment compositions comprise (or consist essentially of, or consist of) a combination of (I) one or more hydrophilic water-soluble polymers in combination with (2) one or more nonionic lipophilic oil soluble polymers together with selected (3) water- and (4) oil-soluble antioxidants or reducing agents in (5) an acceptable cosmetic base. The hair pre-treatment compositions and method of use are effective for protecting hair from damage caused by antibacterial and/or oxidizing agents normally employed in treated pools (e.g., swimming pools). These consist of, but are not limited to, ionic salts containing an oxidized ionic species, such as halogens, consisting of mainly chlorine- and bromine-containing oxidizing agents such as sodium hypochlorite, etc., oxygen bleaches such as sodium perborate, and organic containing oxidants such as isocyanurates.
The hydrophilic water-soluble polymers employed in the hair pre-treatment compositions of the present invention are desirably cationic modified polysaccharides or synthetic polymers, which carry a net cationic charge. The foregoing includes known industrial compounds, which are commercially available from cosmetic suppliers. These include, but are not limited to, guar hydroxypropyl trimonium chlorides (GHPTCs) such as JAGUAR® and AQUACAT® products commercially available from Aqualon Corporation (Wilmington, Del.); cationic modified cellulosics such as polyquaternium 10 (i.e., cellulose 2-(2-hydroxy-3-(trimethylammonio)propoxy)ethyl ether), one of a series of CELQUAT® products from Akzo Nobel (Amsterdam, Netherlands); and diallyl dimethyl ammonium chloride/acrylamide copolymer such as MERQUAT® products (e.g., (polyquaternium-7) commercially available from Nalco Company (Naperville, Ill.).
The charge density of the cationic polymers may be modified to balance substantivity with removal to avoid build-up on hair. The charge density, related to the amine functional cationic groups, is typically from about 0.01 meq/gram to 10 meq/gram, and preferably, from about 0.2 to about 7 meq/gram, and most preferably, between about 0.18 to about 0.36 meq/gram.
The cationic polymers, which can used alone or in combination, are typically employed at a total cationic polymer(s) level of from about 0.1 to about 10% by weight, and preferably from about 0.5 to about 6% by weight, and most preferably from about 1 to about 3% by weight.
The lipophilic nonionic polymers suitable for use in the present invention include, but are not limited to, the following classes of compounds: polyvinyl stearyl ethers commercially available under the trade designation GIOVAREZ® from Phoenix Chemical, Inc. (Sommerville, N.J.), PVP/eicosene copolymers commercially available under the trade designation GANEX® from International Specialty Products (Wayne, N.J.), and hydrogenated castor oil/sebacic acid copolymers commercially available under the trade designation CRODABOND® from Croda (Edison, N.J.), a di-behenyl imidazolinium product such as QUATERNIUM 91 from Croda.
The lipophilic nonionic polymers may be used alone or in combination to achieve optimal wash off/water resistance during use. The total level of lipophilic nonionic polymer(s) employed may be from about 1 to about 15% by weight, preferably, from about 2 to about 10% by weight, and most preferably, from about 4 to about 8% by weight.
The ratio of hydrophilic cationic polymer(s) to lipophilic nonionic polymer(s) may be from about 1:10 to about 10:1, and a preferred ratio is from about 1:7 to about 7:1 by weight in the final composition.
The oil-soluble antioxidants employed by the present invention include, but are not limited to, tocopherol (e.g., alpha tocopherol), tocotrienol (e.g., alpha tocotrienol), and carotenoids. The oil-soluble antioxidants, which can used alone or in combination with one another, are typically present at a total amount of oil-soluble antioxidant(s) of from about 0.1 to about 10% by weight of the formula, and preferably, at about 1 to about 5% by weight, and most preferably, from about 1 to about 3% by weight.
The water-soluble antioxidants suitable for use in the present invention include, but are not limited to, sulfur containing amino acids such as cysteine or methionine, their analogs, and di- or tri-peptides containing at least one cysteine or methionine moiety in the amino acid sequence; sodium thoisulfate; butylhydroxytoluene (BHT); butylhydroxyanisole (BHA); sodium bisulfate; sodium metabisulfite; and bis-phenol extracts of plant origin.
The water-soluble antioxidants may be used alone or in combination with one another. The water-soluble antioxidants are typically present in a total amount of one or more water-soluble antioxidants of from about 0.1 to about 5% by weight, and preferably, at about 1 to about 3% by weight in the finished product.
The above-described active ingredients may be incorporated in a cosmetic base, which exhibits both (i) compatibility with the above-described active ingredients, and (ii) acceptable aesthetics on the treated hair. The cosmetic base components may include, but are not limited to, deionized water; cationic surfactants; fatty alcohols such as cetearyl alcohol; nonionic emulsifiers; rheology modifiers; preservatives; chelators (e.g., EDTA and its salts, such as disodium EDTA); dyes; fragrances (e.g., mentha spicata, coconut, rose oil, sandlewood oil, etc.); pH control agents; and buffers. Humectants, such as glycerin and glycols (e.g., butylene glycol), and oils of mineral or plant origin may be used alone or in combination with any of the above-mentioned cosmetic base components as desired.
Exemplary cationic surfactants suitable for use in the present invention may include, but are not limited to, mono- and di- n-alkyl dimethyl ammonium chlorides, benzalkonium chlorides, and di-steary-di-methyl ammonium chloride. Exemplary fatty alcohols suitable for use in the present invention may include, but are not limited to, C10-C22 carbon chain alcohols (straight or branched), and stearyl alcohol. Exemplary nonionic emulsifiers suitable for use in the present invention may include, but are not limited to, sorbitan esters, ethoxylated fatty alcohols, and polysorbate 20, Exemplary rheology modifiers suitable for use in the present invention may include, but are not limited to, hydroxyalkyl celluloses, zanthan and guar gums, modified starches, and PEG 150 distearate. Exemplary preservatives suitable for use in the present invention may include, but are not limited to, 5-chloro-2-methyl-1,2-thiazol-3-one, 2-methyl-1,2-thiazol-3-one, 1,3-dimethylol-5,5-dimethylhydantoin, 3-iodo-2-propynyl butyl carbamate (e.g., KATHON™ CG commercially available from Sigma-Aldrich, Inc. (St. Louis, Mo.) and GLYDANT PLUS commercially available from Lonza, Ltd. (Basil, Switzerland)), and parabens such as methylparaben and propylparaben. Exemplary dyes suitable for use in the present invention may include, but are not limited to, FD&C AND D&C approved dyes such as D&C Yellow #10, Exemplary pH control agents suitable for use in the present invention may include, but are not limited to, citric acid, and potassium hydroxide. Exemplary buffer agents suitable for use in the present invention may include, but are not limited to, sodium phosphates, mono-, di-, and tribasic; and potassium citrates, mono-, di-, and tribasic. Exemplary oils of mineral or plant origin suitable for use in the present invention may include, but are not limited to, Johoba oil, Camellia Oleifera leaf extract, green tea extract and white tea extract.
The hair pre-treatment compositions of the present invention may comprise up to about 95% by weight of deionized water. Typically, deionized water is present in an amount of from about 45 to about 90% by weight, more typically, from about 65 to about 85% by weight, and even more typically, from about 65 to about 80% by weight, based on a total weight of the hair pre-treatment composition.
Other cosmetic base materials, such as any cationic surfactant, fatty alcohol, nonionic emulsifier, rheology modifier, preservative, chelator (e.g., EDTA or sodium salt thereof), dye, fragrance, pH control agent, buffer, humectants, and/or oil of mineral or plant origin may each independently be present in the hair pre-treatment compositions of the present invention in an amount of up to about 10% by weight, based on a total weight of the hair pre-treatment composition. Typically, each of the above-listed cosmetic base materials (other than deionized water), when present, are each independently present in an amount of from greater than 0 to about 5.0% by weight, more typically, from about 0.0001 to about 3.0% by weight, and even more typically, from about 0.01 to about 1.0% by weight, based on a total weight of the hair pre-treatment composition.
The pH of the resulting hair pre-treatment compositions typically ranges from about 4 to about 7, desirably ranging from about 4 to about 6, more desirably ranging from about 4 to about 5.
It should be noted that the hair pre-treatment compositions of the present invention may comprise, consist essentially of, or consist of any one the above-mentioned composition components or any combination of two or more of the above-mentioned composition components. In one exemplary hair pre-treatment composition of the present invention, the exemplary hair pre-treatment composition comprises (or consists essentially of, or consists of) at least one hydrophilic cationic polymer comprising guar hydroxypropyltrimonium chloride (GHPTC); at least one lipophilic nonionic polymer comprising (i) a polyvinyl stearyl ether, (ii) a vinylpyrrolidone-eicosene copolymer, or (iii) a combination of (i) and (ii); one or more water-soluble antioxidants or reducing agents comprising cysteine, methionine, or any mixture thereof; one or more oil-soluble antioxidants or reducing agents comprising a tocopherol, a tocotrienol, beta carotene, or any mixture thereof; and one or more of the following components: deionized water, cetearyl alcohol, PEG 40 castor oil, stearalkonium chloride, hydrogenated castor oil/sebacic acid copolymer, di-behenzyl imidazolinium, cetrimonium methosulfate, cetearyl alcohol, a polyoxyethylene ether of cetyl/stearyl alcohol, butylene glycol, isopropyl myristate, citric acid, an acrylate/aminoacrylate/C10-30 alkyl PEG-20 itaconate copolymer, trisodium EDTA, amidomethicone, cetrimonium chloride, 2-tridecoxyethanol, Camellia Oleifera leaf extract, Camellia Sinensis (White Tea) extract, methylchloroisothiazolinone, methylisothiazolinone, and a fragrance.
In another exemplary hair pre-treatment composition of the present invention, the exemplary hair pre-treatment composition comprises (or consists essentially of, or consists of) at least one hydrophilic cationic polymer comprising guar hydroxypropyltrimonium chloride (GHPTC); at least one lipophilic nonionic polymer comprising (i) a polyvinyl stearyl ether, (ii) a vinylpyrrolidone-eicosene copolymer, or (iii) a combination of (i) and (ii); one or more water-soluble antioxidants or reducing agents comprising cysteine, methionine, or any mixture thereof; one or more oil-soluble antioxidants or reducing agents comprising a tocopherol, a tocotrienol, beta carotene, or any mixture thereof; and all of the following components: deionized water, cetearyl alcohol, PEG 40 castor oil, stearalkonium chloride, hydrogenated castor oil/sebacic acid copolymer, di-behenzyl imidazolinium, cetrimonium methosulfate, cetearyl alcohol, a polyoxyethylene ether of cetyl/stearyl alcohol, butylene glycol, isopropyl myristate, citric acid, an acrylate/aminoacrylate/C10-30 alkyl PEG-20 itaconate copolymer, trisodium EDTA, amidomethicone, cetrimonium chloride, 2-tridecoxyethanol, Camellia Oleifera leaf extract, Camellia Sinensis (White Tea) extract, methylchloroisothiazolinone, methylisothiazolinone, and a fragrance.
It should be noted that the hair pre-treatment compositions of the present invention comprise, consist essentially of, or consist of one or more composition components, discussed above, that are not present in other hair treatment compositions, for example, shampoos and/or conditioners. In addition, the hair pre-treatment compositions of the present invention typically do not contain composition components found in shampoos and/or conditioners. Composition components that are typically found in shampoos and/or conditioners, but are not typically present in the hair pre-treatment compositions of the present invention, include, but are not limited to, anionic surfactants.
The present invention is described above and further illustrated below by way of examples, which are not to be construed in any way as imposing limitations upon the scope of the invention. On the contrary, it is to be clearly understood that resort may be had to various other embodiments, modifications, and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in—the art without departing from the spirit of the present invention and/or the scope of the appended claims.
EXAMPLES
Example 1
Composition and Preparation of Cosmetic Base
The following cosmetic base ingredients were mixed as described below.
INGREDIENT
PERCENT WT/WT
Part A. WATER PHASE
DEIONIZED WATER
77.4999
HYROXYETHYLCELLULOSE
2.0000
TRISODIUM EDTA
0.5000
GLYCERINE
2.0000
BUTYLENE GLYCOL
2.0000
AMIDOMETHICONE(and)CETRIMONIUM
1.0000
CHLORIDE(and)TRIDECETH 12
CITRIC ACID
0.2000
Part B. OIL PHASE
STEARALKONIUM CHLORIDE
6.0000
CETEARYL ALCOHOL
3.0000
CETEARETH 20
3.0000
ISOPROPYL PALMITATE
1.0000
MINERAL OIL
1.0000
PART C
PRESERVATIVE (KATHON ™ CG)
0.3000
DYE AND FRAGRANCE
0.5001
(i.e., dye - FD&C RED 40, Orco Organic
(E. Providence, RI), 0.0001 wt %; and
fragrance - Belle-Aire #70330,
Belle-Aire Fragrances (Mundelein, IL),
0.5000 wt %)
PROCEDURE:
1 - HEAT PART A TO 70° C. AND HOLD WITH AGITATION
2 - PRE-MELT PART B IN SEPARATE VESSEL AND HEAT TO 70° C.
3 - ADD PART B TO PART A WITH AGITATION
4 - COOL TO 35° C. AND ADD PART C IN ORDER
5 - ADJUST PH TO 5-6 WITH 50% CITRIC ACID IN DEIONIZED WATER
Example 2
Composition and Preparation of Protective Hair Pre-Treatment
The following hair pre-treatment composition components were mixed as described below.
INGREDIENT
PERCENT WT/WT
A. WATER PHASE
DEIONIZED WATER
74.2999
GUAR HYDROXYPROPYLTRIMONIUM
0.5000
CHLORIDE
HYROXYETHYLCELLULOSE
2.0000
GREEN TEA EXTRACT
1.0000
CYSTEINE
1.0000
TRISODIUM EDTA
0.5000
GLYCERINE
2.0000
AMIDOMETHICONE(and)CETRIMONIUM
1.0000
CHLORIDE(and)TRIDECETH 12
CITRIC ACID
0.2000
B. OIL PHASE
STEARALKONIUM CHLORIDE
6.0000
CETEARYL ALCOHOL
3.0000
CETEARETH 20
3.0000
ISOPROPYL PALMITATE
1.0000
TOCOPHEROL
1.0000
POLYVINYL STEARYL ETHER
2.0000
MINERAL OIL
1.0000
PART C
PRESERVATIVE (KATHON ™ CG)
0.3000
DYE AND FRAGRANCE)
0.2001
(i.e., dye - FD&C Blue #1, Orco Organic
(E. Providence, RI), 0.0001 wt %; and fragrance -
spearmint oil 50-6250-00, Lebermuth Company
(South Bend, IN), 0.2000 wt %)
PROCEDURE
1 - HEAT PART A TO 70° C. AND HOLD WITH AGITATION
2 - PRE-MELT PART B IN SEPARATE VESSEL AND HEAT TO 70° C.
3 - ADD PART B TO PART A WITH AGITATION
4 - COOL TO 35° C. AND ADD PART C IN ORDER
5 - ADJUST PH TO 5-6 WITH 50% CITRIC ACID IN DEIONIZED WATER
Examples 3-7
The following examples consist of compositions made via the procedure outlined in Examples 1 and 2 above.
PERCENT WT/WT
EXAMPLE
INGREDIENT
3
4
5
6
7
Guar Hydroxypropyltrimonium
1.0
—
3.0
—
1.0
Chloride
Polyquaternium 10
2.0
—
—
5.0
—
Polyquaternium 7
—
1.0
—
3.0
—
Polyvinyl Stearyl Ether
1.0
8.0
5.0
—
2.0
PVP/Eicosene Copolymer
8.0
4.0
—
1.0
—
Hydrogenated Castor Oil/Sebacic
—
—
—
—
5.0
Copolymer
Methionine
0.5
—
—
0.1
2.0
Cysteine
—
3.0
—
2.5
—
BHT
0.1
—
—
—
—
BHA
—
2.0
—
—
—
Sodium thiosulfate
0.3
—
—
—
—
Sodium metabisulfite
—
—
1.0
—
—
Sodium sulfite
—
0.1
—
—
—
Green tea extract
—
—
—
—
1.0
White tea extract
—
—
—
—
1.0
Polyphenols of plant origin 1
—
—
5.0
—
—
Tocopherol
0.1
—
0.5
1.0
0.5
Tocotrienols
—
0.3
1.0
—
—
Beta Carotene
—
—
—
2.0
—
Cosmetic Base (from Example 1)
87.0
81.6
84.5
85.4
87.5
1 Resveratrol commercially available from Arch Corporation (South Plainfield, NJ).
Example 8
Method of Application
A series of six measurements were taken on swimmers after 2-4 hours immersion in a swimming pool in North Carolina. The object was to determine the efficacy regarding control of residual chlorine on swimmers hair with and without pre-treatment using the composition of example 7 in the foregoing examples. The composition of 7 above was applied to the hair and rinsed using tap water prior to swimming. The amount of product was judged in relation to length and fullness of the hair. The controls received no pre-treatment prior to pool immersion. The pool pH together with total and free chlorine was monitored using indicator strips during the measurements for consistency. Results are shown below.
AVERAGES OF SIX MEASUREMENTS
Control
Pre-treated
Measurements
(no pre-treatment)
with Example 7
Pool pH
7.6
7.6
Pool total chlorine
3*
3
Pool free chlorine
3
3
Hair pH
7.7
6.5
Hair total chlorine
1.6
0
Hair free chlorine
0.33
0
*Scale for chlorine analysis: 1 - low, 2 - moderate, 3 - high
While the specification has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. Accordingly, the scope of the present invention should be assessed as that of the appended claims and any equivalents thereto. | Compositions for treating hair are disclosed. Methods of making and using compositions for treating hair are also disclosed. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of application Ser. No. 13/396,338, filed Feb. 14, 2012, which is a division of Ser. No. 11/809,133, filed May 30, 2007, now U.S. Pat. No. 8,148,011 issued Apr. 30, 2012, which claims the benefit of provisional application Ser. No. 60/809,478 filed May 31, 2006, each of which is incorporated herein by reference in its entirety.
CONTRACTUAL ORIGIN OF THE INVENTION
[0002] The United States Government has rights in this invention pursuant to Contract No. DE-AC02-06CH11357 between the United States Government and UChicago Argonne, LLC representing Argonne National Laboratory.
FIELD OF THE INVENTION
[0003] This invention relates to improved metal-oxide- and lithium-metal-oxide electrodes for lithium cells and batteries, notably rechargeable lithium-ion cells and batteries. These batteries are used to power a wide range of applications such as portable telecommunications equipment, computers, medical devices, electric vehicles and hybrid-electric vehicles. The invention relates preferably to lithium-metal-oxide electrodes with layered- and spinel-type structures that are chemically preconditioned prior to cell assembly or in situ in an electrochemical cell to improve the capacity, cycling efficiency and stability of lithium cells and batteries when charged to high potentials.
BACKGROUND OF THE INVENTION
[0004] State-of-the-art lithium-ion cells have a lithiated carbon negative electrode, or anode, (Li x C 6 ) and a lithium-cobalt-oxide positive electrode, or cathode, Li 1-x CoO 2 .
[0005] During charge and discharge of the cells, lithium ions are transported between the two host structures of the anode and cathode with the simultaneous oxidation or reduction of the host electrodes, respectively. When graphite is used as the anode, the voltage of the cell is approximately 4 V. The LiCoO 2 cathode, which has a layered structure, is expensive and becomes unstable at low lithium content, i.e., when cells reach an overcharged state at x>0.5. Alternative, less expensive electrode materials that are isostructural with LiCoO 2 , such as LiNi 0.8 Co 0.2 O 2 , LiNi 0.5 Mn 0.5 O 2 and LiMn 0.33 Ni 0.33 CO 0.33 O 2 are being developed with the hope of replacing at least part of the cobalt component of the electrode. However, these layered structures, when extensively delithiated become unstable, because of the high oxygen activity at the surface of the particles. Therefore, the delithiated electrode particles tend to react with the organic solvents of the electrolyte or lose oxygen. Such reactions at the surface of metal-oxide- and lithium-metal-oxide electrodes, in general, are detrimental to the performance of the lithium cells and batteries, and methods are required to combat these reactions to ensure that maximum capacity and cycle life can be obtained from the cells.
[0006] Several efforts have already been made in the past to overcome the stability and solubility problems associated with lithium-metal-oxide electrodes. For example, considerable success has been achieved by stabilizing electrodes by pre-treating the electrode powders with oxide additives such as Al 2 O 3 or ZrO 2 obtained from metal alkoxide precursors such as solutions containing aluminum ethylhexanoate diisopropoxide (Al(OOC 8 H 15 )(OC 3 H 7 ) 2 or zirconium ethylhexanoisopropoxide (Zr[(OOC 8 H 15 ) 2 (OCH 3 H 7 ) 2 ]) as described, for example, by J. Cho et al in Chemistry of Materials, Volume 12, page 3788 (2000) and J. Cho et al in Electrochemical and Solid State Letters, Volume 4 No. 10, page A159 (2001), respectively, or a zirconium oxide, polymeric precursor or zirconium oxynitrate (ZrO(NO 3 ) 2 .×H 2 O) as described by Z. Chen et al in Electrochemical and Solid State Letters, Volume 5, No. 10, page A213 (2002), prior to the fabrication of the final electrode thereby making the surface of the LiCoO 2 particles more resistant to electrolyte attack, cobalt dissolution or oxygen loss effects.
[0007] The loss of oxygen from lithium metal oxide electrodes, such as layered LiCoO 2 and LiNi 1-y Co y O 2 electrodes can contribute to exothermic reactions with the electrolyte and with the lithiated carbon negative electrode, and subsequently to thermal runaway if the temperature of the cell reaches a critical value. Although some success has been achieved in the past to improve the performance of lithium-ion cells by coating electrode particles, the coatings can themselves impede lithium diffusion in and out of the layered electrode structure during electrochemical discharge and charge. Further improvements in the composition of high potential metal-oxide- and lithium-metal oxide electrodes, particularly at the surface of the electrodes, and in methods to manufacture them are still required to improve the overall performance and safety of lithium cells.
[0008] Lithium metal oxides that have a spinel-type structure are alternative electrodes for commercial lithium-ion cells and batteries, notably those used in high-power applications. Of particular significance is the lithium-manganese-oxide spinel, LiMn 2 O 4 , and its cation-substituted derivatives, LiMn 2-x M x O 4 , in which M is one or more metal ions typically a monovalent or a multivalent cation such as Li + , Mg 2+ and Al 3+ , as reported by Gummow et al. in U.S. Pat. No. 5,316,877 and in Solid State Ionics, Volume 69, page 59 (1994). It is well known that LiMn 2 O 4 and LiMn 2-x M x O 4 spinel electrodes are chemically unstable in a lithium-ion cell environment, particularly at high potentials and/or when the cell operating temperature is raised above room temperature, when manganese ions from the spinel electrodes tend to dissolve in the electrolyte. This process is believed to contribute to the capacity loss of the cells at elevated temperatures. Moreover, the removal of all the lithium from LiMn 2 O 4 and LiMn 2-x M x O 4 electrodes yields a MnO 2 component, which itself is a strong oxidizing agent. The surface of such delithiated spinel electrodes can have a high oxygen activity, thereby possibly inducing unwanted oxidation reactions with the electrolyte. Although considerable progress has been made to suppress the solubility and high-temperature performance of spinel electrodes and to improve their stability by cation doping, as described for example by Gummow et al. in U.S. Pat. No. 5,316,877, or by forming oxyfluoride compounds as described by Amatucci et al. in the Journal of the Electrochemical Society, Volume 149, page K31 (2002) and by Choi et al. in Electrochemical and Solid-State Letters, Volume 9, page A245-A248 (2006), or by surface coatings as described by Kim et al. in the Journal of the Electrochemical Society, Volume 151, page A1755 (2004), these treatments have not yet entirely overcome the cycling instability of cells containing manganese-based spinel electrodes.
[0009] Furthermore, other metal-oxide- and lithium-metal-oxide electrode materials that are good oxidants are of interest for lithium batteries are known, for example, V 2 O 5 , and materials containing a V 2 O 5 component, such as LiV 3 O 8 and AgV 3 O 8 , that can be written alternatively in two-component notation as Li 2 O.3V 2 O 5 and Ag 2 O.V 2 O 5 , respectively, and Ag 2 V 4 O 11 that can be written alternatively in two-component notation as Ag 2 O.2V 2 O 5 . The silver-containing materials, notably Ag 2 V 4 O 11 , are of particular interest for primary lithium cells in medical devices such as cardiac defibrillators. In this case, a preconditioned electrode with a stable surface layer will help prolong the life of the cell, particularly if left standing in the charged state or partially charged state for long periods of time. The invention extends to include MnO 2 and MnO 2 -containing compounds which, like V 2 O 5 , are strong oxidants, such as Li 2 O.×MnO 2 and Ag 2 O.×MnO 2 (x>0) electrode compounds.
[0010] It is clear from the prior art that further advances are required, in general, to improve the surface stability of metal-oxide and lithium-metal-oxide electrodes for non-aqueous lithium cells and batteries. This invention relates to such improvements, notably those that are achieved from stabilized electrode surfaces that are engineered by preconditioning electrode particles with aqueous or, preferably, non-aqueous solutions in which the dissolved salts contain both stabilizing cations and anions. The invention relates more specifically to uncycled, preconditioned metal oxide- or lithium metal oxide electrodes, the electrodes being preconditioned in an aqueous or a non-aqueous solution containing stabilizing cations and anions, such that the stabilizing ions are etched into the electrode surface to form a protective layer. Methods of preconditioning the electrodes are disclosed as are electrochemical cells and batteries containing the electrodes.
SUMMARY OF THE INVENTION
[0011] This invention relates, in general, to improved metal-oxide and lithium-metal-oxide electrodes, including cathodes and/or anodes for lithium cells and batteries, preferably rechargeable lithium-ion cells and batteries. More specifically, the invention relates to metal-oxide and lithium-metal-oxide electrodes that are chemically preconditioned prior to cell fabrication and assembly or in situ in an electrochemical cell by treating the electrode particles with an aqueous or a non-aqueous solution containing dissolved salts of both stabilizing cations and anions. The invention relates more specifically to electrode particles with surfaces that are simultaneously etched and protected by the solutions, preferably, but not necessarily, mildly acidic solutions containing stabilizing ammonium, phosphorus, titanium, silicon, zirconium, aluminum and boron cations and fluoride anions, such as those found in NH 4 PF 6 , (NH 4 ) 2 TiF 6 , (NH 4 ) 2 SiF 6 , (NH 4 ) 2 ZrF 6 , (NH 4 ) 3 AlF 6 , NH 4 BF 4 or derivatives thereof, optionally in the presence of lithium ions to form a protective surface layer on the electrode particles, thereby improving the capacity, cycling efficiency and cycling stability of lithium cells and batteries when charged to high potentials. The invention relates, in particular, to high potential metal oxide- and lithium-metal oxide electrodes that in the charged state are strong oxidants, for example, those selected from the family of charged layered electrodes, Li 1-x MO 2 , and those derived from lithium-rich Li 1+z M 1−z O 2 compounds. Such lithium Li 1+z M 1−z O 2 compounds can also be represented in two-component notation as ×Li 2 M′O 3 .(1−x)LiMO 2 (0≦x<1) in which M′ is one or more metal ions with an average tetravalent oxidation state and in which M is one or more metal ions with an average trivalent oxidation state. It stands to reason that the invention will also apply to other high-potential metal oxide and lithium-metal oxide electrodes such as spinel lithium-metal-oxides, LiM 2 O 4 , in which M is one or more metal cations with an average oxidation state of 3.5. The spinel electrodes are selected preferably from the subset of substituted spinel lithium-manganese-oxides LiMn 2-y M y O 4 , and two-component ‘layered-spina’ ×Li 2 M′O 3 (1−x)LiM 2 O 4 (0≦x<1) composite electrodes in which M′ is one or more metal ions with an average tetravalent oxidation state, as described above. The invention also applies to the family of V 2 O 5 -containing compounds, such as V 2 O 5 itself, and lithium- and silver-derivative compounds such as LiV 3 O 8 (Li 2 O.3V 2 O 5 ) and Ag 2 V 4 O 11 (Ag 2 O.2V 2 O 5 ) and to MnO 2 , and MnO 2 -containing compounds, such as Li 2 O.×MnO 2 and Ag 2 O.×MnO 2 (x>0) electrode compounds. The invention extends to methods for synthesizing the preconditioned metal-oxide and lithium-metal-oxide electrodes.
[0012] The principles of the invention are demonstrated with respect to the following samples:
Sample A: untreated 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 . Sample B: Sample A treated with 0.86 wt % NH 4 F in methanol. Sample C: Sample A treated with 0.66 wt % NH 4 PF 6 in methanol. Sample D: Sample A treated with 0.76 wt % (NH 4 ) 3 AlF 6 in water. Sample E: Sample A treated with 1 wt % H 3 PO 4 +0.66 wt % NH 4 PF 6 in methanol. Sample F: Sample A treated with 0.61 wt % NH 4 BF 4 in methanol.
[0019] The molarity of the fluorinated salt solutions was approximately 2.5×10 −3 M in all cases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The invention consists of certain novel features hereinafter fully described, and illustrated in the accompanying drawings, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
[0021] FIG. 1 illustrates the powder X-ray diffraction patterns of (a) an untreated 0.1 Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 electrode (Sample A); (b) a 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 electrode treated with a 2 . 5 × 10 −3 M solution of NH 4 PF 6 in methanol and dried at 600° C. in air (Sample C); and (c) a 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 electrode treated with a 2.5×10 −3 M solution of (NH 4 ) 3 AlF 6 in water and dried at 600° C. in air (Sample D).
[0022] FIG. 2 illustrates the charge and discharge voltage profiles of lithium half cells after the initial charge/discharge cycle, containing electrode samples A to F between 3.0 and 4.6 Vat 0.1 mA/cm 2 at room temperature.
[0023] FIG. 3( a - f ) illustrates the charge and discharge voltage profiles of the 3rd and 42nd cycles of lithium half cells containing electrode samples A to F between 3.0 and 4.6 V at 0.5 mA/cm 2 at room temperature.
[0024] FIG. 4 illustrates the capacity vs. cycle number of lithium half cells containing electrode samples A-F, between 3.0 and 4.6 V for the first 42 cycles at room temperature.
[0025] FIG. 5 illustrates the capacity of lithium half cells containing electrode samples A-E delivered between 4.6 and 3.0 V at current rates between 0.16 and 8 mA at room temperature.
[0026] FIG. 6( a - e ) illustrates the charge and discharge voltage profiles of the 3rd and 102nd cycles of lithium-ion (full) cells containing electrode samples A, C, D, E and F between 3.0 and 4.6 V at 0.5 mA/cm 2 at room temperature.
[0027] FIG. 7 illustrates the capacity vs. cycle number of lithium half cells containing electrode samples A, C, D, E and F, between 3.0 and 4.6 V for the first 100 cycles at room temperature.
[0028] FIG. 8 illustrates a schematic representation of an electrochemical cell.
[0029] FIG. 9 illustrates a schematic representation of a battery consisting of a plurality of cells connected electrically in series and in parallel.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0030] Metal oxide- or lithium-metal-oxide electrodes that provide a high electrochemical potential, typically above 3 V, against lithium metal, such as oxides containing the first-row transition metal ions, V 5+ , Mn 4+ , Co 4+ and Ni 4+ ions tend to be strong oxidizing agents and therefore can react with the non-aqueous electrolytes of lithium cells, particularly at the surfaces of electrode particles. For example, highly delithiated layered Li 1-x MO 2 and spinel Li 1-x Mn 2-y M y O 4 electrodes can react spontaneously with the organic-based electrolyte solvents such as ethylene carbonate, diethyl carbonate or dimethyl carbonate; in extreme cases, the electrodes can release oxygen into the cell compartment that may cause possible thermal runaway, venting or explosion, sometimes with fire. Even without the catastrophic failure described above, the release of oxygen from the electrode lowers the average oxidation state of the electrochemically active transition metal ions, particularly at the electrode surface, which can increase cell impedance, and reduce the capacity and long term cycling stability of the cells. It is therefore important to find effective methods to reduce the high activity of charged metal-oxide- and lithium-metal-oxide electrode surfaces without compromising the energy and power of the cells, while at the same time enhancing safety.
[0031] This invention relates, in general, to uncycled preconditioned metal-oxide or lithium-metal-oxide electrodes, including cathodes and/or anodes for non-aqueous lithium electrochemical cells and batteries, the electrodes being preconditioned in an aqueous or, preferably, a non-aqueous solution containing stabilizing cations and anions, such as phosphorus, titanium, silicon, zirconium and aluminum cations and fluoride anions, that are chemically etched into the surface of the electrodes to form a protective layer in order to improve the electrochemical properties of said cells and batteries and to methods of making same. The invention relates, more specifically, to electrodes that are preconditioned prior to cell assembly or in situ in an electrochemical cell to improve the capacity, cycling efficiency and cycling stability of lithium cells and batteries when charged to high potentials. The invention relates, in particular, to metal oxide- and lithium-metal oxide electrode materials that in their unconditioned, charged state are strong oxidants.
[0032] In a first embodiment, the invention relates to preconditioned lithium-metal oxide electrodes selected from the family of layered compounds, LiMO 2 , including lithium-rich materials, Li 1+z M 1−z O 2 , that can be represented, alternatively, in two-component notation as ×Li 2 M′O 3 .(1−x)LiMO 2 (0≦x<1) in which M′ is one or more metal ions with an average tetravalent oxidation state, selected preferably from Mn, Ti, and Zr, and in which M is one or more metal ions with an average trivalent oxidation state, and M is selected preferably from Mg, Al, Ti, V, Cr, Mn, Fe, Co, and Ni.
[0033] In a second embodiment, the invention relates to preconditioned lithium-metal oxide electrodes selected from the family of spinel lithium-metal-oxides, LiM 2 O 4 , in which M is one or more metal cations, selected preferably from the subset of substituted spinel lithium-manganese-oxides LiMn 2-y M y O 4 , in which M is one or more metal ions selected preferably from Li, Mg, Al, Ti, V, Cr, Mn, Fe, Co, Ni, Cu and Zn, and two-component ×Li 2 M′O 3 .(1−x)LiM 2 O 4 (0≦x<1) composite electrodes in which M′ is one or more metal ions selected preferably from Mn, Ti, and Zr. The relative amounts of M′ and M cations are selected such that there is charge balance in the electrode. The ×Li 2 M′O 3 .(1−x)LiMO 2 and ×Li 2 M′O 3 .(1−x)LiM 2 O 4 (0≦x<1) composite electrodes have complex and disordered structures, as described in detail by Thackeray et al. in J. Materials Chemistry, Volume 15, page 2257, (2005) and references cited therein.
[0034] In a third embodiment, the invention relates to preconditioned metal-oxide- or lithium-metal-oxide electrodes from the family of V 2 O 5 -containing and MnO 2 -containing compounds, such as V 2 O 5 and MnO 2 themselves, and lithium and silver derivatives thereof, such as LiV 3 O 8 (Li 2 O.3V 2 O 5 ), Ag 2 V 4 O 11 (Ag 2 O.2V 2 O 5 ), Li 2 O.×MnO 2 and Ag 2 O.×MnO 2 (x>0) compounds.
[0035] In a fourth embodiment, the invention relates to methods for fabricating the preconditioned metal-oxide and lithium-metal-oxide electrodes by treating the metal-oxide- and lithium-metal-oxide electrode particles prior to cell fabrication and assembly with either an aqueous or a non-aqueous solution containing dissolved salts containing stabilizing cations and anions. In a preferred embodiment, the solutions are mildly acidic, for example, with a pH between 4 and 7, preferably between 5 and 7, and most preferably between 6 and 7. Because water reacts readily with lithium at the negative electrode and can result in undesirable H + —Li + ion-exchange reactions at lithium-metal-oxide electrodes, it is preferable to precondition the electrodes in non-aqueous solutions, such as alcohols, for example, methanol, ethanol and the like. Combinations of aqueous and non-aqueous solvents for dissolving the salts can be used, for example, methanol and water. If aqueous solutions are used, then it stands to reason that the electrodes must be sufficiently heated and dried to reduce the water content as much as possible without damaging the electrochemical properties of the electrode. The invention relates more specifically to preconditioned metal-oxide- and lithium-metal-oxide electrode particles with surfaces etched by solutions, preferably mildly acidic solutions with 4<pH<7, more preferably 5<pH<7, and most preferably 6<pH<7, the solutions containing stabilizing ammonium, phosphorus, titanium, silicon, zirconium, aluminum and boron cations and fluoride anions, such as those found in NH 4 PF 6 , (NH 4 ) 2 TiF 6 , (NH 4 ) 2 SiF 6 , (NH 4 ) 2 ZrF 6 , (NH 4 ) 3 AlF 6 , NH 4 BF 4 salts or derivatives thereof, to improve the capacity, cycling efficiency and cycling stability of lithium cells and batteries when charged to high potentials. These preconditioning reactions can take place optionally in the presence of lithium ions.
[0036] The following examples describe the principles of the invention and possible methods for synthesizing the pre-reduced electrodes of this invention as contemplated by the inventors, but they are not to be construed as limiting examples.
EXAMPLES
Synthesis of 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 and Preconditioned 0.1 Li 2 MnO 3 .0.9 LiCo 0.372 Ni 0.372 Mn 0.256 O 2 Electrode Materials
[0037] Electrode materials with the formula 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 are prepared typically as follows. First, a Mn 0.33 Ni 0.33 Co 0.33 (OH) x precursor is prepared by co-precipitation of the required stoichiometric amounts of metal nitrates M(NO 3 ) 2 .×H 2 O (M=Mn, Ni, and Co). Li 2 CO 3 is then intimately mixed with the (Mn 0.330 Ni 0.335 Co 0.335 )(OH) x (x approximately 2) precursor in a ratio of Li 2 CO 3 :(Mn 0.330 Ni 0.335 Co 0.335 )(OH) x =0.55:1 (or Li:(Mn+Ni+Co)=1.1:1). The powder mixture is calcined at 700° C. for 16 hours in air and then at 950° C. for 12 hours in air to make 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 .
[0038] For the experiments of this invention, parent 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 electrode samples, referred to as Sample A, were preconditioned prior to cell assembly with various mild acids. For example, Sample A was treated with a 2.5×10 −3 M NH 4 F solution in laboratory grade methanol containing trace amounts of water (typically up to 0.1%), the pH of which was approximately 6.5. The sample was stirred in the solution at room temperature for 12 hours and then dried (still under stirring) at about 50° C., prior to heating at 600° C. in air for 6 hours (Sample B).
[0039] In a second example, Sample A was treated with a 2.5×10 −3 M NH 4 PF 6 solution in laboratory grade methanol containing trace amounts of water (typically up to 0.1%), the pH of which was approximately 6.5. The sample was stirred in the solution at room temperature for 12 hours and then dried (still under stirring) at about 50° C., prior to heating at 600° C. in air for 6 hours (Sample C).
[0040] In a third example, Sample A was treated with a 2.5×10 −3 M (NH 4 ) 3 AlF 6 solution in water, the pH of which was approximately 6.5. The sample was stirred in the solution at room temperature for 12 hours and then dried (still under stirring) at about 50° C., prior to heating at 600° C. in air for 6 hours (Sample D).
[0041] In a fourth example, Sample A was treated with 1 wt % H 3 PO 4 aqueous solution together with a 2.5×10 −3 M NH 4 PF 6 solution in laboratory grade methanol containing trace amounts of water (typically up to 0.1%), the pH of which was approximately 6.5. The sample was stirred in the solution at room temperature for 12 hours and then dried (still under stirring) at approximately 50° C., prior to heating at 600° C. in air for 6 hours (Sample E).
[0042] In a fifth example, Sample A was treated with a 2.5×10 −3 M NH 4 BF 4 solution in laboratory grade methanol containing trace amounts of water (typically up to 0.1%), the pH of which was approximately 6.5. The sample was stirred in the solution at room temperature for 12 hours and then dried (still under stirring) at approximately 50° C., prior to heating at 600° C. in air for 6 hours (Sample F).
[0043] The X-ray diffraction patterns of Samples A, C and D are shown, by way of example, in FIG. 1( a - c ). There were no significant differences in the X-ray patterns of Samples A, C and D, indicating that no significant changes had occurred to the bulk structure of the individual compounds during the preconditioning reactions. The X-ray diffraction patterns of Samples B, E and F were essentially identical to those of Samples A, C and D.
[0000] Electrochemical Evaluation of 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 Electrodes and Preconditioned 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 Electrodes
[0044] Electrochemical evaluations of 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 electrodes and preconditioned 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 positive electrodes were carried out as follows. The electrodes for the lithium cells were fabricated from an intimate mixture of 84 wt % of 0.1 Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 electrode powder (or preconditioned 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 electrode powder), 8 wt % polyvinylidene difluoride (PVDF) polymer binder (KYNAR binder, Elf-Atochem), 4 wt % acetylene black (Cabot), and 4 wt % graphite (SFG-6, Timcal) slurried in 1-methyl-2-pyrrolidinone (NMP) (Aldrich, 99+%). An electrode laminate was cast from the slurry onto an Al current collector foil using a doctor-blade. The laminate was subsequently dried, first at 75° C. for 10 hours, and thereafter under vacuum at 70° C. for 12 hours. The electrolyte was 1 M LiPF 6 in ethylene carbonate (EC):ethylmethyl carbonate (EMC) (3:7 mixture). The electrodes were evaluated at room temperature in lithium half cells (coin-type, size CR2032, Hohsen) with a lithium foil counter electrode (FMC Corporation, Lithium Division) and a polypropylene separator (CELGARD 2400). They were also evaluated at room temperature in full, lithium-ion-type coin cells against a MCMB 1028 graphite electrode. Cells were assembled inside an argon-filled glovebox (<5 ppm, H 2 O and O 2 ) and cycled on a MACCOR Series 2000 tester under galvanostatic mode using a constant current density initially of 0.1 mA/cm 2 for the first two cycles and, thereafter, at a higher current rate of 0.5 mA/cm 2 . Lithium half cells were cycled between 4.6 and 3.0 V, whereas lithium-ion full cells were cycled between 4.5 and 3.0 V.
[0045] The charge/discharge voltage profiles of lithium half cells after the initial charge/discharge cycle containing an untreated 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 electrode (Sample A) and 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 electrodes that had been preconditioned with mildly acidic solutions containing various stabilizing cations and stabilizing fluorine anions (Samples B-F) are shown in FIG. 2( a - f ), respectively. The figure demonstrates unequivocally that the initial discharge capacities of the preconditioned electrodes (Samples B to E) are superior to that of the parent, unconditioned electrode (Sample A).
[0046] The charge and discharge voltage profiles of the 3rd and 42nd cycles of lithium half cells containing electrode samples A to F between 4.6 and 3.0 V at 0.5 mA/cm 2 at room temperature are shown in FIG. 3( a - f ), respectively. It is clear from these data that the preconditioned electrodes (Samples B to F) provide enhanced capacity compared to the parent, untreated electrode (Sample A).
[0047] The cycling stability of untreated electrode (Sample A) and preconditioned electrodes (Samples B-F) in lithium half cells are compared graphically in capacity vs. cycle number plots in FIG. 4 . It is clearly evident from the data that the preconditioned electrodes provide significantly superior capacity and cycling stability to the parent, untreated electrode. The data also show that slightly superior cycling stability is achieved from samples C, D, E and F that had been preconditioned with solutions containing stabilizing P, Al, and B cations as well as NH 4 cations and stabilizing F anions, compared to Sample B that had been preconditioned with NH 4 F. In this respect, it is noted that any basic ammonium or residual nitrogen-containing species will likely remain on the surface of the electrodes and may serve to counter acid attack from the electrolyte, rather than being etched into the electrode surface as occurs with the P, Al and B cations that stabilize the electrode surface structure.
[0048] The capacity delivered by Samples A-E as a function of current rate is shown in FIG. 5 . These data also clearly demonstrate the superior electrochemical properties of the preconditioned electrodes (Samples B-E) that are able to withstand higher current discharge rates than the parent, untreated electrode (Sample A).
[0049] The charge and discharge voltage profiles of the 3rd and 102nd cycles of lithium-ion (full) cells containing electrode samples A, C, D, E and F between 4.5 and 3.0 V at 0.5 mA/cm 2 at room temperature are shown in FIG. 6( a - e ), respectively; corresponding capacity vs. cycle number plots for the full 102 cycles are shown in FIG. 7 . They demonstrate that significantly improved capacity is obtained from cells containing the preconditioned electrodes (Samples C—F) compared to the parent, untreated electrode (Sample A); moreover, the lithium-ion cells containing the preconditioned electrodes of the invention cycle with excellent capacity retention/stability.
Electrolyte Additives
[0050] In a further embodiment of the invention, it was discovered that instead of chemically preconditioning the electrodes with acid prior to cell assembly, the electrodes can be chemically conditioned, in situ, in an electrochemical lithium cell by salts containing one or more cations of ammonium, phosphorus, titanium, silicon, zirconium, aluminum and boron cations and stabilizing fluoride anions, for example, NH 4 PF 6 , (NH 4 ) 2 TiF 6 , (NH 4 ) 2 SiF 6 , (NH 4 ) 2 ZrF 6 , (NH 4 ) 3 AlF 6 and NH 4 BF 4 . Two lithium-ion cells were assembled containing an MCMB 1028 graphite anode, a 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 cathode and an electrolyte comprising 1.2 M LiPF 6 in ethylene carbonate (EC): ethylmethyl carbonate (EMC). One of the cells contained 2 wt % NH 4 BF 4 as an additive to chemically precondition the cathode surface in situ in the electrochemical cell. The two cells were subjected to 3 formation cycles during which the cells were charged and discharged between 4.1 and 3.0 V at approximately 0.2 mA (approximately C/10 rate). The cells were subsequently cycled and aged at an accelerated rate between 3.9 and 3.6 V at 55° C. at 2 mA (approximately C/1 rate) for 2 weeks. The impedance of each cell was measured before and after the aging process at 3.72 V at room temperature. It was observed that the impedance growth of the cathode in the cell containing the NH 4 BF 4 electrolyte additive was significantly suppressed during the aging process, thereby providing evidence that the cathode surface had been passivated, confirming the beneficial effects of preconditioning the electrodes of this invention with mild acid, as described hereinbefore.
[0051] The examples and results described in this application clearly demonstrate the principles and advantages of this invention. It has been shown, in particular, that superior electrochemical properties, for example, enhanced capacity and cycling stability, can be obtained from 0.1Li 2 MnO 3 .0.9LiCo 0.372 Ni 0.372 Mn 0.256 O 2 electrodes that are preconditioned in aqueous or non-aqueous solutions containing both stabilizing cations and anions, such as phosphorus, aluminum and boron cations and fluoride anions as well as ammonium ions, particularly when cells are cycled between 4.6 and 3.0 V. The superior electrochemical properties are attributed particularly to etched electrode surfaces that contain both stabilizing cations and anions, the stabilized surface layer being robust to the diffusion of lithium ions from the electrode/electrolyte interface into the bulk of the electrode structure and vice versa To those skilled in the art, it is easy to recognize that the principles of this invention in forming protective surfaces can be extended to other high potential metal-oxide and lithium-metal-oxide electrodes, such as the family of lithium-manganese-oxide spinels and V 2 O 5 -based or MnO 2 -based electrode materials, as described herein. This invention therefore relates to preconditioned metal-oxide and lithium-metal-oxide electrodes for both primary and secondary (rechargeable) lithium cells, a typical cell being shown schematically in FIG. 8 , represented by the numeral 10 having a negative electrode 12 separated from a positive electrode 16 by an electrolyte 14 , all contained in an insulating housing 18 with suitable terminals (not shown) being provided in electronic contact with the negative electrode 12 and the positive electrode 16 . Binders and other materials normally associated with both the electrolyte and the negative and positive electrodes are well known in the art and are not fully described herein, but are included as is understood by those of ordinary skill in this art. FIG. 9 shows a schematic illustration of one example of a battery in which two strings of electrochemical lithium cells, described above, are arranged in parallel, each string comprising three cells arranged in series. The invention also includes methods of making the preconditioned electrodes, cells and batteries including the same.
[0052] While there has been disclosed what is considered to be the preferred embodiments of the present invention, it is understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention. It is also understood that additional improvements in the capacity and stability of the electrodes can be expected to be made in the future by improving and optimizing the processing techniques whereby metal-oxide and lithium-metal-oxide electrode materials are chemically etched in an aqueous or a non-aqueous solution containing stabilizing cations and anions to form a protective layer prior to their incorporation as electrodes in electrochemical lithium cells. | A stabilized electrode comprising a metal oxide or lithium-metal-oxide electrode material is formed by contacting a surface of the electrode material, prior to cell assembly, with an aqueous or a non-aqueous acid solution having a pH greater than 4 but less than 7 and containing a stabilizing salt, to etch the surface of the electrode material and introduce stabilizing anions and cations from the salt into said surface. The structure of the bulk of the electrode material remains unchanged during the acid treatment. The stabilizing salt comprises fluoride and at least one cationic material selected from the group consisting of ammonium, phosphorus, titanium, silicon, zirconium, aluminum, and boron. | 2 |
RELATED APPLICATIONS
[0001] This application is based on, and claims the benefit of, U.S. Provisional Application No. 60/354,425, filed Feb. 4, 2002 and which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a method for stimulating the growth of mammalian hair comprising the application to mammalian skin of a cyclopentane heptanoic acid, 2-cycloalkyl or arylalkyl derivative or a pharmacologically acceptable acid addition salt thereof, alone, or in association with a topical pharmaceutical carrier.
BACKGROUND OF THE INVENTION
[0003] Dermatologists recognize many different types of hair loss, the most common by far being “alopecia” wherein human males begin losing scalp hair at the temples and on the crown of the head as they get older. While this type of hair loss is largely confined to males, hence its common name “male pattern baldness,” it is not unknown in women. No known cure has yet been found despite continuing attempts to discover one.
[0004] A good deal is known about various types of human hair and its growth patterns on various parts of the body.
[0005] For purposes of the present invention, it is necessary to consider various types of hair, including, terminal hairs and vellus hairs and modified terminal hairs, such as seen in eye lashes and eye brows. Terminal hairs are coarse, pigmented, long hairs in which the bulb of the hair follicle is seated deep in the dermis. Vellus hairs, on the other hand, are fine, thin, non-pigmented short hairs in which the hair bulb is located superficially in the dermis. As alopecia progresses, a transition takes place in the area of approaching baldness wherein the hairs themselves are changing from the terminal to the vellus type.
[0006] Another factor that contributes to the end result is a change in the cycle of hair growth. All hair, both human and animal, passes through a life cycle that includes three phases, namely, the anagen phase, the catagen phase and the telogen phase. The anagen phase is the period of active hair growth and, insofar as scalp hair is concerned, this generally lasts from 3-5 years. The catagen phase is a short transitional phase between the anagen and telogen phases which, in the case of scalp hair, lasts only 1-2 weeks. The final phase is the telogen phase which, for all practical purposes, can be denominated a “resting phase” where all growth ceases and the hair eventually is shed preparatory to the follicle commencing to grow a new one. Scalp hair in the telogen phase is also relatively short-lived, some 3-4 months elapsing before the hair is shed and a new one begins to grow.
[0007] Under normal hair growth conditions on the scalp, approximately 88% of the hairs are in the anagen phase, only 1% in catagen and the remainder in telogen. With the onset of male pattern baldness, a successively greater proportion of the hairs are in the telogen phase with correspondingly fewer in the active growth anagen phase.
[0008] Alopecia is associated with the severe diminution of hair follicles. A bald human subject will average only about 306 follicles per square centimeter, whereas, a non-bald human in the same age group will have an average of 460 follicles per square centimeter. This amounts to a one-third reduction in hair follicles which, when added to the increased proportion of vellus hair follicles and the increased number of hair follicles in the telogen phase, is both significant and noticeable. Approximately 50% of the hairs must be shed to produce visible thinning of scalp hair. It is thus a combination of these factors: transition of hairs from terminal to vellus, increased number of telogen hairs—some of which have been shed, and loss of hair follicles that produces “baldness”.
[0009] While a good deal is known about the results of male pattern baldness, very little is known about its cause. The cause is generally believed to be genetic and hormonal in origin although, the known prior art attempts to control it through hormone adjustment have been singularly unsuccessful.
[0010] One known treatment for male pattern alopecia is hair transplantation. Plugs of skin containing hair are transplanted from areas of the scalp where hair is growing to bald areas with reasonable success; however, the procedure is a costly one in addition to being time-consuming and quite painful. Furthermore, the solution is inadequate from the standpoint that it becomes a practical, if not an economic, impossibility to replace but a tiny fraction of the hair present in a normal healthy head of hair.
[0011] Other non-drug related approaches to the problem include such things as ultra-violet radiation, massage, psychiatric treatment and exercise therapy. None of these, however, has been generally accepted as being effective. Even such things as revascularization surgery and acupuncture have shown little, if any, promise.
[0012] By far, the most common approach to the problem of discovering a remedy for hair loss and male pattern alopecia has been one of drug therapy. Many types of drugs ranging from vitamins to hormones have been tried and only recently has there been any indication whatsoever of even moderate success. For instance, it was felt for a long time that since an androgenic hormone was necessary for the development of male pattern baldness, that either systemic or topical application of an antiandrogenic hormone would provide the necessary inhibiting action to keep the baldness from occurring. The theory was promising but the results were uniformly disappointing.
[0013] The androgenic hormone testosterone was known, for example, to stimulate hair growth when applied topically to the deltoid area as well as when injected into the beard and pubic regions. Even oral administration was found to result in an increased hair growth in the beard and pubic areas as well as upon the trunk and extremities. While topical application to the arm causes increased hair growth, it is ineffective on the scalp and some thinning may even result. Heavy doses of testosterone have even been known to cause male pattern alopecia.
[0014] Certain therapeutic agents have been known to induce hair growth in extensive areas of the trunk, limbs and even occasionally on the face. Such hair is of intermediate status in that it is coarser than vellus but not as coarse as terminal hair. The hair is generally quite short with a length of 3 cm. being about maximum. Once the patient ceases taking the drug, the hair reverts to whatever is normal for the particular site after six months to a year has elapsed. An example of such a drug is diphenylhydantoin which is an anticonvulsant drug widely used to control epileptic seizures. Hypertrichosis is frequently observed in epileptic children some two or three months after starting the drug and first becomes noticeable on the extensor aspects of the limbs and later on the trunk and face. (The same pattern of hypertrichosis is sometimes caused by injury to the head.) As for the hair, it is often shed when the drug is discontinued but may, in some circumstances, remain.
[0015] Streptomycin is another drug that has been found to produce hypertrichosis, in much the same way as diphenylhydantoin, when administered to children suffering from tuberculous meningitis. About the same effects were observed and the onset and reversal of the hypertrichosis in relation to the period of treatment with the antibiotic leave little question but that it was the causative agent.
[0016] Two treatments have been demonstrated as showing some promise in reversing male pattern alopecia. These treatments include the use of a microemulsion cream containing both estradiol and oxandrolone as its active ingredients and the use of organic silicon.
[0017] In addition to the foregoing, it has been reported in U.S. Pat. Nos. 4,139,619 and 4,968,812 that the compound minoxidil is useful for the treatment of male pattern baldness. That compound, among others, has proven to have considerable therapeutic value in the treatment of severe hypertension. It is a so-called “vasodilator” which, as the name implies, functions to dilate the peripheral vascular system. Dermatologists and others have recognized that prolonged vasodilation of certain areas of the human body other than the scalp sometimes result in increased hair growth even in the absence of any vasodilating therapeutic agent. For instance, increased hair growth around surgical scars is not uncommon. Similarly, arteriovenous fistula have been known to result in increased vascularity accompanied by enhanced hair growth. Externally-induced vasodilation of the skin, such as, for example, by repeated biting of the limbs by the mentally retarded and localized stimulation of the shoulders by water carries has been known to bring on hypertrichosis in the affected areas. Be that as it may, similar techniques such as continued periodic massage of the scalp have been found to be totally ineffective as a means for restoring lost hair growth to the scalp. Scar tissue on the scalp inhibits rather than promotes hair growth.
[0018] U.S. Pat. No. 6,262,105 to Johnstone suggests that prostaglandins and derivatives thereof are useful in a method of enhancing hair growth.
[0019] Bimatoprost, which is sold by Allergan, Inc. of Irvine, Calif., U.S.A. as Lumigan® ophthalmic solution, for treating glaucoma now has been found as being effective to increase the growth of eyelashes when applied in the FDA approved manner.
[0020] It is, therefore, a principal object of the present invention to provide a novel and effective treatment for the stimulation of hair growth and the treatment of male pattern baldness.
[0021] Another object of the invention is to provide a method of stimulating hair growth in humans and non-human animals that is compatible with various types of therapeutic agents or carriers and, therefore, would appear to be combinable with those which, by themselves, demonstrate some therapeutic activity such as, for example, microemulsion creams or topical compositions containing estradiol and oxandrolone, minoxidil or agents that block the conversion of testosterone to dihydrotesterone (Procipia).
[0022] Still another objective is the provision of a treatment for the stimulation of hair growth which, while effective for its intended purpose, is apparently non-toxic and relatively free of unwanted side effects.
[0023] An additional object of the invention herein disclosed and claimed is to provide a method for treating hair loss in men or women which can be applied by the patient under medical supervision no more stringent than that demanded for other topically-administered therapeutic agents.
[0024] Other objects of the invention are to provide a treatment for male pattern alopecia which is safe, simple, painless, cosmetic in the sense of being invisible, easy to apply and quite inexpensive when compared with hair transplants and the like.
SUMMARY OF THE INVENTION
[0025] This invention provides pharmaceutical compositions for topical application to enhance hair growth comprising an effective amount of a cyclopentane heptanoic acid, 2-cycloalkyl or arylalkyl compound represented by the formula I
wherein the dashed bonds represent a single or double bond which can be in the cis or trans configuration, A is an alkylene or alkenylene radical having from two to six carbon atoms, which radical may be interrupted by one or more oxa radicals and substituted with one or more hydroxy, oxo, alkyloxy or akylcarboxy groups wherein said alkyl radical comprises from one to six carbon atoms; B is a cycloalkyl radical having from three to seven carbon atoms, or an aryl radical, selected from the group consisting of hydrocarbyl aryl and heteroaryl radicals having from four to ten carbon atoms wherein the heteroatom is selected from the group consisting of nitrogen, oxygen and sulfur atoms; X is —N(R 4 ) 2 wherein R 4 is selected from the group consisting of hydrogen, a lower alkyl radical having from one to six carbon atoms,
wherein R 5 is a lower alkyl radical having from one to six carbon atoms; Z is ═O; one of R 1 and R 2 is ═O, —OH or a —O(CO)R 6 group, and the other one is —OH or —O(CO)R 6 , or R 1 is ═O and R 2 is H, wherein R 6 is a saturated or unsaturated acyclic hydrocarbon group having from 1 to about 20 carbon atoms, or —(CH 2 )mR 7 wherein m is 0 or an integer of from 1 to 10, and R 7 is cycloalkyl radical, having from three to seven carbon atoms, or a hydrocarbyl aryl or heteroaryl radical, as defined above in free form or a pharmaceutically acceptable salt thereof, in association with a pharmaceutical carrier adapted for topical application to mammalian skin.
[0026] Preferably, the compound is a cyclopentane heptanoic acid, 2-(phenyl alkyl or phenyloxyalkyl) represented by the formula II
wherein y is 0 or 1, x is 0 or 1 and x and y are not both 1, Y is a radical selected from the group consisting of alkyl, halo, e.g. fluoro, chloro, etc., nitro, amino, thiol, hydroxy, alkyloxy, alkylcarboxy, halo substituted alkyl wherein said alkyl radical comprises from one to six carbon atoms, etc. and n is 0 or an integer of from 1 to 3 and R 3 is ═O, —OH or —O(CO)R 6 wherein R 6 is as defined above or a pharmaceutically acceptable salt thereof.
[0027] More preferably the compound is a compound of formula III.
wherein hatched lines indicate α configuration, solid triangles are used to indicate β configuration.
[0028] More preferably y is 1 and x is 0 and R 1 , R 2 and R 3 are hydroxy.
[0029] Most preferably the compound is cyclopentane N-ethyl heptanamide-5-cis-2-(3α-hydroxy-5-phenyl-1-trans-pentenyl)-3,5-dihydroxy, [1 α ,2 β ,3 α ,5 α ], also known as bimatoprost.
[0030] Another aspect of the invention provides methods for stimulating the rate of hair growth and for stimulating the conversion of vellus hair or intermediate hair to growth as terminal hair in a human or non-human animal by administering to the skin of the animal an effective amount of a compound wherein the compound has the formula:
wherein the dashed bonds represent a single or double bond which can be in the cis or trans configuration, A is an alkylene or alkenylene radical having from two to six carbon atoms, which radical may be interrupted by one or more oxa radicals and substituted with one or more hydroxy, oxo, alkyloxy or akylcarboxy groups wherein said alkyl radical comprises from one to six carbon atoms; B is a cycloalkyl radical having from three to seven carbon atoms, or an aryl radical, selected from the group consisting of hydrocarbyl aryl and heteroaryl radicals having from four to ten carbon atoms wherein the heteroatom is selected from the group consisting of nitrogen, oxygen and sulfur atoms; X is —N(R 4 ) 2 wherein R 4 is selected from the group consisting of hydrogen, a lower alkyl radical having from one to six carbon atoms,
wherein R 5 is a lower alkyl radical having from one to six carbon atoms; Z is ═O; one of R 1 and R 2 is ═O, —OH or a —O(CO)R 6 group, and the other one is —OH or —O(CO)R 6 , or R 1 is ═O and R 2 is H, wherein R 6 is a saturated or unsaturated acyclic hydrocarbon group having from 1 to about 20 carbon atoms, or —(CH 2 )mR 7 wherein m is 0 or an integer of from 1 to 10, and R 7 is cycloalkyl radical, having from three to seven carbon atoms, or a hydrocarbyl aryl or heteroaryl radical, as defined above in free form or a pharmaceutically acceptable salt thereof.
[0031] These and other aspects of the invention will become apparent from the description of the invention which follows below.
BRIEF DESCRIPTION OF THE DRAWING FIGURE
[0032] The FIGURE shows the effect on the eyelashes of one patient treated for glaucoma with Lumigan® bimatoprost for six months.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] Alopecia (baldness) a deficiency of either normal or abnormal hair, is primarily a cosmetic problem in humans. It is a deficiency of terminal hair, the broad diameter, colored hair that is readily seen. However, in the so-called bald person although there is a noticeable absence of terminal hair, the skin does contain vellus hair which is a fine colorless hair which may require microscopic examination to determine its presence. This vellus hair is a precursor to terminal hair. In accordance with the invention as described herein, compounds represented by
wherein R 1 , R 2 , A, B, Z and X are defined above, can be used to stimulate, such as stimulating the conversion of vellus hair to growth as terminal hair as well as increasing the rate of growth of terminal hair.
[0034] The present invention was discovered as follows:
[0035] In the course of treating patients having glaucoma, treatment may only be appropriate in one eye. Within the course of daily practice it was discovered that a patient who been treated with bimatoprost has lashes that were longer, thicker and fuller in the treated eye than in the non-treated eye. On examination the difference was found to be very striking. The lashes were longer and had a more full dense appearance in the treated eye. The lash appearance on the lids of the treated eye would have appeared quite attractive if it represented a bilateral phenomenon. Because of its asymmetric nature, the long lashes on one side could be construed as disturbing from a cosmetic standpoint. Because of the very unusual appearance a systematic examination of other patients who were taking bimatoprost in only one eye was made. It soon became apparent that this altered appearance was not an isolated finding. Comparison of the lids of patients who were taking bimatoprost in only one eye revealed subtle changes in the lashes and adjacent hairs of the bimatoprost-treated side in several patients. Definite differences could be identified to varying degrees in the lashes and adjacent hairs of all patients who were taking the drug on a unilateral basis for longer than 6 months.
[0036] These findings were totally unexpected and surprising. Minoxidil is thought to stimulate hair growth by its ability to cause vasodilation suggesting that agents with such a capability may be uniquely effective in stimulating hair growth. The finding that bimatoprost, which, as explained below, is not a prostaglandin derivative, such as latanoprost stimulates hair growth is especially surprising and unexpected.
[0037] The changes in the lashes were apparent on gross inspection in several patients once attention was focused on the issue. In those with light colored hair and lashes, the differences were only seen easily with the aid of the high magnification and lighting capabilities of the slit lamp biomicroscope. In the course of a glaucoma follow up examination, attention is generally immediately focused on the eye itself. Because of the high power magnification needed only one eye is seen at a time and the eye is seen at a high enough power that the lashes are not in focus. At these higher powers, any lash asymmetry between the two eyes is not likely to be noticed except by careful systematic comparison of the lashes and adjacent hairs of the eyelids of the two eyes.
[0038] Observed parameters leading to the conclusion that more robust hair growth occurred in the treated area following administration of bimatroprost were multiple. They included increased length of lashes, increased numbers of lashes along the normal lash line, increased thickness and luster of lashes, increased auxiliary lash-like terminal hair in transitional areas adjacent to areas of normal lash growth, increased lash-like terminal hairs at the medial and lateral canthal area, increased pigmentation of the lashes, increased numbers, increased length, as well as increased luster, and thickness of fine hair on the skin of the adjacent lid, and finally increased perpendicular angulation of lashes and lash-like terminal hairs. The conclusion that hair growth is stimulated by bimatoprost is thus supported not by evidence of a difference in a single parameter but is based on multiple parameters of hair appearance in treated vs. control areas in many subjects. This finding is entirely unexpected and represents a previously unrecognized effect of bimatoprost on stimulation of hair follicles. The modified hairs of the lashes normally turn over slowly and are in their resting phase longer than hair on, for example, the scalp. The ability to cause differences in appearance of lashes, the ability to stimulate conversion of vellus or intermediate hair to terminal hairs in transitional areas and the ability to stimulate growth of vellus hair on the skin indicates that bimatoprost is a diversely effective and efficacious agent for the stimulation of hair growth. Thus, the present invention provides a treatment by bimatoprost of hair of the scalp, eyebrows, beard and other areas that contain hair that results in increased hair growth in the corresponding areas.
[0039] Patients that are treated in or around the eye with compounds of the invention, such as bimatoprost, regularly develop hypertrichosis including altered differentiation, numbers, length, thickness, curvature and pigmentation in the region of treatment.
[0040] Some examples of representative compounds useful in the practice of the present invention include the compounds shown in Table 1:
TABLE 1 cyclopentane heptenamide-5-cis-2-(3α-hydroxy-5-phenyl-1-trans-pentenyl)-3,5-dihydroxy, [1 α , 2 β , 3 α , 5 6 α] cyclopentane N,N-dimethylheptenamide-5-cis-2-(3α-hydroxy-5-phenyl-1-trans- pentenyl)-3,5-dihydroxy, [1 α , 2 β , 3 α , 5 α ] cyclopentane heptenylamide-5-cis-2-(3α-hydroxy-4-meta-chlorophenoxy-1-trans- pentenyl)-3,5-dihydroxy, [1 α , 2 β , 3 α , 5 α ] cyclopentane heptenylamide-5-cis-2-(3α-hydroxy-4-trifluoromethylphenoxy-1- trans-pentenyl)-3,5-dihydroxy, [1 α , 2 β , 3 α , 5 α ] cyclopentane N-isopropyl heptenamide-5-cis-2-(3α-hydroxy-5-phenyl-1-trans- pentenyl)-3,5-dihydroxy, [1 α , 2 β , 3 α , 5 α ] cyclopentane N-ethyl heptenamide-5-cis-2-(3α-hydroxy-5-phenyl-1-trans- pentenyl)-3,5 dihydroxy, [1 α , 2 β , 3 α , 5 α ] cyclopentane N-methyl heptenamide-5-cis-2-(3α-hydroxy-5-phenyl-1-trans- pentenyl)-3,5-dihydroxy, [1 α , 2 β , 3 α , 5 α ] cyclopentane heptenamide-5-cis-2-(3α-hydroxy-4-meta-chlorophenoxy-1-trans- butenyl)-3,5-dihydroxy, [1 α , 2 β , 3 α , 5 α ]
[0041] One presently preferred compound for use in the practice of the present invention is cyclopentane N-ethyl heptanamide-5-cis-2-(3α-hydroxy-5-phenyl-1-trans-pentenyl)-3,5-dihydroxy, [1 α ,2 β ,3 α ,5 α ], also known as bimatoprost and sold under the name of Lumigan® by Allergan, Inc., California, USA. This compound has the following structure:
[0042] The synthesis of the above compounds described above has been disclosed in U.S. Pat. No. 5,607,978. This patent also shows, particularly in Examples 1, 2, 5 and 7 that these compounds are not prostaglandins, in that they do not behave as prostaglandins in art-recognized assays for prostaglandin activity. The invention thus relates to the use of the above compounds, or prodrugs of the active compounds, for treatment for the stimulation of hair growth. As used herein, hair growth includes hair associated with the scalp, eyebrows, eyelids, beard, and other areas of the skin of animals.
[0043] In accordance with one aspect of the invention, the compound is mixed with a dermatologically compatible vehicle or carrier. The vehicle which may be employed for preparing compositions of this invention may comprise, for example, aqueous solutions such as e.g., physiological salines, oil solutions or ointments. The vehicle furthermore may contain dermatologically compatible preservatives such as e.g., benzalkonium chloride, surfactants like e.g., polysorbate 80, liposomes or polymers, for example, methyl cellulose, polyvinyl alcohol, polyvinyl pyrrolidone and hyaluronic acid; these may be used for increasing the viscosity. Furthermore, it is also possible to use soluble or insoluble drug inserts when the drug is to be administered.
[0044] The invention is also related to dermatological compositions for topical treatment for the stimulation of hair growth which comprise an effective hair growth stimulating amount of one or more compounds as defined above and a dermatologically compatible carrier. Effective amounts of the active compounds may be determined by one of ordinary skill in the art but will vary depending on the compound employed, frequency of application and desired result, and the compound will generally range from about 0.0000001 to about 50%, by weight, of the dermatological composition, preferably from about 0.001 to about 50%, by weight, of total dermatological composition, more preferably from about 0.1 to about 30%, by weight of the composition.
[0045] The present invention finds application in all mammalian species, including both humans and animals. In humans, the compounds of the subject invention can be applied for example, to the scalp, face, beard, head, pubic area, upper lip, eyebrows, and eyelids. In animals raised for their pelts, e.g., mink, the compounds can be applied over the entire surface of the body to improve the overall pelt for commercial reasons. The process can also be used for cosmetic reasons in animals, e.g., applied to the skin of dogs and cats having bald patches due to mange or other diseases causing a degree of alopecia.
[0046] The pharmaceutical compositions contemplated by this invention include pharmaceutical compositions suited for topical and local action.
[0047] The term “topical” as employed herein relates to the use of a compound, as described herein, incorporated in a suitable pharmaceutical carrier, and applied at the site of thinning hair or baldness for exertion of local action. Accordingly, such topical compositions include those pharmaceutical forms in which the compound is applied externally by direct contact with the skin surface to be treated. Conventional pharmaceutical forms for this purpose include ointments, liniments, creams, shampoos, lotions, pastes, jellies, sprays, aerosols, and the like, and may be applied in patches or impregnated dressings depending on the part of the body to be treated. The term “ointment” embraces formulations (including creams) having oleaginous, water-soluble and emulsion-type bases, e.g., petrolatum, lanolin, polyethylene glycols, as well as mixtures of these.
[0048] Typically, the compounds are applied repeatedly for a sustained period of time topically on the part of the body to be treated, for example, the eyelids, eyebrows, skin or scalp. The preferred dosage regimen will generally involve regular, such as daily, administration for a period of treatment of at least one month, more preferably at least three months, and most preferably at least six months.
[0049] For topical use on the eyelids or eyebrows, the active compounds can be formulated in aqueous solutions, creams, ointments or oils exhibiting physiologically acceptable osmolarity by addition of pharmacologically acceptable buffers and salts. Such formulations may or may not, depending on the dispenser, contain preservatives such as benzalkonium chloride, chlorhexidine, chlorobutanol, parahydroxybenzoic acids and phenylmercuric salts such as nitrate, chloride, acetate, and borate, or antioxidants, as well as additives like EDTA, sorbitol, boric acid etc. as additives. Furthermore, particularly aqueous solutions may contain viscosity increasing agents such as polysaccharides, e.g., methylcellulose, mucopolysaccharides, e.g., hyaluronic acid and chondroitin sulfate, or polyalcohol, e.g., polyvinylalcohol. Various slow releasing gels and matrices may also be employed as well as soluble and insoluble ocular inserts, for instance, based on substances forming in-situ gels. Depending on the actual formulation and compound to be used, various amounts of the drug and different dose regimens may be employed. Typically, the daily amount of compound for treatment of the eyelid may be about 0.1 ng to about 100 mg per eyelid.
[0050] For topical use on the skin and the scalp, the compound can be advantageously formulated using ointments, creams, liniments or patches as a carrier of the active ingredient. Also, these formulations may or may not contain preservatives, depending on the dispenser and nature of use. Such preservatives include those mentioned above, and methyl-, propyl-, or butyl-parahydroxybenzoic acid, betain, chlorhexidine, benzalkonium chloride, and the like. Various matrices for slow release delivery may also be used. Typically, the dose to be applied on the scalp is in the range of about 0.1 ng to about 100 mg per day, more preferably about 1 ng to about 10 mg per day, and most preferably about 10 ng to about 1 mg per day depending on the compound and the formulation. To achieve the daily amount of medication depending on the formulation, the compound may be administered once or several times daily with or without antioxidants.
[0051] The invention is further illustrated by the following non-limiting examples:
EXAMPLE 1
[0000] In Vivo Treatment
[0052] A study is initiated to systematically evaluate the appearance of lashes and hair around the eyes of patients who are administering bimatoprost in only one eye. The study involves 10 subjects, 5 male, 5 female, average age 70 years, (ranging from 50-94 years). All patients have glaucoma. Each subject is treated daily by the topical application of one drop of bimatoprost at a dosage of 1.5.mu.g/ml/eye/day (0.03%, by weight, ophthalmic solution, sold under the name Lumigan® by Allergan, Irvine, Calif., U.S.A.) to the region of one eye by instilling the drop onto the surface of the eye. The region of the fellow control eye is not treated with bimatoprost and served as a control.
[0053] In the course of treatment with eye drops, there is typically spontaneous tearing, and excess fluid from the drops and associated tears gathers at the lid margins. In the course of wiping the drug containing fluid from the lid margins and adjacent lid, a thin film of the fluid is routinely spread to contact the adjacent skin of the lid area. This widespread exposure of the skin around the lid to the effect of drops is regularly demonstrated in patients who develop a contact dermatitis. Typically the entire area of the upper and lower lid are involved with induration, erythema and edema demonstrating the regular extensive exposure of the ocular adnexa to the influence of topically applied drugs.
[0054] The study is limited to subjects who have administered bimatoprost to one eye for more than 3 months. The mean duration of exposure to bimatoprost prior to assessing the parameter of lash growth between the control and study eye is 129 days (range 90-254 days). Observations are made under high magnification at the slit lamp biomicroscope. Documentation of differences between the control and treatment areas is accomplished using a camera specially adapted for use with the slit lamp biomicroscope.
[0055] The results of the observations are as follows:
[0056] Length of lashes: Increased length of eyelashes is regularly observed on the side treated with bimatoprost. The difference in length varies from approximately 10% to as much as 30%.
[0057] Number of lashes: Increased numbers of lashes are observed in the treated eye of each patient. In areas where there are a large number of lashes in the control eye, the increased number of lashes in the bimatoprost-treated eye gave the lashes on the treated side a more thickly matted overall appearance.
[0058] Auxiliary lash-like hair growth: Several patients have an apparent increase in lash-like hair in transitional areas adjacent to areas of normal lash distribution. These prominent robust appear lash-like hairs appeared to be of comparable length to the actual lashes. These long, thick lash-like hairs were present in the central portion of the lids of several patients in a linear arrangement just above the lash line. Hairs are present at similar locations in the control eyes but are by contrast thinner or more fine in appearance, have less luster and pigment and are more flat against the skin of the lid typical of vellus or intermediate hairs. In several patients, lash-like terminal hairs grow luxuriantly in the medial canthal area in the treated eye. In the corresponding control eye, vellus hairs are seen at the same location. Lash-like hairs are also present in the lateral canthal area of the treated eye but not the control eye in several subjects. Large lashes are not normally present at the lateral canthus and the area is generally free of all but a few occasional very fine lashes or vellus hairs.
[0059] Increased growth of vellus hair on lids: Fine microscopic vellus hair is present on the skin of the lids and is easily seen with the slit lamp biomicroscope. This vellus hair is typically denser adjacent to and below the lateral portion of the lower lids. While remaining microscopic, vellus hairs are increased in number, appear more robust and are much longer and thicker in treated than in control eyes in the areas below and lateral to the lower lid.
[0060] Perpendicular angulation of hairs: In areas where there are lash-like hairs above the lash line and in the medial and lateral canthal areas, the hairs are much longer, thicker and heavier. They also leave the surface of the skin at a more acute angle, as though they are stiffer or held in a more erect position by more robust follicles. This greater incline, pitch, rise or perpendicular angulation from the skin surface gives the appearance of greater density of the hairs.
[0061] The foregoing observations clearly establish that bimatoprost can be used to increase the growth of hair in man. This conclusion is based on the regular and consistent finding of manifestations of increased hair growth in treated vs. control areas in human subjects. The conclusion that the drug bimatoprost is capable of inducing increased robust growth of hair is based not on a single parameter, i.e., length, but is based on multiple lines of evidence as described in the results. Detailed examination and description of multiple parameters of differences in hair is greatly facilitated by the ability to examine the hairs at high magnification under stable conditions of fixed focal length and subject position utilizing the capabilities of the slitlamp biomicroscope.
[0062] The FIGURE shows the actual results on the eyelashes of a patient treated for glaucoma with Lumigan® bimatoprost for 6 months.
EXAMPLE 2
[0000] Topical Cream
[0063] A topical cream is prepared as follows: Tegacid and spermaceti are melted together at a temperature of 70-80° C. Methylparaben is dissolved in about 500 gm of water and propylene glycol, polysorbate 80, and bimatoprost are added in turn, maintaining a temperature of 75-80° C. The methylparaben mixture is added slowly to the Tegacid and spermaceti melt, with constant stirring. The addition is continued for at least 30 minutes with additional stirring until the temperature has dropped to 40-45° C. Finally, sufficient water is added to bring the final weight to 1000 gm and the preparation stirred to maintain homogeneity until cooled and congealed.
EXAMPLE 3
[0000] Topical Cream
[0064] A topical cream is prepared as follows: Tegacid and spermaceti are melted together at a temperature of 70-80° C. Methylparaben is dissolved in water and propylene glycol, polysorbate 80, and bimatoprost are added in turn, maintaining a temperature of 75-80° C. The methylparaben mixture is added slowly to the Tegacid and spermaceti melt, with constant stirring. The addition is continued for at least 30 minutes with additional stirring until the temperature has dropped to 40-45° C. Finally, sufficient water is added to bring the final weight to 1000 gm and the preparation stirred to maintain homogeneity until cooled and congealed.
[0065] The composition is applied to bald human scalp once daily to stimulate the growth of hair.
EXAMPLE 4
[0000] Topical Ointment
[0066] An ointment containing 2% by weight bimatoprost is prepared as follows:
[0067] White petrolatum and wool fat are melted, strained and liquid petrolatum is added thereto. The bimatoprost, zinc oxide, and calamine are added to the remaining liquid petrolatum and the mixture milled until the powders are finely divided and uniformly dispersed. The mixture is stirred into the white petrolatum, melted and cooled with stirring until the ointment congeals.
[0068] The foregoing ointment can be applied topically to mammalian skin for increased rate of hair growth, and can be prepared by omitting the zinc oxide and calamine.
EXAMPLE 5
[0000] Ointment
[0069] A dermatological ophthalmic ointment containing 10% by weight bimatoprost is prepared by adding the active compound to light liquid petrolatum. White petrolatum is melted together with wool fat, strained, and the temperature adjusted to 45-50° C. The liquid petrolatum slurry is added and the ointment stirred until congealed. Suitably the ointment is packaged in 30 gm tubes.
[0070] The foregoing ointment can be applied to the eyelid to enhance the growth of eyelashes. Similarly the composition can be applied to the brow for eyebrow growth.
EXAMPLE 6
[0000] Solution
[0071] An aqueous solution containing 5%, by weight, bimatoprost is prepared as follows. Bimatoprost is dissolved in water and the resulting solution is sterilized by filtration. The solution is aseptically filled into sterile containers.
[0072] The composition so prepared can be used in the topical treatment of baldness by application to the scalp daily.
EXAMPLE 7
[0000] Lotion
[0073] A sample of bimatoprost is dissolved in the vehicle of N-methyl pyrrolidone and propylene glycol. The composition can be used for application to dogs or cats having hair loss due to mange or alopecia of other causes.
EXAMPLE 8
[0000] Aerosol
[0074] An aerosol containing approximately 0. 1% by weight bimatoprost is prepared by dissolving the bimatoprost in absolute alcohol. The resulting solution filtered to remove particles and lint. This solution is chilled to about minus 30° C. To the solution is added a chilled mixture of dichlorodifluoromethane and dichlorotetrafluoroethane.
[0000] Thirteen ml plastic-coated amber bottles are cold filled with 11.5 gm each of the resulting solution and capped.
[0075] The composition can be sprayed on the scalp daily to stimulate the growth of hair.
EXAMPLE 9
[0000] Dusting Powder
[0076] A powder of the compound bimatoprost is prepared by mixing in dry form with talcum powder at a weight/weight ratio of 1:10. The powdered mixture is dusted on the fur of minks or other commercially valuable fur bearing animals and show animals for increased rate of hair growth.
EXAMPLE 10
[0000] Related Compounds
[0077] Following the procedure of the preceding Examples, compositions are similarly prepared substituting an equimolar amount of a compound of Table 1 for the bimatoprost disclosed in the preceding Examples. Similar results are obtained.
[0078] While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
[0079] The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: | Methods and compositions for stimulating the growth of hair are disclosed wherein said compositions include a cyclopentane heptanoic acid, 2-cycloalkyl or arylalkyl compound represented by the formula I
wherein the dashed bonds represent a single or double bond which can be in the cis or trans configuration, A, B, Z, X, R 1 and R 2 are as defined in the specification. Such compositions are used in treating the skin or scalp of a human or non-human animal. Bimatoprost is preferred for this treatment. | 0 |
FIELD OF THE INVENTION
This invention relates generally to tree-structured data representations, and more particularly to locating spatial data stored in quadtrees, octrees, and their N-dimensional counterparts.
BACKGROUND OF THE INVENTION
Tree-structured data representations are pervasive. Because of their long history and many different forms and uses, there are a large variety of “trees” that appear superficially alike, or that have similar names, even though they are quite different in detail and use.
Therefore, a “bi-tree,” as defined herein, is a spatial partitioning of an N-dimensional space into a hierarchy of cells. A root cell, enclosing the N-dimensional space, is conditionally partitioned into 2 N equally sized child cells along its mid-planes. Each child cell is then successively and conditionally partitioned in a similar manner.
Each cell of the bi-tree has associated characteristics comprising application specific data such as graphical elements, e.g., triangles, of a graphical object, e.g., a three-dimensional triangle mesh. Child cells in the bi-tree are indexed directly from their parent cell. Bi-trees can be fully populated, or sparse. In fully populated bi-trees, each cell is partitioned down to a deepest common level; in sparse bi-trees only selected cells are partitioned to reduce storage requirements.
FIG. 1 shows an example bi-tree 100 as defined herein. Although the example bi-tree 100 is a quadtree, i.e., a two-dimensional bi-tree, the method according to the invention can be extended to octrees, i.e., three-dimensional bi-trees, as well as lower and higher dimensional bi-trees because our method treats each dimension independently.
Cells branch from a root cell 101 , through intermediate cells 102 , to leaf cells 103 . Typically, the cells are associated with application specific data and characteristics, e.g., a cell type for region quadtrees, or object indices for point quadtrees. The child cells are indexed 110 directly from their parent cell. Direct indexing can be done by ordering the child cells or pointers to the child cells in a memory.
A depth of the bi-tree 100 is N LEVELS . The level of the root cell 101 is LEVEL ROOT =N LEVELS −1. The level of a smallest possible cell is zero. The bi-tree 100 is defined over a normalized space [0, 1]×[0, 1]. Similarly, an N-dimensional bi-tree is defined over [0, 1] N . Although this may seem restrictive, in practice most spatial data can be represented in this normalized space by applying transformations to the coordinates of the data.
Quadtrees and octrees are used in many diverse fields such as computer vision, robotics, and pattern recognition. In computer graphics, quadtrees and octrees are used extensively for storing spatial data representing 2D images and 3D objects, see Samet, “ The Quadtree and Related Hierarchical Data Structures ,” Computing Surveys, Vol. 16, No. 2, pp. 187-260, June 1984, and Martin et al., “ Quadtrees, Transforms and Image Coding ,” Computer Graphics Forum, Vol. 10, No. 2, pp. 91-96, June 1991.
As shown in FIG. 2 , quadtrees successively partition a region of space into four equally sized quadrants, i.e., cells. Starting from a root cell, cells are successively subdivided into smaller cells under certain conditions, such as when the cell contains an object boundary (region quadtree), or when the cell contains more than a specified number of objects (point quadtree). Compared to methods that do not partition space or that partition space uniformly, quadtrees and octrees can reduce the amount of memory required to store the data and improve execution times for querying and processing the data, e.g., collision detection and rendering.
Managing information stored in a bi-tree generally requires three basic operations: point location, region location, and neighbor searches.
Point location finds a leaf cell 201 containing a given point 200 . For example, a quadtree that stores geographical data, such as city locations, is partitioned according to geographical coordinates, i.e., longitude and latitude. Point location can be used to find cities near a given geographical coordinate, i.e., the point 200 .
Region location finds a smallest cell or set of cells that encloses a specified rectangular region 210 represented by a minimum vertex v 0 211 and a maximum vertex v 1 212 . With the geographical quadtree example, region location can be used to determine all the cities that are within a given range of specified geographical coordinates.
A neighbor search finds a cell, in a specified direction, that is adjacent to a given cell. In the geographical quadtree, point location can be combined with neighbor searching to first locate a cell containing a given city and then to find nearby cities in a given direction. In all of these operations, the bi-tree is traversed by following pointers connecting the cells.
A fourth operation, called ray tracing, is used by graphics applications to render three-dimensional models on a display, see Foley et al., “ Computer Graphics Principles and Practice ,” Addison-Wesley, 1992. In these applications, graphical elements comprising a scene are placed in leaf cells of an octree. Ray tracing requires a sequential identification of leaf cells along a ray. One method for identifying these leaf cells combines point location and neighbor searching.
Traditional point location operations in a bi-tree require a downward branching through the bi-tree beginning at the root node. Branching decisions are made by comparing each coordinate of a point's position to a mid-plane position of a current enclosing cell.
Traditional neighbor searching in a bi-tree requires a recursive upward branching from a given cell to a smallest common ancestor of the given cell and a neighboring cell, and then a recursive downward branching to locate the neighbor. Each branch in the recursion relies on comparing values that depend on the current cell and its parent. Typically, the values are stored in tables.
Prior art point location, region location, and neighbor searching are time consuming because Boolean operations, i.e., comparisons, are used. Boolean operations are typically implemented by predictive branching logic in modern CPUs. Predictive branching will stall the instruction pipeline on incorrectly predicted branch instructions, see Knuth, The Art of Computer Programming , Volume 1, Addison-Wesley, 1998, and Knuth, MMIXware: A RISC Computer for the Third Millennium , Springer-Verlag, 1999.
Mispredictions occur frequently for traditional tree traversal operations because previous branch decisions generally have no relevance to future branch decisions, see Pritchard, “ Direct Access Quadtree Lookup ,” Game Programming Gems 2, ed. DeLoura, Charles River Media, Hingham, Mass., 2001.
In addition, traditional neighbor searching methods are recursive. Recursion increases overhead as a result of maintaining stack frames and making function calls. Also, prior art neighbor searching methods use table lookups which require costly memory accesses in typical applications. Finally, prior art neighbor searching methods are limited only to quadtrees and octrees and it is exceedingly complex to extend these methods to higher dimensional bi-trees.
FIG. 3 shows a typical prior art point location operation 300 . The operation begins with a position of a given point 301 and a starting cell 302 . First, characteristics (C) 303 associated with the cell 302 are tested 310 . If true (T), then the cell 302 is a target cell 309 containing the point 301 . If false (F), then each coordinate of the position of the point 301 is compared 320 to a corresponding mid-plane position of the cell 302 . The comparisons 320 allow one to compute 330 an index to a next (child) cell 304 to be tested.
As stated above, the comparisons 320 require Boolean operations. For an N-dimensional bi-tree, at least N such Boolean operations are required for each cell visited during the traversal of the bi-tree. As stated above, these Boolean operations are likely to stall the instruction pipeline thereby degrading performance.
Pritchard, in “ Direct Access Quadtree Lookup ,” describes a region location operation for quadtrees that uses locational codes of the x and y boundaries of the bounding box of a region. Pritchards's quadtree is not a bi-tree under the above definition, because his child cells cannot be indexed directly from a parent cell.
That method operates on a hierarchy of regular arrays of cells, where each level is fully subdivided and contains four times as many cells as a previous level. His two-dimensional representation of spatial data requires a significant amount of memory, and would require even more memory for three- and higher-dimensional spatial data. Hence, that method is impractical for many applications.
Pritchard's method has two steps. First, that method uses locational codes of the left and right x boundaries and the top and bottom y boundaries of a region bounding box to determine a level of an enclosing cell. Then a scaled version of a position of a bottom-left vertex of the region bounding box is used to index into a regular array at this level.
Traditionally, locational codes have been used with “linear quadtrees” and “linear octrees”, see H. Samet, “ Applications of Spatial Data Structures: Computer Graphics, Image Processing, GIS ,” Addison-Wesley, Reading, Mass., 1990. Linear quadtrees and linear octrees are not bi-trees under our definition. Rather, linear quadtrees and linear octrees are comprised of a list of leaf cells where each leaf cell contains its interleaved locational code and other cell specific data. In general, linear quadtrees and linear octrees are more compact than bi-trees, e.g., they do not represent intermediate cells and they do not provide explicit links for direct indexing, at the expense of more costly and complicated processing methods.
Locational codes for linear quadtrees and linear octrees interleave bits that comprise coordinate values of a cell's minimum vertex such that linear quadtrees use locational codes of base 4 (or 5 if a “don't care” directional code is used) and linear octrees use locational codes of base 8 (or 9), see H. Samet, “ Applications of Spatial Data Structures: Computer Graphics, Image Processing, GIS ,” Addison-Wesley, Reading, Mass., 1990.
In computer graphics and volume rendering, ray tracing methods often make use of octrees to accelerate tracing rays through large empty regions of space. Those methods determine non-empty leaf cells along a ray passing through the octree and then process ray-surface intersections within these cells.
There are two basic approaches for tracing a ray through an octree: bottom-up and top-down. Bottom-up methods start at the first leaf cell encountered by the ray and then use neighbor finding techniques to find each subsequent leaf cell along the ray. Top-down methods start from the root cell and use a recursive procedure to find offspring leaf cells that intersect the ray. An extensive summary of methods for traversing octrees during ray-tracing is described by Havran, “ A Summary of Octree Ray Traversal Algorithms ,” Ray Tracing News, 12(2), pp. 11-23, 1999.
Stolte and Caubet, in “ Discrete Ray - Tracing of Huge Voxel Spaces ,” Computer Graphics Forum, 14(3), pp. 383-394, 1995, describe a top-down ray tracing approach that uses locational codes for voxel data sets stored in an octree. They first locate a leaf cell containing a point where a ray enters the octree. Then, for each leaf cell without a ray-surface intersection, a 3D DDA is used to incrementally step along the ray, in increments proportional to a size of a smallest possible leaf cell, until a boundary between the leaf cell and a neighboring next cell is encountered. The neighboring next cell is then found by popping cells from a recursion stack to locate a common ancestor of the leaf cell and the neighboring next cell and then traversing down the octree using their point location method. However, their method requires Boolean comparisons and thus suffers from the misprediction problems described above.
Therefore, it is desired to provide a traversal method for N-dimensional bi-trees that improves performance over the prior art by avoiding Boolean operations and eliminating recursion and memory accesses for table lookup, without increasing memory requirements.
SUMMARY OF THE INVENTION
The invention provides an efficient traversal method for bi-trees, e.g., quadtrees, octrees, and their N-dimensional counterparts. The method uses locational codes, is inherently non-recursive, and does not require memory accesses for table lookup. The method also reduces the number of mispredicted comparisons. The method includes procedures for point location, region location, neighbor searching, and ray tracing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating a data structure for a two-dimensional bi-tree in accordance with the present invention;
FIG. 2 is a diagram illustrating a spatial partitioning for a two-dimensional bi-tree in accordance with the present invention;
FIG. 3 is a diagram of a flow chart for a typical prior art point location method;
FIG. 4 is a diagram illustrating a hierarchical tree structure and associated locational codes for a one-dimensional bi-tree in accordance with the present invention;
FIG. 5 is a diagram illustrating a spatial partitioning and associated locational codes for a one-dimensional bi-tree in accordance with the present invention;
FIG. 6 is a diagram of a flow chart for point location according to the present invention; and
FIG. 7 is a diagram illustrating a ray intersecting a two-dimensional bi-tree in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 4 shows a hierarchical tree structure 400 and associated locational codes for a one-dimensional bi-tree. Locational codes 401 are used by a bi-tree traversal method according to the present invention. Each locational code 401 is represented in binary form in a data field with a bit size that is greater than or equal to the maximum number of levels in the tree, N LEVELS . For example, each locational code for a bi-tree with up to eight levels can be represented by eight bits.
The bits in each locational code 401 are numbered from right (LSB) to left (MSB) starting from zero. Each bit in the locational code indicates a branching pattern at a corresponding level of the bi-tree, i.e., bit k represents the branching pattern at level k in the bi-tree. Unlike the prior art where locational codes are interleaved, we use separate locational codes for each dimension of the cell, e.g., a set of locational codes for each cell of a two-dimensional bi-tree, i.e., a quadtree, comprises both an x locational code and a y locational code.
The locational codes for a cell can be determined in two ways. A first method multiplies the value of each coordinate of the cell's minimum vertex by 2 LEVEL ROOT , e.g., 2 5 =32, and then represents the product in binary form. FIG. 5 illustrates a spatial partitioning and associated locational codes 500 for the one-dimensional bi-tree 400 . For example, the cell 501 , [0.25, 0.5), has locational code 502 , binary(0.25*32)=binary(8)=001000.
A second method follows a branching pattern from the root cell to a given cell, setting each bit according to the branching pattern of a corresponding level. Starting by setting bit LEVEL ROOT to zero, the second method then sets each subsequent bit k to zero if a branching decision from level k+1 to k branches to the left, and to one if it branches to the right. For sparse bi-trees, lower order bits are set to zero if leaf cells are larger than a smallest possible cell.
In quadtrees, octrees, and higher dimensional bi-trees, locational codes for each dimension are determined separately from the value of the corresponding coordinate of the cell's minimum vertex (the first method) or from the left-right, bottom-top, (back-front, etc.) branching pattern used to reach the given cell from the root cell (the second method).
Several properties of these locational codes can be used to provide bi-tree traversal according to the present invention.
First, just as locational codes can be determined from branching patterns, branching patterns can be determined from locational codes. That is, a cell's locational code can be used to traverse the bi-tree from the root cell to a target cell by using the appropriate bit in each of the locational codes to index a corresponding child of each intermediate cell. As an advantage, our method avoids the costly Boolean comparisons of the prior art.
Second, the position of any point in [0,1) N can be converted into a set of locational codes by using the first method.
These properties enable point and region location according to the present invention as described below in greater detail. In addition, the locational codes of a cell's neighbors can be determined by adding and subtracting bit patterns to the cell's locational codes. This property is used to eliminate recursion and memory accesses for table lookup during neighbor searches.
Point Location
As shown in FIG. 6 , a point location operation, according to the invention, locates a leaf cell that contains a given point located in [0,1) N in a bi-tree defined over a region [0,1] N .
A first step converts the values of the coordinates of the point's position to a set of locational codes 601 by multiplying each value by 2 LEVEL ROOT and truncating the resultant products to integers. The integers are represented in binary form.
A second step selects a starting cell 602 , e.g., the root cell. The characteristics 603 of the cell 602 are tested 610 , e.g., “is the cell 602 a leaf cell?”. If true, the cell 602 is a target cell 609 containing the point.
While false, at each level k in the bi-tree, the (k−1) st bits from each of the locational codes 601 are used to determine 630 an index to an appropriate next (child) cell 604 to be tested 610 .
Note that all children of a cell are consecutively ordered to enable this indexing. The ordering can be done by storing the child cells or pointers to the child cells consecutively in a memory. When the indexed child cell has no children, the desired leaf cell has been reached and the point location operation is complete.
Unlike the prior art point location operation 300 , our point location operation 600 does not require comparisons between the point position and mid-plane positions of each cell at each branching point. This eliminates N comparisons at each level during a traversal of an N-dimensional bi-tree.
For example, to locate a point in a level 0 cell of an eight-level octree, the prior art operation requires an additional 24=(3*8) comparisons to branch to the appropriate children of intermediate cells. These additional comparisons in the prior art operation exhibit mispredictions as described above.
Region Location
Region location finds a smallest cell or set of cells that encloses a given region. Our method finds a single smallest cell entirely enclosing a rectangular, axis-aligned bounding box.
Our method provides for region location in N-dimensional bi-trees. Our method first determines a size of a smallest enclosing cell. Then, a variation of the point location method described above is used to traverse the bi-tree from a root cell to the smallest enclosing cell.
We determine the size, i.e., level, of the smallest enclosing cell by XOR'ing each corresponding pair of locational codes (lc) of a minimum vertex v 0 and a maximum vertex v 1 defining the region to generate a binary code (bc), i.e., bc=(lc v0 XOR lc v1 ).
Each binary code is then searched from the left (MSB) to find the first “one” bit of the set of binary codes, indicating a first level below a root level where at least one of the pairs of locational codes differ. The level of the smallest enclosing cell is then equal to a bit number of the “zero” bit immediately preceding this “one” bit.
Given this level, our method then traverses the bi-tree downward from the root cell following the bit pattern of the locational codes of any of the region vertices, e.g., the minimum vertex, until a leaf cell is encountered OR a cell of the determined size is reached. This yields the desired enclosing (target) cell. We use the logical OR operator here to indicate either one or both conditions will terminate the traversal of the bi-tree.
Note that there are several methods for identifying the highest order “one” bit in the binary codes ranging from a simple shift loop to processor specific single instructions, which bit-scan a value, thereby eliminating the loop and subsequent comparisons.
As a first one-dimensional example, a region [0.31, 0.65) of the bi-tree 400 has left and right locational codes 001001 and 010101 respectively. By XOR'ing these location codes, a binary code 011100 is obtained, with a first “one” bit from the left (MSB) encountered at bit position four (recall that bit positions are numbered from zero starting at the right-most, LSB, bit), so that the level of a smallest enclosing cell is five, i.e., the enclosing target cell of the region [0.31, 0.65) is the root cell.
As a second one-dimensional example, a region [0.31, 0.36) of the bi-tree 400 has locational codes 001001 and 001010. The XOR step yields 000011, with a first “one” bit from the left encountered at bit position one, so that the level of a smallest enclosing cell is two. The smallest enclosing cell is then found by traversing the bi-tree 400 downward from the root cell following the left locational code 001001, until the target level 3 leaf cell 501 , [0.25, 0.50), is encountered.
Neighbor Searches
Neighbor searching finds a cell adjacent to a given cell in a specified direction, e.g., left, top, and top-left. Several variations exist, including finding a neighbor with a common vertex, edge, or face, finding neighbors of a same size or larger than the given cell, or finding all leaf cell neighbors of the given cell.
In order to determine neighbors of the given cell, we first note that bit patterns of locational codes of two neighboring cells differ by a binary distance between the two cells. For example, a left boundary of every right neighbor of a cell, including intermediate and leaf cells, is offset from the cell's left boundary by the cell's size. Hence, the locational code corresponding to the x coordinate, i.e., the cell's x locational code, of every right neighbor of a cell can be determined by adding the binary form of the cell's size to the cell's x locational code.
The binary form of a cell's size is determined from the cell's level, i.e., cellSize≡binary(2 cellLevel ). Hence, the x locational code for a cell's right neighbor is the sum of the cell's x locational code and cellSize.
As an example, a cell 501 , [0.25, 0.5), has a locational code 502 , 001000, and is at level three. Hence, the x locational code of a neighbor touching its right boundary is 001000+binary(2 3 )=001000+001000=010000.
Determining the x locational codes of a cell's left neighbors is more complicated. Because the cell's left neighbors' sizes are unknown, the correct binary offset between the cell's x locational code and the x locational codes of its left neighbors are also unknown. However, a smallest possible left neighbor has level 0. Hence, a difference between the x locational code of a cell and the x locational code of the cell's smallest possible left neighbor is binary(2 0 ), i.e., the smallest possible left neighbor's x locational code is cell's x locational code—binary(1).
Furthermore, the left boundary of this smallest possible left neighbor is located between the left and right boundaries of every left neighbor of the cell, including leaf cells larger than the smallest possible left neighbor and intermediate cells. Hence, a cell's left neighbors can be located by traversing the bi-tree downward from the root cell using the x locational code of this smallest possible left neighbor and stopping when a neighbor cell of a specified level is reached, OR a leaf cell is encountered.
As an example, a smallest possible left neighbor of a cell 501 , [0.25, 0.5), has x locational code 001000−000001=000111. Traversing the bi-tree 400 downwards from the root cell using this locational code, and stopping when a leaf cell is reached yields a cell 503 , [0.125, 0.25), with a locational code 504 , 000100, as the cell's left neighbor.
For N-dimensional bi-trees, a neighbor is located by following branching patterns of a set of N locational codes to the neighbor until a leaf cell is encountered OR a specified maximum tree traversal level is reached. The N locational codes to the neighbor are determined from a specified direction. The specified direction determines a corresponding cell boundary. In a two-dimensional bi-tree, the x locational code of a right edge neighbor is determined from the cell's right boundary and the x and y locational codes of a top-right vertex neighbor are determined from the cell's top and right boundaries.
For example, in a two-dimensional bi-tree, i.e., a quadtree, a right edge neighbor of size greater than or equal to a given cell is located by traversing downward from the root cell using the locational codes to the neighbor comprising the x locational code of the given cell's right boundary and the y locational code of the given cell until either a leaf cell OR a cell of the same level as the given cell is reached.
As a second two-dimensional example, a given cell's bottom-left leaf cell vertex neighbor is located by traversing the two-dimensional bi-tree, i.e., the quadtree, downward from the root cell using the x locational code of the given cell's smallest possible left neighbor and the y locational code of the given cell's smallest possible bottom neighbor until a leaf cell is encountered.
After the locational codes of a desired neighbor have been determined, the desired neighbor can be found by traversing the bi-tree downward from the root cell. However, it can be more efficient to first traverse the bi-tree upward from the given cell to a smallest common ancestor of the given cell and its neighbor, and then to traverse the bi-tree downward from the smallest common ancestor to the neighbor, see H. Samet, “ Applications of Spatial Data Structures: Computer Graphics, Image Processing, GIS ,” Addison-Wesley, Reading, Mass., 1990.
Fortunately, our locational codes also provide an efficient means for determining this smallest common ancestor. Assuming a one-dimensional bi-tree, the neighbor's locational code is determined, as described above, from the given cell and the given direction. The given cell's locational code is then XOR'ed with the neighbor's locational code to generate a difference code. Next, the bi-tree is traversed upward from the given cell until a first level is reached where a corresponding bit in the difference code is 0, indicating a first branching point where the two locational codes are the same. We call this the stopping level. The cell reached by this upwards traversal to the stopping level is the smallest common ancestor of the given cell and its neighbor.
In N dimensions, the N locational codes of a cell are XOR'ed with N corresponding locational codes of its neighbor generating N difference codes. The highest level cell reached by the upward traversal using the N difference codes is the smallest common ancestor.
As a first example, a difference code for a level 3 cell 501 , [0.25, 5), in the one-dimensional bi-tree 400 and its right neighbor is 001000^010000=011000. Traversing the bi-tree upward from level 3 considers bits in this difference code to the left of bit 3 . A first 0 bit is reached at LEVEL ROOT , so a smallest common ancestor of cell 501 and its right neighbor is the root cell.
As a second example, a difference code for a level 3 cell 505 , [0.75, 1), in the one-dimensional bi-tree 400 and its left neighbor is 011000^010111=00111. Examining bits to the left of bit 3 yields a first 0 at bit 4 , corresponding to a level 4 cell. Hence, a smallest common ancestor of the cell 505 and its left neighbor is the cell's parent cell 506 , which has a locational code 507 , 010000.
Depending on the application, several different variations of neighbor searches might be required, e.g., finding a smallest left neighbor of size at least as large as the given cell and finding all of the leaf cell neighbors touching a specified vertex of the given cell.
There are several advantages of the neighbor finding method according to the present invention over traditional methods. First, because we treat each dimension independently, our method works in any number of dimensions. In contrast, prior art methods use table lookups that work only for two- and three-dimensional bi-trees. Construction of these tables has relied on being able to visualize spatial relationships in two- and three-dimensions; extending these tables to higher dimensions is thus exceedingly difficult, error prone, and tedious to verify. In fact, although higher-dimensional bi-trees are of great utility in fields such as computer vision, scientific visualization, and color science, tables for neighbor searching in these higher dimensional bi-trees are not known.
Second, our method trades off traditional table lookups, which require memory accesses, for simple register-based computations in the form of bit manipulations. This is advantageous in modern system architectures where processor speeds exceed memory speeds. Even in modern systems with fast cache memory, the application data and the table data compete for the cache in many practical applications, forcing frequent reloading of the table data from memory, thus degrading the performance of table-based prior art methods.
In addition, prior art neighbor searching methods and tables have been devised for a limited variety of neighborhood searches. Traditional neighbor searches require different methods for face, edge, and vertex neighbors and “vertex neighbors are considerably more complex,” see H. Samet, “ Applications of Spatial Data Structures: Computer Graphics, Image Processing, GIS ,” Addison-Wesley, Reading, Mass., 1990. In contrast, our method uses a single approach for all varieties of neighbor searching. Furthermore, prior art tables are specialized for a given cell enumeration and must be re-determined for different cell labeling conventions. Generating tables for different conventions and different types of neighbor searches is difficult, error prone, and tedious to verify.
Finally, our neighbor searching method is inherently non-recursive and requires fewer Boolean operations than traditional methods. In contrast, traditional methods for neighbor searching are inherently recursive and unraveling the recursion is non-trivial. A non-recursive neighbor searching method for quadtrees and octrees is described by Bhattacharya in “ Efficient Neighbor Finding Algorithms in Quadtree and Octree ,” M. T. Thesis, Dept. Comp. Science and Eng., India Inst. Technology, Kanpur, 2001. However, that method is limited to finding neighbors of the same size or larger than a cell. In addition, like Samet's, that method requires table-based traversal to determine the appropriate neighbor. Hence, that method suffers from the same limitations of traditional neighbor searching methods as described above.
Ray Tracing
Ray tracing a three-dimensional graphical object stored in a three-dimensional bi-tree, i.e., an octree, requires determination of an ordered sequence of leaf cells along a ray passing through the bi-tree, testing each non-empty leaf cell for ray-surface intersections, and processing the ray-surface intersections.
Three-dimensional ray tracing is used extensively in computer graphics. In addition, there are numerous applications for the determination of an ordered sequence of leaf cells along a ray passing through an N-dimensional bi-tree in fields such as telecommunications, robotics, and computer vision.
As illustrated in FIG. 7 , according to the present invention, a first step determines a point 702 where a ray 701 first enters a two-dimensional bi-tree. A second step determines a leaf cell 703 and its locational codes using our point location method (described above) for the point 702 . A third step tests the cell 703 for a ray stopping condition, e.g., “is there a ray-surface intersection in the cell?”.
If the test fails, locational codes of a next cell 706 along the ray 701 are determined in two steps from the locational codes of the cell 703 , a direction of the ray 701 , and a size of the cell 703 .
The first step determines a subset of coordinates of an exit point 705 whose values are equal to the values of corresponding coordinates in the maximum or minimum vertices of the cell 703 . This subset depends on where the ray 701 exits the cell 703 , e.g., the subset consists of the x coordinate for the exit point 705 because the ray 701 exits the cell 703 on its right edge 704 (where x=x MAX (cell 703 )). This subset of coordinates determines a corresponding subset of locational codes to the next cell 706 that are then determined from the locational codes and size of the cell 703 according to neighbor searching methods of the present invention described above.
The second step determines the remaining locational codes to the next cell 706 from the locational codes determined in the first step and an equation of the ray 701 . Finally, the locational codes to the next cell 706 are used to traverse up the bi-tree to a common ancestor of the cells 703 and 706 and back down to the neighbor 706 according to neighbor searching methods of the present invention described above.
This process of determining next cells along the ray 701 is repeated to determine an ordered sequence of leaf cells along the ray 701 until the ray stopping condition is satisfied.
Our method can be applied to both top-down and bottom-up tree traversal approaches for ray tracing while avoiding the Boolean operations, recursion, and incremental stepping along the ray in increments proportional to a smallest possible leaf cell, used in the prior art.
Effect of the Invention
The invention provides a method for point location, region location, neighbor searching, and ray-tracing for bi-trees which is simple, efficient, works in any number of dimensions, and is inherently non-recursive. The method according to the invention significantly reduces the number of Boolean operations with poor predictive behavior and does not require accessing memory as necessitated by table lookups.
Although the invention has been described by way of examples of preferred embodiments, it is to be understood that various other adaptations and modifications may be made within the spirit and scope of the invention. Therefore, it is the object of the appended claims to cover all such variations and modifications as come within the true spirit and scope of the invention. | A method traverses a bi-tree stored in a memory to locate application specific data stored in the memory and associated with the bi-tree. The bi-tree comprises a spatial partitioning of an N-dimensional space into a hierarchy of cells. Starting from a root cell enclosing the N-dimensional space, each cell is successively and conditionally partitioned into 2 N child cells along the cell's N mid-planes. Each cell of the bi-tree has associated characteristics comprising the application specific data and child cells are indexed directly from a parent cell. First, a set of locational codes, a cell of the bi-tree, and a termination condition are specified. Next, the characteristics of the cell are tested to see if they satisfy the termination condition. If the termination condition is not satisfied, an arithmetic operation on the set of locational codes is performed to directly index a next cell to be tested. Otherwise, the cell identifies a target cell. Finally, the application specific data of the target cell is retrieved from the memory. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/825,611, filed on Sep. 14, 2006. The disclosure of the above application is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to a power save system in a network and, more particularly to a periodic power save system in an ad-hoc wireless network.
2. Related Art
A wireless network (e.g., Wi-Fi based on IEEE 802.11 standards) may be characterized as an infrastructure mode network or an ad-hoc mode network depending on whether the stations within the wireless network can directly communicate with other stations in the network. FIG. 1(A) illustrates an example of an infrastructure mode wireless network, which may typically comprise an access point 2 and stations 4 , 6 and 8 . In the infrastructure mode network, the stations 4 , 6 and 8 are not configured to directly communicate with each other, and any communication between the stations 4 , 6 and 8 must be channeled through the access point 2 .
In contrast, an ad-hoc mode network allows each station to communicate directly with each other, as illustrated in FIG. 1(B) . Thus, in the ad-hoc mode wireless network, there is no central access point controlling communication among the stations 4 , 6 and 8 . Ad-hoc devices are configured to communicate only with other ad-hoc devices, and they are not able to communicate with any infrastructure devices or any other devices connected to a wired network.
Considering that a significant portion of the Wi-Fi devices are portable devices (e.g., cellular phones, portable gaming devices, wireless headsets, wireless headphones, wireless speakers and the like), power consumption has become an important issue for the Wi-Fi devices. This has led the IEEE to standardize the infrastructure mode network power save protocol. However, due to the decentralized nature of ad-hoc mode networks, it is much more difficult and complicated to implement power save algorithms when there is no central access point that dictates all the decisions related to power consumption in the network.
SUMMARY OF THE INVENTION
The invention allows ad-hoc network devices to enter a power save mode. The invention also provides for power consumption decisions to be made in an ad-hoc network to improve implementation of power save algorithms. Other advantages and benefits of the invention are apparent from the discussion herein.
Accordingly, in one aspect of the invention, a method for saving power in an ad-hoc network including first and second stations each having a wireless capability to directly communicate with each other includes issuing a request to the second station to buffer data traffic intended for the first station for a first predetermined period, granting the request to buffer data traffic, causing the first station to enter a first power save mode for the first predetermined period, and enabling the second station to buffer data traffic intended for the first station for the first predetermined period.
The method may further include causing the first station to exit the first power save mode after the first predetermined period elapses, and sending the buffered data traffic to the first station. Sending the buffered data traffic may include sending the buffered data traffic from the second station to the first station. The method may further include causing the first and second stations to simultaneously enter a second power save mode for a second period time. The method may further include advertising a master capability of the second station to buffer data traffic intended for the first station. The method may further include causing the second station to exit the second power save mode before the first station exits the second power save mode. The ad-hoc network may be a wireless network using protocol selected from the group consisting of IEEE 802.11 standards and Bluetooth standards. The method may further include determining whether the second station has a capability to buffer data traffic intended for the first station. The method may further include issuing a request to the first station to buffer data traffic intended for the second station for a second predetermined period, granting the request to buffer data traffic intended for the second station, causing the second station to enter a second power save mode for the second predetermined period, and enabling the first station to buffer the data traffic intended for the second station for the second predetermined period. The method may further include causing the second station to exit the second power save mode after the second predetermined period elapses, and sending the buffered data traffic to the second station. Sending the buffered data traffic to the second station may include sending the buffered data traffic from the first station to the second station. The method may further include determining whether the first station has a capability to buffer data traffic intended for the second station. The method may further include preventing the first station from entering the first power save mode if the second station requests the first station to buffer the data traffic intended for the second station, and preventing the second station from entering the second power save mode if the first station requests the second station to buffer the data traffic intended for the first station. The method may further include preventing the first station from entering the first power save mode occurs if the request is received within a predetermined period of time from when the first station sends such a request, and preventing the second station from entering the second power save mode occurs if the request is received within a predetermined period of time from when the second station sends such a request. The method may further include causing the slave station to exit the power save mode after the predetermined period elapses, and causing the master station to send the buffered data traffic to the slave station. The method may further include advertising a master capability of the master station to buffer data traffic intended for any of the plurality of stations in the ad-hoc network, and determining if the master station has the master capability to buffer data traffic intended for one of the plurality of stations. The ad-hoc network may be a wireless network using a protocol selected from the group consisting of IEEE 802.11 standards and Bluetooth standards.
According to another aspect of the invention, a method for saving power in an ad-hoc network including a plurality of stations, the plurality of stations including a master station and at least one slave station incapable of buffering traffic for other stations, each station having a wireless capability to directly communicate with other stations, includes issuing a request to the master station to buffer data traffic intended for the slave station for a predetermined period, granting the request to buffer data traffic, causing the slave station to enter a power save mode for the predetermined period, and enabling the master station to buffer data traffic intended for the slave station for the predetermined period.
The first station has a master capability to buffer data traffic intended for other stations in the ad-hoc network for a second predetermined period and may be configured to grant a request from the second station to allow the second station to enter a second power save mode, and wherein the second station may be configured to determine if there may be any station having the master capability in the ad-hoc network. The second station may enter the second power save mode for the second predetermined period when the first station grants the request from the second station, and the first station sends the buffered data traffic to the second station after the second predetermined period elapses. The first station may be configured not to enter the first power save mode if the second station requests the first station to buffer the data traffic intended for the second station, and the second station may be configured not to enter the second power save mode if the first station requests the second station to buffer the data traffic intended for the first station. The first station may not enter the first power save mode if the request is received within a predetermined period of time from when the first station sends such a request, and wherein the second station may not enter the first power save mode if the request is received within a predetermined period of time from when the second station sends such a request. The master and slave stations may be configured to simultaneously enter a second power save mode for a second period time. The master station may be configured to exit the second power save mode before the slave station exits the second power save mode. The ad-hoc network may be a wireless network using a protocol selected from the group consisting of IEEE 802.11 standards and Bluetooth standards.
In yet another aspect of the invention, an ad-hoc network includes a first station having wireless communication capabilities and configured to determine if there is any station in the ad-hoc network having a master capability to buffer data traffic intended for other stations in the ad-hoc network for a first predetermined period, the second station having wireless communication capabilities and the master capability and configured to grant a request from said first station to allow said first station to enter a first power save mode, and wherein the first station enters the first power save mode for the first predetermined period when the second station grants the request and the second station sends the buffered data traffic to the first station after the first predetermined period elapses A system for saving power in an ad-hoc network including first and second stations each having a wireless capability to directly communicate with each other, the system further includes means for issuing a request to the second station to buffer data traffic intended for the first station for a first predetermined period, means for granting the request to buffer data traffic, means for causing the first station to enter a first power save mode for the first predetermined period, and means for enabling the second station to buffer data traffic intended for the first station for the first predetermined period.
A machine-readable medium including stored instructions, which, when executed by a processor cause the processor to implement power saving in an ad-hoc network having a plurality of stations, the instructions including instructions for determining whether a first one of the stations has a capability to buffer data traffic intended for a second station, instructions for requesting the at least one station to buffer data traffic intended for the second station for a first predetermined period, instructions for granting a request to buffer data traffic intended for the second station, instructions for causing the second station to enter a first power save mode for the first predetermined period, and instructions for enabling the first one station to buffer data traffic intended for the second station for a second predetermined period, instructions for causing the second station to exit the first power save mode after the first predetermined period elapses, and instructions for sending the buffered data traffic to the second station.
Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention, are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the detailed description serve to explain the principles of the invention. No attempt is made to show structural details of the invention in more detail than may be necessary for a fundamental understanding of the invention and the various ways in which it may be practiced. In the drawings:
FIGS. 1(A) and 1(B) illustrate an example of an infrastructure mode network and ad-hoc mode network, respectively;
FIG. 2(A) and 2(B) illustrate examples of a symmetrical ad-hoc network;
FIG. 3(A) , 3 (B) and 3 (C) illustrate examples of a asymmetrical ad-hoc network;
FIG. 4(A) is a flow chart for a power save scheme in a symmetrical ad-hoc network constructed according to the principles of the invention; and
FIG. 4(B) is a flow chart for a power save scheme in an asymmetrical ad-hoc network constructed according to the principles of the invention.
FIGS. 5-12 show various exemplary implementations of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The embodiments of the invention and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and detailed in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiments of the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those of skill in the art to practice the embodiments of the invention. For example, the invention is described in terms of Wi-Fi network based on IEEE 802.11 standard, but it will be understood that the invention is not so limited. The invention may be broadly applicable to any ad-hoc mode wireless network and other types of wireless networks that have appropriate features and characteristics. Accordingly, the examples and embodiments herein should not be construed as limiting the scope of the invention, which is defined solely by the appended claims and applicable law. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.
The invention relates to periodic power save protocols for ad-hoc networks. Different devices within the ad-hoc network can take on the role of a master while the other slave devices enter a power save mode. The master device receives data for the other devices and sends the buffered data when those slave devices wake up. This protocol allows for power savings among the devices. Various aspects of the invention will now be described in greater detail below.
FIGS. 2(A) , 2 (B), 3 (A), 3 (B) and 3 (C) illustrate examples of an ad-hoc mode network configuration. Depending on similarity of capabilities among the devices (i.e., stations, nodes or the like) in the network, the ad-hoc mode network may be characterized as a symmetrical ad-hoc mode network or an asymmetrical ad-hoc mode network. FIGS. 2(A) and 2(B) illustrate examples of the symmetrical ad-hoc mode network, in which the devices may have similar capabilities, such as, for example, processing power, memory, battery life or the like. In particular, FIG. 2(A) illustrates two walkie-talkies or cellular phones 12 and 14 with identical or substantially the same capabilities connected via an ad-hoc mode network. This connection allows real-time multi-user voice communication via the ad-hoc mode network. When the devices 12 and 14 are not in use, it may be necessary to turn off one or both devices to save power. Since there is no central access point to carry out a power save mode, a power save protocol may be carried out on all devices in the network without overburdening any particular device. For example, each of the devices 12 and 14 may alternatively take charge by acting as a master device that carries out power save algorithms in the network.
Similarly, FIG. 2(B) illustrates two identical portable gaming devices 16 and 18 (e.g., Sony™ PSP™ or the like) connected to each other via an ad-hoc mode network. This connection may provide real-time multi-player gaming experiences for those using the portable gaming devices 16 and 18 . When the devices 16 and 18 are not being used, the devices 16 and 18 may communicate with each other to decide which device will take charge as a “master” to carry out a power save protocol for the network. The “master” device may allow other devices (i.e., slaves) in the network to enter a power save mode and buffer data traffic for the slave devices, which will be also described below in detail. It should be understood that walkie-talkies, cell phones and gaming devices are merely illustrative of the type of devices that may be connected in a symmetrical, ad-hoc network.
FIGS. 3(A) , 3 (B) and 3 (B) illustrate examples of the asymmetrical ad-hoc mode network configuration, in which the ad-hoc devices have different capabilities. For example, FIG. 3(A) illustrates an asymmetrical ad-hoc mode network including a cellular phone 20 and a wireless headset 22 . Typically, the wireless headset 22 is provided with significantly less capabilities than the cellular phone 20 and may not be able to carry out the power save algorithms for the ad-hoc network. In this case, the power save protocol may exploit the capabilities of the cellular phone 20 , which may permanently take charge as a master while the headset 22 permanently operates as a slave in this situation. Similarly, FIG. 3(B) illustrates a PC 24 and a wireless headphone 26 connected to each other via an ad-hoc mod network, wherein the PC 24 operates as the master while the wireless headphone 26 operates as the slave in carrying out the power save mode. In FIG. 3(C) , an audio device 30 with more capabilities may carry out the power save mode as a permanent master to wireless speakers 32 . Again, these examples are merely illustrative of the type of devices that may be connected in an asymmetrical, ad-hoc network.
FIG. 4(A) illustrates a flow chart for a power save scheme in a symmetrical ad-hoc network constructed according to the principles of the invention. As mentioned above, in a symmetrical ad-hoc mode network, each device may have capabilities to carry out power save algorithms in the network as a master. Thus, it is assumed that stations A and B (e.g., walkie-talkies 12 and 14 in FIG. 2(A) , respectively) are both equally capable of carrying out the power save algorithms without overburdening the other one. As shown in steps 40 and 42 , stations 12 and 14 both advertise their master capabilities to other stations in the network. The master capabilities may include an ability to buffer data designated for other stations in the network that are in a sleep (power save) mode. After confirming that station B has master capabilities, station A may send a power save enter request to station B, as shown in step 44 . The power save enter request may be included in an uplink IEEE action management frame of station A's beacon that is sent to station B. The frame may include information about the sleep period of station A. The power save enter request may be included in an uplink IEEE action management frame sent from slave to master. The capability to implement this protocol may be advertised in the station beacons and probe responses. The power save enter request/response may be sent using IEEE Action Management frames. Further, the power save enter request may include information about the slave station's frequency of wake-ups (referred to as sleep period), while the power save enter response may include information about a number of service periods the master may buffer traffic for slave.
It is possible that both stations A and B send their respective power save enter requests to each other. To avoid the conflict, each station may be configured to stay in a full power mode when the request is received from other stations. Each station may then compute a random back-off and re-attempt to enter the power save mode when the back-off expires or stay in full power mode as the master if other station's back-off expires earlier.
Upon accepting the request from station A, station B becomes the master and station A becomes the slave. As shown in step 46 , station B may send a power save enter response to station A. The power save enter response may be included in an IEEE action management frame. The power save enter response may contain the maximum number of service periods during which the master station B will buffer data traffic for slave station A. According to an embodiment of the invention, a service period may be defined as the period between receiving an uplink trigger from slave station A to the point where master station B sends an end of service period (EOSP) indication. Each uplink frame with a trigger bit set from slave station A may be counted as one service period by master station B. For Wi-Fi multi-media (WMM) applications, for example, the WWM EOSP bit in the quality of service (QOS) information field may be used as the trigger bit by slave station in the uplink direction. For non-WMM applications, for example, the “more-data” bit in the IEEE 802.11 frame control field may be used as the trigger bit.
In step 46 , after receiving the power save enter response from master station B, slave station A may enter power save mode as shown in step 48 . Master station B may start buffering data traffic for slave station A, as shown in step 50 . While in the power save mode, slave station A may not beacon and advertise its capability as a master. Every time slave station A wakes up, it may send an uplink trigger frame to master station B with the trigger bit “set.” Slave station A may send exactly one trigger frame in every wake-up period. If slave station A has more than one frame in every wake-up period, slave station A may transmit subsequent frames with trigger bit “unset.” If slave station A has no uplink data to send, it may send a “null” uplink trigger frame with trigger bit set. Also, all uplink frames from slave station A may have the power management bit set to “ 1 ” in the IEEE 802.11 frame control field. Master station B, in turn, may respond to the trigger frame with downlink data buffered for slave station A. The last downlink frame from master station B may the EOSP bit set. For WMM applications, the WMM EOSP bit in the QOS information field may be used by master station B in the downlink direction to mark EOSP. For non-WMM applications, the “more-data” bit in the IEEE 802.11 frame control field may be used as the EOSP indication. If no downlink data has been buffered for slave station A, master station B may send a null data frame with the EOSP bit set. Also, in one example, the system may be configured so that the uplink frames sent from slave station A with the trigger bit unset may not cause master station B to empty a power save queue for the respective slave station.
After the maximum number of service periods permitted by master station B is reached, master station B may stop buffering data traffic for slave station A. Slave station A may end power save mode in step 52 . The data is buffered by master station B and forwarded to slave station A in step 54 . Slave station A and master station B may enter the full power mode by resuming beaconing and advertising their capability as a master station, as shown in steps 56 and 58 . Both stations A and B then may compute a random back-off and attempt to become slaves on back-off expiry. The steps shown in FIG. 4(A) may be repeated. Since each station may rotate through the role of a slave or master, power consumption issues on all stations in the network may be greatly improved without overburdening a particular station. For example, assuming that each station spends equal time in the master and slave roles, the power save protocol may reduce the power consumption for the slave stations up to about 75%. Further, the protocol may reduce the power consumption for both master and slave stations up to about 38% compared to the full power mode. The power saving may increase as the number of slave stations increases.
FIG. 4(B) illustrates a flow chart for a power save scheme in an asymmetrical ad-hoc network constructed according to the principles of the invention. For example, the asymmetrical ad-hoc network may include the cellular phone 20 as the master and the wireless headset 22 illustrated in FIG. 3(A) . As mentioned above, in the asymmetrical ad-hoc network, only one station may have the master capabilities. Thus, step 60 of advertising the master capabilities and the master/slave power save enter request/response steps 62 and 64 (i.e., master/slave handshake) are implemented. For example, the master station may return 0xFFFF in the maximum service period field as the “master indefinite” indication. Some implementations with pre-provisioned master/slave configurations may bypass the master/slave handshake among the stations as their roles may have been already decided at the production stage. Other than those differences, the power save protocol illustrated in FIG. 4(B) may perform steps similar to the steps performed for the symmetrical ad-hoc power save mode shown in FIG. 4(A) . For example, after executing the master/slave handshake shown in steps 62 and 64 , the slave station 22 may enter the power save mode at step 66 while the master station 20 may buffer the data traffic for the slave station 22 at step 68 . When the slave station 22 wakes up from the power save mode at step 70 , the master station 20 may send the buffered data traffic to the slave station 20 at step 72 . If the slave station 22 is not frequently used, power save may be greatly increased by allowing the slave station 22 to enter the power save mode.
In order to further improve power saving, the master station 20 may use the sleep period of the slave station 22 to enter the power save mode after sending a downlink frame with the EOSP bit set. For example, upon receiving an uplink frame from the slave station 22 with the trigger bit set, the master station 20 may start a sleep clock timer with a timeout set to expire at a certain point before the slave station 22 wakes up. The sleep clock timer may include an offset that may account for any timing errors in the sleep clock to ensure the master station 20 wakes up before the next slave wakeup. The master station 20 may exchange data with the EOSP bit set in the last downlink frame to the slave station 22 . After sending the frame with the EOSP bit set, the master and slave stations both may enter the power save mode. The slave station 22 may be required not to transmit any frames after receiving the downlink with the EOSP bit set. In this case, if both the master and slave stations have 75% power savings in the power save mode, the overall system may be able to save power up to 75%.
Referring now to FIGS. 5 , 6 , 7 , 8 , 9 , 10 , 11 and 12 , various exemplary applications of the invention are shown. Referring to FIG. 5 , the invention may be embodied in a hard disk drive 500 . The invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 5 at 502 . In some implementations, signal processing and/or control circuit 502 and/or other circuits (not shown) in HDD 500 may process data, perform coding and/or encryption, perform calculations, and/or format data that is output to and/or received from a magnetic storage medium 506 .
HDD 500 may communicate with a host device (not shown) such as a computer, mobile computing devices such as personal digital assistants, cellular phones, media or MP 3 players and the like, and/or other devices via one or more wired or wireless communication links 508 . HDD 500 may be connected to memory 509 , such as random access memory (RAM), a low latency nonvolatile memory such as flash memory, read only memory (ROM) and/or other suitable electronic data storage.
Referring first to FIG. 6 , the invention may be embodied in a digital versatile disc (DVD) drive 511 . The invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 6 at 512 , and/or mass data storage 518 of the DVD drive 511 . Signal processing and/or control circuit 513 and/or other circuits (not shown) in the DVD 511 may process data, perform coding and/or encryption, perform calculations, and/or format data that is read from and/or data written to an optical storage medium 516 . In some implementations, signal processing and/or control circuit 512 and/or other circuits (not shown) in DVD 511 can also perform other functions such as encoding and/or decoding and/or any other signal processing functions associated with a DVD drive.
DVD drive 511 may communicate with an output device (not shown) such as a computer, television or other device via one or more wired or wireless communication links 517 . DVD 511 may communicate with mass data storage 518 that stores data in a nonvolatile manner. DVD 511 may be connected to memory 519 , such as RAM, ROM, low latency nonvolatile memory such as flash memory, and/or other suitable electronic data storage.
Referring now to FIG. 7 , the invention may be embodied in a high definition television (HDTV) 520 . The invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 7 at 522 , a WLAN interface and/or mass data storage of the HDTV 520 . HDTV 520 receives HDTV input signals in either a wired or wireless format and generates HDTV output signals for a display 526 . In some implementations, the signal processing circuit and/or control circuit 522 and/or other circuits (not shown) of HDTV 520 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other type of HDTV processing that may be required.
HDTV 520 may communicate with a mass data storage 527 that stores data in a nonvolatile manner such as optical and/or magnetic storage devices. At least one DVD may have the configuration shown in FIG. 6 . HDTV 520 may be connected to a memory 528 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. HDTV 520 also may support connections with a WLAN via a WLAN network interface 529 .
Referring now to FIG. 8 , the invention may be implemented in a control system of a vehicle 530 , a WLAN interface and/or mass data storage of the vehicle control system. In some implementations, the invention implements a powertrain control system 532 that receives inputs from one or more sensors 536 such as temperature sensors, pressure sensors, rotational sensors, airflow sensors and/or any other suitable sensors and/or that generates one or more output control signals from an output 538 such as engine operating parameters, transmission operating parameters, and/or other control signals.
The invention may also be embodied in other control systems 540 of vehicle 530 . Control system 540 may likewise receive signals from input sensors 542 and/or output control signals to one or more output devices 544 . In some implementations, control system 540 may be part of an anti-lock braking system (ABS), a navigation system, a telematics system, a vehicle telematics system, a lane departure system, an adaptive cruise control system, a vehicle entertainment system such as a stereo, DVD, compact disc and the like. Still other implementations are contemplated.
Powertrain control system 532 may communicate with mass data storage 546 that stores data in a nonvolatile manner. Mass data storage 546 may include optical and/or magnetic storage devices for example hard disk drives HDD and/or DVDs. At least one DVD may have the configuration shown in FIG. 6 . Powertrain control system 532 may be connected to memory 547 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. Powertrain control system 532 also may support connections with a WLAN via a WLAN network interface 548 . The control system 540 may also include mass data storage, memory and/or a WLAN interface (all not shown).
Referring now to FIG. 9 , the invention may be embodied in a cellular phone 550 that may include a cellular antenna 551 . The invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 9 at 552 , a WLAN interface and/or mass data storage of the cellular phone 550 . In some implementations, cellular phone 550 includes a microphone 556 , an audio output 558 such as a speaker and/or audio output jack, a display 560 and/or an input device 562 such as a keypad, pointing device, voice actuation and/or other input device. Signal processing and/or control circuits 552 and/or other circuits (not shown) in cellular phone 550 may process data, perform coding and/or encryption, perform calculations, format data and/or perform other cellular phone functions.
Cellular phone 550 may communicate with a mass data storage 564 that stores data in a nonvolatile manner such as optical and/or magnetic storage devices for example hard disk drives HDD and/or DVDs. At least one DVD may have the configuration shown in FIG. 6 . Cellular phone 550 may be connected to a memory 566 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. Cellular phone 550 also may support connections with a WLAN via a WLAN network interface 568 .
Referring now to FIG. 10 , the invention may be embodied in a set top box 580 . The invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 10 at 584 , a WLAN interface and/or mass data storage of the set top box 580 . Set top box 580 receives signals from a source such as a broadband source and outputs standard and/or high definition audio/video signals suitable for a display 588 such as a television and/or monitor and/or other video and/or audio output devices. Signal processing and/or control circuits 584 and/or other circuits (not shown) of the set top box 580 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other set top box function.
Set top box 580 may communicate with mass data storage 590 that stores data in a nonvolatile manner. Mass data storage 590 may include optical and/or magnetic storage devices for example hard disk drives HDD and/or DVDs. At least one DVD may have the configuration shown in FIG. 6 . Set top box 580 may be connected to memory 594 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. Set top box 580 also may support connections with a WLAN via a WLAN network interface 596 .
Referring now to FIG. 11 , the invention may be embodied in a media player 600 . The invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 11 at 604 , a WLAN interface and/or mass data storage of the media player 600 . In some implementations, media player 600 includes a display 607 and/or a user input 608 such as a keypad, touchpad and the like. In some implementations, media player 600 may employ a graphical user interface (GUI) that typically employs menus, drop down menus, icons and/or a point-and-click interface via display 607 and/or user input 608 . Media player 600 further includes an audio output 609 such as a speaker and/or audio output jack. Signal processing and/or control circuits 604 and/or other circuits (not shown) of media player 600 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other media player function.
Media player 600 may communicate with mass data storage 610 that stores data such as compressed audio and/or video content in a nonvolatile manner. In some implementations, the compressed audio files include files that are compliant with MP3 format or other suitable compressed audio and/or video formats. The mass data storage may include optical and/or magnetic storage devices for example hard disk drives HDD and/or DVDs. At least one DVD may have the configuration shown in FIG. 6 . Media player 600 may be connected to memory 614 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. Media player 600 also may support connections with a WLAN via a WLAN network interface 616 .
Referring to FIG. 12 , the invention may be embodied in a Voice over Internet Protocol (VoIP) phone 650 that may include an antenna 618 . The invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 12 at 604 , a wireless interface and/or mass data storage of the VoIP phone 650 . In some implementations, the VoIP phone 650 includes, in part, a microphone 610 , an audio output 612 such as a speaker and/or audio output jack, a display monitor 614 , an input device 616 such as a keypad, pointing device, voice actuation and/or other input devices, and a Wireless Fidelity (Wi-Fi) communication module 608 . Signal processing and/or control circuits 604 and/or other circuits (not shown) in VoIP phone 650 may process data, perform coding and/or encryption, perform calculations, format data and/or perform other VoIP phone functions.
VoIP phone 650 may communicate with mass data storage 602 that stores data in a nonvolatile manner such as optical and/or magnetic storage devices, for example hard disk drives HDD and/or DVDs. At least one DVD may have the configuration shown in FIG. 6 . The VoIP phone 650 may be connected to memory 606 , which may be a RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. The VoIP phone 650 may be configured to establish communications link with a VoIP network (not shown) via Wi-Fi communication module 608 . Still other implementations in addition to those described above are contemplated.
In accordance with various embodiments of the invention, the methods described herein are intended for operation with dedicated hardware implementations including, but not limited to, semiconductors, application specific integrated circuits, programmable logic arrays, and other hardware devices constructed to implement the methods and modules described herein. Moreover, various embodiments of the invention described herein are intended for operation with as software programs running on a computer processor. Furthermore, alternative software implementations including, but not limited to, distributed processing or component/object distributed processing, parallel processing, virtual machine processing, any future enhancements, or any future protocol can also be used to implement the methods described herein.
It should also be noted that the software implementations of the invention as described herein are optionally stored on a tangible storage medium, such as: a magnetic medium such as a disk or tape; a magneto-optical or optical medium such as a disk; or a solid state medium such as a memory card or other package that houses one or more read-only (non-volatile) memories, random access memories, or other re-writable (volatile) memories. A digital file attachment to email or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. Accordingly, the invention is considered to include a tangible storage medium or distribution medium, as listed herein and including art-recognized equivalents and successor media, in which the software implementations herein are stored.
While the invention has been described in terms of exemplary embodiments, those skilled in the art will recognize that the invention can be practiced with modifications in the spirit and scope of the appended claims. By way of example, the stations of the inventions may be any device capable of wireless communication and standards other than the IEEE 802.11 standard may be used to implement the invention, such as Bluetooth and similar standards. These examples given above are merely illustrative and are not meant to be an exhaustive list of all possible designs, embodiments, applications or modifications of the invention. | Symmetrical and asymmetrical ad-hoc, wireless networks and a method for saving power in the same may include causing a first station to determine whether a second station has a master capability to buffer data traffic for the first station. A first station requests the second station to buffer the data traffic intended for the first station for a first predetermined period. The first station enters a first power save mode, and the second station buffers the data traffic for the first station for the first predetermined period. The first station exits the first power save mode after the first predetermined period and the second station sends the buffered data traffic to the first station. Both the first and second stations may have master capabilities, or only one of the first and second stations may have a master capability. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to unidirectional force machines, and more particularly, to an impulse converter especially adapted to effect a conversion of angular impulses into linear impulses.
2. Description of the Prior Art
Impulse converters in the form of contra-rotating and unbalanced massed frames are known in the art of unidirectional force generation.
Thus, while the foregoing body of prior art indicates it to be well known to use unbalanced masses radially accelerated by arms on rotating frames to generate unidirectional force, the provision of a more simple and effective device is not contemplated. Nor does the prior art described above teach or suggest an impulse converting device which may be used by individuals needing greater conversion efficiencies and magnitudes of impulse output. The foregoing disadvantages are overcome by the unique mass passage and structure of the present invention as will be made apparent from the following description thereof. Other advantages of the present invention over the prior art also will be rendered evident.
SUMMARY OF THE INVENTION
To achieve the foregoing and other advantages, the present invention, briefly described, provides an impulse converter for converting angular impulses into linear impulses. The impulse converter includes a frame with frame members adapted to be oppositely rotated on the frame. The frame members may be rotated by any rotation generating device. Arms and masses are provided on the frame members, the masses are to be accelerated both radially and tangentially by the arms due to the rotation of the frame members. A rack and pinion mass retrieval unit is provided on each of the arms to retrieve the masses back along the length of the arm. The masses are re-accelerated along the arms, and re-retrieved by the rack and pinion mass retrieval unit which converts the radial and tangential accelerations into linear impulses.
The above brief description sets forth rather broadly the more important features of the present invention in order that the detailed description thereof that follows may be better understood, and in order that the present contributions to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least three of preferred embodiments of the invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood, that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for designing other structures, methods, and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms of phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. Accordingly, the Abstract is neither intended to define the invention or the application, which only is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved impulse converter which has all of the advantages of the prior art and none of the disadvantages.
It is another object of the present invention to provide a new an improved impulse converter which may be easily and efficiently manufactured and marketed.
It is a further objective of the present invention to provide a new and improved impulse converter which is of durable and reliable construction.
An even further object of the present invention is to provide a new and improved impulse converter which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such an impulse converter available to the buying public.
These together with still other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated, preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and the above objects as well as objects other than those set forth above will become more apparent after a study of the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a top view showing the impulse converter and the paths followed by the motors.
FIG. 2 is a close up view showing the motor mounted on a rack and pinion and a magnetic clutch.
FIG. 3 is a side view of the impulse converter.
FIG. 4 is a front view of the motor and the rack and pinion assembly.
FIGS. 5a through 5d show a diagram of the reversing direction change possible of the coriolis accelerations as the motor mass passes through the center of rotation of the rotatable members on the impulse converter.
FIG. 6A represents the motor travelling diametrically on the rotating frame members capable of passing through the center of rotation of the rotatable members.
FIG. 6B represents the motor travelling on the rotating frame at a discrete time interval passing through the center of rotation.
FIG. 6C represents the two motor mass embodiment of the invention, the constant running motors travelling in either diametrical direction on the rotating frame.
FIGS. 6D through 6I inclusive diagrams the changing radial motor mass position as the frame member rotates with respect to the coriolis accelerations developed on the frame.
FIGS. 7A through 7E diagrams the accelerations in the over developed coriolis embodiment of the instant invention with a two motor mass passing through the center of rotation.
FIG. 8 shows the two gyromass embodiment and the accelerations developed thereon.
FIG. 9 show the resultant unidirectional force generated in the over developed coriolis acceleration embodiment.
FIGS. 10a and 10b diagrams two amplified coriolis impulse embodiments generated from two oppositely rotating frame members.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, a new and improved impulse converter embodying the principles and concepts of the present invention will be described.
Turning initially to FIGS. 1-3 there is shown a first exemplary embodiment of the impulse converter generally designated by reference numeral 10. Impulse converter 10, shown in FIG. 1, generates a propelling force in the direction indicated by arrow 37. Generally, impulse converter 10 includes a frame 11, constant running motor mass assembly 15, and controlling apparatus 12 (FIG. 4) or controlling the movement of constant running motor mass assembly 15.
Frame 11 is adapted to be secured to a vehicle which is to be imparted motion through propulsion. Frame 11 includes two oppositely rotating frame members 20 having thrust bearings 21 encircling each rotating frame member 20 on frame 11. Each rotating frame member 20 with thrust bearings 21 are mounted at their centers to drive shaft 25 (FIG. 3) for rotation by primary power source motor 22.
Each constant running motor mass assembly 15 includes a motor platform 17 upon which is mounted a constant running motor 16 with pinions 18. The pinions 18 are coupled to the constant running motor 16 by magnetic particle clutches 14. Pinions 18 are linked by gear teeth to racks 19 (FIGS. 2 and 4) which are mounted on rotating frame member 20 in abscissa and ordinate fashion.
Constant running motor mass assemblies 15 are disposed on the surface of rotatable frame member 20. Constant running motor mass assemblies 15 experience an acceleration in the radial direction with respect to the rotatable frame member 20, when the rotatable frame member 20 is rotated by the primary power source motor 22. Arrow C represents the direction of rotation of a rotatable element, e.g. frame member 20, shaft 25 and shaft 26 etc. Constant running motor mass assemblies 15 are simultaneously given increasing tangential velocity relative to the frame 11 by their position on rotating frame member 20.
Not shown are the reducing motors within primary power source motor 22 for controlling angular velocities and angular accelerations of the drive shaft 25.
Control apparatus 12 includes linear motion bearings 13 secured to the top surface of the rotatable frame member 20. Linear motion bearings 13 mounted on the underside of motor platform 17 guide constant running motor mass assemblies 15 for mating travel of pinions 18 on racks 19 mounted on the rotatable frame member 20. Magnetic particle clutches 14 are coupled between the shafts of constant running motor 16 and pinions 18 as a coupling means for engaging and disengaging pinions 18 to the shafts of the constant running motor 16.
Electrical contacts 23A and 24B serve to energize magnetic particle clutch 14 and constant running motor 16 respectively as seen in FIG. 4.
The impulse converter 10 operates as follows. Primary motor 22 rotates frame members 20, as frame members 20 is rotated, each constant running motor mass assembly 15 is rotated in a rigid and radially free manner to follow a predetermined asymmetrical spiral path 29 as rotatable frame member 20 rotates.
As each constant running motor mass assembly 15 reaches a predetermined point on the spiral path 29 contact is made on the electrical contact 23A which energizes magnetic particle clutch 14 to engage pinion 18 to the shafts of the constant running motor 16 to complete the asymmetrical spiral path 29 to generate an impulse output and radial displacement, the constant running motor mass assemblies 15 to return upon the frame member 20 and in turn onto thrust bearing 21 and then to frame 11.
A propelling force having a direction indicated by arrow 27 is generated from the time the constant running motor mass assembly 15 goes into the radial return path 30 until the constant running motor mass assembly 15 is radially freed by the de-energizing of the magnetic particle clutches 14 through electrical contacts 23A to begin the cycle all over again. Through the repetition of this cycle conversion of rotational energy as angular impulses into linear impulses in a desired direction as a uni-directional force is achieved.
Referring now to the FIGS. 6A through 6I, when two oppositely rotating constant running motors 330 and 340 pass through the center of rotation with mass 150 of the constant running motors 330 and 340 being on opposite sides of the center, coriolis acceleration will be eliminated by the action of a shifting couple, i.e. conservation of angular momentum acting as a balanced couple. There will be little or no generation of coriolis acceleration occurring when this kind of torque is applied in a coupled manner outside the center of rotation. FIGS. 6A through 6I show the instantaneous emergence of motor mass assembly 15 from the dead center of rotation when the coriolis acceleration changes 180 degrees. This action is used in radial spiral throws, strategic torquing, amplified coriolis accelerations and over developed coriolis accelerations and is shown by the elements A, B, and C of FIGS. 6A through 6I and in B of FIGS. 7A through 7E.
The arrows A in FIGS. 5a through 5d and 6A through 6I represents coriolis accelerations. Arrows B represent radial and diametrical travel of the motor mass 150. Arrows C represents the rotational direction of the rotatable member 200. A coriolis acceleration embodiment uses an overdeveloped coriolis acceleration to propel the impulse converter as shown in FIGS. 5a through 5d. Each rotatable frame member has a single diametrical rack which extends from edge to edge on the rotatable frame member 200. Motor mass assembly 150 is free to pass from edge to edge through the center of rotation of frame member 200. The cross arrows C, ie, those arrows crossing arrow A (indicating coriolis acceleration), show the rotation direction of the frame member 200 as shown in FIGS. 6D through FIG. 6I. Over developed coriolis acceleration has the added acceleration of the motor mass 150 whereas the amplified coriolis acceleration uses the precessional forces which are gyroscopically added as accelerations. FIGS. 5a through 5d shows the over-developed coriolis acceleration embodiment with the mass assembly passing near or through the center of rotation in the last half of the first quadrant, the second quadrant, the third quadrant and the first half of the fourth quadrant. The over-developed coriolis accelerations are over-developed by the additive throw-out and return accelerations given to the motor mass assembly 150 in the second half of the fourth quadrant and the first half of the first quadrant. Either of the two constant running motors 330 or 340 may be engaged for this motion depending on the direction of radial travel desired, i.e., depending on the direction of the radial throw-out or return relative to the platform. A Complementary Resultant Force, (CRF) as shown in FIG. 7A, of propulsion can be generated between the radial return of mass assembly 150 and the coriolis acceleration generated up to and through that return. The magnetic clutches 140 (not shown) strategically engage pinions 180 and motor 160 only in the second half of the fourth quadrant and the first half of the first quadrant to maximize the resultant force between the radially returned mass assembly 150 and the over developed coriolis force as a unidirectional force.
Referring now to FIG. 8 gyromass 32 can be placed on the motor mass assembly with its precession direction set at 45 degrees to both the plane of the rotating member and to the radial direction of the rack on the rotating member 140 (not shown). This facing of the precession direction will amplify the resulting coriolis acceleration by the amount of precessional force generated from the gyroscopic inertia available. The rotational directions and critical angle settings of the optimum precession facing the gyromass are shown in FIG. 8 by arrow C indicating rotation and arrow D indicating precessional direction respectively. The torque on the gyromass 32 generated by the angular velocity of the rotating member is represented by E and F showing the direction of the radial acceleration on the gyromass 32.
If two contra-rotating mass systems are used in the over-developed coriolis acceleration embodiment, then the radial return force will be canceled since the radial return force would be diametrically opposed to each other. Furthermore, when the over-developed coriolis acceleration embodiment is being used, two oppositely rotating constant running motors are needed on the same motor platform as explained above. However, only a single rotating mass system can be used to recoup both the amplified radial return force and the over-developed coriolis acceleration as shown in FIG. 9.
An amplified coriolis acceleration embodiment uses the precession from oriented gyromasses to amplify the propulsion generated from the coriolis accelerations. This amplification can be used with or without over-developed coriolis accelerations. Even though the radial return will also be canceled when overdeveloped coriolis acceleration is employed in the two contra-rotating mass systems and the radial return will be canceled, the efficiency of the system will still be increased by the amount of the over-developed increase in coriolis acceleration.
FIG. 9 shows that only one rotating frame can be used to combine coriolis acceleration A and amplified radial throw-out G and rapid radial return H in complement to form a resultant over-developed coriolis acceleration ROCA as a linear impulse. W represents the window for H to generate and express resultant over developed coriolis acceleration.
Two oppositely rotating and framed impulse converters can be loaded with gyroscopic masses 32. The plane of rotation of each of the gyroscopic masses 32 contains the precessional force direction. These planes are set at an angle of 45 degrees to the plan of the impulse converter's rotation as shown in FIG. 8. The rotation plane of these gyroscopes will therefore also be at a 45 degree angle to the radial plane of the impulse converter. The coriolis acceleration will be amplified by the gyroscopic precession force generated by the framed gyroscopic masses as the torque from the impulse converter's rotation is applied to the framed gyroscopes, thus producing precessional force.
In the amplified coriolis impulse converter (ACI) embodiment both the extension and retrieval directions of the gyroscopic mass are always perpendicular to both the developed impulse for translation and the net precessional force generated at any instant on a point location in the rotation of the impulse converter.
FIG. 10a and 10b depict the two possible directions for rotations of the frame members to oppositely rotate and generate coriolis impulse A from the precessional force. The gyroscopic mass 32 has a radial travel direction F and an amplified coriolis acceleration (ACI). The directions of the precessional force will be developed at 45 degrees to both the rotational plane of the rotational member 200 and the radial travel plane F.
The vector products for angular momentum, torque, and the angular velocity of precession are to be included in calculating the linear impulse generated with respect to time and a single direction from the coriolis impulse. The impulses generated from the gyroscopic vector product and the coriolis acceleration A are justifiable called amplified coriolis impulses (ACI).
The efficiencies of the various impulse converter embodiments can be dramatically increased by using two counter rotating continuously running motors for developing over developed radial accelerations. The increase in efficiencies will be proportional to the quantity of impulses delivered. Furthermore the oriented gyromass will improve coriolis accelerations used in the amplified coriolis accelerations by the amount of available precession.
Improvements in the efficiencies is limited only by the angular velocities achieved, the size of the throw masses and the strengths of materials employed.
It is apparent from the above that the present invention accomplishes all of the objectives set forth by providing a new and improved impulse converter which converts angular impulses into linear impulses in an efficient and simple manner.
With respect to the above description, it should be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to those skilled in the art, and therefore, all relationships equivalent to those illustrated in the drawings and described in the specification are intended to be encompassed only by the scope of appended claims.
While the present invention has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiments of the invention, it will be apparent to those of ordinary skill in the art that many modifications thereof may be made without departing from the principles and concepts set forth herein. Hence, the proper scope of the present invention should be determined only by the broadest interpretation of the appended claims so as encompass all such modifications and equivalents. | An impulse converter is provided for converting angular impulses into linear impulses. The impulse converter includes a frame with frame members adapted to be oppositely rotated on the frame. The frame members may be rotated by any rotation generating device. Arms and masses are provided on the frame members, the masses are to be accelerated both radially and tangentially by the arms due to the rotation of the frame members. A rack and pinion mass retrieval unit is provided on each of the arms to throw out and/or retrieve the masses back along the length of the arm. The masses are re-accelerated along the arms, and re-retrieved by the rack and pinion mass retrieval unit which converts the radial and tangential accelerations into linear impulses. | 8 |
This is a continuation-in-part of application Ser. No. 730,514, filed Oct. 7, 1976, and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a joint for a large diameter casing adapted to extend deeply downwardly under the ground or water for use in the drilling or oil wells, and more particularly to a joint structure or configuration which provides excellent hermetically pressure tight capability and which is suitable for connection and coupling of large diameter casings.
Tubular members of large diameter have heretofore had their tube and joint sections subjected to an excessive tension stress resulting from their own weight when the tubular members are lowered to a predetermined depth within a well or the like. Loads of 200-300 tons at maximum are applied to the tubular member when suspended, and the tubular member is required to withstand pressure of 200-300 kg/cm 2 per unit area in section. Thus, in the conventional joint, the connection with the tubular member must be designed to provide the maximum possible extent of thread contact. This however, may result in difficulty in connecting pipe sections. Alternatively, the joint may be constructed to allow for an easy and ready connection, but this however sacrifices sealing capability.
Successive connections of the tubular members impose an excessive torque on the joints as a result of tightening to the fullest possible extent to secure a pressure tight seal. Consequently, all of the joints may be deformed into a flat configuration and thus become unusable. Improvements on the external and internal thread configurations of such joints have been proposed to increase the yeild strength for a load on the tubular member when it is suspended. However, such proposals have failed, since the actual connecting operation leads to cross threading between the thread faces or turns. This results in cracks in the threaded portion crossing the axis of the tubular member and, contrary to reinforcing the yield strength, deteriorates the sealing capability of the joint. Accordingly, the casing is not usable over a long period of time.
SUMMARY OF THE INVENTION
The present invention eliminates the aforementioned defects inherent in the conventional pipe joint, and provides a new and useful joint structure which is conspicuous in its pressure tightness, sealing capability, and workability.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and additional features of the invention will become apparent from the following detailed description, taken with the accompanying drawings, wherein:
FIG. 1 is a fragmentary side elevation of a large diameter casing in longitudinal section, showing joint sections welded to each other;
FIG. 2 is a partial sectional view showing the general configuration of the threads, in buttress form, of a joint section according to the present invention, and a threaded engagement therebetween;
FIG. 3 is an enlarged and expanded view of the threads shown in FIG. 2, illustrating a theoretical gap between abutting butt faces; and
FIG. 4 is a view similar to FIG. 2, but illustrating the threads as having rounded crests and roots and also illustrating in more detail the precise structural configuration of the threads.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown a pipe section P of large diameter and adapted to be extended downwardly into a drilled well. Pipe P has attached thereto at the upper end thereof a female screw portion A and at the lower end thereof a male screw portion B, with these screw portions being firmly secured, e.g. by butt welded seams W, to the pipe section P. A unitary large diameter conductor pipe, having a length dependent on the depth of drilling, may be formed by successively joining plural pipe sections P through threaded connections of the female and male screw portions A and B from bottom to top. The female screw portion A which defines a portion of a joint element between two pipe sections P is fabricated to have at its lower end a shoulder 20 directed inwardly at a right angle. This facilitates gripping the tubular member when it is suspended. The male screw portion B, in opposition to and downwardly of the shoulder 20 of female screw portion A, is provided at its upper end with an upwardly and inwardly sloping shoulder 21.
As shown in the drawings, the joint element of the present invention is so arranged that a tubular member 1 (formed by a male screw portion B of a first pipe section P) with an external thread portion 3 formed on the exterior thereof is adapted to engage an internal thread portion 4 formed on the interior of another tubular member 2 (formed by a female screw portion A of a second pipe section P). One of the external and internal thread portions 3 and 4 is threaded and presents a tooth-shaped profile which includes at least three sections I, II, and III, each of which is different from the others in configuration.
Each of the threads may be configured in the buttress manner illustrated in FIGS. 2 and 3 or in a "rounded crest and root buttress" manner as illustrated in FIG. 4. The discussion herein will refer to the features of the invention by reference to both the buttress configuration of FIG. 2 and the "rounded buttress" configuration of FIG. 4. It is to be understood that the concept and features of the invention are equally applicable to both configurations.
In either case, butt face 14 or 15 (FIG. 3) of each of the threads when engaged with each other forms a flank angle α of 1°-5° with a plane perpendicular to the longitudinal axis or center line C of the tubular member. Each meshing thread also includes a crest 12 or a root 13, extending parallel to respective pitch diameter lines, and a back pressure face 10 or 11.
As shown in FIG. 4, a straight line DZ represents a pitch diameter line of the female screws of member 2. A boundary point X between the first and second sections I and II and a boundary point Y between the second and third sections II and III lie on straight line DZ. In other words, the pitch diameter line of one of the threads, i.e. of the female thread in the illustrated embodiment, is inclined at a predetermined small angle β with respect to a center line C of the pipe. The female threads of member 2 are thus in the form of a normal tapered buttress-type thread.
On the other hand, the pitch diameter of the male screw threads within the first section I fully equals and coincides with that of the female screw threads. The male screw threads fully abut against the female screw threads at surfaces or areas i, ii, iii and iv, as will be described hereinafter.
The pitch diameter line of the male screw threads gradually moves away from the pitch diameter line of the female screw threads during the length of the second section II, i.e. along a line X--Y' inclined toward the axis C of the pipe. The pitch diameter lines X--Z and Y'--Z' of the male and female screw threads extend parallel with one another within the third section III.
As above described, the male and female screw threads are maintained in full engagement with one another at the surfaces i-iv within the first section I. However, in the section II the pitch diameter line of the male screw threads diverges away from that of the female screw threads at a small angle γ. This provides a gap a 2 between the threads of the female and male screw threads at the surface ii, and other gaps a 3 and a 4 therebetween at the surfaces iii and iv, respectively. These gaps may be further defined in the following.
As seen from FIG. 3, the gaps (perpendicular to the axis of the pipe P) at the surfaces ii and iv are denoted by a 2 and a 4 . The gap at the abutment surface i and the gap at the bearing surface iii are designated by a 1 and a 3 , respectively. This may be expressed by the following equation:
a.sub.2 = a.sub.4 = p {tan (β + γ) - tan β}(1)
wherein p is a length obtained from measurement of the second section starting from a boundary point of section II in the direction of the axis of the pipe (in the drawings, p is the distance from a perpendicular line including X to a line E--E'), and β is the angle of the pitch diameter line DZ to the axis C of the pipe P. α o is the angle at which the bearing or back pressure face 11 is inclined to a line perpendicular to the axis C of the pipe. The relation of the gaps at the respective surfaces may be further defined as follows:
a.sub.1 = a.sub.2 tan α = p tan α {tan (β + γ) - tan β} (2)
a.sub.3 = a.sub.2 tan α.sub.o = p tan α.sub.o {tan (β + γ) - tan β} (3)
Consequently, the pitch of the male screw threads in the second section II is made larger by the gap a 1 when employing a normal thread cutting operation.
However, according to the present invention the screws threads are constructed so as to fully abut against one another at the abutment surface i (i.e. such that a 1 = 0). Accordingly, gaps will be provided at the respective surfaces ii, iii and iv. In order to have the screw threads abut against one another at the thread forming surface i in the second section II, the pitch of the male screw threads is continuously reduced by the gap a 1 . In other words, the pitch of the male screw threads in the second section II is made smaller than in the first and third sections I and III. That is, the pitch of the male screw threads continuously varies with variation in the pitch diameter line in the second section II, i.e. diverges with respect to that in the first section I, wherein a 2 and a 4 are set, the value of a 3 also being set from the equation (3), and a 1 is continuously corrected depending thereupon. This continuous correction may be attained by varying the pitch diameter line in the second section II in such a manner that the abutment surfaces 14 and 15 of all the thread surfaces of the male and female screw threads, respectively, contact at a uniform abutment force.
The tubular member 1 has at its bottom end, adjacent the top of threaded portion 3, a relatively widely dimensioned shoulder 8 to impart to an upper end 7 of the internal threaded portion 4 of the tubular member 2 an axial impulsive force derived from a blow of a pile driver or the like exerted on the tubular member 1. The butt faces defined by the upper end 7 and the shoulder 8 form an angle equal to the flank angle α of the butt faces 14 and 15 of the threaded portions 3 and 4 with a plane perpendicular to the axis C of the pipe. The tubular member 2 is provided at the upper end of the internally threaded portion 4 thereof with an annular recess 9, of trapezoidal shape as shown in longitudinal section. O-rings 6, forming auxiliary seal members, of plastic material are mounted and held between the recess 9 and the exterior of the bottom end of the externally threaded portion 3.
In the section I, the externally and internally threaded portions 3 and 4 are so engaged with respect to one another that, when in fully threaded meshing engagement, the crests and roots (surfaces ii and iv), the butt faces 14 and 15 (surfaces i), and back pressure faces 10 and 11 (surfaces iii) are tightly abutted against each other. Thus, the joint structure will form an extremely tight sealing zone in cooperation with the sealing action of the O-rings 6 to thereby withstand a considerably high pressure of fluid passing through the pipe section. As mentioned above, the externally and internally threaded portions 3 and 4 in the third section III are dimensioned and configured to have a relatively large degree of clearance therebetween, so that the tubular member 1 may be smoothly inserted in the tubular member 2 without axial alignment and then turned with respect thereto for easier starting of threading.
As mentioned above, there is one clearance a 3 between the back pressure faces 10 and 11, and another clearance (a 2 or a 4 ) between the crests 12 and the roots 13. The threads in the second section II provide a progressive change from the wholly meshed threads of section I to the loosely meshed threads of section III. That is, in section II the clearances between the back pressure faces 10 and 11 and between crests 12 and roots 13 gradually enlarge from the first section I to the third section III.
In the past, threading to obtain the successively varying thread configurations such as in section II would have been practically difficult. However, recent developments in numerical control of machine tools enable the use of mechanical machining to obtain joints in which the thread configurations successively and ungradually vary. This invention makes practical use of such development to obtain a thread joint having the thread configurations of second section II.
According to the embodiment as set forth hereinbefore, the tapered external and internal threads in the third section III, which extend along about one-third of the entire thread length, are threadedly meshed with each other to have a relatively great clearance therebetween to thereby facilitate a rapid and ready tightening operation. The first section I has a length equal to at least two turns of the threads to achieve a tight engagement of the respective threads and to maintain the joint structure safe and stable. This arrangement will continuously and hermetically withstand heat and pressure, even when used in an oil well which extends downwardly to a great depth. In addition, the threads in the second section II, i.e. "transition" section, which also extends along about one-third of the entire thread length, enable the joint to be tightly and threadedly connected. The external and internal threaded portions have butt faces 14 and 15, respectively, which form the flank angle α of 1°-5°, preferably about 2°, with a plane perpendicular to the axis C of the tubular member, and are strong enough to withstand or resist forces of axial compressive stress generated in the thread faces during connection of the pipes.
The internal portion 4 is tapered and diminished in size, and the end portion 7 thereof is thinner than the bottom end 8 of the external threaded portion 3. However, cracking of portion 7 due to compressive stress derived from threading torque, fluid pressure when the pipe is lowering in a well, or impact of the pipe on a hard stratum is avoided due to the presence of the flank angle α between the faces 7 and 8.
The threaded joint structure of the present invention affords strength enough to avoid chipping of the threads even if the structure is subjected to tensile stress resulting from the great weight of plural suspended pipe sections when the latter are joined together from the bottom to the top while moving downwardly into a deep well. Thus, the joint structure of the present invention provides an excellent practically workable connection. With a relatively small torque, the butt faces and the threads formed in the first section I are fully and tightly held against each other to obtain a pressure tight seal, such that the connection is highly practical.
Although the invention has been described with reference to specific embodiments, it is apparent that many modifications may be made by one skilled in the art without departing from the scope of the invention. For instance, the threads may be divided into more sections than the three sections I, II, and III shown and described. | Pipe joints for a large diameter casing, which are lowered inside an oil well or the like and are successively connected to one another, are subjected to critical conditions such as load on the casing when suspended, and pressure. A pipe joint of this class is also required to provide torque during the connecting operation and sealing capability after connection. Tooth profiles or thread configurations formed in the pipe joints welded to the intervening large diameter tubular member extend over at least three sections. In the first section, each of the external threads is engaged with each of the internal threads in such a manner that its crest and root are fully meshed to allow its butt face to abut against its back pressure face. In the second section adjacent the first section, the threads are so formed as to involve an easy transition to the thread configuration formed in the third section where the threads are so shaped that the external threads are readily meshed with the internal threads. Threaded in this manner, a pipe joint can be obtained that satisfies operative characteristics such as pressure tightness, sealing capability, and workability. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a new and improved wet section of a twin wire papermaking machine.
Generally speaking, the wet section of the twin wire papermaking machine is of the type comprising two revolving endless wires, especially an upper wire and a lower wire, travelling in a predetermined direction of movement. The web-supporting portion of the lower wire has a section which extends in essentially horizontal direction, and at one region the upper and lower wires are guided together. Further, there is provided at least one headbox from which emerges the fiber stock suspension in a wide jet which arrives at the one region between both of the guided together upper and lower wires where there is dewatered the fiber stock suspension and the web formed therefrom.
2. Discussion of the Background and Material Information
As a general rule, such type papermaking machines are employed for the manufacture of a paper or cardboard web --hereinafter sometimes generally simply broadly referred to as a paper web--which is formed by dewatering a fiber stock suspension at a wire or between two wires.
It is well known in the papermaking art that there are available quite a number of different constructions of papermaking machines of the aforementioned type. For example, in the commonly assigned German Patent No. 3,138,133, published Mar. 24, 1983, there is schematically disclosed in FIGS. 1, 2 and 3 papermaking machines which, through the use of an upper wire and a lower wire, render possible the fabrication of a paper 3,910,892, published Oct. 11, 1990, there is disclosed the forming region of a twin wire papermaking machine comprising a forming roll located at the lower wire and a section of the twin wire which extends upwardly over a curved forming shoe.
However, the heretofore known papermaking machines of this type are afflicted with the drawback that the operating range thereof is limited in that such papermaking machines can not be operated at velocities below a predetermined value and then only when producing paper products of relatively low basis weight, for example, paper used for printing newspapers. Such prior art papermaking machines possess the feature that the centrifugal force present at the forming roll, at velocities particularly below 500 meters per minute, is too small in order to adequately upwardly propel the water of the stock suspension and to remove such water at a collecting vat or trough provided for such water. This aspect of water removal is additionally made more difficult due to the fact that such papermaking machines exhibit an ascending course of the forming wire as viewed in the lengthwise direction of the papermaking machine, also referred to as the machine direction, in other words, in the direction of travel of the forming wire. Additionally, by virtue of the ascent of the guidance of the forming wire at the sheet forming zone of the papermaking machine there can arise differential velocities between the fiber stock suspension and the forming wire, resulting in alignment of the fibers in the lengthwise or machine direction of the papermaking machine.
This phenomenon is attributable, on the one hand, to a deceleration of the flow velocity of the fiber stock suspension due to having to overcome an increase in height in accordance with Bernoulli's equation. A further reduction in the velocity of the fiber stock suspension is caused by the presence of additional friction and stock turning losses due to the presence of the suction boxes.
The result of all of this is that there occurs a relatively pronounced fiber alignment in the lengthwise direction of the papermaking machine. The tear length ratio, namely L/Q, measured in the lengthwise and transverse directions of the paper web, can lie in the range of 2.5 to 4, which is frequently undesirable, for example, during the manufacture of liner or test liner paper or board or the like. In that case, there is desired a relatively low L/Q ratio in the order of between 1.0 and 1.5.
Furthermore, when there are present relatively high web weights, drawbacks arise by virtue of the small selected wrap angle at the forming roll of the prior art papermaking machines. At the subsequent region of the papermaking machine there also prevails the danger that the paper web is unduly compressed by the action of the forming elements arranged at the upper wire when there is present a high sheet weight or basis weight of the paper web.
A different construction of papermaking machine, as for example disclosed in U.S. Pat. No. 4,830,709, granted May 16, 1989, is devoid of any forming roll at the lower wire. Moreover, the first suction box at the lower wire, as viewed in the machine direction, is ascendingly arranged. Consequently, the water effluxing through the upper wire can flow back opposite to the machine direction, especially in the presence of relatively low machine velocities. Also, with this construction of papermaking machine there is not present any upper apex point of the lower wire at the front section or region of the sheet formation.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide an improved twin wire papermaking machine which is not afflicted with the aforementioned shortcomings and drawbacks of the prior art.
Another and more specific object of the present invention aims to provide an improved twin wire papermaking machine which can be advantageously employed for the manufacture of paper or the like throughout a wide range of operating velocities and for the most varied basis weights of the fabricated paper or the like.
Still a further noteworthy object of the present invention and in keeping with the immediately preceding object relates to an improved twin wire papermaking machine wherein the former can be advantageously used for the manufacture of paper or the like having a web weight in the order of between 30 grams/ 2 and 300 grams/m 2 and at machine velocities in the range of from 200 meters/min. to beyond 1000 meters/min.
Now in order to implement these and still further objects of the present invention, which will become more readily apparent as the description proceeds, the wet section of the papermaking machine of the present development is manifested, among other things, by the features that a forming roll is provided in the lower wire and about which there is partially trained both the upper and lower wires. In the lower wire there is provided at least one suction box, and in the upper wire there is provided at least one top or upper suction device. Downstream of the at least one top or upper suction device, as viewed with respect to the predetermined direction of movement of the upper and lower wires, there is arranged at least one vacuum suction box in the upper wire, and downstream of the at least one vacuum suction box, as viewed with respect to the predetermined direction of movement of the upper and lower wires, there is arranged at least one separation element in the lower wire, especially a separation suction device or a separation roll.
By virtue of the aforementioned combination of features as contemplated by the present invention, the wet section of the papermaking machine is designed such that at the region of the twin wire wrap established at the forming roll there arises a favorable formation of the web with effective dewatering of the web. In this regard, a positive effect is realized by virtue of the geometric conditions which exist at this region, such as, for instance, the relatively large wrap angle of both wires at the forming roll, which is in the order of about 45°, as well as the rapid unhindered removal of the water. This is achieved if the forming section arranged after the forming roll, extends at least partially downwardly in the direction of the force of gravity. The losses in the flow velocity of the fiber stock suspension caused by the suction boxes at the upper and lower wires are at least partially compensated by the acceleration of the fiber stock suspension between the upper and lower wires due to the action of the force of gravity.
The water effluxing at the upper wire is removed above the upper wire by a top or upper suction device. Following the forming roll both the upper and lower wires are either guided substantially horizontally, descendingly or slightly ascendingly over one or more curved surfaces, and further forming of the web is accomplished due to the suction action of the at least one suction box at the lower wire and the vacuum suction box at the upper wire.
According to a further feature of the present invention, the upper apex point of the forming roll is situated at a higher elevational position than the web-supporting portion of the lower wire which has a section extending in essentially horizontal direction.
As to a still further feature, the upper apex point of the forming roll constitutes the highest point of the lower wire.
It is contemplated to provide at least one further suction box in the lower wire. Also a suction roll can be provided in the lower wire.
Still further, the at least one suction box provided in the lower wire contacts the uppermost point of the lower wire.
It is further contemplated to arrange the at least one top or upper suction device provided in the upper wire between the forming roll and the at least one suction box provided in the lower wire.
According to a further aspect, the at least one suction box provided in the lower wire has a surface contacted by the lower wire, and at least part of this surface contacted by the lower wire, as viewed in the predetermined direction of movement of the upper and lower wires, is substantially convexly curved with respect to the lower wire.
According to another feature, the at least one vacuum suction box provided in the upper wire has a surface contacted by the upper wire, and at least part of this surface contacted by the upper wire, as viewed in the predetermined direction of movement of the upper and lower wires, is substantially convexly curved with respect to the upper wire.
A further development of the present invention contemplates that the front edge of the at least one vacuum suction box provided in the upper wire is located at a greater elevational positional than the section of the lower wire which extends in essentially horizontal direction.
Moreover, the at least one suction box provided in the lower wire has a predetermined length in the predetermined direction of movement of the lower wire and the at least one vacuum suction box provided in the upper wire has a predetermined length in the predetermined direction of movement of the upper wire. The predetermined length of the at least one vacuum suction box provided in the upper wire is greater than the predetermined length of the at least one suction box provided in the lower wire.
According to a further feature, pressure elements are arranged beneath the at least one vacuum suction box provided in the upper wire and these pressure element means are elastically pressable towards the lower wire.
Still further, the at least one separation element includes an active surface arranged intermediate planes extending through the upper apex point and the lower apex point of the forming roll.
It is also contemplated to arrange the at least one headbox forwardly of the forming roll so as to define a gap former. Such at least one headbox can comprise a multi-ply headbox.
According to a further concept, a longitudinal wire section provided with the at least one headbox is arranged forwardly of the forming roll so as to define a hybrid former. This longitudinal wire section advantageously constitutes part of the lower wire.
A further aspect envisages the lower wire including a rear portion as viewed with respect to the predetermined direction of movement of the upper and lower wires, and this rear portion of the lower wire extends in substantially horizontal direction. Moreover, such rear portion of the lower wire can be arranged downstream of the at least one separation element as viewed with respect to the predetermined direction of movement of the upper and lower wires.
Furthermore, the invention also foresees that the at least one top suction device provided in the upper wire defines a first top suction device, and that a second upper suction device is provided in the upper wire. Additionally, the at least one suction box provided in the lower wire defines a first vacuum suction box, and a second vacuum suction box is provided in the lower wire.
Moreover, it is possible for the first vacuum suction box to have a surface contacting the lower wire which is substantially flat and the second vacuum suction box to have a surface contacting the lower wire which is substantially convex with respect to the lower wire.
As to a further feature of the present invention, the at least one vacuum suction box provided in the upper wire has a surface which contacts the upper wire and this surface comprises a first portion which is substantially flat and a subsequently arranged second portion which is substantially convexly curved with respect to the upper wire.
According to a still further feature, the total length of the upper and lower wires contacted by the suction boxes provided in the upper and lower wires is greater than the circumferential length of the forming roll wrapped by the upper and lower wires.
A further development of the invention contemplates that the suction boxes in the upper and lower wires define a forming path and the entire forming path descends as viewed with respect to the predetermined direction of movement of the upper and lower wires.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein there have been generally used throughout the various figures the same reference characters to denote the same or analogous components and wherein:
FIG. 1 is a schematic side view of the wet section of a papermaking machine according to the present invention and defining a gap former;
FIG. 2 is a schematic side view of a second embodiment of the wet section defining the forming region of a papermaking machine according to the present invention and defining a gap former;
FIG. 3 is a schematic side view of a third embodiment of the wet section defining the forming region of a papermaking machine according to the present invention and defining a gap former;
FIG. 4 is a schematic side view of a fourth embodiment of the wet section of a papermaking machine according to the present invention defining a gap former and embodying separated suction boxes;
FIG. 5 is a schematic side view of a fifth embodiment of the wet section of a papermaking machine according to the present invention defining a hybrid former; and
FIG. 6 is a schematic side view of a sixth embodiment of the wet section of a papermaking machine according to the present invention defining a hybrid former.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that only enough of the construction of the different embodiments of a wet section of a papermaking machine has been depicted therein, in order to simplify the illustration, as needed for those skilled in the art to readily understand the underlying principles and concepts of the present invention.
Turning attention now to FIG. 1, there is disclosed therein a most preferred embodiment of the wet section of a papermaking machine which is equipped with a headbox 10 from which emerges a fiber stock suspension jet, for example, a wide stock suspension jet which directly arrives between both of the converging forming wires 8 and 9, specifically the upper wire 8 and the lower wire 9. These upper and lower wires 8 and 9 travel in a predetermined direction of movement as indicated by the arrows 50 in FIG. 1 in order to form therebetween the web forming section 52 of the papermaking machine. Furthermore, it will be seen that the lower wire 9 contains a web supporting portion 54 having a section 56 extending in essentially horizontal direction and defining a rear portion of the lower wire 9.
Downstream of the headbox 10, which can be a multi-ply headbox, there is arranged a forming roll or roller 1, here, for instance, an open forming roll, about which there is partially trained at one region of the web forming section 52 both of the upper and lower wires 8 and 9, yet at a region forwardly of the place where there are wrapped both of these wires 8 and 9 this forming roll 1 is only partially wrapped by the lower wire 9. Since here the headbox 10 is arranged directly forwardly of the forming roll 1 the arrangement defines a so-called gap former, as is also the case for the modified embodiments of FIGS. 2 to 4.
In the embodiment under consideration, the departure of both of the travelling forming wires 8 and 9 from the forming roll 1 occurs at the upper right-hand region of such forming roll 1. This forming roll I can comprise a grill structure which is secured to a closed shell body. The water of the stock suspension can be temporarily stored or collected at the forming roll 1 and then can be propelled out of such forming roll 1 due to the action of the prevailing centrifugal force. This forming roll 1 also can be designed as a suction roll. Forming roll 1 can have a radius in the order of between 0.3 to 1 meter. Furthermore, this forming roll 1 has an upper apex point 58 and a lower apex point 60. The upper apex point 58 will be seen to constitute the highest point of the lower wire 9. Moreover, the upper apex point 58 of the forming roll 1 is situated at a higher elevational position than the web-supporting portion 54 of the lower wire 9 which has the section 56 extending in essentially horizontal direction.
The water of the fiber stock suspension which departs through the upper wire 8 is removed by means of a top or upper suction device 3 with or without the assistance of vacuum. The top or upper suction device 3 is shown arranged between the forming roll 1 and a suction box 2 provided in the lower wire 9. The suction box 2 has a surface 62 contacted by the lower wire 9 and at least part of this surface 62 is substantially convexly curved with respect to the lower wire 9. This top or upper suction device 3 can contact the upper wire 8, immerse into such upper wire 8 or advantageously can be spaced from such upper wire 8. Consequently, there can be avoided the presence of too great shearing forces at the fiber stock suspension which, for the here contemplated field of application, would be disadvantageous. Downstream of the forming roll 1, that is, as viewed with regard to the direction of movement 50 of the upper and lower wires 8 and 9, both of these wires 8 and 9 are transported in substantially horizontal direction, descending direction or slightly ascending direction over the suction box 2, or also a plurality of such suction boxes, each of which can comprise arched or domed surfaces provided with transverse ledges or the like. The radius of curvature of such domed suction box or boxes 2 amounts to between 2 and 20 meters. However, it is here specifically pointed out that there also can be used an arrangement in which the suction box contains a straight section or portion, for example, at the terminal region thereof, so that there is ensured a relatively gentle directional reversal of both of the wires 8 and 9 without danger of damage to the formed web. The suction box or boxes 2 at the lower wire 9 can be operated with or without vacuum. Moreover, the open surface of the suction box 2 can amount to between 20% and 80%. Furthermore, each of the suction boxes 2 can be provided with ledges extending in the cross-machine direction over the width thereof and/or with a hole or perforation pattern. As will be seen by inspecting FIG. 1, the suction box 2 provided in the lower wire 9 will be seen to have a portion 2e which contacts the uppermost point of such lower wire 9.
In the embodiments of FIGS. 1 and 5, immediately downstream of the forming roll 1 both of the wires 8 and 9 are transported in descending direction over the curved suction box 2, and in the embodiment of FIG. 4 such descending travel of these wires 8 and 9 is over the separate suction boxes 2' and 2". On the other hand, in the embodiment of FIG. 2 these wires 8 and 9 initially ascend from the forming roll 1 over a starting region of the curved suction box 2 and then travel in descending fashion thereover. In the embodiments of FIG. 3 and 6 the wires 8 and 9 leave the forming roll 1 in substantially horizontal direction and for the most part travel in this disposition over the adjacent suction box 2.
Continuing, it will be seen that at the upper wire 8 there is provided a vacuum suction box 4 which comprises a number of chambers or compartments which can be operated with different vacuums. This vacuum suction box 4 has a surface 64 contacted by the upper wire 8 and at least part of such surface 64 is substantially convexly curved with respect to such upper wire 8. Also such vacuum suction box 4 has a front edge 4a which is located at a greater elevational position than the section 56 of the lower wire 9 which extends in essentially horizontal direction. An inclined disposition of the vacuum suction box 4, here, as shown, descending in the direction of travel of the revolving endless wires 8 and 9, facilitates the removal of water from the web at the starting region of the vacuum suction box 4, particularly at relatively low operating velocities or speeds of the papermaking machine, for instance, amounting to approximately 200 meters/min. At greater machine velocities water which has been outwardly propelled by centrifugal force above the suction box or boxes 2 arranged at the lower wire 9 can be readily removed by individual additional top or upper suction devices 3. It is here further indicated that in the arrangement of FIG. i and as viewed in the direction of movement 50 of the upper and lower wires 8 and 9, the length of the vacuum suction box 4 provided in the upper wire 8 is greater than the length of the suction box 2 provided in the lower wire 9.
Downstream of the vacuum suction box 4 there is located a separation or separating element 5 which is located upstream of the horizontally extending rear portion 56 of the lower wire 9. In the embodiment of FIG. 1, this separation or separating element 5 comprises a curved box containing ledges extending over the width thereof in the cross-machine direction and having a radius of curvature in the order of between 1.5 meters and 20 meters. This separation or separating element 5 has an active surface 5a which here is located at a position intermediate the planes extending through the upper apex point 58 and lower apex point 60 of the forming roll 1. As a modification, this box defining the separation or separating element 5, can comprise a linear or straight box which is operated under vacuum conditions. It is also conceivable to use a register roll as the separation or separating element 5.
FIG. 2 schematically depicts and without greater detail a different possible course of the converging or joined together upper and lower wires 8 and 9 at the region between the forming roll 1 and the vacuum box 4, as previously considered. It will be observed that the vacuum box 2 initially has a slightly ascending contour or shape followed by a more pronounced descending contour or shape.
The modification of FIG. 3 demonstrates the possibility that the suction box 2 and the vacuum suction box 4 not only can comprise curved contours but also straight contours at the surfaces contacted by the upper and lower wires 8 and 9. In this way there can be achieved a particularly protective removal of water from the formed web and thus a favorable web formation, especially with relatively heavy web weights. As here illustrated, it is possible to select a form of the suction boxes 2 and 4 where the surface contacted by the associated wire 8 or 9, as the case may be, first has a straight or planar shape followed by a curved shape, but also the converse arrangement can be of advantage depending upon the requirements and prevailing geometric conditions. More specifically, it will be seen that the suction box 2 has a substantially linear surface 2a followed by a curved or arcuate surface 2b, which surfaces 2a and 2b are contacted by the lower wire 9. On the other hand, the suction box 4 has a somewhat curved or arched surface 4a followed by a substantially straight or linear surface 4b, and these surfaces 4a and 4b are contacted by the upper wire 8.
FIG. 4 depicts a further embodiment comprising an arrangement containing a suction box 2' arranged at the lower wire 9 and having a curved or domed form at the surface 2c thereof which is contacted by such lower wire 9. Arranged following or downstream of this suction box 2' is a second or further suction box 2" having a substantially linear or straight surface 2d with respect to the adjacent lower wire 9. Within the upper wire 9 there are provided the separate top or upper suction boxes 3' and 3". The vacuum suction box 4 arranged at the upper wire 8 is sub-divided into a number of regions or zones or chambers, namely, the region or zone 4' which is followed by the further region or zone 4" and which are operated at different vacuums or negative pressures, and at the upstream region of this vacuum suction box 4 there is provided an extra or supplementary suction device 4"'.
Moreover, it will be seen in FIG. 4 that the lower wire 9 is provided with a suction roll 7 located at the downstream end of the lower wire 9 with respect to the predetermined direction of movement 50 of the revolving endless upper and lower wires 8 and 9. Furthermore, pressure elements 6, such as elastic ledges, are arranged beneath the vacuum suction box 4 and are elastically pressable in the direction of the lower wire 9. Finally, it is here observed that the vacuum suction box 4 provided in the upper wire 8 has a surface 70 which contacts such upper wire 8 and this surface 70 comprises a first portion 4c which is substantially flat and a subsequently arranged second portion 4d which is substantially convexly curved with respect to the upper wire 8.
Finally, FIGS. 5 and 6 depict two further embodiments, each of which contain a longitudinal wire section 66 arranged forwardly or upstream of the location where the upper wire 9 and lower wire 8 converge or join one another. The headbox 10 is disposed at the starting portion of this longitudinal wire section 66 which constitutes part of the lower wire 9. Such arrangements are also referred to in the papermaking art as 10 hybrid formers. Depending upon the desired operating conditions and the geometry, it is also possible to design a deflection roll, which is arranged forwardly or at the upstream end of the upper wire 8, as a forming cylinder 11, as particularly depicted for the embodiment of FIG. 6.
While there are shown and described present preferred embodiments of the invention, it is distinctly to be understood the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. | The wet section of a twin wire papermaking machine is provided with an open forming roll at the lower wire and with the combination of a suction box at the lower wire and a vacuum suction box at the upper wire. Furthermore, by selecting the elevational position or level of the individual wire sections there can be obtained particularly advantageous conditions for the operation of the papermaking machine throughout a wide field of application, especially heavy types of paper at relatively low operating velocities of the papermaking machine. Gap-former and hybrid-former constructions of the papermaking machine are possible. | 3 |
BACKGROUND OF THE INVENTION
[0001] The present subject matter relates generally to interlocking siding. More specifically, the present invention relates to an interlocking siding design that provides an external profile though which there are no perforations exposed after installation.
[0002] Siding provides an exterior barrier for walls and surfaces in order to protect the under layers from the effects of weather and moisture. Siding can also contribute to the aesthetic value of a house or structure, by adding a tasteful color or texture to the surface. Aesthetic value also can affect the property value of a structure or building, so the appearance of the siding is important. Siding is usually affixed to the outside of a building in panels in an overlapping assembly. Since the siding is traditionally applied in segments, it allows for the expansion and contraction of the building materials that is caused by various temperatures and humidity. Siding can be composed of many different materials including but not limited to wood, vinyl, metal, cement, or plastic.
[0003] Certain kinds of siding can be very labor intensive to manufacture and install. Some siding is made of expensive materials, which increases the total cost of the installation and purchase of the siding. Installing siding can be labor intensive because it must be installed in such a way that seals the outside layer from the elements. Also, siding is only typically installed during moderate weather, thus limiting the possibility of installation in some regions with harsh winters.
[0004] During installation, constant attention must be given to the distance of overlap of the siding segments, and the placement, to make sure the segments are appropriately spaced. The placement of the siding is important to create a uniform pattern on the outer surface thus giving the attractive aesthetic appearance in addition to the functional barrier.
[0005] Accordingly, a need exists for an interlocking siding product and method as described and claimed herein.
BRIEF SUMMARY OF THE INVENTION
[0006] In order to meet the ever growing need to provide an interlocking siding that is easy to assemble, install and provides an effective barrier and is aesthetically appealing, the present subject matter discloses a siding with a unique structure. The siding panel includes an indicia for a fastener placement combined with a unique mating potion geometry. The top edge of the siding has a front face for facing outside towards the elements and a rear face for facing the internal structure. The panel includes a top front edge that extends above the top rear edge. The lower edge of the panel includes three sections adapted for mating to the top edge of an adjacent panel. The front face of the lower edge extends the lowest, the middle section is recessed, and the rear section falls between the lowest extension and the recessed portion. A barrier may be formed using identical panels, making installation easy and maintenance free.
[0007] When two or more panels are mated together, they form a barrier to moisture and other elements. In addition to forming a barrier and keeping out moisture, the mating mechanism facilitates a mistake-free assembly. When mated, the front face of the lower edge of an upper panel extends far enough down the front face of the lower panel to cover the indicia for fastener placement located on the front face of the lower panel. Therefore when assembled, all of the fasteners used to secure the panels to the internal structure will be hidden, thus providing an effective barrier that is visually pleasing. No evidence of the fasteners is left to be seen at an outward view, they will all be hidden underneath the overlapping structure of the siding.
[0008] The front face of the panel may include a fastener notch. The notch allows the fastener head to sit inside the body of the siding panel rather than protrude beyond the front face. Also, the notch provides indicia for fastener placement such that an installer may be assured the fasteners are properly located to be covered by the adjacent overlapping panel, thus making it easier to assemble and mistake proof.
[0009] In some embodiments the body of the interlocking siding may be made of recycled or waste materials. Recycled or waste materials may be cost effective and may also reduce placement in landfills, thus helping the environment. For example, the panels may be formed from a single or multilayer extrusion process. In a multilayer extrusion, the one or more inner layers may include recycled or waste products, while the outer layer may be from another material entirely.
[0010] In some embodiments the body and rear face of the interlocking siding panels may incorporate various patterns and cut outs to decrease the amount of material needed to create the siding. This decreased amount of material will keep the overall cost of materials down thus making the siding more affordable. Decreasing the amount of material will also lessen the weight of the siding and made the product more flexible, which will also make the installation easier.
[0011] The method of installation is simple and easy. The first piece to fit at the base of the structure may be a starter strip. The starter strip has a flat bottom and a two tier top face for mating with the bottom edge of the adjacent panel. After the starter strip is fixed where indicated, the installer may fit the first piece of panel siding onto the starter strip, the bottom edge of the panel overlapping and interlocking the top edge of the starter strip. Once the first panel is secured to the starter strip, it may be fastened into the structure where indicated. All subsequent siding panels will fit accordingly in a uniform pattern, using this same method without the need for measuring or use of a spacer to assure consistency, saving time and money. Since all of the siding panels are identical, it will be easy to stack the panels together without needing to differentiate between the panels. The starting strip and unvarying design of siding will allow for a mistake proof installation that can be accomplished by a non-expert.
[0012] In one example, an interlocking panel system includes: a first panel including: a front face including a fastener notch; a rear face; a top edge, wherein the top edge includes a top front edge that extends above a top rear edge; and a lower edge, wherein the lower edge includes a front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge; and a second panel including: a front face including a fastener notch; a rear face; a top edge, wherein the top edge includes a top front edge that extends above a top rear edge; and a lower edge, wherein the lower edge includes a front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge; wherein, when the lower edge of the first panel is placed onto the top edge of the second panel, the bottom front edge of the first panel covers the fastener notch of the second panel.
[0013] The fastener notch may be V shaped, U shaped, or other. In some embodiments, when the lower edge of the first panel is placed onto the top edge of the second panel, the bottom rear edge of the first panel abuts the top rear edge of the second panel. Similarly, in some embodiments, when the lower edge of the first panel is placed onto the top edge of the second panel, the bottom middle edge of the first panel abuts the top front edge of the second panel. In some versions, the rear face of the first panel includes a plurality of notches.
[0014] In some examples, the interlocking panel system includes a starter strip, wherein the starter strip includes a front face including a fastener notch, a rear face, a top edge wherein the top edge includes a top front edge that extends above a top rear edge, and a base edge including a drip channel, wherein when the lower edge of the second panel is placed onto the top edge of the starter strip, the bottom front edge of the second panel covers the fastener notch of the starter strip. In such an embodiment, when the lower edge of the second panel is placed onto the top edge of the starter strip, the bottom rear edge of the second panel abuts the top rear edge of the starter strip and, when the lower edge of the second panel is placed onto the top edge of the starter strip, the bottom middle edge of the second panel abuts the top front edge of the starter strip.
[0015] In some versions of the interlocking panel system, the first panel is a multilayer construction wherein an inner layer is made from waste material.
[0016] An advantage of the siding is that it is interlocking.
[0017] Another advantage of the siding is it is easy to install
[0018] A further advantage of the siding is that it provides a superior barrier surface.
[0019] Yet another advantage of the siding is there are no exposed fasteners.
[0020] Yet another advantage of the siding is all panels are the same size and consistent color.
[0021] Another advantage of the siding is maintenance free and can be installed in any climate condition.
[0022] Additional objects, advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawings or may be learned by production or operation of the examples. The objects and advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.
[0024] FIG. 1 is a side view of an interlocking panel.
[0025] FIG. 2 is a side view of an alternative design for an interlocking panel.
[0026] FIG. 3 is a side view of another alternative design for an interlocking panel.
[0027] FIG. 4 is a side view of another alternative design for an interlocking panel.
[0028] FIG. 5 is a side view of another alternative design for an interlocking panel.
[0029] FIG. 6 is a perspective view of a body structure and the finish surface of an interlocking panel with multi-lamination.
[0030] FIG. 7 is a side view of a starter strip.
[0031] FIG. 8 is a side view of an alternative design of a starter strip.
[0032] FIG. 9 is a side view of an arrangement of interlocking panels beginning with the starter strip.
[0033] FIG. 10 is a flow chart depicting a method of installing interlocking panels and starter strip.
[0034] FIG. 11 a illustrates an example of V shaped fastener notch that may be used in the interlocking panel shown in FIG. 1 .
[0035] FIG. 11 b illustrates an example of U shaped fastener notch that may be used in the interlocking panel shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0036] FIG. 1 illustrates an example of an interlocking panel 10 . As shown in FIG. 1 , the interlocking panel includes a body 12 with a front face 14 and a rear face 16 . The front face 14 is the exterior of the panel 10 , which faces the elements, and the rear face 16 will be the interior of the panel 10 that faces the wall of the house, stud, sheathing, or other structure. The interlocking panel 10 includes a top edge 18 and a lower edge 20 . The top edge 18 includes a top front edge 17 that extends above a top rear edge 19 . The configuration of the top edge 18 allows it to connect to the lower edge 20 when the interlocking panels 10 are stacked adjacently. The lower edge 20 includes a front edge 21 extending below a recessed bottom middle edge 23 and bottom rear edge 25 , which falls between the bottom front edge 21 and the bottom middle edge 23 . Accordingly, the top edge 18 connects by interlocking to the lower edge 20 when stacked adjacently.
[0037] As shown in FIG. 1 , the interlocking panel 10 includes a fastener notch 22 . The fastener notch 22 provides placement indicia to indicate where the fasteners should be placed. When the lower edge 20 is placed on top of a corresponding top edge 18 of another plank, the front face 14 of the lower edge 20 will cover the fastener notch 22 , thus covering any evidence of an opening through the panel 10 and preserving the integrity of the barrier. The fastener notch 22 may be routed in a “V” or “U” so the screw head sits slightly recessed when installed, thereby allowing the next siding panel 10 to fit together easily without catching on the screw head. In FIG. 1 , the front face of the lower edge 20 extends down a considerable amount, but it is contemplated that this distance may be more or less as long as it still covers the fastener notch 22 of the next panel. Examples of fastener notches 22 are shown in FIG. 11 a and FIG. 11 b. However, other fastener notch 22 configurations may be used.
[0038] The interlocking panel 10 in FIG. 1 can be made out of many different materials such as wood, plastic, cement, or vinyl. It is suggested that the panels be composed of a waste material, or recycled material, to contribute to conservation and keep costs down. However, it is contemplated that in other embodiments, the interlocking panel 10 can be made of any material that is capable of providing a barrier from the elements.
[0039] FIG. 2 is an alternative design, very similar to FIG. 1 where the front face 14 includes a two-tiered profile for aesthetic value. The front face 14 includes a ridge 27 giving the panel 10 additional texture. In FIG. 2 there is one ridge 27 on the front face 14 , but it is contemplated that in other embodiments, there may be any variation of ridges 27 .
[0040] FIG. 3 is another design of an interlocking panel. This variation includes a number of notches 29 on the rear face 16 to conserve the amount of material used to form the panel 10 . Also, FIG. 3 contains an outside layer 24 that may be composed of a more expensive, protective, and aesthetically pleasing material, because the outside layer 24 is a thin high quality layer. Then the rest of the body 12 can be composed of a more cost efficient material.
[0041] As shown in FIG. 3 , the top edge 18 and lower edge 20 are shaped differently than in the example shown in FIG. 1 . In FIG. 1 the top edge 18 and lower edge 20 include squared corners to rest against each other, whereas in FIG. 3 the top edge 18 and lower edge 20 include an interlocking shape. Accordingly, the top edge 18 connects by interlocking to the lower edge 20 when stacked adjacently.
[0042] FIG. 4 is yet another variation of an interlocking panel 10 that is very similar to FIG. 3 . The difference between FIG. 4 and FIG. 3 is the top edge 18 and lower edge 20 profiles.
[0043] FIG. 5 is another variation of an interlocking panel 10 in which there are several cut outs 31 in the body 12 , thus saving on materials, and providing an alternative design. In FIG. 5 there are two cut outs in a generally oval shape, but the cut outs may be in any shape, and can be in various numbers.
[0044] FIG. 6 shows further how in the inner portion of the panel 10 may be composed of a different material than the outer portion. As discussed previously, the inner material may be composed of a waste material, recycled material, or any material that is more economical. The multilayer panel 10 in FIG. 6 may be formed using a multilayer extrusion process.
[0045] FIG. 7 shows the starter strip 30 that may be used as the base upon which adjacent panels 10 may be stacked. The starter strip 30 contains a body 32 with a front face 34 and a rear face 36 , similar to the panel 10 . The starter strip 30 is smaller than the panels, and is sturdy enough to stabilize the first panel, so the others may follow. The starter strip 30 also contains a top edge 38 and a base edge 40 . The top edge 38 will connect to the lower edge 20 or one of the first siding panels to connect to the starter strip 30 . The base edge 40 will be placed at the base of the house or structure. The base edge 40 also provides a drip channel 42 to prevent water from returning to the inner structure. The top edge 38 will be shaped to correspond with the design of the panels 10 .
[0046] FIG. 8 also shows a starter strip 30 that is very similar to FIG. 7 . The base edge 40 in FIG. 8 is shaped slightly different than the base edge 40 in FIG. 7 , in that the drip channel 42 is in a different position. It is understood that the drip channel 42 in the base edge 40 may be in any location along the base edge 40 , left, right or center.
[0047] As further shown in FIGS. 7 and 8 , the front face 34 may take on any of numerous profiles. Accordingly, it is contemplated that the starter strip 30 may be any shape, as long as it is adapted to integrate with the siding panels 10 .
[0048] FIG. 9 demonstrates how the panels 10 would fit together to form the siding, starting with the starter strip 30 at the bottom. The starter strip 30 would sit at the base of the structure, and the panels 10 would stack on top of the starter strip 30 .
[0049] FIG. 10 depicts the method 110 of assembling the siding panels. The first step 120 is mounting the starter strip at the base of the structure. While the presently preferred method of mounting the starter strip at the base of the structure is by screwing the starter strip to the structure, in alternative embodiments, the starter strip may be mounted by nailing, gluing or otherwise securing the starter strip to the structure. The second step 130 is aligning the first siding panel with the starter strip and locking them in place. The starter strip and the siding panel have the corresponding notches that are meant to be locked in place and provide an effective moisture barrier. It is obvious when the starter strip and the panel are locked in place because they will lock or snap in place and fit together easily. The next step 140 is screwing the first siding panel to the structure. It is apparent to place the screws in the screw fastener notches that are indicated on the siding panels. Again, in alternate embodiments, the siding panels may be secured via other means. Once the siding panel is screwed to the structure, it is secure. The last step 150 is aligning and mounting the subsequent siding panels. The subsequent siding panels are secured just as the first siding panel was secured to the siding strip. They snap or lock into place and then are screwed to the wall or stud. In instances in which the panels do not span the width of a structure, the seams of the panels should be staggered (not aligned) to help to prevent water penetration through the siding to the substructure and butt joints (for example, 45% angle butt joints) may be provided along the seams, whereby the siding panels may be glued, caulked or otherwise adhered or sealed.
[0050] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. | An interlocking panel system including: a pair of panels, each including: a front face including a fastener notch; a rear face; a top edge, wherein the top edge includes a top front edge that extends above a top rear edge; and a lower edge, wherein the lower edge includes a front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge; wherein, when the lower edge of the first panel is placed onto the top edge of the second panel, the bottom front edge of the first panel covers the fastener notch of the second panel. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present Utility patent application claims priority benefit of the U.S. provisional application for patent Ser. No. 61/365,497, entitled “Attachable & Detachable Lint Remover Product, filed on Jul. 19, 2010 under 35 U.S.C. 119(e). The contents of this related provisional application are incorporated herein by reference for all purposes to the extent that such subject matter is not inconsistent herewith or limiting hereof.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER LISTING APPENDIX
[0003] Not applicable.
COPYRIGHT NOTICE
[0004] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office, patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
[0005] One or more embodiments of the invention generally relate to clothing care. More particularly, the invention relates to a lint remover attachment system.
BACKGROUND OF THE INVENTION
[0006] The following background information may present examples of specific aspects of the prior art (e.g., without limitation, approaches, facts, or common wisdom) that, while expected to be helpful to further educate the reader as to additional aspects of the prior art, is not to be construed as limiting the present invention, or any embodiments thereof, to anything stated or implied therein or inferred thereupon. Ironing of clothing and removing of lint from the same piece of clothing is conventionally a two-step process. Typically, the cloth is ironed first and then a lint remover is rolled over the clothing.
[0007] By way of educational background, an aspect of the prior art generally useful to be aware of is that typical lint removers are handheld devices that are rolled or brushed over the item from which the lint is to be removed. FIG. 1 illustrates an exemplary adhesive lint remover, in accordance with the prior art. This lint remover comprises a cylindrical roll 101 of mildly adhesive material capable of expunging lint and other undesirable elements from clothing materials and a handle 103 for driving cylindrical roll 101 over clothing.
[0008] In view of the foregoing, it is clear that these traditional techniques are not perfect and leave room for more optimal approaches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
[0010] FIG. 1 illustrates an exemplary adhesive lint remover, in accordance with the prior art;
[0011] FIGS. 2A and 2B illustrate an exemplary hook for a lint remover attachment system, in accordance with an embodiment of the present invention. FIG. 2A is a diagrammatic side view of the hook, and FIG. 2B is a diagrammatic side view of the hook attached to an iron; and
[0012] FIGS. 3A and 3B illustrate an exemplary lint remover attachment system, in accordance with an embodiment of the present invention. FIG. 3A is a diagrammatic side view, and FIG. 3B is a diagrammatic top view.
[0013] Unless otherwise indicated illustrations in the figures are not necessarily drawn to scale.
SUMMARY OF THE INVENTION
[0014] To achieve the forgoing and other objects and in accordance with the purpose of the invention, a variety of apparatus and systems for lint removal are described.
[0015] In one embodiment an apparatus comprises a lint removal unit being configured to be operable for removing particles from a surface of a material. A connector mechanism comprises a first end and a second end. The first end is configured for joining to the lint removal unit. The second end is configured for joining to an iron where using the iron on the material places the lint removal unit on the surface of the material for removing particles. In another embodiment the lint removal unit comprises a cylindrical member being operable for collecting the particles. In yet another embodiment the first end of the connector mechanism is rotatably joined to the cylindrical member for enabling the cylindrical member to roll on the surface of the material. In still another embodiment the cylindrical member is removable from the connector mechanism. In another embodiment the second end of the connector mechanism comprises a part of a joining mechanism for joining to the iron. In yet another embodiment the connector mechanism comprises two members. Each of the two members comprises a first member end and a second member end. The first member ends are joined to the cylindrical member. In still another embodiment each of the first member ends is joined to separate ends of the cylindrical member. In another embodiment the second member ends are joined to the part of a joining mechanism. In yet another embodiment the part of a joining mechanism comprises a hook shaped structure. In still another embodiment the hook shaped structure comprises a hook joined to each of the second member ends. In another embodiment each of the two members comprises a rod. In yet another embodiment the lint removal unit comprises an adhesive material for collecting the particles. In still another embodiment the adhesive material is layered.
[0016] In another embodiment a system comprises means for joining to an iron, means for removing particles from a surface of a material, and means for connecting the particle removing means to the iron joining means where using the iron on the material places the particle removing means on the surface of the material for removing particles.
[0017] In another embodiment a system comprises a joining mechanism comprising a first part and a second part. The first part is configured for joining to an iron. A lint removal unit is configured to be operable for removing particles from a surface of a material. A connector mechanism comprises a first end and a second end. The first end is configured for joining to the lint removal unit. The second end is configured for joining to the second part of the joining mechanism where using the iron on the material places the lint removal unit on the surface of the material for removing particles. In another embodiment the lint removal unit comprises a cylindrical member comprising a surface comprising an adhesive material being operable for collecting the particles. The cylindrical member is rotatably joined to the cylindrical member for enabling the cylindrical member to roll on the surface of the material. The cylindrical member further being configured to be removable from the connector mechanism. In yet another embodiment the connector mechanism comprises two members. Each of the two members comprises a first member end and a second member end. Each of the first member ends is joined to separate ends of the cylindrical member. The second member ends are joined to the second part of the joining mechanism. In still another embodiment the first part of the joining mechanism comprises two hook shaped structures each comprising an adhesive pad for joining to a surface of the iron. In another embodiment the second part of the joining mechanism comprises two hook shaped structures being configured for removably joining to the first part of the joining mechanism. In yet another embodiment each of the two members comprises a rod.
[0018] Other features, advantages, and objects of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The present invention is best understood by reference to the detailed figures and description set forth herein.
[0020] Embodiments of the invention are discussed below with reference to the Figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. For example, it should be appreciated that those skilled in the art will, in light of the teachings of the present invention, recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein, beyond the particular implementation choices in the following embodiments described and shown. That is, there are numerous modifications and variations of the invention that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive.
[0021] It is to be further understood that the present invention is not limited to the particular methodology, compounds, materials, manufacturing techniques, uses, and applications, described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. Similarly, for another example, a reference to “a step” or “a means” is a reference to one or more steps or means and may include sub-steps and subservient means. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word “or” should be understood as having the definition of a logical “or” rather than that of a logical “exclusive or” unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.
[0022] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Preferred methods, techniques, devices, and materials are described, although any methods, techniques, devices, or materials similar or equivalent to those described herein may be used in the practice or testing of the present invention. Structures described herein are to be understood also to refer to functional equivalents of such structures. The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings.
[0023] From reading the present disclosure, other variations and modifications will be apparent to persons skilled in the art. Such variations and modifications may involve equivalent and other features which are already known in the art, and which may be used instead of or in addition to features already described herein.
[0024] Although Claims have been formulated in this application to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalization thereof, whether or not it relates to the same invention as presently claimed in any Claim and whether or not it mitigates any or all of the same technical problems as does the present invention.
[0025] Features which are described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination. The Applicants hereby give notice that new Claims may be formulated to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom.
[0026] References to “one embodiment,” “an embodiment,” “example embodiment,” “various embodiments,” etc., may indicate that the embodiment(s) of the invention so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment,” or “in an exemplary embodiment,” do not necessarily refer to the same embodiment, although they may.
[0027] As is well known to those skilled in the art many careful considerations and compromises typically must be made when designing for the optimal manufacture of a commercial implementation any system, and in particular, the embodiments of the present invention. A commercial implementation in accordance with the spirit and teachings of the present invention may configured according to the needs of the particular application, whereby any aspect(s), feature(s), function(s), result(s), component(s), approach(es), or step(s) of the teachings related to any described embodiment of the present invention may be suitably omitted, included, adapted, mixed and matched, or improved and/or optimized by those skilled in the art, using their average skills and known techniques, to achieve the desired implementation that addresses the needs of the particular application.
[0028] It is to be understood that any exact measurements/dimensions or particular construction materials indicated herein are solely provided as examples of suitable configurations and are not intended to be limiting in any way. Depending on the needs of the particular application, those skilled in the art will readily recognize, in light of the following teachings, a multiplicity of suitable alternative implementation details.
[0029] A practical embodiment of the present invention provides a lint remover attachment system. In many practical embodiments the lint remover attachment system is designed as an attachment to an iron, such that it enables both ironing and lint removal from a piece of cloth simultaneously.
[0030] FIGS. 2A and 2B illustrate an exemplary hook 201 for a lint remover attachment system, in accordance with an embodiment of the present invention. FIG. 2A is a diagrammatic side view of hook 201 , and FIG. 2B is a diagrammatic side view of hook 201 fastened to the rear surface of an iron 203 . In the present embodiment, means for joining to the iron, hook 201 comprises an adhesive pad 205 that is capable of attaching hook 201 to a surface such as, but not limited to, iron 203 . Hook 21 is made of plastic; however, hooks in some alternate embodiments may be made of various different materials including, without limitation, metal. It is contemplated that some alternate embodiments may be implemented in which hooks are integrated into the body of the iron rather than being attached to the iron with adhesive.
[0031] FIGS. 3A and 3B illustrate an exemplary lint remover attachment system, in accordance with an embodiment of the present invention. FIG. 3A is a diagrammatic side view, and FIG. 3B is a diagrammatic top view. In the present embodiment, the lint remover attachment system comprises a cylindrical lint remover 301 and two connector rods 303 attached to two hooks 305 , which are fastened to an iron 307 . Means for removing particles from a surface of a material, cylindrical lint remover 301 comprises a roll of adhesive material capable of removing lint from clothing by allowing the lint to stick onto its sticky surface and an axle mechanism that allows lint remover 301 to roll like a wheel. The axle mechanism runs through the center of cylindrical lint remover 301 and is exposed on both circular end surfaces where means for connecting to hook 201 , connector rods 303 , fit into the axle mechanism, with one rod 303 on each side of lint remover 301 . In some alternate embodiments, the cylindrical lint remover may be implemented without an axle mechanism. In these embodiments, alternate means for enabling the lint remover to roll may be used such as, but not limited to, attaching the connector rods to the lint remover in such a way that the lint remover rotates around this connection point or providing end caps on the lint remover that comprise rotating means. In other alternate embodiments, non-rolling lint removers may be used. In embodiments comprising non-rolling lint removers, these lint removers may have shapes other than cylindrical shapes such as, but not limited to, flat rectangles.
[0032] In typical use of the present embodiment, the lint remover attachment system enables an end-user to iron a piece of clothing and remove lint at the same time. Connector rods 303 emanating from cylindrical lint remover 301 are latched onto hooks 305 that are fastened to the rear of iron 307 . As a user moves iron 307 across a cloth item to be ironed, connector rods 303 pull or push cylindrical lint roller 301 along with iron 307 . The axle mechanism within cylindrical lint remover 301 enables cylindrical lint remover 301 to roll as it moves across the cloth, and the sticky surface of cylindrical lint remover 301 collects any lint or other particulates that may be present on the cloth. It is believed that the heat from iron 307 may increase the effectiveness of lint remover 301 .
[0033] After using the lint remover attachment system for simultaneous ironing and lint removing, the user can detach connector rods 303 from hooks 305 and store cylindrical lint remover 301 and connector rods 303 away. In some alternate embodiments, the connector rods may be permanently attached to the iron. In the present embodiment, the sticky surface of cylindrical lint remover 301 can be peeled away after it has gathered sufficient lint, thereby exposing a fresh adhesive surface for more lint removal. When the roll of adhesive material on cylindrical lint remover 301 is completely used up, cylindrical lint remover 301 can be replaced with a new lint remover. To remove cylindrical lint remover 301 once it is used, connector rods 303 are detached from the axle mechanism of cylindrical lint remover 301 and lint remover 301 is removed. Then, connector rods 303 are attached to a new lint remover via the axle mechanism of the new lint remover. In some alternate embodiments, the connector rods may be permanently attached to the lint remover. In these embodiments the entire lint remover connector rod assembly is removed and replaced when the roll of adhesive material is used. In some alternate embodiments the lint remover attachment systems may be implemented with various different types of lint removers rather than rolls of adhesive material such as, but not limited to, washable adhesive rollers, fabric lint removers, sponges, combs, brushes, etc.
[0034] The attachable/detachable lint remover attachment system according to the present embodiment can be used on many types of irons irrespective of manufacturer, source of energy and other factors that can differentiate irons. Those skilled in the art, in light of the teachings of the present invention, will readily recognize that a multiplicity of suitable attachment means may be used to attach the connection rods to the iron such as, but not limited to, snaps, elastic bands, clips, etc. Some alternate embodiments of the present invention may be implemented that can be attached to an iron with a single hook. In these embodiments the connector rods may both latch onto the single hook. Alternatively, the connector rods may attach to a cross rod that runs parallel to the cylindrical lint roller. This cross rod may then latch onto the hook.
[0035] In another alternate embodiment, an iron comprises an embedded lint remover assembly that is permanently fixed to the iron. In this embodiment, the iron comprises a hollow section with a cover at its rear end where the lint remover assembly is stored. When the cover is opened, the lint removal assembly is activated and becomes a trailer to the iron. When the cover is closed, the lint removal assembly is safely tucked away in the hollow. Other alternate embodiments may comprise permanent lint removal assemblies that do not store away within the iron.
[0036] Further exemplary and ALTERNATIVE embodiments and implementation variations are described in the following.
[0037] The lint assembly system provides a mechanism to remove a ply of sticky surface after it has fully collected lint from clothing or provides a convenient way for the user to easily remove a spent ply of sticky surface.
[0038] Example Implementations
[0039] Described in some detail are two example implementations (A and B), without limitation, of an embodiment of the invention, as follows: Attachable and Detachable Lint Removal Assembly. Permanently affixed Lint Removal Assembly.
[0040] [A] Attachable and Detachable Lint Removal Assembly.
[0000] The attachable and detachable Lint Removal assembly can be used with any iron in the market today. The sticky surfaces of the 2 hooks are affixed to the rear end of the iron. The two connector rods are attached to the hooks. A cylindrical lint remover roll is fixed in between the two connector rods. This assembly makes the lint remover a trailer to the iron, where the cylindrical lint remover fully rests on the clothing being ironed and thus as the iron is operated on the clothing is both pressed and cleaned of lint.
[0041] [B] Permanently Affixed Lint Removal Assembly.
[0042] The Permanently affixed Lint Removal Assembly is an implementation of the invention that can be used to manufacture a combo iron (Iron+Lint remover assembly). This implementation embodies an iron which has a hollow at the rear end. The lint remover assembly will reside in the hollow when it is not in use and safely stored away by a hollow cover. The lint remover assembly is held in place in the hollow by the 2 connector rods. On one end, the two rods are permanently affixed to corners inside the hollow. The cylindrical lint removal assembly then fixed to the other end of the two rods. When lint remover is in use, it resembles the appearance of an aerator dragged by a lawn mower. The cylindrical lint remover, can be replaced when its layers are exhausted with a new roll. The connector rods can/cannot be removed. The hollow will have a cover. The cover will have a latch that can be released and locked. (Just like a battery component of a toy car. The battery housing is the hollow, the battery is the lint remover assembly and the cover can be released to let the battery fall out or closed to make the battery stay in.) such that when lint assembly is not in use, the cover seals it off the ironing board. And when the user desires to iron and remove lint from the clothing material, removing the latch engages the lint assembly for action. This assembly makes the lint remover a trailer to the iron, where the cylindrical lint remover fully rests on the clothing being ironed and thus as the iron is operated on the clothing is both pressed and cleaned of lint.
[0043] All the features disclosed in this specification, including any accompanying abstract and drawings, may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[0044] Having fully described at least one embodiment of the present invention, other equivalent or alternative methods of providing a lint remover attachment system according to the present invention will be apparent to those skilled in the art. The invention has been described above by way of illustration, and the specific embodiments disclosed are not intended to limit the invention to the particular forms disclosed. For example, the particular implementation of the connector rods may vary depending upon the particular type of connection used. The connections described in the foregoing were directed to rear-mounted implementations; however, similar techniques are to connect the lint remover attachment system to various different locations on an iron including, without limitation, the front or the sides. Implementations of the present invention that can be mounted to the iron in different locations are contemplated as within the scope of the present invention. The invention is thus to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the following claims. | An apparatus and a system comprise a joining mechanism comprising a first part and a second part. The first part is configured for joining to an iron. A lint removal unit is configured to be operable for removing particles from a surface of a material. A connector mechanism comprises a first end and a second end. The first end is configured for joining to the lint removal unit. The second end is configured for joining to the second part of the joining mechanism where using the iron on the material places the lint removal unit on the surface of the material for removing particles. | 3 |
[0001] This application claims the benefit, pursuant to 35 U.S.C. §119, to U.S. Patent Application Serial No. 60/298,691, filed on Jun. 15, 2001.
BACKGROUND
[0002] The invention generally relates to a power system for a well, such as a power system to deliver power to electrical equipment of a subsea well, for example.
[0003] A subterranean well typically includes various pieces of electrical equipment (an electrical submersible pump and an electrical flow pump, as examples) that are located downhole inside the well. For purposes of providing power to operate this electrical equipment, electrical cables may be run through an annular area between a production tubing and casing string of the well down to the electrical equipment.
[0004] The primary purpose of production tubing is to communicate produced well fluids from subterranean formations of the well to the surface of the well. Typically, a tubing hanger interface suspends the production tubing in the well. In this manner, the tubing hanger interface is secured to a well tree of the well, and the top end of the production tubing typically is threaded into the tubing hanger interface.
[0005] One or more electrical cables typically communicate power from an external power source (i.e., a power source that is located outside of the well) to the electrical cable(s) that are located inside the well. For purposes of forming electrical connections between the electrical cable(s) that are inside of the well and the electrical cable(s) that are outside of the well, a conventional technique involves penetrating the well tree with electrical connections so that these electrical connections enter the well either through the tubing hanger interface or above the tubing hanger interface. In this manner, downhole electrical cables typically are connected to these penetrating electrical connections and routed through the tubing hanger interface into the annular area between the production tubing and casing string. The electrical cables extend down the annular area to the downhole electrical equipment.
[0006] The above-described arrangement may present various design challenges. For example, the tubing hanger body is often crowded due to the presence of electrical connections, hydraulic control lines, etc. Therefore, to prevent the tubing hanger body from becoming too constricted, a limitation may be imposed on the cross-sectional area of each electrical cable, and a limitation may be imposed on the total number of electrical cables that may be extended downhole. These limitations, in turn, restrict the amount of power that may be communicated downhole.
[0007] Thus, there is a continuing need for a technique and/or system for delivering power to electrical equipment that is located in a well.
SUMMARY
[0008] In an embodiment of the invention, a system that is usable with a well includes a structure that has a region that is adapted to receive a tubing hanger interface. The system also includes at least one communication connection that penetrates the structure below the region that receives the tubing hanger interface.
[0009] In another embodiment of the invention, a power system for providing power communications to downhole devices in a well that has a tubing hanger interface includes an external power source, a downhole structure and a power structure. The downhole structure has external electrical contacts that are connected therethrough the downhole structure to internal electrical contacts. The external electrical contacts are in communication with the external power source and are located below the tubing hanger interface. The power structure has outer electrical contacts in communication with inner electrical contacts. The outer electrical contacts are adapted for communication with the internal electrical contacts of the downhole structure, and the inner electrical contacts are adapted to supply power to the downhole devices.
[0010] Advantages and other features of the invention will become apparent from the following description, drawing and claims.
BRIEF DESCRIPTION OF THE DRAWING
[0011] [0011]FIG. 1 is a schematic diagram of a well before installation of a power hanger and a tubing hanger interface according to an embodiment of the invention.
[0012] [0012]FIG. 2 is a schematic diagram of an electrical connector of the well of FIG. 1 according to an embodiment of the invention.
[0013] [0013]FIG. 3A is a schematic diagram of the well of FIG. 1 after the entry of a power hanger and a power hanger running tool into the well according to an embodiment of the invention.
[0014] [0014]FIG. 3B is a more detailed schematic diagram of a selected portion of the well of FIG. 3A depicting electrical connections according to an embodiment of the invention.
[0015] [0015]FIG. 4A is a schematic diagram of the well of FIG. 1 after the installation of the power hanger according to an embodiment of the invention.
[0016] [0016]FIG. 4B is a more detailed schematic diagram of a selected portion of the well of FIG. 4A depicting electrical connections according to an embodiment of the invention.
[0017] [0017]FIG. 5A is a schematic diagram of the well of FIG. 1 after the installation of a tubing hanger interface according to an embodiment of the invention.
[0018] [0018]FIG. 5B is a more detailed schematic diagram of a selected portion of the well of FIG. 5A depicting electrical connections according to an embodiment of the invention.
[0019] [0019]FIG. 6A is a schematic diagram of a well according to another embodiment of the invention depicting the well before installation of a tubing hanger interface.
[0020] [0020]FIGS. 6B and 6C are more detailed schematic diagrams of selected portions of the well of FIG. 6A depicting electrical connections according to an embodiment of the invention.
[0021] [0021]FIG. 7A is a schematic diagram of the well of FIG. 6A after the installation of the tubing hanger interface according to an embodiment of the invention.
[0022] [0022]FIGS. 7B and 7C are more detailed schematic diagrams of selected portions of the well of FIG. 7A depicting electrical connections according to an embodiment of the invention.
DETAILED DESCRIPTION
[0023] [0023]FIG. 1 depicts an embodiment 10 of a well (a subsea well, for example) in accordance with the invention. The full cross-sections of tubular members in FIG. 1 and the proceeding figures are not shown, but rather, the left-hand cross-sections of these members are shown in relation to a longitudinal axis 14 of the well. Thus, it is understood that the left-hand cross-sections of a particular tubular member may be rotated about the longitudinal axis 14 to form the corresponding right-hand cross-section of the tubular member.
[0024] One such tubular member that is depicted in FIG. 1 is a wellhead 12 , a structure that provides support for a well casing that extends into the wellbore. For a subsea well, the wellhead 12 extends into the sea floor. Depending on the particular embodiment of the invention, either a small diameter well casing hanger 34 (from which a small diameter casing 40 hangs and extends into the wellbore) or a larger diameter well casing hanger 36 (from which a larger diameter well casing 42 hangs and extends into the wellbore) may be secured to the wellhead 12 . The well casing hanger 34 may be sealed to the wellhead 12 via a seal 30 , and the well casing hanger 36 may be sealed to the wellhead 12 via a seal 32 .
[0025] The well 10 may have one or more pieces of downhole electrical equipment 17 , such as flow pumps and submersible pumps (as examples), that need electrical power to operate. As described below, the well 10 has features that facilitate the communication of electrical power from wires of an external electrical power cable assembly 16 to the electrical equipment 17 inside the well. The power cable assembly 16 communicates power from an external power source 18 . As an example, the external power source 18 may be located on a surface platform for the case in which the well 10 is a subsea well.
[0026] In some embodiments of the invention, for purposes of communicating electrical power from outside the well to inside the well, insulated electrical conduits 26 penetrate the sidewall of the wellhead 12 . Seals are formed between the conduits 26 and the sidewall of the wellhead 12 where the conduits 26 penetrate the sidewall to preserve the pressure sealing capability of the wellhead 12 . The conduits 26 are electrically connected to electrical connectors 22 that are exposed on the exterior surface of the sidewall of the wellhead 12 . A power interface connector 20 mates with the connectors 22 , seals the connectors 22 from the surrounding environment and communicates electricity from wires of the cable assembly 16 to the connectors 22 .
[0027] The conduits 26 extend through the sidewall of the wellhead 12 to electrical connectors 28 that are exposed on an interior surface on the sidewall of the wellhead 12 . As described below, a power hanger (not depicted in FIG. 1) is installed inside the wellhead 12 for purposes of extending electrical connections from the connectors 28 to one or more power cables (not depicted in FIG. 1) that are run downhole to the electrical equipment 17 .
[0028] As described below, a tubing hanger interface (not depicted in FIG. 1) is installed in the well 10 above the connectors 28 in a region 15 (see also FIG. 5A) that is adapted to receive the tubing hanger interface. As described below, this region 15 may be formed by part of a well tree of the well. Due to the penetration of the electrical connections below the tubing hanger interface, the downhole cable(s) that are electrically connected to the connectors 28 may be run along the outside surface of a production tubing (not depicted in FIG. 1) of the well 10 , and are not limited to the restrictions imposed through the tubing hanger body.
[0029] Referring to FIG. 2, as an example, a particular connector 28 may include an interior electrically conductive region 50 , in some embodiments of the invention. This conductive region 50 provides a contact point for purposes of electrically mating the connector 28 with a corresponding electrically conductive region of another connector (described below) inside the well 10 . The conductive region 50 is surrounded by a dielectric material 52 that insulates the conductive region 50 from the surrounding conductive wellhead 12 . Other connectors described herein may have a similar structure. Other types of connectors may alternatively be used in other embodiments of the invention.
[0030] [0030]FIG. 3A depicts the well 10 when a power hanger running tool 70 is disposed within the well 10 . FIG. 3B depicts a more detailed illustration of a portion 59 of the well 10 , showing the electrical connections that penetrate the wellhead 12 . Referring both to FIGS. 3A and 3B, as its name implies, the power hanger running tool 70 is used to run a power hanger 74 in the wellhead 10 . The power hanger 74 provides protection for the electrical connectors 28 (FIG. 3B), as well as provides electrical connections between these connectors 28 and electrical connectors (described below) of a tubing hanger extension.
[0031] The power hanger 74 is run downhole inside the well 10 via the tool 70 and is attached to the wellhead 12 by activation of the running tool 70 . In this manner, for purposes of running the tool 70 into the well 10 , the power hanger 74 is latched or secured to the running tool 70 . When the power hanger 74 is in the appropriate position inside the well 10 , the running tool 70 activates a locking mechanism (dogs, for example) of the power hanger 74 so that the power hanger 74 latches onto the interior surface of the sidewall of the wellhead 12 .
[0032] Before the running tool 70 sets the power hanger, a dielectric fluid may be injected into the well for purposes of cleaning the exposed electrical connections in the well. In this manner, this cleaning ensures effective electrical contacts and effective insulation surrounding these contacts. Thus, in some embodiments of the invention, when the power hanger running tool 70 is positioned near the electrical connectors 28 , a dielectric fluid may be injected into the well to clean exposed electrical connectors, such as the connectors 28 . As an example, the dielectric fluid may be injected into the well via radial ports 53 (FIG. 3A) of the running tool 70 . The dielectric fluid may be introduced from the surface of the well and flow downhole from the surface to these ports 53 , in some embodiments of the invention.
[0033] For purposes of setting the power hanger 74 , the running tool 70 orients the position of the power hanger 74 so that the electrical connectors 28 are aligned with corresponding electrical connectors 29 (FIG. 3B) of the power hanger 74 . When the power hanger 74 is set, the electrical connectors 28 and 29 mate. As an example, the electrical connectors 28 may be female connectors, and the electrical connectors 29 may be male connectors. Other variations are possible.
[0034] When latched to the power hanger 74 , the running tool 70 has electrical connectors 63 (FIG. 3B) that mate with corresponding electrical connectors 62 of the power hanger 74 . The electrical connectors 62 are located on the inner surface of the tubing hanger 74 and are connected to the connectors 29 on the outer surface of the tubing hanger 74 via insulated electrical conduits 69 . Due to this arrangement, the tool 70 may communicate with circuitry at the surface of the well for purposes of determining whether the running tool 70 has placed the power hanger 74 in the proper position inside the wellhead 12 . In this manner, proximity to the electrical contacts 28 may be sensed by using the electrical connectors 29 so that the orientation of the tool 70 (and power hanger 74 ) may be determined. In some embodiments of the invention, power from the power cable assembly 16 may be used to power the running tool 70 either before or after the power hanger 74 has been set, according to the particular embodiment of the invention.
[0035] Among the other features depicted in FIG. 3A, in some embodiments of the invention, the power hanger 74 includes a protective sleeve 76 that is positioned on the interior surface of the power hanger 74 . In this manner, the sleeve 76 includes a dielectric material and is biased (by a spring, for example) to extend upwardly to place the dielectric material over the connectors 62 after installation of the power hanger 74 and removal of the running tool 70 . However, when the tool 70 is run downhole with the power hanger 74 attached, the protective sleeve 76 is retracted, a position that removes the dielectric material from the connectors 62 , thereby preventing exposure to the connectors 62 so that the connectors 62 may be electrically coupled to the corresponding connectors 63 of the running tool 70 .
[0036] [0036]FIG. 4A depicts the well 10 after the power hanger 74 has been set and the running tool 70 has been retrieved. The electrical connections in the well 10 are depicted in more detail in the portion 59 (of the well 10 ) that is shown in FIG. 4B. Referring both to FIGS. 4A and 4B, commands may be sent from the surface to cause the running tool 70 to set the power hanger 74 . After verifying that the power hanger 74 has been properly set, commands may be communicated from the surface to unlatch the running tool 70 from the power hanger 74 . In response to the running tool 70 being released and removed from the power hanger 74 , the protective sleeve 76 extends to its protective position to cover the otherwise exposed electrical connectors 62 (FIG. 4B) on the interior surface of the power hanger 74 .
[0037] [0037]FIG. 5A depicts the well after installation of a production tubing 110 . FIG. 5B depicts a more detailed schematic diagram of the portion 59 showing electrical connections in the well 10 . Referring to FIGS. 5A and 5B, for purposes of completing the well 10 , the production tubing 110 is inserted into the wellbore of the well 10 with the top of the tubing 110 being connected (threadably connected, for example) to a tubing hanger extension 92 . The extension 92 , in turn, is threadably coupled to a tubing hanger interface 90 . In this manner, the tubing hanger interface 90 rests on a corresponding annular shoulder 100 (part of the region 15 ) of the well tree 12 such that in this position, the production tubing 110 hangs into the wellbore.
[0038] As depicted in FIGS. 5A and 5B, the electrical connections for the well 10 penetrate the well 10 beneath the tubing hanger interface 90 . This arrangement permits a cable 112 to be run downhole along the outside of the production tubing 110 . In this manner, in some embodiments of the invention, the tubing hanger extension 92 includes electrical connectors 93 that, when the extension 92 is installed, align with the interior surface connectors 62 (FIG. 5B) of the power hanger 74 . When the tubing hanger extension 92 is run into the well 10 , the extension 92 pushes down on the protective sleeve 76 to retract the sleeve 76 for purposes of exposing the electrical connectors 62 . Insulated electric wires 95 of the extension 92 extend through the tubing hanger extension 92 down to the cable 112 that houses the wires 95 . The cable is located on the exterior surface of the production tubing 110 (FIG. 5A) and may be attached to the tubing 110 by clamps 114 (FIG. 5A), for example.
[0039] In some embodiments of the invention, part of the string may include radial ports 93 to inject dielectric fluid into the well prior to the mating of the electrical connectors 93 with the connectors 62 . Similar to the radial ports 53 (FIG. 3A), the radial ports 93 flush the exposed electrical contact areas to improve contact connections and improve electrical insulation around these contacts. The flushing may be performed via a string that is run downhole separately from the string containing the tubing hanger 90 and tubing hanger extension 92 , in some embodiments of the invention.
[0040] In some embodiments of the invention, the power connections pierce the well tree below the tubing hanger and do not pierce the wellhead. In this manner, FIG. 6A depicts a well 200 with such an arrangement. FIGS. 6B and 6C depict more detailed schematic diagrams of portions 201 and 203 , respectively, of the well, showing in more detail the electrical connections in the well 200 .
[0041] Referring to FIGS. 6A, 6B and 6 C, in some embodiments of the invention, the power cable 16 extends from the power source 18 to a connector 240 that has contacts that mate with corresponding connectors 242 (FIG. 6B) that are located on the exterior surface of a sidewall of a well tree 204 . Each connector 242 is associated with and connected to a different insulated conduit 241 . The conduits 241 , in turn, communicate electricity from the connectors 242 to corresponding connectors 247 (FIG. 6B) that are located on the interior surface of the sidewall of the well tree 204 .
[0042] The well tree 204 is threadably connected to an interior sleeve 260 that has connectors 261 (FIG. 6B) that mate with the connectors 247 , and furthermore, the sleeve 260 includes internal insulated wires 250 (FIG. 6B) that extend along the longitudinal length of the sleeve 260 to lower electrical connectors 264 (FIG. 6C) that are exposed on the interior surface of the sidewall of the sleeve 260 . In some embodiments of the invention, a dielectric material of a protective sleeve 266 (FIG. 6C) covers the contacts 264 in an extended position of the sleeve 266 . Similar to the protective sleeve 76 , the protective sleeve 266 is biased (by a spring, for example) to extend to cover the contacts 264 when not pushed down by the presence of a tubing hanger extension, described below.
[0043] Also depicted in FIG. 6A, the well 200 may include a casing hanger 220 that is sealed to a wellhead 210 of the well 200 via a seal 214 . The casing hanger 220 hangs a smaller diameter casing 232 into the well 200 . Alternatively, a casing hanger 222 may be used in place of the casing hanger 220 . The casing hanger 222 hangs a larger diameter well casing 230 into the well.
[0044] Referring to FIG. 7A, the electrical connections described above work in the following manner after a tubing hanger interface 270 and a tubing hanger extension 274 are installed in the well 200 . FIGS. 7B and 7C depict more detailed schematic diagrams of portions 201 and 203 , respectively, of the well, showing in more detail the electrical connections in the well 200 .
[0045] Referring to FIGS. 7A, 7B and 7 C, the tubing hanger extension 274 is threadably coupled to the lower end of the tubing hanger interface 270 . The tubing hanger interface 270 , in turn, rests on a corresponding annular shoulder 277 of the well tree 204 .
[0046] After the tubing hanger 270 and tubing hanger extension 274 are installed, electrical connectors 271 (FIG. 7C) of the tubing hanger extension 274 , which are formed on the exterior surface of the sidewall of the tubing hanger extension 274 , contact corresponding electrical connectors 264 that extend on the interior sidewall of the sleeve 260 . Insulated wires 280 of the tubing hanger extension 274 extend to a cable 292 that houses the wires 280 . The cable 292 extends downhole on a production tubing 290 that is connected (threadably connected, for example) to the tubing hanger extension 274 . The cable 292 may be held in place, for example, by one or more clamps 294 (FIG. 7A). Other variations are possible.
[0047] Similar to the other arrangements described above, in some embodiments of the invention, part of the string that includes the tubing hanger 270 and tubing hanger extension 274 may be used to inject dielectric fluid into the well prior to the mating of the electrical connectors 271 with the connectors 264 . In this manner, the dielectric fluid flushes the exposed electrical contact areas to improve contact connections and improve electrical insulation around these contacts. The flushing may be performed via a string that is run downhole separately from the string that contains the tubing hanger 270 and tubing hanger extension 274 , in some embodiments of the invention.
[0048] Other embodiments are within the scope of the following claims. For example, in some embodiments of the invention, the techniques and systems described above for electrical penetration of the well below the tubing hanger interface may be applied to extend chemical injection into the well. In this manner, the techniques described above may be applied to extending any type of communication into the well tree or wellhead below the tubing hanger interface. Such techniques and systems allow an effective increase in the cross-sectional area of the production tubing. As another example, the communication lines that penetrate the well tree or wellhead below the tubing hanger interface may be hydraulic control lines. Other variations are possible.
[0049] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, 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. | A system that is usable with a well includes a structure that has a region that is adapted to receive a tubing hanger interface. The system also includes at least one communication connection that penetrates the structure below the region to receive the tubing hanger interface. | 4 |
This is a division, of application Ser. No. 812,192, filed July 1, 1977, now U.S. Pat. No. 4,120,891.
BACKGROUND OF THE INVENTION
The term "complement" refers to a complex group of proteins in body fluids that, working together with antibodies or other factors, play an important role as mediators of immune, allergic, immunochemical and/or immunopathological reactions. The reactions in which complement participates take place in blood serum or in other body fluids, and hence are considered to be humoral reactions.
With regard to human blood, there are at present more than 11 proteins in the complement system. These complement proteins are designated by the letter C and by number: C1, C2, C3 and so on up to C9. The complement protein C1 is actually an assembly of subunits designated C1q, C1r and C1s. The numbers assigned to the complement proteins reflect the sequence in which they become active, with the exception of complement protein C4, which reacts after C1 and before C2. The numerical assignments for the proteins in the complement system were made before the reaction sequence was fully understood. A more detailed discussion of the complement system and its role in body processes can be found in, for example, Bull. World Health Org., 39, 935.938 (1968); Ann. Rev. Medicine, 19, 1-24 (1968); The John Hopkins Med. J., 128, 57-74 (1971); Harvey Lectures, 66, 75-104 (1972); The New England Journal of Medicine, 287, 452-454; 489-495; 545-549; 592-596; 642-646 (1972); Scientific American, 229, (No. 5), 54-66 (1973); Federation Proceedings, 32, 134-137 (1973); Medical World News, October 11, 1974, pp. 53-58; 64-66; J. Allergy Clin. Immunol., 53, 298-302 (1974); Cold Spring Harbor Conf. Cell Proliferation 2/Proteases Biol. Control/229-241 (1975); Annals of Internal Medicine, 84, 580-593 (1976); "Complement: Mechanisms and Functions," Prentice-Hall, Englewood Cliffs, N.J. (1976).
The complement system can be considered to consist of three sub-systems: (1) a recognition unit (C1q) which enables it to combine with antibody molecules that have detected a foreign invader; (2) an activation unit (C1r, C1s, C2, C4, C3) which prepares a site on the neighboring membrane; and (3) and attack unit (C5, C6, C7, C8 and C9) which creates a "hole" in the membrane. The membrane attack unit is non-specific; it destroys invaders only because it is generated in their neighborhood. In order to minimize damage to the host's own cells, its activity must be limited in time. This limitation is accomplished partly by the spontaneous decay of activated complement and partly by interference by inhibitors and destructive enzymes. The control of complement, however, is not perfect, and there are times when damage is done to the host's cells. Immunity is therefore a double-edged sword.
Activation of the complement system also accelerates blood clotting. This action comes about by way of the complement-mediated release of a clotting factor from platelets. The biologically active complement fragments and complexes can become involved in reactions that damage the host's cells, and these pathogenic reactions can result in the development of immune-complex diseases. For example, in some forms of nephritis, complement damages the basal membrane of the kidney, resulting in the escape of protein from the blood into the urine. The disease disseminated lupus erythematosus belongs in this category; its symptoms include nephritis, visceral lesions and skin eruptions. The treatment of diphtheria or tetanus with the injection of large amounts of antitoxin sometimes results in serum sickness, an immune-complex disease. Rheumatoid arthritis also involves immune complexes. Like disseminated lupus erythematosus, it is an autoimmune disease in which the disease symptoms are caused by pathological effects of the immune system in the host's tissues. In summary, the complement system has been shown to be involved with inflammation, coagulation, fibrinolysis, antibody-antigen reactions and other metabolic processes.
In the presence of antibody-antigen complexes the complement proteins are involved in a series of reactions which may lead to irreversible membrane damage if they occur in the vicinity of biological membranes. Thus, while complement constitutes a part of the body's defense mechanism against infection it also results in inflammation and tissue damage in the immunopathological process. The nature of certain of the complement proteins, suggestions regarding the mode of complement binding to biological membranes and the manner in which complement effects membrane damage are discussed in Annual Review in Biochemistry, 38, 389 (1969).
A variety of substances have been disclosed as inhibiting the complement system, i.e., as complement inhibitors. For example, the compounds 3,3'-ureylenebis-[6-(2-amino-8-hydroxy-6-sulfo-1-naphthylazo)]benzenesulfonic acid, tetrasodium salt (chlorazol fast pink), heparin and a sulphated dextran have been reported to have an anticomplementary effect, British Journal of Experimental Pathology, 33, 327-339 (1952). The compound 8-(3-benzamido-4-methylbenzamido)naphthalene-1,3,5-trisulfonic acid (Suramin) is described as a competitive inhibitor of the complement system, Clin. Exp. Immunol., 10, 127-138 (1972). German Pat. No. 2,254,893 or South African Pat. No. 727,923 discloses certain 1-(diphenylmethyl)-4-(3-phenylallyl)piperazines useful as complement inhibitors. Other chemical compounds having complement inhibiting activity are disclosed in, for example, Journal of Medicinal Chemistry, 12, 415-419; 902-905; 1049-1052; 1053-1056 (1969); Canadian Journal of Biochemistry, 47, 547-552 (1969); The Journal of Immunology, 93, 629-640 (1964); The Journal of Immunology, 104, 279-288 (1970); The Journal of Immunology, 106, 241-245 (1971); and The Journal of Immunology, 111, 1061-1066 (1973).
It has been reported that the known complement inhibitors epsilon-aminocaproic acid, Suramin and tranexamic acid all have been used with success in the treatment of hereditary angioneurotic edema, a disease state resulting from an inherited deficiency or lack of function of the serum inhibitor of the activated first component of complement (C1 inhibitor), The New England Journal of Medicine, 286, 808-812 (1972). It has also been reported that the drug pentosan-poly-sulfoester has an anticomplementary activity on human serum both in vitro and in vivo, as judged by the reduction in total hemolytic complement activity; Pathologie Biologie, 25, 33-36 (1977).
SUMMARY OF THE INVENTION
This invention is concerned with tetranaphthalene sulfonic acid ureylene salts, having complement inhibiting activity, which are new compounds of formula I: ##STR1## wherein R is selected from the group consisting of hydrogen and methyl; R 1 is selected from the group consisting of hydrogen and carboxyl; A is selected from the group consisting of alkali metal; and the pharmaceutically acceptable salts thereof.
A preferred embodiment of the instant invention consists of those compounds wherein R 1 is hydrogen; and R and A are as previously defined.
A second preferred embodiment of the instant invention consists of those compounds wherein R 1 is carboxyl; and R and A are as previously defined.
A most preferred embodiment of the second preferred embodiment consists of those compounds wherein A is sodium.
This invention is also concerned with compounds of formula II: ##STR2## wherein R 2 is selected from the group consisting of nitro and amino; R 3 is selected from the group consisting of hydrogen and methyl; R 4 is selected from the group consisting of hydrogen and carboxyl; and A is selected from the group consisting of alkali metal.
A preferred embodiment of the instant invention consists of those compounds wherein R 4 is hydrogen; and R 2 , R 3 and A are as previously defined.
A second preferred embodiment of the instant invention consists of those compounds wherein R 4 is carboxyl; and R 2 , R 3 and A are as previously defined.
The compounds described immediately above are useful as intermediates for the preparation of the complement inhibiting ureide compounds previously described. Certain of the instant intermediates possess complement inhibiting activity.
DESCRIPTION OF THE INVENTION
The compounds of the present invention may be prepared by the following method outlined in Flow Chart A. ##STR3## wherein X is selected from the group consisting of hydrogen and methyl; Y is selected from the group consisting of hydrogen and carbomethoxy; Z is selected from the group consisting of hydrogen and carboxyl; and A is selected from the group consisting of alkali metal.
The novel intermediate nitro (I) and amino (II) compounds of the invention are prepared by reacting 8-amino-1,3,5-naphthalenetrisulfonic acid trialkali metal salt with the appropriate substituted nitro, substituted methyl or carbomethoxy aryl carbonyl chloride in basic aqueous medium for about 4 to about 5 hours. After acidification and neutralization, the solution is diluted with ethanol to provide the corresponding substituted nitro, substituted methyl or carbomethoxy aryl carbonylimino substituted trialkali metal salt of 1,3,5-naphthalenetrisulfonic acid. The methyl ester compound is converted to the carboxylic acid by treatment with alkali metal hydroxide, acidification with dilute hydrochloric acid and precipitation from water:ethanol (1:10). Hydrogenation of the preceding nitro trialkali metal salt using 10% palladium-carbon catalyst, filtration, concentration and treatment with absolute ethanol provides the corresponding substituted amino, substituted methyl or carboxylic acid aryl carbonylimino substituted trialkali metal salt of 1,3,5-naphthalenetrisulfonic acid. The amino trialkali metal salt dissolved in aqueous medium and neutralized to pH 7.2 is reacted with 5-nitro-isophthaloyl chloride for about 2 to about 3 hours, in the presence of alkali metal acetate. Filtration and evaporation of the filtrate provides a residue which is dissolved in water, acidified to pH 2.0-2.5 and diluted with absolute ethanol to precipitate the nitro-phenylenebiscarbonylimino substituted phenylenecarbonylimino di-1,3,5-naphthalenetrisulfonic acid hexaalkali metal salt (I). Hydrogenation of (I) using 10% palladium-carbon catalyst in water, filtration and evaporation of the filtrate produces a residue which is dissolved in water and precipitated with absolute ethanol, (water:ethanol 1:10) to yield the amino-phenylenebiscarbonylimino substituted phenylenecarbonylimino di-1,3,5-naphthalenetrisulfonic acid hexaalkali metal salt (II). Phosgenation of (II) in aqueous medium with alkali metal carbonate and adjustment to pH 7.0-7.2, filtration and evaporation provides a residue. The residue is dissolved in water and reprecipitated from water:ethanol (1:3) to provide the carbonyldiimino symmetrical phenenylbiscarbonylimino substituted phenylenecarbonylimino tetra-1,3,5-naphthalenetrisulfonic acid dodecaalkali metal salt (III).
The compounds of the present invention may be administered internally, e.g., orally, intra-articularly or parenterally, e.g., intra-articular, to a warm-blooded animal to inhibit complement in the body fluid of the animal, such inhibition being useful in the amelioration or prevention of those reactions dependent upon the function of complement, such as inflammatory process and cell membrane damage induced by antigen-antibody complexes. A range of doses may be employed depending on the mode of administration, the condition being treated and the particular compound being used. For example, for intravenous or subcutaneous use from about 5 to about 50 mg/kg/day, or every six hours for more rapidly excreted salts, may be used. For intra-articular use for large joints such as the knee, from about 2 to about 20 mg/joint per week may be used, with proportionally smaller doses for smaller joints. The dosage range is to be adjusted to provide optimum therapeutic response in the warm-blooded animal being treated. In general, the amount of compound administered can vary over a wide range to provide from about 5 mg/kg to about 100 mg/kg of body weight of animal per day. The usual daily dosage for a 70 kg subject may vary from about 350 mg to about 3.5 g. Unit doses of the acid or salt can contain from about 0.5 mg to about 500 mg.
While in general the sodium salts of the acids of the invention are suitable for parenteral use, other salts may also be prepared, such as those of primary amines, e.g., ethylamine; secondary amines, e.g., diethylamine or diethanol amine; tertiary amines, e.g., pyridine or triethylamine c 2-dimethylaminomethyl-dibenzofuran; aliphatic diamines, e.g., decamethylenediamine; and aromatic diamines, can be prepared. Some of these are soluble in water, others are soluble in saline solution, and still others are insoluble and can be used for purposes of preparing suspensions for injection. Furthermore as well as the sodium salt, those of the alkali metals, such as potassium and lithium; of ammonia; and of the alkaline earth metals, such as calcium or magnesium, may be employed. It will be apparent, therefore, that these salts embrace, in general derivatives of salt-forming cations.
In therapeutic use, the compounds of this invention may be administered in the form of conventional pharmaceutical compositions. Such compositions may be formulated so as to be suitable for oral or parenteral administration. The active ingredient may be combined in admixture with a pharmaceutically acceptable carrier, which carrier may take a wide variety of forms depending on the form of preparation desired for administration, i.e., oral or parenteral. The compounds can be used in compositions such as tablets. Here, the principal active ingredient is mixed with conventional tabletting ingredients such as corn starch, lactose, sucrose, sorbitol, talc, stearic acid, magnesium stearate, dicalcium phosphate, gums, or similar materials as non-toxic pharmaceutically acceptable diluents or carriers. The tablets or pills of the novel compositions can be laminated or otherwise compounded to provide a dosage form affording the advantage of prolonged or delayed action or predetermined successive action of the enclosed medication. For example, the tablet or pill can comprise an inner dosage and an outer dosage component, the latter being in the form of an envelope over the former. The two components can be separated by an enteric layer which serves to resist disintegration in the stomach and permits the inner component to pass intact into the duodenum or to be delayed in release. A variety of materials can be used for such enteric layers or coatings, such materials including a number of polymeric acids or mixtures of polymeric acids with such materials as shellac, shellac and cetyl alcohol, cellulose acetate and the like. A particularly advantageous enteric coating comprises a styrene maleic acid copolymer together with known materials contributing to the enteric properties of the coating. The tablet or pill may be colored through the use of an appropriate non-toxic dye, so as to provide a pleasing appearance.
The liquid forms in which the novel compositions of the present invention may be incorporated for administration include suitable flavored emulsions with edible oils, such as, cottonseed oil, sesame oil, coconut oil, peanut oil, and the like, as well as elixirs and similar pharmaceutical vehicles. Sterile suspensions or solutions can be prepared for parenteral use. Isotonic preparations containing suitable preservatives are also desirable for injection use.
The term dosage form, as described herein, refers to physically discrete units suitable as unitary dosage for warm-blooded animal subjects, each unit containing a predetermined quantity of active component calculated to produce the desired therapeutic effect in association with the required pharmaceutical diluent, carrier or vehicle. The specification for the novel dosage forms of this invention are indicated by characteristics of the active component and the particular therapeutic effect to be achieved or the limitations inherent in the art of compounding such an active component for therapeutic use in warm-blooded animals as disclosed in this specification. Examples of suitable oral dosage forms in accord with this invention are tablets, capsules, pills, powder packets, granules, wafers, cachets, teaspoonfuls, dropperfuls, ampules, vials, segregated multiples or any of the foregoing and other forms as herein described.
The complement inhibiting activity of the compounds of this invention has been demonstrated by one or more of the following identified tests: (i) Test, Code 026 (C1 inhibitor)-This test measures the ability of activated human C1 to destroy fluid phase human C2 in the presence of C4 and appropriate dilutions of the test compound. An active inhibitor protects C2 from C1 and C4; (ii) Test, Code 035 (C3-C9 inhibitor)-This test determines the ability of the late components of human complement (C3-C9) to lyse EAC 142 in the presence of appropriate dilutions of the test compound. An active inhibitor protects EAC 142 from lysis by human C3-C9; (iii) Test, Code 036 (C-Shunt inhibitor)--In this test human erythrocytes rendered fragile are lysed in autologous serum via the shunt pathway activated by cobra venom factor in the presence of appropriate dilutions of the test compound. Inhibition of the shunt pathway results in failure of lysis; (iv) Forssman Vasculitis Test--Here, the well known complement dependent lesion, Forssman vasculitis, is produced in guinea pigs by intradermal injection of rabbit anti-Forssman antiserum. The lesion is measured in terms of diameter, edema and hemorrhage and the extent to which a combined index of these is inhibited by prior intraperitoneal injection of the test compound at 200 mg/kg is then reported, unless otherwise stated; (v) Forssman Shock Test--Lethal shock is produced in guinea pigs by an i.v. injection of anti-Forssman antiserum and the harmonic mean death time of treated guinea pigs is compared with that of simultaneous controls; (vi) Complement Level Reduction Test--In this test, the above dosed guinea pigs, or others, are bled for serum and the complement level is determined in undiluted serum by the capillary tube method of U.S. Pat. No. 3,876,376 and compared to undosed control guinea pigs; and (vii) Cap 50 Test--Here, appropriate amounts of the test compound are added to a pool of guinea pig serum in vitro, after which the undiluted serum capillary tube assay referred to above is run. The concentration of compound inhibiting 50% is reported.
With reference to Table I, guinea pigs weighing about 300 g were dosed intravenously (i.v.) or intraperitoneally (i.p.) with 200 mg/kg of the test compound dissolved in saline and adjusted to pH 7-8. One hour after dosing, the guinea pigs were decapitated, blood was collected and the serum separated. The serum was tested for whole complement using the capillary tube assay. Percent inhibition was calculated by comparison with simultaneous controls. The results appear in Table I together with results of tests, code 026, 035, 036, Cap 50, % inhibition and Forssman shock. Table I shows that the compounds of the invention possess highly significant in vitro and in vivo, complement inhibiting activity in warm-blooded animals.
Table II indicates the complement inhibiting activity of an intermediate compound of the invention.
TABLE I__________________________________________________________________________Biological Activities In Vivo Activity (Guinea Pig) % Inhibition Cl C-Late Shunt Inhi- Intraperitoneal 026* 035* bition 036* Time (Minutes)Compound Wells Wells Wells Cap 50* 30 60 120__________________________________________________________________________8,8',8",8'"-{Ureylenebis{s-phenylbis-[carbonylimino(4-methyl-3,1-phenylene)- +6** +3 +4 192 -62 -84 -95carbonylimino]}}tetra-1,3,5-naphthalene-trisulfonic acid dodecasodium salt3,3',3",3'"-{Ureylenebis[s-phenenylbis-(carbonylimino)]}tetrakis[5-(4,6,8-tri- +7 +2 +5 72 -90 -94 -89sulfo-1-naphthyl)carbamoyl]benzoic aciddodecasodium salt__________________________________________________________________________ *Code designation for tests employed as referred herein. **Activity in wells a serial dilution assay. Higher well number indicates higher activity. The serial dilutions are twofold.
TABLE II__________________________________________________________________________Biological Activities (Intermediate) In Vivo Activity (Guinea Pig) % Inhibition Cl C-Late Shunt Inhi- Intraperitoneal 026* 035* bition 036* Time (Minutes)Compound Wells Wells Wells Cap 50* 30 60 120__________________________________________________________________________3,3'-[5-Amino-m-phenylenebis(carbonyl-imino)]bis{5-[(4,6,8-trisulfo-1-naph- +4** +2 +2 144 -40 -61 -61thyl)carbamoyl]}benzoic acid hexasodiumsalt__________________________________________________________________________ *Code designation for tests employed as referred herein. **Activity in wells a serial dilution assay. Higher well number indicates higher activity. The serial dilutions are twofold.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
8,8'-{(5-Nitro-1,3-phenylene)bis[carbonylimino(4-methyl-3,1-phenylene)carbonylimino]}di-1,3,5-naphthalenetrisulfonic acid hexasodium salt
To a warm solution of 106.4 g of (80.5%) 8-amino-1,3,5-naphthalenetrisulfonic acid in 100 ml of water and 45.0 ml of 5 N sodium hydroxide is slowly added 500 ml of absolute ethanol with vigorous stirring for 30 minutes. The mixture iw cooled to room temperature and filtered. The precipitate is washed with 80% aqueous ethanol, ethanol and ether and is dried in vacuo at 110° C. for 16 hours to give 103.7 g of 8-amino-1,3,5-naphthalenetrisulfonic acid trisodium salt.
A mixture of 25.0 g of 4-methyl-3-nitrobenzoic acid and 50 ml of thionyl chloride is refluxed for 31/2 hours in a 110° C. oil bath. The resulting solution is evaporated in vacuo to an oil. The oil is distilled at a pressure of 0.5 mm of mercury and an oil bath temperature of 145°-160° C. The fraction, bp 108°-113° C., is collected to give 24.3 g of 3-nitro-p-toluoyl chloride.
To a stirred solution of 22.5 g of 8-amino-1,3,5-naphthalenetrisulfonic acid trisodium salt in 160 ml of water is added 11.0 g of the preceding product with a small amount of ether. Stirring is continued, and after one hour 1.0 g of sodium acetate trihydrate and 1.0 g of 3-nitro-p-toluoyl chloride are added. The mixture is stirred an additional 3 hours and the above addition of sodium acetate and 3-nitro-p-toluoyl chloride is repeated. The mixture is stirred an additional hour, acidified to Congo Red indicator paper with hydrochloric acid and filtered. The filtrate is neutralized with sodium hydroxide, concentrated, dissolved in 50 ml of water and added to one liter of ethanol with stirring for 16 hours. The solid is filtered and forms a gel on washing with ethanol. The gel is dissolved in water and evaporated. The residue is dissolved in 35 ml of hot water and 320 ml of absolute ethanol is added with stirring. The mixture solidifies and water is added to allow filtration. The solid is washed with ether and dried in vacuo. The filtrate is treated by stirring with one liter of ethanol, the separated solid is collected, washed with ether, and dried to yield a combined total of 23.9 g of 8-(3-nitro-p-toluamido)-1,3,5-naphthalenetrisulfonic acid trisodium salt.
A 22.0 g portion of the preceding product, 200 ml of water and 2.5 g of 10% palladium-on-carbon catalyst is hydrogenated in a Parr shaker until no more hydrogen is absorbed. The resulting mixture is filtered through diatomaceous earth, the residue is washed with water, and the filtrate is evaporated, the residue is dissolved in 50 ml of water and added to 900 ml of absolute ethanol. The mixture is warmed on a steam bath and then is stirred at room temperature for 3 hours. The mixture is filtered and the solid is washed with ethanol, then ether and dried in vacuo to give 16.89 g of 8-(3-amino-p-toluamido)-1,3,5-naphthalenetrisulfonic acid trisodium salt.
A mixture of 60.0 g of 5-nitroisophthalic acid, 300 ml of thionyl chloride and one ml of dimethylformamide is stirred at room temperature for 30 minutes, then is refluxed for one hour. The resulting clear solution is allowed to stand 24 hours, then is evaporated to a small volume in vacuo. The evaporation step is repeated with toluene and the resulting liquid is diluted with 250 ml of hexane. The mixture is stirred and cooled until the resulting oil is solidified. The product is ground to a powder and is recrystallized twice from carbon tetrachloride to give 47.4 g of 5-nitroisophthaloyl chloride.
A stirred solution of 10.6 g of 8-(3-amino-p-toluamido)-1,3,5-naphthalenetrisulfonic acid trisodium salt in 60 ml of water is neutralized to pH 7.2, then 2.84 g of sodium acetate trihydrate is added followed by 2.48 g of powdered 5-nitroisophthaloyl chloride with vigorous stirring. Stirring is continued for 2 hours, the reaction mixture is filtered, and the filtrate evaporated in vacuo. The residue is dissolved in 50 ml of hot water and acidified to pH 2.5, then 70 ml of absolute ethanol is added with vigorous stirring to form a precipitate. The mixture is heated until solution results and then allowed to cool with stirring. The reprecipitated product is collected, washed with 70% aqueous ethanol, ethanol and ether, then is dried to yield 10.6 g of the product of the Example.
EXAMPLE 2
8,8'-{5-Amino-1,3-phenylenebis{{[carbonylimino(4-methyl-3,1-phenylene)]carbonyl}imino}}di-1,3,5-naphthalenetrisulfonic acid hexasodium salt
A mixture of 1.98 g of the product of Example 1, 60 ml of water and 500 mg of 10% palladium-on-carbon catalyst is hydrogenated in a Parr shaker. The resulting mixture is filtered, and the filtrate is evaporated. The residue is dissolved in 12 ml of hot water and 125 ml of absolute ethanol is added. The precipitate is collected, washed with ethanol and ether and dried to yield 1.73 g of the product of the Example.
EXAMPLE 3
8,8',8",8'"-{Ureylenebis{s-phenenylbis[carbonylimino(4-methyl-3,1-phenylene)carbonylimino]}}tetra-1,3,5-naphthalenetrisulfonic acid dodecasodium salt
Phosgene gas is bubbled into a mixture of 1.73 g of the product of Example 2, 290 mg of sodium carbonate and 20 ml of water until acidic to Congo Red indicator paper. The mixture is adjusted to pH 7.0 and filtered. The filtrate is evaporated. The residue is dissolved in 10 ml of hot water, then ethanol is added producing a gum. The supernatant is decanted, the gum is triturated with ethanol and solidifies. The solid is collected by filtration, washed with ethanol and ether and dried. The material is dissolved in 15 ml of water, reprecipitated with 50 ml of ethanol, stirred for one hour, filtered, washed as above and dried to yield 1.5 g of the product of the Example.
EXAMPLE 4
3,3'-[5-Nitro-m-phenylenebis(carbonylimino)]bis{5-[(4,6,8-trisulfo-1-naphthyl)carbamoyl]}benzoic acid hexasodium salt
A 35.0 g portion of 5-nitroisophthaloyl chloride is added to 600 ml of methanol with stirring producing a precipitate. The mixture is heated to solution then is chilled, filtered and dried to yield 31.75 g of dimethyl 5-nitroisophthalate.
A mixture of 7.46 g of potassium hydroxide in 87.5 ml of methanol is added to a stirred solution of 31.75 g of the preceding product in 331.0 ml of acetone. A solid is precipitated and stirring is continued for 16 hours. The solid (A) is filtered off, washed with ether and set aside. The filtrate is evaporated, the residue is extracted with 125 ml of warm water and is filtered. The filtrate is acidified with dilute hydrochloric acid to produce a precipitate which is collected and dried to yield 3.4 g of product. The solid (A) above is extracted with 250 ml of warm water and is filtered. The filtrate is filtered again at room temperature, acidified with dilute hydrochloric acid and cooled. The precipitate is collected and dried to give 18.25 g of additional product identified as 5-nitro-isophthalic acid, 3-methyl ester.
A mixture of 18.38 g of the product above, 60 ml of thionyl chloride and 0.37 ml of dimethylformamide is heated at 60° C. for 2.5 hours. The solution is evaporated, then is treated with toluene, and again is evaporated. The residue is slurried in hot diethyl ether and the ether volume is reduced by evaporation. The mixture is chilled and filtered. The precipitate is washed with cold ether and is dried. The material is extracted with 500 ml of boiling hexane by decantation. The hexane is cooled and filtered to yield 14.1 g of 3-carbomethoxy-5-nitrobenzoyl chloride.
To a solution of 14.0 g of 8-amino-1,3,5-naphthalenetrisulfonic acid trisodium salt and 8.96 g of sodium acetate trihydrate in 150 ml of water is added with stirring 8.0 g of 3-carbomethoxy-5-nitrobenzoyl chloride. Stirring is continued for 2 hours then 18.0 ml of diethyl ether is added and stirring is continued for one additional hour. An additional 1.12 g of sodium acetate is added along with 1.0 g of 3-carbomethoxy-5-nitrobenzoyl chloride with continued stirring for one hour. The mixture is filtered and the filtrate is concentrated. The residue is dissolved in 100 ml of hot water, 100 ml of absolute ethanol is added with formation on standing of a precipitate. The material is filtered, washed with 80% aqueous ethanol, ethanol and ether and dried to yield 17.35 g of 5-nitro-N-4,6,8-trisulfo-1-naphthylisophthalamic acid methyl ester trisodium salt.
A 12.0 g portion of the above product in 183.0 ml of 0.1 N sodium hydroxide is stirred for 3 hours. The solution is acidified to pH 2.0 with dilute hydrochloric acid then is evaporated. The residue is dissolved in 35 ml of hot water and 350 ml of absolute ethanol is added. The precipitated product is filtered, washed with ethanol and ether and dried to yield 11.0 g of 5-nitro-N-4,6,8-trisulfo-1-naphthylisophthalamic acid trisodium salt.
A mixture of 11.0 g of the preceding compound and 2.0 g of 10% palladium-on-carbon catalyst in 100 ml of water is hydrogenated in a Parr shaker until no additional hydrogen is absorbed. The resulting mixture is filtered through diatomaceous earth, the filtrate is evaporated, the residue is dissolved in 35 ml of hot water, then is diluted with 350 ml of absolute ethanol to yield a precipitate. The product is collected, washed with ethanol and ether, and dried to give 8.6 g of 5-amino-N-4,6,8-trisulfo-1-naphthylisophthalamic acid trisodium salt.
A stirred solution of 8.6 g of the above compound in 50 ml of water is neutralized to pH 7.2, then 2.2 g of sodium acetate trihydrate is added followed by 1.92 g of powdered 5-nitroisophthaloyl chloride with vigorous stirring. Stirring is continued for an additional 3 hours then the reaction mixture is filtered and evaporated in vacuo. The residue is dissolved in 50 ml of water and acidified to pH 2.0. A solid is precipitated by the slow addition of 120 ml of absolute ethanol with stirring for 1/2 hour. The solid is filtered, washed with 80% aqueous ethanol, ethanol and ether and dried in vacuo to yield 10.1 g of the product of the Example.
EXAMPLE 5
3,3'-[5-Amino-m-phenylenebis(carbonylimino)]bis{5-[4,6,8-trisulfo-1-naphthyl)carbamoyl]}benzoic acid hexasodium salt
A mixture of 9.1 g of the product of Example 4, 1.3 g of 10% palladium-on-carbon catalyst and 150 ml of water is hydrogenated in a Parr shaker until no additional hydrogen is absorbed. The resulting mixture is filtered through diatomaceous earth. The filtrate is evaporated, the residue is dissolved in 50 ml of hot water and 500 ml of absolute ethanol is added with stirring. Stirring is continued for one hour. The product is filtered, washed with ethanol and ether and dried to yield 7.3 g of the product of the Example.
EXAMPLE 6
3,3',3",3'"-{Ureylenebis[s-phenenylbis(carbonylimino]}tetrakis[5-(4,6,8-trisulfo-1-naphthyl)carbamoyl]benzoic acid dodecasodium salt
Phosgene gas is bubbled into a solution of 6.6 g of the product of Example 5 and 1.56 g of sodium carbonate in 60.0 ml of water until acidic to Congo Red indicator paper. The mixture is adjusted to pH 7.2 with sodium carbonate, treated with activated charcoal and filtered. The filtrate is concentrated and the residue is dissolved in 40.0 ml of hot water then ethanol is added to a volume of 140 ml to form a gum. The supernatant is decanted and the gum is triturated with ethanol to yield a solid. The solid is filtered, washed with ethanol and ether and dried. The material is dissolved in 40.0 ml of hot water and is added to 140 ml of ethanol to again give a gum. The gum is collected, dissolved in water and evaporated. The residue is dissolved in 50 ml of water, adjusted to pH 2.0 with hydrochloric acid and treated with 140 ml of ethanol. The supernatant is decanted and the residue is triturated with ethanol, filtered, washed with ethanol and ether and dried to yield 5.1 g of the product of the Example as a tan solid.
EXAMPLE 7
Preparation of Compressed Tablet
______________________________________Ingredient mg/Tablet______________________________________Active Compound 0.5-500Dibasic Calcium Phosphate N.F. qsStarch USP 40Modified Starch 10Magnesium Stearate USP 1-5______________________________________
EXAMPLE 8
Preparation of Compressed Tablet - Sustained Action
______________________________________Ingredient mg/Tablet______________________________________Active Compound 0.5-500(as acidas Aluminum Lake*, Micronized equivalent)Dibasic Calcium Phosphate N.F. qsAlginic Acid 20Starch USP 35Magnesium Stearate USP 1-10______________________________________ *Complement inhibitor plus aluminum sulfate yields aluminum complement inhibitor. Complement inhibitor content in aluminum lake ranges from 5-30%.
EXAMPLE 9
Preparation of Hard Shell Capsule
______________________________________Ingredient mg/Capsule______________________________________Active Compound 0.5-500Lactose, Spray Dried qsMagnesium Stearate 1-10______________________________________
EXAMPLE 10
Preparation of Oral Liquid (Syrup)
______________________________________Ingredient % W/V______________________________________Active Compound 0.05-5Liquid Sugar 75.0Methyl Paraben USP 0.18Propyl Paraben USP 0.02Flavoring Agent qsPurified Water qs ad 100.0______________________________________
EXAMPLE 11
Preparation of Oral Liquid (Elixir)
______________________________________Ingredient % W/V______________________________________Active Compound 0.05-5Alcohol USP 12.5Glycerin USP 45.0Syrup USP 20.0Flavoring Agent qsPurified Water qs ad 100.0______________________________________
EXAMPLE 12
Preparation of Oral Suspension (Syrup)
______________________________________Ingredient % W/V______________________________________Active Compound 0.05-5as Aluminum Lake, Micronized (acid equivalent)Polysorbate 80 USP 0.1Magnesium Aluminum Silicate,Colloidal 0.3Flavoring Agent qsMethyl Paraben USP 0.18Propyl Paraben USP 0.02Liquid Sugar 75.0Purified Water qs ad 100.0______________________________________
EXAMPLE 13
Preparation of Injectable Solution
______________________________________Ingredient % W/V______________________________________Active Compound 0.05-5Benzyl Alcohol N.F. 0.9Water for Injection 100.0______________________________________
EXAMPLE 14
Preparation of Injectable Oil
______________________________________Ingredient % W/V______________________________________Active Compound 0.05-5Benzyl Alcohol 1.5Sesame Oil qs ad 100.0______________________________________
EXAMPLE 15
Preparation of Intra-Articular Product
______________________________________Ingredient Amount______________________________________Active Compound 2-20 mgNaCl (physiological saline) 0.9%Benzyl Alcohol 0.9%Sodium Carboxymethylcellulose 1-5%pH adjusted to 5.0-7.5Water for Injection qs ad 100%______________________________________
EXAMPLE 16
Preparation of Injectable Depo Suspension
______________________________________Ingredient % W/V______________________________________Active Compound 0.05-5 (acid equivalent)Polysorbate 80 USP 0.2Polyethylene Glycol 4000 USP 3.0Sodium Chloride USP 0.8Benzyl Alcohol N.F. 0.9HCl to pH 6-8 qsWater for Injection qs ad 100.0______________________________________ | Ureylenebis-symmetrical-phenenylbiscarbonylimino-substituted phenylenecarbonylimino-tetranaphthalenepolysulfonic acid benzoic acid salts, and nitro- and amino-substituted phenylenebiscarbonylimino-substituted benzamido-phenylenedicarbonyl-dinaphthalenepolysulfonic acid benzoic acid salts which are intermediates for the preparation of the active ureides which have complement inhibiting activity. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. application Ser. No. 10/459,341 filed on Jun. 11, 2003 for METHOD AND APPARATUS FOR ORGANIZING AND PLAYING DATA, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of organizing and playing data.
[0004] Portions of the disclosure of this patent document contain material that are subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office file or records, but otherwise reserves all rights whatsoever.
[0005] 2. Description of Related Art
[0006] The personal computer has become a resource for entertainment as well as traditional data processing functionality. In many cases, the personal computer has replaced home stereo systems as a source of audio entertainment. Many users have replaced hard copies of books and magazines with electronic copies often referred to as reading materials for review via a computer. Another popular use for personal computers is the presentation of media information and entertainment.
[0007] Often, the providing of media entertainment, such as audio or video entertainment, occurs via a network, such as the internet. Certain web sites are known for the availability of video clips of movies and television programs, or audio program files, that a computer user can view, listen to, and possibly purchase. In some cases, television or radio networks provide web sites devoted to their own shows or to a single show. Many times a web site is designed to provide an “enhanced” experience in real time during the broadcast of a television program. Such enhanced features may include comprehensive statistics in the case of sporting events, commercial tie-in and purchase opportunities in the case of entertainment programs, play-along quizzes, or even competition during game shows.
[0008] In some cases, additional media content is made available to internet users between broadcasts of programs to promote interest, loyalty, and viewing opportunities, when a program is not otherwise airing. There are a number of disadvantages with many of the current systems for obtaining such content via the internet as will be described below.
[0009] A number of web sites purport to provide a central location where a variety of media can be obtained and experienced by a user on a personal computer via a network. A disadvantage with many of these sites is a failure to provide a consistent interface for content from different sources. Another disadvantage is the failure to provide to the user only content that is actually playable by the user. Often the user is prompted to mistakenly buy player capability that the user doesn't want or need.
[0010] Certain web sites purport to provide a portal or central location for accessing media data and content from a variety of sources, including from different networks and internet media sources. A problem for a user on such a site is the inconsistency of the presented interface for different content. In a typical situation, a user may elect to view a content clip from a program from one of the broadcast networks. When the clip is selected, the user may actually be transferred to the network's own web site for viewing of the clip.
[0011] When the user is transferred, the entire interface for viewing clips is often changed to the interface supported by the source site. This diminishes the viewing experience for the user and requires the user to pay extra attention to where navigation and activation controls are located in order to effectively use the site for viewing of content.
[0012] Another problem occurs when a user is part of a tiered membership or subscription service on a portal site. Lower tiers of membership may have restrictions on which content is available. When the portal switches the user to the content source site, the user may be presented with all possible content, even though the user is able to view only a subset of the listed content. This diminishes the user's experience because the user is made aware of a limited experience.
[0013] Finally, the user may be referred to data that is not playable on the user's currently installed content player. The user may be presented with a list of available content that does not indicate which player is used or required to play the content. When a user selects a clip or content that requires a player that the user does not currently have, the user may be directed to a site where a new player can be obtained. Often these sites are confusing. A free player is often available, but the user is urged to purchase a “professional” or “full featured” version of a player not really needed for the clip that the user wants to play. Often the user mistakenly purchases the “for purchase” player instead of simply accepting the free player.
SUMMARY OF THE INVENTION
[0014] The present invention solves the foregoing and other needs. In certain embodiments, a method and system is provided for generating an interface at a web site on a network, with consistent features and navigation capabilities by collecting a plurality of media files for use with the website, associating metadata attributes with each of the media files and mapping the metadata attributes with locations on the interface.
[0015] In another embodiment, a playlist is created by compiling a data file that contains one or more sequentially placed unique identifiers that identify one or more pieces of content; and allowing the user to access the content out of sequence.
BRIEF DESCRIPTION OF DRAWINGS
[0016] [0016]FIG. 1 illustrates a website of one embodiment of the present invention in an initial state;
[0017] [0017]FIG. 2 illustrates a web site of one embodiment of the present invention after a user menu selection;
[0018] [0018]FIG. 3 illustrates a web site of one embodiment of the present invention after a show has been selected;
[0019] [0019]FIG. 4 illustrates a web site of one embodiment of the present invention after an episode has been selected;
[0020] [0020]FIG. 5 illustrates a player of one embodiment of the present invention in an initial state;
[0021] [0021]FIG. 6 illustrates a player of one embodiment of the present invention after a user menu selection;
[0022] [0022]FIG. 7 illustrates a player of one embodiment of the present invention after a show has been selected;
[0023] [0023]FIG. 8 illustrates a player of one embodiment of the present invention after an episode has been selected;
[0024] [0024]FIG. 9 is a flow diagram illustrating an embodiment of the operation of the present invention;
[0025] [0025]FIG. 10 is a flow diagram illustrating an embodiment of the invention;
[0026] [0026]FIG. 11 is a flow diagram illustrating one embodiment of the present invention being implemented as computer software in the form of computer readable code;
[0027] [0027]FIG. 12 is a flow diagram illustrating the content invocation flow of one embodiment of the present invention;
[0028] [0028]FIG. 13 is a flow diagram illustrating the confirmation of media playback capability;
[0029] [0029]FIG. 14 is a flow diagram illustrating site-map hierarchy of one embodiment of the present invention;
[0030] [0030]FIG. 15 is a player of one embodiment of the present invention; and
[0031] [0031]FIG. 16 is a flow diagram illustrating one embodiment of the present invention.
DETAILED DESCRIPTION
[0032] A method and apparatus for presenting and playing content on a network is described. In the following description, numerous details are set forth in order to provide a more thorough description of the embodiments of the present invention. It will be apparent, however, to one skilled in the art, that the present embodiment may be practiced without these specific details. In other instances, well known features have not been described in detail so as not to unnecessarily obscure the present invention.
[0033] The present embodiment invention provides a consistent interface and user navigation system for media clips from all sources. In the following description, an example of organizing and playing viewable content, such as video content, is described. It is understood that the invention has equal application to audio media content as well. FIG. 1 illustrates one embodiment of the interface of the present invention. The embodiment contemplates a drill down approach to certain aspects of navigation with FIG. 1 illustrating the top or home level of navigation. The display includes two display areas 101 and 102 . Area 101 is referred to as an “editorial” area and can include show titles and logos, navigation tools, and other information. Region 102 is an area reserved for promotions and can include still promotions or advertisements or those provided in any other form such as created with Macromedia Corp.'s Flash tool and the like.
[0034] An area 103 includes links to a number of categories or “channels” that the user can select to be presented with viewing choices falling within a particular genre or type. FIG. 1 illustrates a number of channels by way of example, including “Featured Today” 104 , News 105 , Sports 106 , Entertainment 107 , and Coming Soon 108 . By selecting one of these categories, the user is able to access another interface that provides choices related to the genre. Featured Today 104 is a channel that is suitable for breaking news or even for sponsored clips that may relate to a current film or to a broadcast event of the same or impending day. The selections may represent pre-recorded media or live broadcast media.
[0035] The provision of choices of selected shows, news, and sports is indicated in region 117 . The show title, logo, or brand is indicated in regions 111 and 112 . Below each logo bar is an information region 115 and 116 , respectively, that provides program information to the user. This information includes the episode title and a brief description of the episode. It also includes a thumbnail image of the available show or clip in region 113 and 114 .
[0036] A region 109 is also provided to the user that lists available content. The content may be sorted in a number of ways. In the example of FIG. 1, the content is listed as Most Popular, which may be based on any of a number of time periods, including by the day, the week, or even the hour. Also in the example of FIG. 1, the most popular clip listed may include a thumbnail 110 to provide additional information to the user of the available clip. The Most Popular listing may be with respect to all content, by channel, by category, or by any other suitable or desired population of media clips. It should be appreciated that in different embodiments of the present invention, the pixel size of the display can vary between different images. For instance, in the example illustrated in FIG. 1, the promotion in area 102 has a pixel size of 300×250 dots per inch (dpi) while the thumbnail 110 has a size of 88×66 dpi.
[0037] [0037]FIG. 2 illustrates the interface of one embodiment of the invention after the user has selected a channel. A user can select a channel by clicking upon the particular channel in the area 103 . In the example shown, the user has selected the Entertainment 107 channel. This selection presents a slightly changed interface to the user with a channel indicator 201 displayed at the top of the editorial section 101 . In addition, region 117 now only presents show selections which correspond to the user's selection.
[0038] [0038]FIG. 3 illustrates the display of an embodiment of the invention when a user has selected a particular show. A user can select a show by clicking on that show title in area 117 . When a show is selected, the Editorial area 101 is divided into two areas 301 A and 301 B. Area 301 A displays a title, logo, or other indicator of the show selected and a text description of the show. Area 301 B displays a thumbnail 302 of the episodes that are available for the show that is selected for viewing, along with text having a short written description of the selected episode. Additionally channel indicator 201 also indicates the name of the show that was selected. In one embodiment of the invention, a number of other clips available for viewing are displayed below area 301 B and use a similar geography to display data, including a thumbnail image and text description. In this particular embodiment, the channel selections 104 - 108 remain visible and available in region 103 , as does the Most Popular list in region 109 .
[0039] [0039]FIG. 4 illustrates the display in an embodiment when the user selects an episode of a show by clicking on the episode in area 301 B. When the episode is selected the editorial section 301 B then displays a plurality of chapter or clip selections of the selected episode such as selections 401 , 402 , and 403 . The user can select one of the for viewing in region 102 of this embodiment of the invention.
[0040] In this particular embodiment only three clip selections are displayed in area 301 B listed at the bottom of the screen. If more clips are available, a bar 412 listing the amount of clips that are available can be displayed alerting the user that the additional clip selections are available. If the user clicks on bar 412 , additional clips will be displayed in area 301 B.
[0041] A desired feature of one embodiment of the present invention is that a user is only presented with data that the user can actually view at the subscription level of which the user is a member. This distinguishes the present embodiment of the invention from prior art schemes where the user may be presented with data that is not viewable based on the subscription level or even based on the player or connection speed of the user. One of the embodiments of the invention that makes this possible is that the data resides in a database on the web site of the invention. Unlike prior art schemes that link to external data sources, the present embodiment of the invention maintains data locally.
[0042] The present embodiment is able to customize content presentation because of the data structure of the database used for the local data storage. In one embodiment, data is stored using a unique XML template. This allows metadata to be included which facilitates the sorting and presentation of data to the user, making a consistent interface and experience possible. In one embodiment, XML data is stored locally but some or all content is stored remotely and linked to a local site. It should be appreciated that the actual content or any images which are displayed on the website (e.g., thumbnail images) need not be stored locally in the website's local storage. Rather the content or any other image can come directly from an outside provider and be displayed in any of the interfaces of this invention. This provides the added benefit of being able to display a wide variety of content without having to overburden local storage capacity.
[0043] The template below is an example of one embodiment of an XML datastore template. The template is for a “FEEDITEM” which is associated with a clip for viewing. XML documents may have multiple FEEDITEMS. It should be noted that items are not required to have all elements listed and the values for each element are merely exemplary. Similarly, additional elements providing different information may be used.
<CMSFEED> <CONTACT EMAIL=“” TELEPHONE=“”></CONTACT> <FEEDITEM TYPE=“”MEDIA=“” ID=“” SORTORDER=“”> <TITLE><TITLE> <DESCRIPTION></DESCRIPTION> <DURATION></DURATION> <VALIDTIME TZ=“”></VALIDTIME> <EXPIRATIONTIME TZ=“”><EXPIRATIONTIME> <BLACKOUT REGION=“”></BLACKOUT> <STREAM BITRATE=“” FORMAT=“”></STREAM> <AIRTIME TZ=“”></AIRTIME> <IMAGE USE=“”></IMAGE> <FEEDITEM> </CMSFEED>
[0044] XML Element Description
[0045] The XML elements described here are by way of example only. Additional or fewer elements may be included without departing from the spirit and scope of the present invention.
[0046] CMSFEED is the container for XML content feeds to the present embodiment of the invention and contains a number of other XML elements.
[0047] CONTACT xml specs
[0048] The CONTACT element contains the name of the contact at the content publisher who is responsible for the content feed. (example: “Joe Smith”)
[0049] EMAIL: Email address of the person who is publishing this show. (example: “joesmith@yahoo-inc.com”).
[0050] TELEPHONE: Telephone number of the person who is publishing this show. (example: “800-555-1212”).
[0051] FEEDITEM xml specs
[0052] The FEEDITEM element holds the data for either a category or a clip.
[0053] TYPE: This is the type of node being described. For the allowed values, “category” is a container for clips. Depending on the time of media being played in the invention, this could be equivalent to an episode of a TV show, or it could be used to represent another type of clips container.
[0054] MEDIA: The type of media being described. This is only used for clips. “Video” refers to a video file. Audio” refers to an audio-only file.
[0055] ID: Pathname of the show. (example: “/episode1” or “/episode3/clip1”). Maximum length for this field is 50 characters. Valid values for this field: In one embodiment the ID only consists of letters and numbers [i.e., A- 51 a- 51 0-9] and no symbols [i.e., no #, @, etc.] are allowed in the ID.
[0056] SORT ORDER: Valid values for this field include any number from 100 to 10000. In one embodiment of a list of clips or categories, the item with the highest number is displayed first, then the item with the second highest number is displayed next, and so on. The difference in SORTORDER between each item is in multiples of 10 in this embodiment. It is understood that the sorting can be in reverse order as well and any suitable difference between items may be employed.
[0057] TITLE xml Specs
[0058] The TITLE element is for the title of the piece of media. Referring briefly to FIG. 2, the title data is displayed in location 201 when it is category information and at location 320 in FIG. 3 when it is a show or clip title. In one embodiment, the maximum length of this field depends on the TYPE of FEEDITEM being described:
[0059] For a “category” piece of media, the title length can be, e.g., up to 25 characters.
[0060] For a “clip” piece of media, the title length can be, e.g., up to 50 characters.
[0061] DESCRIPTION xml Specs
[0062] The DESCRIPTION element is a description of the clip. It is displayed in the metadata pane and on the web site, such as at location 301 A in FIG. 3. The length of this field depends on the TYPE of FEEDITEM being described:
[0063] For a “category” piece of media, the length can be, e.g., up to 75 characters.
[0064] For a “clip” piece of media, this field can be, e.g., up to 260 characters.
[0065] DURATION xml Specs
[0066] The DURATION element is the length of the clip in a format of hh:mm:ss.
[0067] VALIDTIME xml Specs
[0068] The VALIDTIME element is the date and time that the content will start being displayed on the invention site and will become available to subscribers. In some embodiments, this field is not required. The format for the element is mm/dd/yyyy hh:mm AM/PM.
[0069] TZ: time zone of publish start and end times. Valid values:
[0070] “CST”|“CDT”|“EST”|“EDT”|“MST”|“MDT”|“PST”|“PDT”
[0071] EXPIRATIONTIME xml Specs
[0072] The EXPIRATIONTIME element is the date and time that the content will be automatically removed from the invention site, and will no longer be available to subscribers. This field is not required in all embodiments. The format is mm/dd/yyyy hh:mm AM/PM.
[0073] TZ: time zone of publish start and end times. Valid values:
[0074] “CST”|“CDT”|“EST”|“EDT”|“MST”|“MDT”|“PST”|“PDT”
[0075] BLACKOUT xml Specs
[0076] The BLACKOUT element makes it possible to “black out” a piece of content from users whose account information indicates they are in a specific DMA (Designated Market Area). This could, for example, be used for sporting events which cannot be rebroadcast in specific areas. Valid values for this field depend on the REGION setting: For DMA, an example of a valid value is “SAN FRANCISCO-OAK-SAN JOSE,” for ZIP (Zip code), an example of a valid value is “94089.” This element is optional.
[0077] REGION: Sets system for selecting geographic areas to blackout.
[0078] Valid values: “DMA”|“ZIP”.
[0079] STREAM xml Specs
[0080] The present embodiment of the invention can have multiple STREAM elements. However, for each FEEDITEM, the streams represented by these elements must have the same content. The only difference is the speed and media type. In one embodiment, a default value is such that each FEEDITEM clip has 6 streams (56 k windows media, 100 k windows media, 300 k windows media, 56 k real, 100 k real, 300 k real).
[0081] FORMAT: Stream format. Valid values
[0082] =“wm”|“asf”|“wmv”|“wma”|“rnv”|“rm”|“rna”|“ra”
[0083] “wm” or “asf”=windows media file
[0084] “wmv”=windows media video file
[0085] “wma”=windows media audio-only file
[0086] “rmv” or “rm”=real networks video file
[0087] “rna” or “ra”=real networks audio-only file
[0088] BITRATE: Stream Speed. Valid values=“56”|“100”|“300”
[0089] AIRTIME xml Specs
[0090] The AIRTIME element is the date and time that the clip was originally broadcast (if it was in fact broadcast). The format is mm/dd/yyyy hh:mm AM/PM
[0091] TZ: time zone of publish start and end times. Valid values:
[0092] “CST”|“CDT”|“EST”|“EDT”|“MST”|“MDT”|“PST”|“PDT”
[0093] IMAGE xml Specs
[0094] The IMAGE element is an image for a FEEDITEM. The size for this image is, for example, 120×90, and is in a format such as GIF, JPEG, or any other suitable format in one embodiment. The IMAGE can be displayed in regions 206 , 207 , 302 , 401 , 402 , or 403 , for example.
[0095] USE: This describes how the content should be used. Each piece of media may, for example, have a “largethumb” and “smallthumb” associated with it—these images should be images from the piece of media. Valid values: “SMALLTHUMB”|“LARGETHUMB”
[0096] SMALLTHUMB: The size for this image may be, e.g., 88×66, and it may be in JPEG, GIF, or any other suitable format.
[0097] LARGETHUMB: The size for this image may be 120×90, and it may be in JPEG, GIF, or any other suitable format.
[0098] Content Provider Accounts
[0099] A content provider that desires to interact with the site of the present embodiment of the invention has an assigned Content Management System (CMS) account with provider names and passwords. The providers can FTP (file transfer protocol) media files, images and XML feed documents using the template described above. The transferred media files, with the associated metadata according to the XML template, are then provided to a page generation tool and assembled into a window and accompanying channel modules. This process can be automated so that content can be published (assuming its availability date is current) almost instantly.
[0100] The database is accessible by content providers and partners via password, allowing remote editing and updating of the content. For example, a clip can easily be removed from the site by changing the expiration time entry to a date that has already passed. Data content may also inherit metadata attributes from its category and from its associated show. For example, an external site link may be inherited by a clip (such as to an official site for a show). In addition, copyright information may be inherited at a show or category level as well. Clips are associated with a show and shows are associated with a category.
[0101] [0101]FIG. 5 illustrates an alternate embodiment showing an interface on a media player. A media playing window 501 is provided at an upper-left location of the player geography. The viewing window 501 includes a control bar 509 just below the viewing window with player controls, such as play, pause, stop, progress bar, volume, etc. XML metadata associated with content can be mapped to areas of the player geography. Additionally, in one embodiment, various textual images may be placed in the viewing window while the video is buffering or while any audio content is playing. For example, while a news clip is buffering, information about the news provider may be displayed in the viewing window until the video is ready to be streamed.
[0102] Region 502 is an informational area reserved for a logo of the content provider. This could be a network, a show, a series, etc. Region 503 is another informational area reserved for a show logo graphic. Region 504 is reserved for a thumbnail of an available or selected clip. Regions 505 and 506 display the clip title metadata and airdate metadata, respectively. The metadata description text of the clip is displayed in region 507 . Region 508 is reserved for additional available clips and displays thumbnails in regions 510 , 511 , and 512 , for example, along with associated title and/or description metadata. Additional text and hyperlinks can also be displayed in area 508 . For example advertising information allowing the user to link to additional material that is being offered.
[0103] [0103]FIG. 6 illustrates the interface of the player after a user has signed in. The bottom portion of the display geography is now changed to add channel selections 602 - 607 to region 601 . In addition, Region 620 now displays a number of thumbnails of available clips such as thumbnails 621 - 624 . This region can be scrolled horizontally in one embodiment to permit the display of additional thumbnails of available clips. In other embodiments, additional metadata and or hypertext links can be inserted throughout the interface to include additional features and functionality. For example, information and or hypertext links to external content provider sites might be added to the interface.
[0104] [0104]FIG. 7 illustrates the interface of the player when one of the channels in region 601 is selected. In this example, Entertainment Channel 604 has been selected. This causes a pull-down menu 701 to be displayed in the region adjacent to region 601 and displays available content for the selected channel. The example illustrates one of the advantages of the present embodiment of the invention. One of the selections, namely the NCAA Tournament 2003 , includes a following star symbol 702 . This indicates premium content and the user knows that this content is not available unless the user has a premium account. This is possible because of the local storage of content by the present embodiment of the invention and the use of the XML metadata to store access levels which are required for certain content. In another embodiment, only available permitted content at the user level is shown, with premium or other unavailable content filtered out. This makes the viewing experience more desirable using the present embodiment of the invention. In one embodiment, the indication is not marked. When a user attempts to play content for which the user does not have access, the user may be redirected to a presentation that offers the ability to subscribe to the service.
[0105] It should be understood that in certain embodiments the player may be a third-party player which is “skinned” or altered to provide the desired consistent interface. In other embodiments, the player is a purpose built player.
[0106] [0106]FIG. 8 illustrates the interface when a show has been selected in region 701 . The title of the show is displayed in region 801 and thumbnails of available episodes are shown in regions 802 - 803 . In one embodiment, region 801 is scrollable so that all available episodes can be accessed via that region. An additional region 804 which lists a description for a future episode may also be displayed. In one embodiment a user is given the option to add the future episode description to a personal calendar so that the user will be reminded at the time that the episode becomes available.
[0107] The present embodiment includes additional information in a local database in addition to the metadata provided by a content provider. This information can also be XML metadata or it can be associated attributes of the database in any suitable form. This data includes subscription information such as active/inactive, and level of subscription (e.g., regular, premium, package, etc.).
[0108] [0108]FIG. 9 is a flow diagram illustrating the operation of the present embodiment. At step 901 , a user makes a selection and the system then goes through a number of decision blocks 902 - 904 to determine the appropriate display update to provide. At step 902 , it is determined if the user has selected a channel. If so, the display is updated at step 905 and provides a display such as shown in FIGS. 2 and 7.
[0109] At step 903 , it is determined if the user has selected a show. If so, the display is updated at step 906 and provides a display on the site such as shown in FIG. 3 or on the player such as shown in FIG. 8. At step 904 , it is determined if the user has selected an episode. If so, the site display is updated such as shown in FIG. 4 and the player is updated such as is shown in FIG. 8.
[0110] [0110]FIG. 10 illustrates some of the operation of an embodiment of the invention when a channel is selected. At step 1001 , the user has selected a channel. At step 1002 , the system updates the display by placing the name of the selected channel in region 201 for the site. For the player, the display provides a pull down menu 701 . At step 1003 , a “Most Popular” display region 208 is provided at the site. For the player, the database is examined so that premium shows in the list can be identified by a marker, such as “star” 702 .
[0111] In another embodiment of the invention, it is possible to create playlists related to user preferences. These lists can be either automatically generated based on content provider relationships, or editorially. These playlists will be discussed in more detail with reference to FIGS. 16 and 17 below.
[0112] Content Invocation
[0113] [0113]FIG. 12 illustrates the operation of content invocation in one embodiment of the invention, or in other words the steps that are followed once a user selects a particular piece of content. At step 1201 of FIG. 12, the user invokes a content uniform resource locator (URL) by clicking on a clip link from the browser, activating a bookmarked URL, being redirected from another website, accessing the link from within the a player popup or by a variety of other means as are all well known in the art. Once the content URL is invoked, it is determined whether there is an existing clip that corresponds to the requested clip I.D. number corresponding to the link(step 1202 ). If it is determined that the clip I.D. does not have a corresponding existing clip, the browser redirects the user to an error message, which may advise the user that there is no existing clip that matches their requested clip I.D. number. Other error messages can include additional text that informs the user that there is some error in receiving the content. These messages can additionally include details about the clip and possible reasons why the clip can not be displayed, and can direct the user to possible solutions to correct this error. Otherwise, if it is determined that the requested clip I.D. has a clip available, it is next determined whether the user has requested to view sample marketing content (step 1203 ). Sample marketing content includes content that can be viewed by any user regardless of whether the user has subscribed to view non-sample content or whether the user has purchased the rights to view additional clips. It should be appreciated that an advantage to making sample content available to any user is to allow users the ability to test the system before actually subscribing or purchasing any particular service.
[0114] If it is determined that the user has chosen to view sample marketing content, the process will proceed to step 1204 where it is determined whether the operating software (OS) and browser platforms on the user's computer are acceptable for playing the requested content. For example, an acceptable OS platform could be Windows and an acceptable browser platform could be Internet Explorer 5.0 or higher. If it is determined that the platforms are not acceptable, the browser page redirects the user to an error message, which may inform the user that the platforms running on his computer are not compatible with the web site's platform(s). Otherwise, if it is determined that the platforms are acceptable, the system will determine if the user has a proper subscription to access the clip at Step 1205 as will be discussed in greater detail below.
[0115] If it is determined however at Step 1203 that the user does not choose to view sample marketing content, and rather wishes to view content that is only available to users who are signed into the website, it is then determined whether the user has signed into the web site (step 1205 ). If it is determined that the user has not signed in, the browser page redirects the user to a sign in page to allow the user to sign into the website. Once the user signs in or if it is determined that the user has previously signed in, it is then determined whether the web page identification (I.D.) is still fresh (step 1206 ). It should be appreciated that checking whether an I.D. is still fresh allows the system to determine whether the user has recently signed into the website or whether the sign in took place past an allotted period of time. This prevents an unauthorized user from using an old sign in to access the system at a later time. The amount of time that an sign in remains fresh can be determined by the system operator or by the user and can range for example from a few minutes to many days. If it is determined that the I.D. is not fresh, the browser page redirects the user to a sign in page, which can advise the user that the session has expired and request the user to sign in again.
[0116] Once the user has signed in again, or if it is determined that the I.D. is still fresh, it will next be determined whether the user's computer is configured to be accept cookies (step 1207 ). If it is determined that the user's computer is unable to accept cookies, the browser redirects the user to an error message, which may request that the user configure his computer to accept cookies. If it is determined that the user's computer is able to accept cookies, the system proceeds to Step 1204 as was discussed above to determine whether the operating software and browser platforms on the user's computer are acceptable. If it is determined that the platforms are not acceptable, the browser page redirects the user to an error message, which can inform the user that the platforms running on their computer are not compatible with the web site's platform(s). Otherwise, if it is determined that the platforms are acceptable, the system will then determine whether the user has the subscription to be able to access the requested clip (step 1208 ). It should be appreciated that the system can have many different levels of subscriptions to control different levels of access for different users. These different levels can be determined by various factors (e.g., price of subscription). If the user does not have the proper subscription to access the clip, the browser redirects the user to an error message, which can advise the user that their subscription level does not permit access to this clip. Additionally the error message may provide information to the user about how to upgrade their current subscription to allow access to the clip or provide details regarding other benefits of obtaining a higher subscription.
[0117] If it is determined at the previously discussed logic gate located at step 1208 , that the user does have access to the clip, the player will be invoked and begin to play the content (step 1209 ). It should be appreciated that the player that is invoked can be any of the media players that are widely known in the art (e.g., Windows Media Player, Real Player) or can be a purpose built player as was discussed above.
[0118] In one embodiment, an additional step is carried out prior to the playing of content to assure that the content request is valid and to protect the system from unauthorized access.
[0119] After successful content invocation, the embodiment may undergo a logic sequence to confirm media playback capability. One possible logic process is depicted in FIG. 13. Once content has been invoked (step 1301 ), at a logic gate (step 1302 ), it is determined whether the user's computer has the necessary clip media player available. This decision is made by determining whether the user's computer has the correct software to play the content, (e.g., Real or WinMP). If it is determined that the necessary software has not been installed onto the user's computer, the browser redirects to a software error message, which may advise the user that he will need to install specific software onto his computer in order to view the content. Otherwise, if it is determined that the necessary software has been installed onto the user's computer, the process proceeds to step 1303 where the audio/video content will be played as discussed above with reference to FIG. 8.
[0120] WebPage Site Map
[0121] One embodiment of the present invention can be represented by a web page hierarchy site map. FIG. 14 depicts one possible site map hierarchy for a content invocation structure.
[0122] [0122]FIG. 14 illustrates the path of web pages that a user navigates through in order to invoke audio/video clip content. Page 1401 represents the web site home page, which allows the user to make a number of various choices. On the home page, the user is given various options from which to choose. The pages on level 1402 illustrate the different options that the user can choose from. Some of the choices presented in this embodiment are “genre channel” (page 1403 ), which includes a list of shows available for that particular genre; “coming soon channel” (page 1404 ), which includes a list of shows that are currently not available on the system but will be in the future; “my shows channel” (page 1405 ), which includes a list of shows that has previously been chosen by the user; “Options page” (page 1406 ), where the user can manage any account details such as subscription level or personal information or change any particular viewing preferences the user may have; and a “demo tour” (page 1407 ) which gives the user a demonstration of how the website operates. Additionally the user may receive one of an array of error messages if the content can not be displayed for various reasons. Examples of such error messages include, a sign in error if the user does not sign in properly; an unavailable content error if the content is not in the system or if the system is unable to locate the content; or a subscription error message if the user does is not subscribed to the proper service in order to view access the requested content. In addition to the displaying of the error message, the system also redirects the user to another page which will allow the user to correct the error (e.g., a sign in page, a subscription page).
[0123] If the user selects a type of genre in page 1403 , the web site will transfer the user to a lower level on the site map (page 1409 ). At page 1409 , the user is presented with a listing of available shows to choose from which includes a list of episodes or collections for that particular show. Once the user selects a show to watch, the web site will transfer the user to a lower level on the site map (page 1410 ), which lists the available episodes for that particular show which includes a listing of clips that are available for a particular episode. After a user selects an episode from the listing on page 1410 , the process will proceed to step 1411 where the player will be invoked to operate. It should also be appreciated that content can be directly invoked from different web pages as opposed to having to access numerous web pages before actually invoking content. In this particular embodiment those web pages which can directly invoke content are designated with an asterisk. It should also be appreciated that in various embodiments there can be other webpages that list prevalent information. For example one web page might list help topics that the user can access or legal information such as privacy information. These informative web pages can preferably be accessed from any of the above listed web pages.
[0124] Embodiment of a Computer Execution Environment
[0125] An embodiment of the invention can be implemented as computer software in the form of computer readable code executed in a desktop general purpose computing environment such as environment 1100 illustrated in FIG. 11, or in the form of bytecode class files running in such an environment. A keyboard 1110 and mouse 1111 are coupled to a bi-directional system bus 1118 . The keyboard and mouse are for introducing user input to a computer 1101 and communicating that user input to processor 1113 .
[0126] Computer 1101 may also include a communication interface 1120 coupled to bus 1118 . Communication interface 1120 provides a two-way data communication coupling via a network link 1121 to a local network 1122 . For example, if communication interface 1120 is a modem, communication interface 1120 provides a data communication connection to the corresponding type of telephone line, which comprises part of network link 1121 . If communication interface 1120 is a local area network (LAN) card, communication interface 1120 provides a data communication connection via network link 1121 to a compatible LAN. Wireless links are also possible. In any such implementation, communication interface 1120 sends and receives electrical, electromagnetic or optical signals, which carry digital data streams representing various types of information.
[0127] Network link 1121 typically provides data communication through one or more networks to other data devices. For example, network link 1121 may provide a connection through local network 1122 to local server computer 1123 or to data equipment operated by ISP 1124 . ISP 1124 , in turn, provides data communication services through the worldwide packet data communication network now commonly referred to as the “Internet” 1125 . Local network 1122 and Internet 1125 both use electrical, electromagnetic or optical signals, which carry digital data streams. The signals through the various networks and the signals on network link 1121 and through communication interface 1120 , which carry the digital data to and from computer 1100 , are exemplary forms of carrier waves transporting the information.
[0128] Processor 1113 may reside wholly on client computer 1101 or wholly on server 1026 or processor 1113 may have its computational power distributed between computer 1001 and server 1126 . In the case where processor 1113 resides wholly on server 1126 , the results of the computations performed by processor 1113 are transmitted to computer 1101 via Internet 1125 , Internet Service Provider (ISP) 1124 , local network 1122 and communication interface 1120 . In this way, computer 1101 is able to display the results of the computation to a user in the form of output. Other suitable input devices may be used in addition to, or in place of, the mouse 1111 and keyboard 1110 . I/O (input/output) unit 1119 coupled to bi-directional system bus 1118 represents such I/O elements as a printer, A/V (audio/video) I/O, etc.
[0129] Computer 1101 includes a video memory 1114 , main memory 1115 and mass storage 1112 , all coupled to bi-directional system bus 1118 along with keyboard 1110 , mouse 1111 and processor 1113 .
[0130] As with processor 1113 , in various computing environments, main memory 1115 and mass storage 1112 , can reside wholly on server 1126 or computer 1101 , or they may be distributed between the two. Examples of systems where processor 1113 , main memory 1115 , and mass storage 1112 are distributed between computer 1101 and server 1126 include the thin-client computing architecture developed by Sun Microsystems, Inc., the palm pilot computing device, Internet ready cellular phones, and other Internet computing devices.
[0131] The mass storage 1112 may include both fixed and removable media, such as magnetic, optical or magnetic optical storage systems or any other available mass storage technology. Bus 1118 may contain, for example, 32 address lines for addressing video memory 1114 or main memory 1115 . The system bus 1118 also includes, for example, a 32-bit data bus for transferring data between and among the components, such as processor 1113 , main memory 1115 , video memory 1114 , and mass storage 1112 . Alternatively, multiplex data/address lines may be used instead of separate data and address lines.
[0132] In one embodiment of the invention, the processor 1113 is a microprocessor manufactured by Motorola, such as the 680×0 processor or a microprocessor manufactured by Intel, such as the 80×86 or Pentium processor, or a SPARC microprocessor from Sun Microsystems, Inc. However, any other suitable microprocessor or microcomputer may be utilized. Main memory 1115 is comprised of dynamic random access memory (DRAM). Video memory 1114 is a dual-ported video random access memory. One port of the video memory 1114 is coupled to video amplifier 1116 . The video amplifier 1116 is used to drive the cathode ray tube (CRT) raster monitor 1117 . Video amplifier 1116 is well known in the art and may be implemented by any suitable apparatus. This circuitry converts pixel data stored in video memory 1114 to a raster signal suitable for use by monitor 1117 . Monitor 1117 is a type of monitor suitable for displaying graphic images.
[0133] Computer 1101 can send messages and receive data, including program code, through the network(s), network link 1121 and communication interface 1120 . In the Internet example, remote server computer 1126 might transmit a requested code for an application program through Internet 1125 , ISP 1124 , local network 1122 and communication interface 1120 . The received code may be executed by processor 1113 as it is received, and/or stored in mass storage 1112 , or other non-volatile storage for later execution. In this manner, computer 1100 may obtain application code in the form of a carrier wave. Alternatively, remote server computer 1126 may execute applications using processor 1113 , and utilize mass storage 1112 , and/or video memory 1115 . The results of the execution at server 1126 are then transmitted through Internet 1125 , ISP 1124 , local network 1122 , and communication interface 1120 . In this example, computer 1101 performs only input and output functions.
[0134] Application code may be embodied in any form of computer program product. A computer program product comprises a medium configured to store or transport computer readable code, or in which computer readable code may be embedded. Some examples of computer program products are CD-ROM disks, ROM cards, floppy disks, magnetic tapes, computer hard drives, servers on a network, and carrier waves.
[0135] The computer systems described above are for purposes of example only. An embodiment of the invention may be implemented in any type of computer system or programming or processing environment.
[0136] Thus an environment for display of content has been described.
[0137] Playlists
[0138] As was discussed earlier, in one embodiment of the invention, one can create playlists based on various criteria. These playlists can be automatically generated or created manually. For example, a playlist may be automatically generated based on the most popular clips that have been viewed recently or clips that were uploaded onto the system on a certain date or clips as grouped based on any other information or metadata associated therewith. In another instance the playlist may be created based on a certain relationship (e.g., war with Iraq) and put together manually. Additionally, the user themselves can choose which pieces of content are placed into a playlist. Similar to an individual piece of content, content in a playlist and/or the playlist itself can be accessed by a user from the various web page interfaces discussed above. Alternatively, content from a certain category may be automatically grouped into a playlist and when the category is chosen, the playlist will begin to play. It should be appreciated that although the use of playlists is discussed in reference to the present embodiment, such embodiment is exemplary and the playlist features disclosed herein may be implemented on other systems.
[0139] The playlist is preferably a data file that comprises a plurality of unique identifiers (e.g., URLs) for a plurality of pieces or items of content. The data file is created by choosing which content should be included in the playlist and then placing an URL for each piece of content into the file. Thus, when the data file is played, the content will be viewed in the sequence that it has been placed in the playlist. It should be understood that another advantage of utilizing a playlist for organizing content is that the use of a playlist creates an additional pointer to each piece of content thus allowing the user to access each piece of content from different locations and thus making the content more easily accessible.
[0140] One interface used in connection with playlists will now be discussed in reference to FIG. 15. Similar to previous embodiments, the display includes a media playing window 1501 at an upper-left location of the player geography. The viewing window 1501 includes a control bar 1509 just below the viewing window with player controls, such as play, pause, stop, progress bar, volume, etc. XML metadata associated with content can be mapped to areas of the player geography. Region 1502 is an informational area reserved for a logo of the content provider. This could be a network, a show, a series, or any other metadata that the content provider wishes to supply. Region 1503 is another informational area reserved for a show logo graphic. Region 1504 is reserved for a thumbnail of an available or selected clip. Regions 1505 and 1506 display the clip title metadata and airdate metadata, respectively. The metadata description text of the clip is displayed in region 1507 . Region 1508 displays the clips that are available in the playlist which includes a thumbnail image of the available clip which is also a hypertext link to access the clips 1510 . Region 1508 also contains a drop down list of all the playlists that are available for viewing 1511 . This drop down list can include a plurality of playlists which can either be dynamically generated playlists or playlists created manually. If a user clicks onto the drop down list a list similar to list 701 discussed in reference to FIG. 7 is displayed.
[0141] In this particular embodiment only up to five clips in the playlist are listed at the bottom of the screen. If more clips are available, a bar 1512 listing the amount of clips that are available can be displayed alerting the user that the playlist contains additional clips. If the user clicks on bar 1512 , additional clips will be displayed in area 1508 .
[0142] In one embodiment a user can choose whether or not the clips should play in the particular order that they were stored in the playlist. If the user chooses to play the clips sequentially, an “autoplay” function is engaged (e.g., “on”). If the user wishes to alter the order in which the clips are played, the “autoplay” function can be disengaged. For example, if Playlist 1 contains pointers to clips A, B and C, a user can choose to engage the “autoplay” function and play the clips sequentially (i.e., clip A first then clip B and then clip C.) Alternatively, the user can disengage the “autoplay” function and play the clips in a selected order, for example, play clip B first and then the other clips in whichever order the user wishes.
[0143] The process of engaging the “autoplay” function will now be discussed in greater detail with reference to FIG. 16. At first, when a user selects the playlist that he wishes to display or listen to, the system checks whether the “autoplay” function is engaged. Step 1601 . If the “autoplay” function is engaged, the system begins to play the selected clip from the playlist. Step 1602 . When that clip is finished playing, the system automatically searches for the next clip in the sequence. Step 1603 . If there is another clip in the sequence of the playlist then the system begins to play that clip. Step 1604 . If all the clips have been played and there are no remaining clips in the playlist, the system sends a message that the playlist is completed. Step 1605 . This process continues until all clips in the playlist have been played.
[0144] If the “autoplay” function is not engaged (e.g., “off”), the system waits for the user to select a clip. Step 1606 . Alternatively the system may begin playing a predetermined clip. Step 1607 . Once a clip is selected, the system begins to play that clip. Step 1608 . Once the selected clip is finished playing, the system having identified that the “autoplay” function was disengaged does not sequentially play the content in the playlist, and instead waits for the user to select another clip to be played. Step 1606 . A user can select a clip by clicking on the hypertext link associated with that clip. Once another clip is selected, the system plays that selected clip. Step 1608 . This process continues until the user does not want to view any more clips. It should be appreciated that an added benefit of this embodiment is to give the user added control over what content they wish to view and in which order they wish to view it. The user is thus given the ability to manage the content that he or she is viewing in a more editorial role, while at the same time being able to have the benefits of a playlist which include easier accessibility and improved functionality.
[0145] In one embodiment, when the “autoplay” function is engaged (e.g., “on”) a display button 1513 which is also an active hypertext link is displayed on the web page which indicates whether the function is engaged. In the present embodiment of FIG. 16 the “autoplay” function is already engaged. If a user wishes to engage or disengage the “autoplay” function, the user can merely click on that display button and the function will be activated or deactivated respectively. Additional indications that the “autoplay” function is engaged can be utilized as well. For example in FIG. 15, arrows 1514 indicate that the “autoplay” function is active. While the absence of arrows would indicate to the user that the “autoplay” function was disengaged and the clips can be played in non-sequential order.
[0146] Those skilled in the art will recognize that the method and system of the present invention has many applications, may be implemented in many manners and, as such, is not to be limited by the foregoing exemplary embodiments and examples. In this regard, any number of the features of the different embodiments described herein may be combined into one single embodiment and alternate embodiments having fewer than all of the features are possible. Moreover, the scope of the present invention covers conventionally known and future developed variations and modifications to the system components described herein, as would be understood by those skilled in the art. | The present invention provides a general solution to presenting media interface and navigation tools for content provided from a plurality of sources. The invention maintains a user at a single site regardless of the source of the media content. This permits a consistent interface to be presented to the user. Because the user remains at the same site, differences in tiered membership may be tracked so that the user is only presented with content that the user is permitted to view. The invention uses a metadata language to characterize content so that viewer type, membership level, and other information can be maintained and used for an enjoyable viewing experience. | 8 |
CROSS-REFERENCE
This is a Continuation-in-Part of U.S. Ser. No. 746,203, filed June 18, 1985,abandoned.
BACKGROUND OF THE INVENTION
This invention is directed to compounds which act as antagonists of the leukotrienes and inhibitors of their biosynthesis.
The leukotrienes are a novel group of biologically active mediators derived from arachidonic acid through the action of lipoxygenase enzyme systems. There are two groups of leukotrienes derived from the common unstable precursor Leukotriene A 4 . The first of these are the peptido-lipid leukotrienes, the most important being Leukotrienes C 4 , D 4 and E 4 . These compounds collectively account for the biologically active material known as the slow reacting substance of anaphylaxis (SRS-A).
The leukotrienes are potent smooth muscle contracting agents, particularly on respiratory smooth muscle but also on other tissues (e.g. gall bladder). In addition, they promote mucous production, modulate vascular permeability changes and are potent inflammatory agents in human skin. The most important compound in the second group of leukotrienes is Leukotriene B 4 , a dihydroxy fatty acid. This compound is a potent chemotactic agent for neutrophils and eosinophils and in addition, may modulate a number of other functions of these cells. It also effects other cell types such as lymphocytes and for example may modulate the action of T-suppressor cells and natural killer cells. When injected in vivo. in addition to promoting the accumulation of leukocytes, Leukotriene B 4 is also a potent hyperalgesic agent and can modulate vascular permeability changes through a neutrophil dependent mechanism. Both groups of leukotrienes are formed following oxygenation of arachidonic acid through the action of a 5-lipoxygenase enzyme. See for example, D. M. Bailey et al., Ann. Rots. Med. Chem. 17 203 (1982).
The leukotrienes are potent spasmogens of human trachea, bronchus and lung parenchymal strips, and when administered to normal volunteers as aerosols are 3,800 times more potent that histamine at inducing a 50% decrease in air flow at 30% of vital capacity. They mediate increases in vascular permeability in animals and promote mucous production in human bronchial explants. In addition, Leukotriene B 4 may also mediate mucous production and could be an important mediator of neutrophil and eosinophil accumulation in asthmatic lungs. 5-lipoxygenase products are also thought to be regulators of mast cell degranulation and recent studies with human lung mast cells have suggested that 5-lipoxygenase inhibitors, but not corticosteroids, may suppress antigen-induced mast cell degranulation. In vitro studies have shown that antigen challenge of human lung results in the release of leukotrienes and in addition purified human mast cells can produce substantial amount of leukotrienes. There is therefore good evidence that leukotrienes are important mediators of human asthma. Leukotriene antagonists or inhibitors would therefore be a new class of drugs for the treatment of asthma.
Psoriasis is a human skin disease which effects between two and six percent of the population. There is no adequate therapy for psoriasis and related skin conditions. The evidence for leukotriene involvement in these diseases is as follows. One of the earliest events in the development of prepapillary lesions is the recruitment of leukocytes to the skin site. Injection of Leukotriene B 4 into human skin results in a pronounced neutrophil accumulation. There are gross abnormalities in arachidonic acid metabolism in human psoriatic skin. In particular, highly elevated levels of free arachidonic acid can be measured as well as large amounts of lipoxygenase products. Leukotriene B 4 and 8- and 12-HETE have been detected in psoriatic lesions, but not in uninvolved skin, in biologically significant amounts.
Leukotrienes can be measured in nasal washings from patients with allergic rhinitis and are greatly elevated following antigen challenge. Leukotrienes may mediate this disease through their ability to regulate mast cell degranulation, by modulating mucous production and mucocillary clearance and by mediating the accumulation of inflammatory leukocytes.
Leukotrienes can also mediate other diseases. These include atopic dermatitis, allergic conjunctivitis, gouty arthritis, and gall bladder spasms. In addition, they may have a role in cardivascular disease because Leukotrienes C 4 , D 4 and E 4 act as coronary and cerebral arterial vasoconstrictors and these compounds may also have negative inotropic effects on the myocardium. In addition, the leukotrienes are important mediators of inflammatory diseases through their ability of modulate leukocyte and lymphocyte function. See for example, B. Samuelson, Science, 220 568 (1983).
Several classes of compounds exhibit ability to antogonize the action of leukotrienes in mammals, especially humans. See for example: United Kingdom Patent Specification Nos. 2,058,785 and 2,094,301; and European Patent Application Nos. 56,172, 61,800 and 68,739.
DESCRIPTION OF THE INVENTION
The present invention relates to compounds having activity as leukotriene and SRS-A antagonists or inhibitors, to methods for their preparation, to intermediates useful in their preparation and to methods and pharmaceutical formulations for using these compounds in mammals (especially humans). Because of their activity as leukotriene antagonists or inhibitors, the compounds of the present invention are useful as anti-asthmatic, anti-allergic, antipsoriatic, and anti-inflammatory agents and are useful in treating allergic conjunctivitis, allergic rhinitis, and chronic bronchitis and for amelioration of skin diseases like psoriasis and atopic eczema. These compounds are also useful to antagonize or inhibit the pathologic actions of leukotrienes on the cardiovascular and vascular systems for example, actions such as result in angina. The compounds are also useful as cytoprotective agents.
Thus, the compounds of the present invention may also be used to treat or prevent mammalian (especially, human) disease states such as erosive gastritis; erosive esophagitis; inflammatory bowel disease; ethanol-induced hemorrhagic erosions; hepatic ischemia; noxious agent induced damage or necrosis of hepatic, pancreatic, renal, or myocardial tissue; liver parenchymal damage caused by hepatoxic agents such as CCl 4 and D-galactosamine; ischemic renal failure; disease-induced hepatic damage; bile salt induced pancreatic or gastric damage; trauma- or stress-induced cell damage; and glycerol-induced renal failure.
The compounds of the present invention have the formula I: ##STR2## wherein: the broken line represents an optional triple bond;
each R is independently H; OH; lower alkyl; lower alkenyl; trifluoromethyl; lower alkoxy; phenyl; phenyl substituted by alkyl of 1 to 3 carbon atoms or by halogen; benzyl; phenethyl; halogen; N(R 4 ) 2 ; --(C═O)R 1 ; CH 2 OR 4 ; CN; SR 10 ; SOR 10 ; SO 2 R 10 ; or nitro;
R 1 is H; lower alkyl; or lower alkoxy;
R 2 is H; lower alkyl; R 4 CO; or R 4 OCH 2 ;
each R 3 is independently lower alkyl or lower alkenyl;
each R 4 is independently H or lower alkyl;
each R 5 is independently H; OR 2 ; lower alkyl; or both R 5 's may be combined to create a doubly bonded oxygen (═O) or a ═C(R 4 ) 2 group;
each R 6 is independently H; OH; or lower alkyl;
each R 7 is independently COOR 4 ; CHO; CH 2 OH; tetrazole; CONHSO 2 R 10 ; NHSO 2 R 10 ; hydroxymethylketone; acetoxymethylketone; CON(R 4 ) 2 ; CN; Het; or ##STR3## each R 8 is independently H or lower alkyl, and is absent when a triple bond is present;
R 9 is R 3 , ##STR4## wherein the broken line represents an optional triple bond, ##STR5## each R 10 is independently OH: N(R 4 ) 2 ; CF 3 ; lower alkyl; lower alkoxy; phenyl; or phenyl substituted by one or more alkyl or alkoxy groups of 1 to 3 carbon atoms, halogen, hydroxy, COOR 4 , CN, formyl or lower alklacyl;
each R 11 is independently
(A) a monocyclic or bicyclic heterocyclic radical containing from 3 to 12 nuclear carbon atoms and 1 to 2 nuclear heteroatoms selected from N and S with at least one being N, and with each ring in the heterocyclic radical being formed of 5 or 6 atoms, or
(B) the radical W-R 12 ;
each R 12 is independently contains up to 20 carbon atoms and is (1) an alkyl radical or (2) an alkylacyl radical of an organic acyclic or monocyclic carboxylic acid containing not more than one heteroatom in the ring;
each R 13 is independently H or R 10 .
each W is independently O, S or NH;
each X is independently O, S or NR 13 ;
X 1 , X 2 and X 3 are each independently O, S, SO, SO 2 , S(O)═NR 4 , NR 4 , NCOR 1 , NCN, or NCONHR 4 ;
Y 1 is OH or the N-terminus of an amino acid such that Y 1 H is an essential amino acid:
Y 2 is H or the C-terminus of an amino acid such that Y 2 OH is an essential amino acid;
Z is O, H and OH, or H and R 4 ;
each a is independently 0 to 4;
each b is independently 1 to 6;
each n is independently 0 to 6;
each p is independently 0 to 2;
each q is independently 0 to 4;
each r is independently 0 to 4;
each s is independently 0 to 3;
each t is independently 0 to 1;
each Het is independently a heterocyclic or heterobicyclic ring of 5 or 6 atoms each, containing one or more heteroatoms selected from O, N or S, said heterocyclic or heterobicyclic ring containing an acidic proton;
or the pharmaceutically acceptable salts thereof.
Examples of useful heterocyclic rings (represented by Het above) include: ##STR6## wherein the broken line represents an optional double bond.
As used herein, the term "lower alkyl" includes those alkyl groups of from 1 to 7 carbon atoms of either a straight, branched or cyclic structure. Examples of lower alkyl fragments include methyl, ethyl, propyl, isopropyl, butyl sec- and tert-butyl, pentyl, hexyl, heptyl, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, norbornyl and the like.
As used herein, the term alkyl includes lower alkyl and extends to cover carbon fragments having up to 20 carbon atoms in straight, branched or cyclic structures. Examples of alkyl groups include octyl, nonyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, eicosyl, 3,7-ethyl-2,2-methyl4-propylnonyl, cyclododecyl, adamantyl and the like. The terms "lower alkyl" and "alkyl" also include groups having both straight chain and cyclic structures or both branched chain and cyclic structures.
As used herein, the term aryl includes the carbon containing aromatic structures such as phenyl, naphthyl, anthracentyl, phenanthrenyl, pyrenyl, phenyl substituted with one or more alkyls, naphthyl substituted with one or more alkyls, anthracenyl substituted with one or more alkyls, phenanthrenyl substituted with one as more alkyls, and the like.
As used herein, the term halogen includes F, Cl, Br and I.
As used herein, the term "lower alkenyl" includes those alkenyl groups of from 2 to 7 carbon atoms of either a straight, branched or cyclic configuration. Examples of lower alkenyl groups include vinyl, allyl, isopropenyl, pentenyl, hexenyl, heptenyl, cyclopropenyl, cyclobutenyl, cyclopentenyl, cyclohexenyl, cycloheptenyl, 1-propenyl, 2-butenyl, 2-methyl-2-butenyl, norbornenyl and the like.
As used herein, the term "lower alkoxy" includes those alkoxy groups of from 1 to 7 carbon atoms of either a straight, branched or cyclic configuration. Examples of lower alkoxy groups include methoxy, ethoxy, propoxy, isopropoxy, butoxy sec- and tert-butoxy, pentyloxy, hexyloxy, heptyloxy, cyclopropyloxy, cylobutyloxy, cyclopentyloxy, cyclohexyloxy, cycloheptyloxy, norbornyloxy and the like.
As used herein, the term "alkoxy" includes "lower alkoxy" and extends to cover groups having up to 20 carbon atoms in straight, branched or cyclic configurations. Examples of alkoxy groups include octyloxy, nonyloxy, undecyloxy, dodecyloxy, tridecyloxy, tetradecyloxy, pentadecyloxy, eicosyloxy, 3,7-ethyl-2,2-methyl-4-propylnonyloxy, cyclododecyloxy, adamantyloxy and the like.
As used herein, the term "acyl" refers to the carbonyl radical of a carboxylic acid. It will usually be further specified as "alkylacyl" ##STR7## etc., wherein the terms alkyl, lower alkyl and aryl have the meaning given above.
The term essential amino acid is employed to include the following amino acids; alanine, asparagine, aspartic acid, arginine, cysteine, glutamic acid, glutamine, glycine, histidine, isoleucine, leucine, lysine, methionine, phenylalanine, proline, serine, threonine, tryptophan, tyrosine and valine.
In those instances when asymmetric centers are present, more than one stereoisomer is possible, and all possible isomeric forms are deemed to be included within the planar structural representations shown. Optically active (R) and (S) isomers may be resolved using conventional techniques known to the skilled artisan.
A preferred embodiment of the present invention relates to compound of the formula I wherein:
each R, each R 4 , R 6 , R 9 , each R 10 , each R 13 , each
X, Y 1 , Y 2 , Z, each a, each b, each q, each r, t and each Het is as defined above for formula I;
R 1 is H or lower alkyl;
R 2 is H;
each R 3 is independently lower alkyl, lower alkenyl;
each R 5 is independently H; OR 2 ; or both R 4 's may be combined to create a doubly bonded oxygen (═O);
each R 7 is independently COOR 4 ; CHO; CH 2 OH; tetrazole; or Het;
X 1 , X 2 and X 3 are each independently O, S, SO or SO 2 ;
each n is independently 1 or 2; and each p is O; or the pharmaceutically acceptable salts thereof.
A more preferred embodiment of the present invention relates to compounds of the formula I wherein:
each R is independently H; OH; lower alkyl; trifluoromethyl; lower alkoxy; halogen; N(R 4 ) 2 ; --(C═O)R 1 ; CH 2 OR 4 ; CN; SR 10 ; SOR 10 ; or SO 2 R 10 ;
R 1 is lower alkyl;
each n is 1; q=O and
each of the other substituents is as defined for the aforementioned preferred embodiment, or the pharmaceutically acceptable salts thereof.
A still more preferred embodiment of the present invention are compounds of the formula II: ##STR8## wherein R 9 is
(CH.sub.2).sub.a --Het,
where Het is ##STR9## wherein the broken line represents an optional double bond, ##STR10## R 14 is COOR 4 , u is 0 to 4, and each of the other substituents is as defined for the aforementioned more preferred embodiment,
or the pharmaceutically acceptable salts thereof.
Preferred definitions of Het for compounds of Formula II are: ##STR11##
The compounds of the present invention may be prepared by several different routes. According to one method, a hydroxy acid salt of formula X, as described in EP 104,885 (Apr. 4, 1984), converted to the free acid form by acidification and extraction into an organic solvent such as ethyl acetate or ether, and then treated with excess diazomethane to form the ester of formula XI. The ester (XI) is treated with a thiol in 1,2-dichloroethane, or similar inert solvent, in the presence of zinc iodide, or similar Lewis acid catalysts, to form the sulfides of formula XII. Hydrolysis with aqueous base provides the diacids of formula XIII. Hydrolysis to the diacids of formula XIII will cause a conversion to a carboxylic acid or a hydroxycarboxylic acid if SR 9 of formula XII contains an ester or a lactone ring. This synthetic route is illustrated below: ##STR12##
An alternative procedure is provided whereby the ester of formula XI is reacted with thiolacetic acid and zinc iodide (or similar Lewis acid catalysts) in dichloroethane or a similar inert solvent to provide the thiolacetate of formula XV. Reaction of XV with sodium methoxide in methanol followed by acidification gives the ester of formula XVI. Reaction of XVI with a strong base such as sodium hydride in an inert solvent such as THF at low temperature provides the thiolactones (XVIIa, b) which are separated by chromatography on silica gel or the like. Treatment of one isomeric thiolactone, for example XVIIb, with sodium methoxide followed by reaction of the thiolate anion with a reactive ω-halo-alkanoic acid ester or an alpha, beta-unsaturated alkenoic acid ester, provides the adduct XII which is converted to the diacid salts (XIII) by aqueous alcoholic hydrolysis. Alternatively, the lactone (e.g. XVIIb) can be oxidized with m-chloroperbenzoic acid (mCPBA), or other peracids, or hydrogen peroxide, to provide the sulfones of formula XVIII. Treatment of XVIII, as shown above for XVIIb, provides the diacid salts of formula XX. This procedure is illustrated below: ##STR13##
The compounds of Formula I are active as antogonists of SRS-A and the leukotrienes C 4 , D 4 and E 4 . These compounds also have modest inhibitory activity on leukotriene biosynthesis but are primarily of therapeutic interest as antagonists. The activity of the compounds of Formula I can be detected and evaluated by methods known in the art. See for example, Kadin, U.S. Pat. No. 4,296,129.
The ability of the compounds of Formula I to antagonize the effects of the leukotrienes makes them useful for inhibiting the symptoms induced by the leukotrienes in a human subject. The compounds are valuable therefore in the prevention and treatment of such disease states in which the leukotrienes are the causative factor, e.g. skin disorders, allergic rhinitis, and obstructive airway diseases. The compounds are particularly valuable in the prevention and treatment of allergic bronchial asthma. It will be understood that in this paragraph and in the discussion of methods of treatment which follows, references to the compounds of Formula I are meant to include the pharmaceutically acceptable salts and lactone forms.
The cytoprotective activity of a compound may be observed in both animals and man by noting the increased resistance of the gastrointestinal mucosa to the noxious effects of strong irritants, for example, the ulcerogenic effects of aspirin or indomethacin. In addition to lessening the effect of non-steroidal anti-inflammatory drugs on the gastrointestinal tract, animal studies show that cytoprotective compounds will prevent gastric lesions induced by oral administration of strong acids, strong bases, ethanol, hypertonic saline solutions and the like.
Two assays can be used to measure cytoprotective ability. These assays are; (A) an ethanolinduced lesion assay and (B) an indomethacin-induced ulcer assay.
A. Ethanol-Induced Gastric Ulcer Assay
Twenty-four hour fasted Sprague-Dawley (S.D.) rats are perorally (p.o.) dosed with 1.0 ml absolute ethanol. Fifteen to thirty minutes prior to ethanol administration, groups of rats each receive either an aqueous vehicle (aqueous methylcellulose 5% wt.) or the test compound at various doses perorally. One hour later, the animals are sacrificed and stomach mucosae are examined for resulting lesions.
B. Indomethacin-Induced Ulcer Assay
Indomethacin, 10 mg/kg p.o., is used to induce ulcers in 24 hour fasted S.D. rats. Fifteen minutes prior to indomethacin administration, groups of rats each receive either an aqueous vehicle (5% by weight methylcellulose) or the test compound at various doses perorally. Four hours later the animals are sacrificed and stomach mucosae are examined for resulting ulcers.
The magnitude of a prophylactic or therapeutic dose of a compound of Formula I will, of course, vary with the nature of the severity of the condition to be treated and with the particular compound of Formula I and its route of administration. It will also vary according to the age, weight and response of the individual patient. In general, the daily dose range for anti-asthmatic, anti-allergic or anti-inflammatory use and generally, uses other than cytoprotection, lie within the range of from about 0.1 mg to about 40 mg per kg body weight of a mammal, preferably 0.2 mg to about 20 mg per kg, and most preferably 1 to 10 mg per kg, in single or divided doses. On the other hand, it may be necessary to use dosages outside these limits in some cases.
The exact amount of a compound of the Formula I to be used as a cytoprotective agent will depend on, inter alia, whether it is being administered to heal damaged cells or to avoid future damage, on the nature of the damaged cells (e.g., gastrointestinal ulcerations vs. nephrotic necrosis), and on the nature of the causative agent. An example of the use of a compound of the Formula I in avoiding future damage would be co-administration of a compound of the Formula I with a non-steroidal antiinflammatory drug (NSAID) that might otherwise cause such damage (for example, indomethacin). For such use, the compound of Formula I is administered from 30 minutes prior up to 30 minutes after administration of the NSAID. Preferably, it is administered prior to or simultaneously with the NSAID (for example, in a combination dosage form).
The effective daily dosage level for compounds of Formula I inducing cytoprotection in mammals, especially humans, will generally range from about 0.02 mg/kg to about 100 mg/kg, preferably from about 0.2 mg/kg to about 20 mg/kg. The dosage may be administered in single or divided individual doses.
Any suitable route of administration may be employed for providing a mammal, especially a human with an effective dosage of a leukotriene antagonist. For example, oral, rectal, transdermal, parenteral, intramuscular, intravenous and the like may be employed. Dosage forms include tablets, troches, dispersions, suspensions, solutions, capsules and the like.
The pharmaceutical compositions of the present invention comprise a compound of Formula I as an active ingredient or a pharmaceutically acceptable salt thereof, and may also contain a pharmaceutically acceptable carrier and optionally other therapeutic ingredients. The term "pharmaceutically acceptable salts" refers to salts prepared from pharmaceutically acceptable non-toxic bases including inorganic bases and organic bases. Salts derived from inorganic bases include sodium, potassium, lithium, ammonium, calcium, magnesium, ferrous, zinc, copper, manganous, aluminum, ferric, manganic salts and the like. Particularly preferred are the ammonium, potassium, sodium, calcium and magnesium salts. Salts derived from pharmaceutically acceptable organic non-toxic bases include salts of primary, secondary, and tertiary amines, substituted amines including naturally occurring substituted amines, cyclic amines and basic ion exchange resins, such as isopropylamine, trimethylamine, diethylamine, triethylamine, tripropylamine, ethanolamine, N-ethyl morpholine, N-ethyl piperadine, hydrabamine, morpholine, procaine, 2-dimethylaminoethanol, 2-diethylaminoethanol, tromethamine, lysine, arginine, N,N'-dibenzylethylenediamine, histidine, caffeine, procaine, hydrabamine, choline, betaine, ethylenediamine, glucosamine, methylglucamine, theobromine, purines, piperazine, piperidine, N-ethylpiperidine, polyamine resins and the like.
When the compound of the present invention is basic, salts may be prepared from pharmaceutically acceptable non-toxic acids, including inorganic and organic acids. Such acids include acetic, benzenesulfonic, benzoic, camphorsulfonic, citric, ethanesulfonic, fumaric, gluconic, glutamic, hydrobromic, hydrochloric, isethionic, lactic, maleic, malic, mandelic, methanesulfonic, mucic, nitric, panoic, pantothenic, phosphoric, succinic, sulfuric, tataric, p-tolnenesulfonic and the like. Particularly preferred are citric, hydrobromic, hydrochloric, maleic, phosphoric, sulfuric and tartaric acids.
The compositions include compositions suitable for oral, rectal, ophthalmic, pulmonary, nasal, dermal, topical or parenteral (including subcutaneous, intramuscular and intravenous) administration, although the most suitable route in any given case will depend on the nature and severity of the conditions being treated and on the nature of the active ingredient. They may be conveniently presented in unit dosage form and prepared by any of the methods well-known in the art of pharmacy.
For use where a composition for intravenous administration is employed, a suitable dosage range for anti-asthmatic, anti-inflammatory or anti-allergic use is from about 0.1 mg to about 20 mg (preferably from about 0.1 mg to about 10 mg) of a compound of formula I per kg of body weight per day and for cytoprotective use from about 0.02 mg to about 40 mg (preferably from about 0.2 mg to about 20 mg and more preferably from about 1 mg to about 10 mg) of a compound of Formula per kg of body weight per day. In the case where an oral composition is employed, a suitable dosage range for anti-asthmatic, anti-inflammatory or anti-allergic use is, e.g. from about 1 mg to about 40 mg of a compound of formula I per kg of body weight per day, preferably from about 5 mg to about 20 mg per kg and for cytoprotective use from about 0.2 mg to about 40 mg (preferably from about 0.2 mg to about 20 mg and more preferably from about 0.2 mg to about 10 mg) of a compound of Formula I per kg of body weight per day.
For administration by inhalation, the compounds of the present invention are conveniently delivered in the form of an aerosol spray presentation from pressurized packs or a nebuliser. The preferred composition for inhalation is a powder which may be formulated as a cartridge from which the powder composition may be inhaled with the aid of a suitable device. In the case of a pressurized aerosol, the dosage unit may be determined by providing a valve to deliver a metered amount.
In practical use, the compounds of Formula I can be combined as the active ingredient in intimate admixture with a pharmaceutical carrier according to conventional pharmaceutical compounding techniques. The carrier may take a wide variety of forms depending on the form of preparation desired for administration, e.g., oral or intravenous. In preparing the compositions for oral dosage form, any of the usual pharmaceutical media may be employed, such as, for example, water glycols, oils, alcohols, flavoring agents, preservatives, coloring agents and the like in the case of oral liquid preparations, such as, for example, suspensions, elixirs and solutions; or carriers such as starches, sugars, diluents, granulating agents, lubricants, binders, disintegrating agents and the like in the case of oral solid preparations such as, for example, powders, capsules and tablets. Because of their ease of administration, tablets and capsules represent the most advantageous oral dosage unit form, in which case solid pharmaceutical carriers are obviously employed. If desired, tablets may be sugar coated or enteric coated by standard techniques.
In addition to the common dosage forms set out above, the compounds of Formula I may also be administered by controlled release means and/or delivery devices such as those described in U.S. Pat. Nos. 3,845,770; 3,916,899; 3,536,809; 3,598,123; 3,630,200 and 4,008,719, the disclosure of which is hereby incorporated herein by reference.
Pharmaceutical compositions of the present invention suitable for oral administration and by inhalation in the case of asthma therapy 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 or as a solution or a suspension in an aqueous liquid, a non-aqueous liquid, an oil-in-water emulsion or a water-in-oil liquid emulsion. Such compositions may be prepared by any of the methods of pharmacy but all methods include the step of bringing into association the active ingredient with the carrier which constitutes one or more necessary ingredients. In general, the compositions are prepared by uniformly and intimately admixing the active ingredient with liquid carriers or finely divided solid carriers or both, and then, if necessary, shaping the product into the desired presentation. For example, a tablet may be prepared 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 powder or granules, optionally mixed with a binder, 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. Desirably, each tablet contains from about 25 mg to about 500 mg of the active ingredient and each cachet or capsule contains from about 25 mg to about 500 mg of the active ingredient.
The following are examples of representative pharmaceutical dosage forms for the compounds of Formula I:
______________________________________Injectable Suspension mg/ml______________________________________Compound of Formula I 2.0Methylcellulose 5.0Tween 80 0.5Benzyl alcohol 9.0Methyl paraben 1.8Propyl paraben 0.2Water for injection to a total volume of 1 ml______________________________________Tablet mg/tablet______________________________________Compound of Formula I 25.0Microcrystalline Cellulose 325.0Providone 14.0Microcrystalline Cellulose 90.0Pregelatinized Starch 43.5Magnesium Stearate 2-2.5 500______________________________________Capsule mg/capsule______________________________________Compound of Formula I 25.0Lactose Powder 573.5Magnesium Stearate 1.5 600______________________________________
In addition to the compounds of Formula I, the pharmaceutical compositions of the present invention can also contain other active ingredients, such as cyclooxygenase inhibitors, non-steroidal anti-inflammatory drugs (NSAIDs), peripheral analgesic agents such as zomepirac diflunisal and the like. The weight ratio of the compound of the Formula I to the second active ingredient may be varied and will depend upon the effective dose of each ingredient. Generally, an effective dose of each will be used. Thus, for example, when a compound of the Formula I is combined with an NSAID the weight ratio of the compound of the Formula I or XII to the NSAID will generally range from about 200:1 to about 1:200. Combinations of a compound of the Formula I and other active ingredients will generally also be within the aforementioned range, but in each case, an effective dose of each active ingredient should be used.
NSAIDs can be characterized into five groups:
(1) the propionic acid derivatives;
(2) the acetic acid derivatives;
(3) the fenamic acid derivatives;
(4) the biphenylcarboxylic acid derivatives; and
(5) the oxicams
or a pharmaceutically acceptable salt thereof.
NSAIDs which are within the scope of this invention are those disclosed in EP 140,684 (May 8, 1985) which is hereby incorporated by reference.
Pharmaceutical compositions comprising the Formula I compounds may also contain inhibitors of the biosynthesis of the leukotrienes such as are disclosed in EP 138,481 (Apr. 24, 1985), EP 115,394 (Aug. 8, 1984), EP 136,893 (Apr. 10, 1985), and EP 140,709 (May 8, 1985) which are incorporated herein by reference.
The compounds of the Formula I may also be used in combination with leukotriene antagonists such as those disclosed in EP 106,565 (Apr. 25, 1984) and EP 104,885 (Apr. 4, 1984) which are incorporated herein by reference and others known in the art such as those disclosed in European Patent Application Nos. 56,172 and 61,800; and in U.K. Patent Specification No. 2,058,785, which are incorporated herein by reference.
Pharmaceutical compositions comprising the Formula I compounds may also contain as the second active ingredient, antihistaminic agents such as benadryl, dramamine, histadyl, phenergan and the like. Alternatively, they may include prostaglandin antagonists such as those disclosed in European Patent Application 11,067 (May 28, 1980) or thromboxane antagonists such as those disclosed in U.S. Pat. No. 4,237,160. They may also contain histidine decarboxyase inhibitors such as α-fluoromethylhistidine, described in U.S. Pat. No. 4,325,961. The compounds of the Formula I may also be advantageously combined with an H 1 or H 2 -receptor antagonist, such as for instance cimetidine, ranitidine, terfenadine, famotidine, aminothiadiazoles disclosed in EP 40,696 (Dec. 2, 1981) and like compounds, such as those disclosed in U.S. Pat. Nos. 4,283,408; 4,362,736; and 4,394,508. The pharmaceutical compositions may also contain a K + /H + ATPase inhibitor such as omeprazole, disclosed in U.S. Pat. No. 4,255,431, and the like. Each of the references referred to in this paragraph is hereby incorporated herein by reference.
The following examples are provided to aid in the interpretation of the present invention. They are not intended to limit the scope of the invention in any manner. Infrared (IR) spectra were measured as KBr disks or as thin films and absorption bands are reported in reciprocal centimeters (cm -1 ). Nuclear magnetic resonance (NMR) spectra (90 MHz) were measured in deuterochloroform (CDCl 3 ), perdeuterodimethyl sulfoxide (DMSO-d 6 ), perdeuteromethanol (CD 3 OD), deuterium oxide (D 2 O) or deuterated trifluoroacetic acid (CF 3 COOD) and peak positions are expressed in parts per million (ppm) downfield from an internal reference, tetramethylsilane. The following abbreviations are used for peak shapes: s, singlet; d, doublet; t, triplet; q, quartet; and m, multiplet. All melting and boiling Points are reported in degrees Centigrade (° C.) and are uncorrected. Standard abbreviations are used for chemical compounds. For example: THF, tetrahydrofuran; MeOH, methanol; DMF, dimethylformamide; Et 2 O, di-ethyl ether; and EtOAc, ethyl acetate.
In the following Examples, R* and S* represent a racemic mixture of RS:SR in the ratio of 1:1.
EXAMPLE 1
Preparation of αR*, βR* and αR*, βS* 7-((α-(4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio) phenyl)-γ-carboxy-β-methylpropyl)thio)-4-oxo-4-H-1-benzopyran-2-carboxylate disodium salt mixture of diastereomers
Step A: Preparation of Methyl 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-beta-methyl-gamma-hydroxybenzenebutanoate
To the 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy) propyl)thio)-beta-methyl-gamma-hydroxybenzene butanoic acid γlactone (8.84 g, 20 mM) described in EP 104,885 (Apr. 4, 1984) was added a mixture of 2N NaOH (12 ml, 24 mM), THF (50 ml) and MeOH (20 ml) and the mixture was stirred 12 hours under N 2 . The reaction mixture was evaporated to dryness and dissolved in water (75 ml) and cooled to 0° C.; 1N HCl was added drop wise until the PH was lower than 6 and the organic compound was extracted into EtOAc (200 ml). The organic layer was washed with brine (100 ml) and dried with Na 2 SO 4 . The solvent was removed in vacuo with no heating and the residue was dissolved in Et 2 O (100 ml) and cooled to 0° C. Diazomethane (in Et 2 O) was added in excess and the reaction mixture was evaporated to dryness with no heat and dried under high vacuum to yield the title compound as an oil slightly contaminated (by less than 10 percent of the starting lactone).
1 H-250-MHz-NMR/CDCl 3 :
______________________________________Delta(ppm) Number m______________________________________12.7 1H s7.6 1H d7.35 2H d7.25 2H d6.42 1H d4.6 1H d4.15 2H t3.68 3H s3.1 2H t 2.8-2.95 1H bs2.65 2H t2.55 3H s 2.5-2 5H m1.55 2H m0.85-1 6H m______________________________________
Step B: Preparation of methyl 7-((1-(4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)phenyl)-3-methoxycarbonyl)-2-methylpropyl)thio)-4-oxo-4H-1-benzopyran-2-carboxylate
To a solution of the ester obtained in Step A (950 mg, 2 mM) of this Example in dry dichloroethane (5 ml) was added dry ZnI 2 (20 mM, 6.4 g) and the Methyl 7-mercapto-4-oxo-4H-1-benzopyran-2carboxylate described in EP 123, 543 (Apr. 19, 1984) (566 mg) and the suspension was efficiently stirred for 3 hours. To the reaction was added IN HCl (20 ml) and methylenedichloride (25 ml). The organic layer was washed with brine (15 ml) and dried with Na 2 SO 4 . Solvents were removed in vacuo and the residue purified by flash chromatography on silica gel (1:1, hexane:ethyl acetate) and by passing over basic alumina (activity 1) with CH 2 Cl 2 . Removal of the solvent yielded the title compound as an oil.
1 H-250-MHz-NMR:
______________________________________Delta(ppm) Number m______________________________________12.7 1H s7.85-8 1H dd 7.55 1H d7.4 1H d7.0-7.35 6H m6.4 1H d4.5 1H t 4.15 2H t4 3H s3.6 3H d3.1 2H t2.6 7H m 2-2.4 3H m1.5 2H m1 and 1.1 3H 2d0.9 3H t______________________________________
Step C: Preparation of αR*, βR* and αR*, 62 S* 7-((α-(4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy) propyl)thio)phenyl)-γ-carboxy-β-methylpropyl) thio)-4-oxo-4-H-1-benzopyran-2-carboxylic acid disodium salt mixture of diastereomers
To a solution of the diester obtained in Step B of this Example (188 mg), MeOH (2 ml), and H 2 O (2 ml) was added 1M Na 2 CO 3 (2 ml) and the mixture was stirred for 96 hours at room temperature. The mixture was then cooled to 0° C. and 1M NaOH (235 §1) was added. The reaction was then stirred for another 48 hours at 5° C. The reaction mixture was evaporated to dryness and absorbed on XAD-8 neutral resin in water, washed with water and then eluted off with ethanol. Evaporation of the solvent in vacuo yielded the title compound.
1H-250 MHz-NMR/DMSO-d 6 :
______________________________________Delta(ppm) Number m______________________________________12.9 1 broad s6.6-7.9 10 m4.8-4.9 1 t4.1-4.3 2 t3.1 2 t0.8-2.9 18 m______________________________________
EXAMPLE 2
Preparation of d,l 4-((1-(4-((3-(4-acetyl-3-hydroxy-2-Propylphenoxy)propyl)thio)phenyl)-3-carboxypropyl) thio)-gamma-oxobenzenebutanoic acid
Step A: Preparation of Methyl 4(3-bromopropylthio)gamma-hydroxy-benzenebutanoate
To methyl 4(3-bromopropylthio)-gamma-oxobenzene butanoate (described in EP 104,885 (Apr. 4, 1984)) (17.26 g, 50 mM) in 1,2-dimethoxy ethane (100 ml) and MeOH (100 ml) cooled to 0° C., was added CeCl 3 (10 mg) and NaBH 4 (945 mg) portion-wise, over 1/2 hours and the reaction mixture was maintained at 0° for an additional 1/2 hour. Thereafter, NaBH 4 (300 mg) was added and reaction stirred for another 1/2 hour at 0° C. The reaction was slowly poured on cold 1N HCl (200 ml) and extracted with ethyl acetate (300 ml). The organic layer was then washed with brine, dried with Na 2 SO 4 and solvents were removed in vacuo at less than 30° C. to yield the title compound as an oil which as used immediately in Step D.
Step B: Preparation of Methyl 4-(methylthio)-gamma-oxo-benzenebutanoate
Thioanisole (12.4 g) and 1,4-dioxo-4-methoxybutyl chloride (16.5 g) in dichloroethane (100 ml) were cooled to 0° C. and aluminum chloride (16 g) was added, followed by another equivalent (16 g) and the reaction mixture was stirred at 0° C. for 2 hours. Ice was added, followed by 1N HCl. Dichloromethane (100 ml) was then added and the organic layer was separated, washed with water and then brine and dried with Na 2 SO 4 . Removal of the solvents yielded the title compound as an oil.
Analysis calculate: C, 60.48; H, 5.92; S, 13.45.
Found: C, 60.50; H, 5.99; S, 13.27.
Step C: Preparation of Methyl (4-mercapto)-gamma-oxo-benzenebutanoate
To a solution of Methyl (4 methylthio)-gamma- ketobenzene-butanoate (476 mg) in chloroform (15 ml), cooled to 0° C., was added m-chloroperoxybenzoic acid (345 mg) and the mixture was stirred at 0° C. for 1 hour. Excess Ca(OH) 2 was added. The mixture was stirred 0.5 hours at room temperature. Thereafter, filtration through Celite and removal of the solvent left an oily residue of the sulfoxide. Trifluoroacetic anhydride (20 ml) was then added and the mixture was warmed to 40° C. for 15 minutes. Removal of the volatiles left a residue to which was added 50 ml of a 1:1 mixture of MeOH and triethylamine. Solvents were removed in vacuo and further methanol-triethylamine was added and this process was repeated two times. Ethyl acetate (25 ml) was added to the resulting residue. The solution was washed with 1N HCl (10 ml) and then with brine (20 ml) and the organic layer was dried with Na 2 SO 4 . Removal of the solvents yielded the title compound which was immediately used in the coupling reaction described in the following step (to avoid formation of the disulfide).
Step D: Preparation of methyl 4((1-(4-(3-bromopropylthio) phenyl)-3-(methoxy carbonyl) propyl)thio)-gamma-oxo-benzenebutanoate
To a well stirred suspension of the alcohol obtained in Step A of this Example (694 mg) and ZnI 2 (6.4 g) in dichloroethane (10 ml), was added the thiol obtained in Step C of this Example (448 mg) and the mixture was stirred for 3 hours. It was then quenched with 1N HCl (10 ml) and diluted with CH 2 Cl 2 (20 ml). The organic layer was then washed with 1N HCl (10 ml) and then with brine (10 ml) and dried with Na 2 SO 4 . Removal of the solvent yielded an oily residue which was purified by flash chromatography (toluene:ethylacetate, 10:1) to yield the pure title compound.
1 H-250-MHz-NMR/CDCl 3 :
______________________________________Delta(ppm) Number m______________________________________7.9 2H d7.3 2H d7.25 4H s4.4 1H m3.75 3H s3.7 3H s3.52 2H t3.25 2H t3.1 2H t2.75 2H t2-2.7 6H m______________________________________
Step E: Preparation of methyl 4-((1-(4-(3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl) thio)phenyl)-3-(methoxycarbonyl)propyl) thio)-gamma-oxo-benzenebutanoate
A suspension of the bromide obtained in Step D of this Example (553 mg), 2,4-dihydroxy-3-propyl acetophenone (235 mg), potassium carbonate (400 mg, milled) and methyl ethyl ketone (20 ml) was refluxed for 6 hours. The reaction mixture was then cooled to room temperature and the insolubles removed by filtration through Celite. Solvents were removed in vacuo and the residue was purified on Prep-500 Waters apparatus using toluene: ethyl acetate, 10:1, to yield the title compound.
1 H-250 MHz-NMR:
______________________________________Delta(ppm) Number m______________________________________12.75 1H s7.80 2H d7.55 1H d7.35 2H d7.2-7.3 4H m6.4 1H d4.4 1H m4.15 2H t3.6-3.7 6H 2s3.25 2H t3.15 2H t2.7-2.8 2H t2.6-2.7 2H t2.58 3H s 2-2.45 6H m1.45-1.55 2H m0.95 3H t______________________________________
Step F: Preparation of 4-((1-(4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)phenyl)-3-carboxypropyl)thio)-gamma-oxo-benzenebutanoic acid
A solution of the diester obtained in Step E of this Example (922 mg), IN NaOH (4.2 ml), MeOH (4 ml) and THF (4 ml) was stirred, under N 2 , for 4 hours, at room temperature. The reaction mixture was then evaporated to dryness and the residue mixed with water (20 ml), acidified with 1N HCL and extracted with diethyl ether (50 ml). The organic layer was washed with brine and dried with Na 2 SO 4 . The solvent was removed in vacuo to yield the title compound as a white solid which was purified by trituration with ethyl acetate hexane, 1:5.
Analysis calculated: C, 63.93; H, 6.00; S, 10.04.
Found: C, 64.10; H, 5.99; S, 9.73.
EXAMPLE 3
Preparation of βR*, γR* and βS*, γR* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-gamma-(3-((carboxyacetyl)amino)phenyl)thio-Beta-methylbenzenebutanoic acid
Step A: Preparation of ethyl 3-oxo-3-(3-mercaptophenylamino) propanoate
A mixture of 3-aminothiophenol (5.0 g) and diethyl malonate (6.41 g) was heated under a nitrogen atmosphere for 2 hours at from 165° to 170° C. The mixture was chromatographed on silica gel to yield the title compound, m.p. 52°-54°.
Analysis calculated: C, 55.21; H, 5.47; N, 5.85; S, 13.39.
Found: C, 54.64; H, 5.41; N, 5.80; S, 13.02.
Step B: Preparation of Methyl 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-gamma-((3-ethoxy-1,3-dioxopropylamino)phenyl)thio)beta-methylbenzenebutanoate
To a well stirred suspension of the alcohol obtained in Step A, Example 1 (1.422 g) and ZnI 2 (6 g) in dichloroethane (25 ml) was added the thiol obtained in step A, Example 3 (550 mg) and the mixture was stirred for 3 hours. Thereafter, 1N HCl (20 ml) was added, followed by dichloromethane (50 ml). The organic layer was separated, washed with brine and then dried with Na 2 SO 4 . The solvents were removed in vacuo to give a residue which was purified by flash chromatography using 33% ethyl acetate in hexane to yield the title compound as an oil (1.76 g, 84%).
1 H-250 MHz-NMR/CDCl 3 :
______________________________________Delta(ppm) Number m______________________________________12.75 1H s9.2 1H bs7.5 1H d7.52 1H s6.8-7.4 7H m6.4 1H d 4.2-4.35 3H m4.15 2H t3.65 3H 2s3.45 2H s3.1 2H t2-2.85 10H m1.55 2H m1.3 3H t 0.9-1.15 6H m______________________________________
Step C: Preparation of 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-gamma-((3-carboxyacetate) amino)phenyl)thio)beta-methylbenzenebutanoic acid
To a cooled (0° C.) solution of the ester obtained in Step B of this Example (615 mg), MeOH (5 ml) and THF (5 ml) was added 1N NaOH (2.6 ml) and the reaction mixture was allowed to return to room temperature and was stirred for 12 hours. Thereafter, the solvents were removed in vacuo and the residue was diluted with water (10 ml), acidified with 1N HCL (5 ml) and extracted with ether (30 ml). The organic layer was washed with brine, dried with Na 2 SO 4 and evaporated to dryness in vacuo to yield the title compound as a beige foam (520 mg, 90%).
Analysis calculated: C, 62.46; H, 6.01; N, 2.14; S, 9.81.
Found C, 62.00; H, 6.24; N, 2.07; S, 9.98.
EXAMPLE 4
Preparation of 1R*, γR* and 1R*, γS* 4-((1-(4((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio) phenyl)-3-carboxypropyl)thio)-beta-methyl-gammaoxobenzenebutanoic acid (mixture of diastereoisomers)
Step A: Preparation of Methyl (1((4(3-bromopropylphenyl)-3-methoxycarbonyl-propyl)thio)-β-methyl-gamma-oxobenzene-butanoate
To a solution of the alcohol obtained in
Step A of Example 2 (1.041 g), ZnI 2 (9.6 g) and dichloroethane (15 ml), was added methyl 4-mercaptobeta-methyl-gamma-oxobenzenebutanoate from Example 9, Step E (714 mg) under efficient stirring and the reaction mixture was stirred for 3 hours. The reaction mixture was then quenched with water (10 ml) and then diluted with CH 2 Cl 2 (25 ml). The organic layer was then washed with 1 N HCl (25 ml) and then with brine and was then dried with Na 2 SO 4 . Removal of the solvents in vacuo yielded a residue which was purified by flash chromatography (10:1, toluene:ethylacetate) to yield the title compound as an oil (1.6 g, 94%).
1 -250 MHz-NMR/CDCl 3 :
______________________________________Delta(ppm) Number m______________________________________7.84 2H d7.29 2H d7.24 4H s4.4 1H m3.86 1H m3.64 6H 2s3.51 2H t3.07 2H t2.94 1H m2.05-2.54 7H m1.19 3H d______________________________________
Step B: Preparation of Methyl 4-((1-(4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)phenyl)-3-methoxycarbonylpropyl)thio)-beta-methyl-gammaoxobenzene butanoate
A solution made of the bromide obtained in Step A of this Example (1.55 g), 2,4-dihydroxy-3-propyl acetophenone (652 mg), and milled K 2 CO 3 (1.16 g) in MEK (methyl ethyl ketone) (25 ml) was refluxed for hours and then cooled to room temperature. The mixture was filtered and removal of the solvent left a residue which was purified by flash chromatography with 30% ethyl acetate in hexane to yield the title compound as an oil (1.05 g, 55%).
1 -250 MHz-NMR(CDCl 3 ):
______________________________________Delta(ppm) Number m______________________________________12.75 1H s7.83 2H d7.6 1H d7.45 2H d7.3 4H s6.42 1H s4.4 1H m4.15 2H t3.85 1H m3.65 6H 2s3.12 2H t2.65 2H AB2.1-2.7 11H m1.55 2H m1.2 3H d0.95 3H t______________________________________
Step C: Preparation of 1R*γR*, 1R*γS* 4-((1-4-((3-(4-acetyl-3-hydroxy-propylphenoxy) propyl)thio)phenyl)-3-carboxypropyl)thio)-beta-methyl-gamma-oxobenzenebutanoic acid (mixture of diastereoisomers)
To a solution of the diester from Step B of this Example (940 mg) in MeOH (4 ml) and THF (4 ml) was added 1N NaOH (4.2 ml) and the reaction mixture was stirred for 3 hours at room temperature. Solvents were removed in vacuo and the residue mixed with water (20 ml) and acidified with 1N HCl (10 ml). The aqueous layer was extracted with ether (50 ml) and the organic layer was washed with brine (10 ml) and then dried with Na 2 SO 4 . The solvents were removed in vacuo to give the title compound as a beige foam (740 mg, 82%).
Analysis calculated: C, 64.40; H, 6.18; S, 9.82
Found: C, 64.34; H, 6.12; S, 9.82.
EXAMPLE 5
Preparation of αR*, βR* and αR*, βS* N(S(α-(4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio) phenyl)-γ-carboxy-β-methylpropyl)-cysteinyl)glycine (mixture of diastereoisomers)disodium salt
Step A: Preparation of N(S-(α(4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)phenyl)-γ-methoxycarbonyl-β-methylpropyl)N-trifluoroacetylcysteinyl)glycine methyl ester (mixture of diastereoisomers)
To a well stirred suspension of the ester obtained in Step A, Example 1 (474 mg), ZnI 2 (3.2 g) and dichloroethane (3 ml) was added cysteinylglycine methyl ester and the mixture was stirred for 3 hours. Thereafter, water (5 ml), 1N HCL (5 ml) and dichloromethane (25 ml) were added. The organic layer was washed with brine and then dried with Na 2 SO 4 . The solvents were removed to yield a residue which was chromatographed to yield the title compound as an oil (436 mg, 59%).
1 -250 MHz/CDCl 3 :
______________________________________Delta(ppm) Number of H m______________________________________12.9 1 s7.6 1 d 7.4-7.55 1 m7.15-7.35 4 m6.6-6.7 1 m6.4 1 d4.7-3.5 13 m3.1-3.2 2 t2.9-2 11 m1.5 2 m0.8-1.1 6 m______________________________________
Step B: Preparation of αR*, βS* and αR*, βR* N-(S-(α-(4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy) propyl)thio)phenyl)-γ-carboxy-β-methylpropyl) cysteinyl)glycine (mixture of diastereoisomers) disodium salt
To a solution made of the ester obtained in Step A of this Example (390 mg), MeOH (3 ml) and THF (3 ml) was added 1N NaOH (2 ml) and the mixture was stirred for 12 hours. Thereafter, solvents were removed and the residue passed on a XAD-8 neutral resin to yield the title compound as a beige foam (275 mg, 80%).
Analysis calculated: C, 51.64; H, 5.63; S, 9.19.
Found C, 51.44; H, 5.97; S, 8.54.
EXAMPLE 6
Preparation of βR*, αR* and βR*, αS* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-gamma-((2-carboxyethyl)thio)-beta-methylbenzenebutanoic acid disodium salt (mixture of diastereoisomers)
Step A: Preparation of Methyl 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-gamma((2-methoxycarbonylethyl)thio)-beta-methylbenzenebutanoate (mixture of diastereoisomers)
To an efficiently stirred suspension made of the alcohol obtained from Step A of Example 1 (1.42 g), ZnI 2 (4.8 g) in dichloroethane (20 ml) was added methyl 3-mercaptopropionate (360 mg) and the suspension was stirred for 3 hours. Thereafter, 1N HCl (20 ml) and dichloromethane (50 ml) were added. The organic layer was then washed with brine and dried with Na 2 SO 4 . The solvents were removed in vacuo to yield a residue which was chromatographed on silica gel to yield the title compound as an oil (1.37 g, 80%).
NMR 1 H-250 MHz/CDCl 3 :
______________________________________Delta(ppm) Number of H m______________________________________12.9 1 s7.55 1 d7.2-7.4 4 m6.45 1 d4.15 2 t3.6-3.8 1 m3.65 3 2s3.65 3 s3.15 2 t2.8-2.0 14 m1.55 2 m0.95 6 m______________________________________
Step B: Preparation of βR*, αR* and βR*, αS* 4-((3-(4-Acetyl-3-hydroxy-2-propylphenoxy)propyl) thio-gamma-((2-carboxyethyl)thio)-betamethylbenzenebutanoic acid disodium salt tetrahydrate (mixture of diastereoisomers)
To a solution made of the ester obtained in Step A of this Example (1.3 g), MeOH (10 ml), and THF (10 ml) was added 1N NaOH (6.7 ml) and the mixture was stirred for 12 hours. Thereafter, the solvents were removed in vacuo. The residue was then mixed with water and passed over XAD-8 neutral resin to yield the title compound as a beige foam (780 mg, 60%).
Analysis calculated: C, 50.59; H, 6.37; S, 9.65; Na, 6.92.
Found: C, 50.40; H, 6.31; S, 9.69; Na, 6.36.
EXAMPLE 7
Preparation of βR*, γR* and βR*, γS* 4-((3-(4-Acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-gamma-(butylthio)-beta-methylbenzenebutanoic acid (mixture of diastereoisomers)
Step A: Preparation of Methyl 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-gamma(thioacetyl)-beta-methylbenzenebutanoate (mixtures of diastereoisomers)
To a solution of the alcohol obtained in Step A, of Example 1 (5.69 g), ZnI 2 (19 g) in dichloroethane (50 ml) was added thioacetic acid (1.005 g) with efficient stirring. After 3 hours, 1N HCl (25 ml), water (25 ml) and dichloromethane (150 ml) were added. The organic layer was washed with brine and dried with Na 2 SO 4 . The solvents were then removed in vacuo to yield a residue which was chromatographed to yield the title compound as an oil (5.43 g, 85%).
Analysis calculated: C, 63.13; H, 6.81; S, 12.04.
Found: C, 63.01; H, 6.77; S, 11.77.
NMR, 1 H-250 MHz/CDCl 3 :
______________________________________Delta(ppm) Number of H m______________________________________12.9 1 s7.6 1 d7.1-7.3 4 m6.4 1 d4.5 1 m4.1 2 t3.6-3.7 3 2s 3.15 2 t2.75-2 13 m1.5 2 m0.8-1.1 6 m______________________________________
Step B: Preparation of βR , γR* and βR*, γS* Methyl 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy) propyl)thio)-gamma-(butylthio)-beta-methylbenzenebutanoate (mixture of diastereoisomers)
To a cooled (0° C.) solution of the thioacetate obtained in Step A of this Example (532 mg) in MeOH (5 ml) was added 2N NaOMe (650 microliters) followed, 1/2 hour later, by 1-iodobutane (148 microliters, 240 mg) and the reaction mixture was stirred for 1 hour at 0° C. 1N HCl (5 ml) was added followed by ethyl acetate (25 ml). The organic layer was collected, washed with brine and dried. Solvents were removed in vacuo and the residue purified by chromatography to yield the title compound as an oil (465 mg, 85%).
______________________________________Delta(ppm) Number of H m______________________________________12.9 1 s7.65 1 d7.1-7.4 4 m6.4-6.5 1 d4.15 2 t3.5-3.8 4 m3.1-3.2 2 t 2-2.8 12 m1.2-1.7 6 m0.75-1.15 9 m______________________________________
Step C: Preparation of βR*, γR* and βR*, γS* 4-((3-(4-Acetyl-3-hydroxy-2-propylphenoxy)propyl) thio)-gamma-(butylthio)-beta-methylbenzenebutanoic acid (mixture of isomers)
To a solution of the ester from Step B of this Example (340 mg) in MeOH (3 ml) and THF (3 ml) was added 1N NaOH (1.6 ml) and the mixture was stirred for 12 hours. Thereafter, the solvents were removed and the residue mixed with water (10 ml), acidified with 1N HCl (5 ml) and extracted with ethyl acetate (25 ml). The organic layer was washed with brine and dried with Na 2 SO 4 . The solvents were removed in vacuo to give a residue which was chromatographed to yield the title compound (210 mg, 63%).
Analysis calculated: C, 65.38; H, 7.57; S, 12.04.
Found: C, 65.25; H, 7.68; S, 12.11.
EXAMPLE 8
Preparation of βR*, γR* and βR*, γS* 4-((3-(4-Acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-beta-methyl-gamma-((1H-tetrazol-5-ylmethyl)thio)benzeneanoic acid disodium salt monohydrate
and
Methyl βR*, γR* and 62 R*, γS* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-beta-methylgamma-((1H-tetrazole-5-yl-methyl)thio)benzenebutanoate (diastereoisomer mixture) sodium salt
Step A: Preparation of Methyl βR*, γR* and βR*, γS* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy) propyl)thio)-beta-methyl-gamma-(cyanomethyl) thio)benzenebutanoate (mixture of isomers)
To a cooled (0° C.) solution of the acetate obtained in Step A of Example 7 (2.66 g) in MeOH (30 ml) was added 2N NaOMe (3.25 ml) and the reaction mixture was stirred for 1/2 hour. Thereafter, chloroacetonitrile (491 mg) was added and the mixture stirred for another hour. The mixture was slowly poured on ice cold 1N HCl (100 c.c.). Ethyl acetate (100 ml) was then added and the organic layer was separated. The aqueous layer was extracted with ethyl acetate (50 ml) and the combined organic layers were washed with brine and dried with Na 2 SO 4 . The solvents were removed to yield a residue which was chromatographed to yield the title compound as an oil.
NMR 1 H-250 MHz/CDCl 3 :
______________________________________Delta(ppm) Number of H m______________________________________12.9 1 s7.6 1 d7.15-7.35 4 m6.45 1 d4.15 2 t3.85-4.05 1 m3.5-3.6 3 2s3.1-3.2 2 t2.9-2.0 12 m1.45-1.6 2 m0.85-1.2 6 m______________________________________
Step B: Preparation of βR*, γR* and βR*, γS* 4-((3-(4-Acetyl-3-hydroxy-2-propylphenoxy)propyl) thio)-beta-methyl-gamma-((1H-tetrazole-5-ylmethyl)thio)benzenebutanoic acid sodium salt monohydrate
and
Methyl βR*, γR* and βR*, γS* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl) thio)-beta-methyl-gamma-((1H-tetrazole-5-ylmethyl)thio)benzenebutanoate (diastereoisomer mixture) sodium salt
The ester obtained in Step A (2.54 g) and tri-n-butyltin azide (1.75 g) were heated, neat, under N 2 , to 80° C. for 16 hours. Ether (100 ml) saturated with HCl gas was added and the mixture was stirred at room temperature for 3 hours. It was then diluted with ether (100 ml) and stirred with (100 ml) 2N NaOH at room temperature for 30 minutes. The aqueous layer was separated and the ether layer was extracted back with 2N NaOH (100 ml). The combined aqueous layers were acidified and extracted with ethyl acetate. The ethyl acetate solution was dried with brine and sodium sulfate (anhydrous). The solvent was removed to yield an oil which was purified by flash chromatography. This yielded the tetrazole/acid and the tetrazole/ester. Both were converted to their respective sodium salts with sodium hydroxide and purified on XAD-8 neutral resin.
Analysis calculated for C 27 H 29 O 5 S 2 N 4 Na 2 H 2 O: C, 52.50; H, 5.06; N, 9.07; S, 10.38; Na, 7.44. Found: C, 52.39; H, 5.45; N, 8.72; S, 10.54; Na, 7.03.
Analysis calculated for C 28 H 32 O 5 S 2 N 4 Na H 2 O: C, 55.16; H, 5.62; S, 10.52. Found: C, 55.18; H, 6.10; S, 10.71.
EXAMPLE 9
Preparation of 1R, 2R, βR, γS; 1R, 2S, βR, γS; 1S; 2R, βR, γS; 1S, 2S, βR, γS; 1R, 2R, βS, γR; 1R, 2S, βS, γR; 1S, 2R, βS, γR; 1S, 2S, βS, γR 4-((1-(4-((3-(4-Acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)phenyl)-3-carboxy-2-methylpropyl)thio)-gamma-hydroxy-betamethylbenzenebutanoic acid disodium salt monohydrate
Step A: Preparation of 4-(Methylthio)phenyl-propan-1-one
To a solution of thioanisole (5 g) and propionyl chloride (3.9 ml) in dichloroethane (80 ml) at 0° C. was added, in portions, aluminum chloride (6.4 g). The mixture was stirred overnight at room temperature. The reaction mixture was poured onto a mixture of ice and water (200 ml) and concentrated HCl (2 ml) and extracted with CH 2 Cl 2 . The combined organic layers were washed with water, dried over Na 2 SO 4 and purified on a silica gel column (140 g) using hexane/EtOAc (10:1) as eluant to afford the title compound as a white solid, m.p. 60°-61° C.
Step B: Preparation of Methyl 4-(methylthio)-beta-methyl-gamma-oxobenzenebutanoate
To a solution of potassium hexamethylsilazane (0.158 mole) in toluene (254 ml) and THF (160 ml) at -78° C. was added dropwise the ketone from Step A of this Example (25.8 g) in THF (90 ml). The reaction mixture was stirred 30 minutes at -78° C. Methyl bromoacetate (16.2 ml) in THF (25 ml) was added dropwise. After stirring 1.5 hours at -78° C. the reaction mixture was poured into 1N HCl (400 ml). The organic layer was separated and the aqueous layer was further extracted with ethyl acetate. The combined organic layers were washed with water, dried over Na 2 SO 4 and evaporated to give a yellow oil which was purified on a flash silica gel column (1 kg) using hexane/EtOAc (10:2) as eluant to give the title compound as an oil.
1 H NMR (CDCl 3 ) delta: 1.2 (3H, d, J=6 Hz), 2.45 (3H, s), 2.3-3.1 (2H, m), 3.6 (3H, s), 3.85 (1H, quinteuplet, J=6 Hz), 7.25 (2H, d, J=7 Hz), 7.9 (2H, d, J=7 Hz).
Step C: Preparation of Methyl 4-(methylsulfinyl)beta-methyl-gamma-oxobenzenebutanoate
To a solution of the sulfide from Step 2 (14.6 g) in CH 2 Cl 2 (75 ml) at 0° C. was added dropwise a solution of 85% m-CPBA (11.7 g) in CH 2 Cl 2 (225 ml). The reaction mixture was stirred for 2 hours at 0° C. and solid calcium hydroxide (6.4 g) was added and stirred at room temperature for 15 minutes and filtered through a bed of Celite. The filtrate was evaporated to give an oil which was purified on a flash silica gel column (175 g) using CH 2 Cl 2 /acetone (10:1) as eluant to afford the title compound as a colorless oil (13.5 g, 87%).
1 H NMR (CDCl 3 ) delta: 1.23 (3H, d, J=6 Hz), 2.45-2.57 and 2.95-3.1 (2H, m), 2.78 (3H, s), 3.65 (3H, s), 3.95 (1H, quintuplet), 7.78 (2H, d, J=7 Hz), 8.15 (2H, d, J=7 Hz).
Step D: Preparation of Methyl 4-(trifluoroacetoxymethylthio)-beta-methyl-gamma-oxobenzenebutanoate
A solution of the sulfoxide from Step C of this Example (10 g) in trifluoroacetic anhydride (50 ml) was heated at 45° C. for 25 minutes and the mixture was evaporated, and then coevaporated with toluene, to dryness to give the title compound as an oil (15 g, crude) which was used directly in the following step.
1 H NMR (CDCl 3 ) delta: 1.23 (3H, d, J=6Hz), 1 45-1.52 (1H, dd), 1.93-2.05 (1H, m), 3.65 (3H, s), 3.85-4.0 (1H, m), 5.7 (2H, s), 7.55 (2H, d, J=7 Hz), 7.97 (2H, d, J=7 Hz).
Step E: Preparation of Methyl 4-mercapto-beta-methyl-gamma-oxobenzenebutanoate
To the neat trifluoroacetate from Step D of this Example (12.3 g) was added a mixture of 1:1 MeOH-NEt 3 (600 ml) and the resulting reaction mixture was evaporated under vacuum. The procedure was repeated twice more. The residue was dissolved in CH 2 Cl 2 , washed with 1N HCl and brine and dried over Na 2 SO 4 . Evaporation of the solvent gave the title compound as an oil (7.8 g, 97%).
1 H NMR (CDCl 3 ) delta: 1.23 (3H, d, J=6 Hz), 2.45-2.52 (1H, dd), 2.93-3.05 (1H, m), 3.65 (3H, s), 3.85-4.0 (1H, m), 7.32 (2H, d, J=7 Hz), 7.85 (2H, d, J=7 hz).
Step F: Preparation of Methyl 4-(S-dimethylthiocarbamoyl)-beta-methyl-gamma-oxobenzenebutanoate
To a solution of the thiol from Step E of this Example (7.5 g) in DMF (100 ml) at 0° C. was added in two portions 99% NaH (835 mg) and stirred for 30 minutes at 0° C. To this mixture was added dimethylcarbamoyl chloride (3.8 ml) and stirred for 15 minutes at 0° C. and 30 minutes at room temperature. The reaction mixture was poured onto a mixture of ice and water (300 ml) and extracted with EtOAc. The combined organic layers were washed with brine, dried over Na 2 SO 4 and evaporated to give a yellow oil which was purified on a flash silica gel column (500 g) using hexane/EtOAc (2:1) as eluant to give the title compound as an oil (7.8 g, 77%).
1 H NMR (CDCl 3 ) delta: 1.23 (3H, d, J=6 Hz), 2.45-2.55 (1H, dd), 2.93-3.05 (1H, m), 3.0-3.2 (6H, d(b)), 3.65 (3H, s), 3.85-4.0 (1H, m), 7.62 (2H, d, J=7 Hz), 7.97 (2H, d, J=7 Hz).
Step G: Preparation of 4-(S-Dimethylthiocarbamoyl)beta-methyl-gamma-oxobenzenebutanoic acid
To a solution of the ester from Step F of this Example (7.6 g) in MeOH (110 ml) at 0° C. was added 2N NaOH (37 ml) and the mixture was stirred at 0° C. for 1 hour. The reaction mixture was poured into a mixture of ice and water (300 ml), acidified with concentrated HCl and extracted with EtOAc. The combined organic layers were washed with water, dried over Na 2 SO 4 and evaporated to give the title compound as an oil (7.3 g, 100%).
1 H NMR (CDCl 3 ) delta: 1.23 (d, 3H, J=6 Hz), 2.4-2.55 (1H, dd), 2.85-3.05 (1H, m), 3.0-3.2 (6H, d(b)), 3.8-4.0 (1H, m), 7.6 (2H, d, J=7 Hz), 7.95 (2H, d, J=7 Hz).
Step H: Preparation of βR*, γS* 4-(S-Dimethylthiocarbamoyl) beta-methyl-gamma-hydroxybenzenebutanoic acid gamma-lactone
To a solution of the ketone from Step G of this Example (6.85 g) in dry THF (190 ml) at -78° C. was added dropwise, under nitrogen, a solution of 1.5M diisobutyl aluminum hydride (DIBAL-H) in toluene (37 ml) and stirred at -78° C. for 1.5 hours. The reaction mixture was poured into cold 1N HCl (600 ml) and extracted with EtOAc. The combined organic layers were washed with brine, dried over Na 2 SO 4 and evaporated to give an oil which was dissolved in CH 2 Cl 2 (200 ml) and trifluoroacetic acid (70 drops) was added and the mixture stirred at room temperature for 2 hours. The reaction mixture was diluted with toluene and evaporated to give an oil which was purified on flash silica gel column (350 g) using hexane/EtOAc (1:1) as eluant to give the title compound as a white solid (3.4 g, 52%): m.p. 113°-115° C.
1 H NMR (CDCl 3 ) delta: 0.73 (cis) and 1.2 (trans) (3H, d, J=7 Hz), 2.27-2.45 (1H, dd), 2.75-3.0 (2H, m), 3.0-3.2 (6H, d(b)), 4.97 (trans) and 5.6 (cis) (1H, d, J=5.6 Hz), 7.27 (2H, d, J=7 Hz), 7.55 (2H, d, J=7 Hz).
Unreacted starting material was recovered from the column by eluting with toluene-dioxaneacetic acid (10:2:0.1) to recover 2.2 g (32%) as an oil.
Step I: Preparation of βR*, γS* 4-mercapto-beta-methyl-gamma-hydroxybenzenebutanoic acid gamma-lactone
To a suspension of the thiocarbamate from Step H of this Example (3 g) in MeOH (160 ml) was added 2N NaOH (54 ml) and the mixture refluxed under N 2 for 1.5 hours. The reaction mixture was cooled to room temperature, diluted with water (500 ml), acidified with 2N HCl and extracted with ethyl acetate. The combined organic layers were washed with water, dried over Na 2 SO 4 and evaporated to give an oil which was dissolved in CH 2 Cl 2 (100 ml) and treated with trifluoroacetic acid (30 drops) from 3 hours at room temperature. The reaction mixture was evaporated and coevaporated with toluene to give the title compound as an oil 2.39 g).
1 H NMR (CDCl 3 ) delta: 0.73 and 1.2 (3H, d, J=7 Hz), 2.27-2.45 (1H, dd), 2.75-2.95 (2H, m), 2.5 (1H, s), 4.9 and 5.55 (1H, d, J=5.6 Hz), 7.1 (2H, d, J=7 Hz), 7.3 (2H, d, J=7 Hz).
Step J: Preparation of 1R*, 2R*, βR*, γS* and 1R*, 2S*, βR*, γS* 4-((1-(4-((3-(4-Acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)phenyl)-3-carbomethoxy-2-methylpropyl)thio)-gamma-hydroxy-beta-methylbenzenebutanoic acid gamma lactone
To a solution of the alcohol from Step A, Example 1 (930 mg) and the thiol from Step I of this Example (410 mg) in anhydrous CH 2 Cl 2 (75 ml) was added dry zinc iodide (3.13 g) and the mixture was stirred at room temperature under N 2 for 4.5 hours. The reaction mixture was washed with 0.1N HCl, brine, dried over Na 2 SO 4 and evaporated to dryness to give an oil which was purified on a PREP-500 Waters HPLC using hexane/EtOAc (10:8) as eluant to give the title compound as an oil (700 mg), 54%.
1 H NMR (CDCl 3 ) delta: 0.62 (3H, d, J=6 Hz), 0.85-1.0 (6H, m), 1.15 (2H, d 1.45-1.65 (2H, m), 2.0-2.2 (2H, m), 2.2-2.4 (2H, m), 2.5-2.7 (7H, m, containing a sharp singlet), 2.7-2.9 (2H, m), 3.1 (2H, t, J=6 Hz), 3.65 and 3.7 (3H, 2 singlets), 4.05-4.2 (3H, m), 5.5 (1H, d, J=5.6 Hz), 6.45 (1H, d, J=7 Hz), 7.0-7.3 (8H, m), 7.6 (1H, d, J=7 hz), 12.7 (1H, s).
Step K: Preparation of 1R, 2R, βR, γS; 1R, 2S, βR, γS; 1S, 2R, βR, γS; 1S, 2S, βR, γS; 1R, 2R, βS, γR; 1R, 2S, βS, γR; 1S, 2R, βS, γR; 1S, 2S, βS, γR 4-((1-(4-((3-(4-Acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)phenyl)-3-carboxy-2-methylpropyl)thio)-gamma-hydroxybetamethylbenzenebutanoic acid disodium salt monohydrate
To a solution of the ester lactone from Step J of this Example (664 mg) in THF (10 ml) and MeOH (1 ml) was added 2N NaOH (1.2 ml) and stirred overnight at room temperature. The reaction mixture was evaporated to dryness and passed through a column of neutral XAD-8 resin eluting with water (250 ml) and then with 95% EtOH to give, after evaporation of the ethanol, the title compound as a foam (690 mg, 100%).
Analysis for: C 36 H 42 O 8 S 2 Na 2 .H 2 O: Calc'd: C, 59.16; H, 6.07; S, 8.77; Na, 6.29. Found: C, 59.15; H, 6.28; S, 8.98; Na, 5.40.
EXAMPLE 10
Preparation of 1R*, 2R*, βR*; 1R*, 2R*, βS*; 1R*, 2R*; and 1R*, 2S*, βS* 4-((1-(4-((3-(4-Acetyl-3-hydroxy-2-propylphenoxy)propyl)thio) phenyl)-3-carboxy-2-methylpropyl)thio)-beta-methyl-gamma-oxobenzenebutanoic acid monohydrate
Step A: Preparation of Methyl 4-((1-(4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)phenyl)-4-methoxy-2-methyl-4-oxobutyl)thio)-betamethyl-gamma-oxobenzenebutanoate
To a solution of alcohol from Example 1, Step A (1.6 g) and the thiol from Example 9, Step E (800 mg) in anhydrous CH 2 Cl 2 (170 ml) was added dry zinc iodide (10.7 g) and stirred at room temperature under N 2 for 3.5 hours. The reaction mixture was washed with 0.1N HCl, brine and dried over Na 2 SO 4 to give an oil which was purified on PREP-500 Waters HPLC using hexane-EtOAc (2:1) as eluant to give an oil (1.06 g, 45%).
1 H NMR CDCl 3 delta: 0.85-1.25 (9H, m), 1.45-1.65 (2H, m), 2.0-2.2 (2H, m), 2.2-2.5 (2H, m), 2.5-2.7 (7H, m, containing a sharp singlet), 2.85-3.0 (1H, q), 3.15 (2H, t, J=6 Hz), 3.63 (3H, s), 3.66 and 3.7 (3H, 2s), 3.8-3.9 (1H, m), 4.15 (2H, t, J=6 Hz), 4.35-4.45 (1H, m), 6.45 (1H, d, J=7 Hz), 7.2-7.4 (6H, m), 7.58 (1H, d, J=7 Hz), 7.75-7.85 (2H, m).
Analysis for: C 38 H 46 O 8 S 2 : Calc'd: C, 65.68; H, 6.67; S, 9.23. Found: C, 65.48; H, 6.59; S, 9.51.
Step B: Preparation of 4-((1-(4-((3-(4-Acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)phenyl)-3-carboxy-2-methylpropyl)thio)-beta-methyl-gamma-oxo-benzenebutanoic acid monohydrate
To a solution of ester from Step A of this Example (760 mg) in THF (15 ml) and MeOH (1 ml) was added 2N NaOH (2.4 ml) and stirred overnight at room temperature. The reaction mixture was diluted with H 2 O (50 ml) and acidified with 2N HCl and extracted with CH 2 Cl 2 (2×50 ml). The combined organic layers were washed with brine, dried over Na 2 SO 4 and purified on a column of flash silica gel 230-400 mesh using toluene-dioxane-acetic acid (10:2:0.1) as eluant to give the title compound as a foam (580 mg, 79%).
Analysis for: C 36 H 42 O 8 S 2 .H 2 O: Calc'd: C, 63.13; H, 6.47; S, 9.36. Found: C, 62.64; H. 6.25; S, 9.46.
EXAMPLE 11
Preparation of 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((4-(3-carboxy-1-hydroxypropyl)phenyl)thio-benzene butanoic acid, disodium salt, monohydrate, mixture of isomers
Step A: Methyl 4(3-bromopropylthio)-γ-((4-(3-methoxycarbonyl-1-hydroxy-propyl)phenyl)thio)-henzenebutanoate, mixture of isomers
To a cooled (0° C.) solution made of the ketone obtained in Step D of Example 2 (2.72 g) in DME (1,2-dimethoxyethane) (25 c.c.) and MeOH (5 c.c.) containing CeCl 3 (5 mg), was added portion-wise NaBH 4 (138 mg) and the mixture was kept at this temperature until the starting ketone had disappeared. The mixture was then poured into ice-cold water, acidified with 1N HCl and the organic material was extracted into ethyl acetate; the organic layer was washed with brine, dried with Na 2 SO 4 and the solvents were removed in vacuo to yield an oil which was purified on silica gel to yield the title compound as an oil.
Analysis Calc'd: C, 54.05; H, 5.62; S, 11.54. Found: C, 53.83; H, 5.70; S, 11.55.
Step B: Preparation of 4-((1-(4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)phenyl)3-(methoxycarbonyl)propyl)thio)-γ-hydroxybenzenebutanoic acid, -γ-lactone, mixture of isomers
A suspension of the bromide from the previous step (2.05 g), 2,4-dihydroxy-3-propylacetophenone (933 mg), and milled potassium carbonate (765 mg) in MEK (methylethylketone) (20 c.c.) was refluxed for 6 hours. Thereafter it was cooled to room temperature, the solids were filtered off and the solvent was removed in vacuo to yield an oil which was purified on silica gel to yield the title compound as an oil.
NMR 1 H-250 MHz/CDCl 3
______________________________________δ(ppm) No. of H m J(Hz)______________________________________12.75 1 s --7.58-7.62 1 d 8.37.15-7.3 8 m -- 6.4-6.48 1 d 8.35.4-5.5 1 t 6.0 4.1-4.25 3 m --3.65 3 s -- 3.1-3.18 2 t 5.02.05-2.7 15 m --1.5-1.6 2 m --0.9-1.0 3 t 5.0______________________________________
Step C: Preparation of 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((4-(3-carboxy-1-hydroxypropyl)phenyl)thio)benzene butanoic acid, disodium salt, monohydrate, mixture of isomers
To a solution of the lactone from the previous step (1.64 g) in MeOH (5 c.c.) and THF (20 c.c.) was added 2N NaOH (3.9 c.c.) and the mixture was stirred for 2 hours The reaction mixture was evaporated to dryness in vacuo and absorbed onto XAD-8 neutral resin in water, washed with water and then eluted off with ethanol. Evaporation of the solvent in vacuo yielded the title compound.
Analysis Calc'd: C, 58.11; H, 5.74; S, 9.12; Na, 6.54 Found: C, 58.57; H, 5.97; S, 9.31; Na, 5.16
EXAMPLE 12
Preparation of βR*, γS* and βS*, γR* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((2-carboxymethyl)thio)-β-methylbenzenebutanoic acid disodium salt (mixture of diastereoisomers),
Step A: Preparation of Methyl 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propylthio)-γ-((-2-methoxycarbonylmethyl)thio)-β-methylbenzenebutanoate (mixture of diastereoisomers, monohydrate
To an efficiently stirred solution of the alcohol (948 mg) from Step A of Example 1 and methyl thioglycolate (233 mg) in dichloroethane (10 c.c.) was added ZnI 2 (1.92 g) and the suspension was stirred for 3 hours. Thereafter, in HCl (20 c.c.), H 2 O (20 c.c.) and dichloromethane (50 c.c.) were added. The organic layer was separated, washed with brine, and dried with Na 2 SO 4 . The solvents were removed in vacuo to yield a residue which was chromatographed on silica gel to yield the title compound as an oil.
Analysis Calc'd: C, 59.97; H, 6.94; S, 11.04. Found: C, 59.91; H, 7.09; S, 10.94.
Step B: Preparation of βR*, γS* and βS*, γR* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((2-carboxymethyl)thio)-β-methylbenzenebutanoic acid disodium salt, hemihydrate (mixture of diastereoisomers)
A solution of the diester from the previous step (790 mg) in 2N NaOH (2.1 c.c.), MeOH (2 c.c.) and THF (10 c.c.) was stirred for 4 hours. The reaction mixture was evaporated to dryness and absorbed onto XAD-8 neutral resin in water, washed with water and then eluted off with ethanol. Evaporation of the solvent in vacuo yielded the title compound.
Analysis Calc'd: C, 55.18; H, 5.66; S, 10.91; Na, 7.82. Found: C, 55.60; H, 5.66; S, 9.96; Na, 7.17.
EXAMPLE 13
Preparation of βR*, γR* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)γ-((2-carboxyethyl)thio)-β-methylbenzenebutanoic acid, disodium salt, mixture of enantiomers
and
preparation of βR*, γS* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)γ-((2-carboxyethyl)-thio)-β-methylbenzenebutanoic acid, disodium salt, mixture of enantiomers
Step A: Preparation of βR*, γR* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-(thio)-.beta.-methylbenzenebutanoic acid-γ-thiolactone, mixture of enantiomers
A solution of the thioacetate obtained from Step A of Example 7 (42 g) in THF (250 c.c.) was cooled to 0° C., a solution of NaOMe (6.5 g) in MeOH (100 c.c.) was added, and the mixture was kept at 0° C. for 30 minutes. Thereafter, it was poured into ice-cold 1N HCl (200 c.c.); the organic material was extracted into ethyl acetate and the organic layer successively washed with 10% NaHCO 3 and brine, dried with Na 2 SO 4 and concentrated in vacuo to yield a residue which was then dissolved in dry THF (250 c.c.) and cooled to 0° C. Thereafter, a suspension of NaH (1.6 g) in THF (50 c.c.) was added dropwise and the mixture kept at 0° C. for 6 hours. It was then poured into ice-cold 1N HCl (300 c.c.) and extracted into ethyl acetate. The organic layer was washed with 10% NaHCO 3 , brine and then dried with Na 2 SO 4 and concentrated in vacuo to yield a residue which was purified on silica gel to yield the mixture of the βR*, γR* and the βR*, γS* thiolactones from which the βR*, γR* lactone was purified by repetitive preparative HPLC.
Analysis Calc'd: C, 65.47; H, 6.59; S, 13.98. Found: C, 64.72; H, 6.32; S, 13.18.
NMR 1 H-250 MHz/CDCl 3 for βR*, γR*
______________________________________δ(ppm) No. of H M J(Hz)______________________________________4.50 1 d 6.61.09 3 d 6.6______________________________________
Step B: Preparation of βR*, γS* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-(thio)-.beta.-methylbenzenebutanoic acid -γ-thiolactone, mixture of enantiomers
This lactone was isolated by repetitive preparative HPLC purification of the mixture of the βR*, γR* and βR*, γS* thiolactones obtained in the previous step.
Analysis Calc'd: C, 65.47; H, 6.59; S, 13.98. Found: C, 64.69; H, 6.03; S, 13.48.
NMR 1 H-250 MHz/CDCl 3 for βR*, γS*
______________________________________δ(ppm) No. of H M J(Hz)______________________________________5.0 1 d 6.60.8 3 d 6.6______________________________________
Step C: Preparation of βR*, γR* methyl 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((2-methoxycarbonylethyl)thio)-β-methylbenzenebutanoate, mixture of enantiomers
To an ice cold solution of Na (19 mg) in MeOH (5 c.c.) was added a THF (5 c.c.) solution of the lactone (290 mg) obtained in Step A of this Example and the mixture was reacted at 0° C. for 1 hour. Methyl 3-bromopropionate (127 mg) was then added and reacted for 2 hours at 0° C. Dowex 50-WX-8 resin was then added and stirred for 15 minutes and removed by filtration. The filtrate was concentrated in vacuo, then diluted with CH 2 Cl 2 (15 c.c.), washed with brine and the organic layer was dried with Na 2 SO 4 . Removal of the solvents in vacuo, followed by purification of the residue on silica gel yielded the title compound as an oil.
Analysis Calc'd: C, 62.47; H, 6.99; S, 11.12. Found C, 62.44; H, 7.67; S, 10.70.
Step D: Preparation of βR*, γS* methyl 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((2-methoxycarbonylethyl)thio)-β-methylbenzenebutanote mixture of enantiomers
To an ice cold solution of Na (28 mg) in MeOH (10 c.c.) was added a THF (10 c.c.) solution of the lactone (430 mg) obtained in Step B of this Example and the mixture was reacted for 1 hour at 0° C. Methyl 3-bromopropionate (200 mg) was then added and reacted for 2 hours. Dowex 50-WX-8 resin was then added, stirred for 15 minutes and removed by filtration. The filtrate was concentrated in vacuo, diluted in CH 2 Cl 2 (25 c.c.), washed with brine and the organic layer was dried with Na 2 SO 4 . Removal of the solvent in vacuo, followed by purification of the residue on silica gel yielded the title compound as an oil.
Analysis Calc'd: C, 62.47; H, 6.99; S, 11.12. Found: C, 62.51; H, 7.04; S, 11.05.
Step E: Preparation of βR*, γR* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((2-carbomyethyl) thio)-β-methylbenzenebutanoic acid, disodium salt, mixture of enantiomers
To a solution of the product obtained in Step C of this Example (231 mg) in MeOH (5 c.c.), THF (5 c.c.) and H 2 O (2 c.c.) was added 2N NaOH (0.6 c.c.) and the mixture was stirred at room temperature for 12 hours. The solvents were then removed in vacuo and the residue absorbed on XAD-8 neutral resin in water, washed with water and then eluted off with ethanol. Evaporation of the solvent in vacuo yielded the title compound as a highly hygroscopic foam.
NMR 1 H-250 MHz/CD 3 OD
______________________________________δ(ppm) No. of H m J(Hz)______________________________________7.59-7.64 1 d 8.37.12-7.21 4 m6.41-6.45 1 d 8.34.0-4.1 2 t 5.53.59-3.65 1 d 8.32.97-3.05 2 t 5.51.65-2.55 14 m1.35-1.45 2 m0.9-1.0 3 d 6.10.75-0.82 3 t 5.5______________________________________
Step F: Preparation of βR*, γS 4-((3(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((2-carboxyethyl)thio)-β-methyl benzenebutanoic acid, disodium salt, mixture of enantiomers
To a solution of the product obtained in Step D of this Example (387 mg) in MeOH (5 c.c.), THF (5 c.c.) and H 2 O (2 c.c.) was added 2N NaOH (1.0 c.c.) and the mixture was stirred at room temperature for 12 hours. The solvents were then removed in vacuo and the residue absorbed on XAD-8 neutral resin in water, washed with water and then eluted off with ethanol. Evaporation of the solvent in vacuo yielded the title compound as a highly hygroscopic foam.
NMR 1 H-250 MHZ/CD 3 OD
______________________________________δ(ppm) No. of H m J(Hz)______________________________________7.59-7.65 1 d 8.37.12-7.22 4 m6.41-6.45 1 d 8.34.0-4.1 2 t 5.53.59-3.65 1 d 8.32.95-3.05 2 t 5.51.65-2.55 14 m1.35-1.45 2 m0.75-0.85 3 t 5.50.69-0.75 3 d 6.1______________________________________
EXAMPLE 14
Preparation of βR*, γS* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)sulfonyl)-γ-((2-carboxyethyl)thio)-β-methylbenzenebutanoic acid, disodium salt, mixture of enantiomers, monohydrate
Step A: Preparation of βR*, γS* 4-((3-hydroxy-2-propylphenoxy)propyl)sulfonyl)-γ-(thio)-β-methylbenzene butanoic acid, -γ-thiolactone, mixture of enantiomers
To a cooled (0° C.) solution of the lactone (230 mg) obtained in Step B of Example 13 in chloroform (5 c.c.) was added m-chloroperoxybenzoic acid (m-CPBA) (105 mg) and the suspension was stirred at 0° C. for 45 minutes. Another portion (10.5 mg) of m-CPBA was then added and reacted for 1 hour at 0° C. The suspension was warmed up to room temperature and Ca(OH) 2 (111 mg) was added and the mixture stirred for 1 hour. Insolubles were then filtered off and the filtrate concentrated to dryness to yield the title compound.
Analysis Calc'd.1H 2 O: C, 59.22; H, 6.34; S, 12.61. Found: C, 59.24, H, 5.87; S, 12.43.
Step B: Preparation of βR*, γS* methyl 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)sulfonyl)-γ-((2-methoxycarbonyl ethyl)thio)-β-methylbenzenebutanoate, mixture of enantiomers
To a cooled (0° C.) solution of the lactone obtained in the previous step (800 mg) in MeOH (25 c.c.) was added NaOMe (110 mg) followed, one-half hour later, by methyl acrylate (215 mg). After 45 minutes at this temperature, 1N HCl (25 c.c.) was added and most of the methanol removed in vacuo; organic materials were extracted into ethyl acetate (3×25 c.c.), the organic layer washed with brine, dried with Na 2 SO 4 and concentrated to dryness to yield a residue which was purified by chromatography on silica gel, yielding the title compound as an oil.
Analysis Calc'd: C, 59.19; H, 6.62; S, 10.53. Found: C, 58.74; H, 6.56; S, 9.60.
Step C: Preparation of βR*, γS* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)sulfonyl)-γ-((2-carboxyethyl)thio)-β-methylbenzenebutanoic acid, disodium salt, mixture of enantiomers, monohydrate
To a cooled (0° C.) solution of the compound obtained in the previous step (925 mg) in THF (10 c.c.) and MeOH (5 c.c.) was added 2N NaOH (2.3 c.c.) and the mixture was stirred for 48 hours while being warmed up to room temperature. The solvents were then removed in vacuo and the residue absorbed on XAD-8 neutral resin in water, washed with water and then eluted off with ethanol. Removal of the solvent from the ethanolic fraction yielded the title compound as a foam.
Analysis Calc'd.1H 2 O: C, 52.53; H, 5.65; S, 9.98 Found: C, 52.31; H, 5.43; S, 9.45.
EXAMPLE 15
Preparation of βR*, γS* and βR*, γR* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((2-N,N-dimethylcarbonylethyl)thio)-β-methylbenzenebutanoic acid, sodium salt
Step A: Preparation of βR*, γS* and βR*, γR* methyl 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((2-N,N-dimethylcarbonylethyl)thio)-β-methylbenzenebutanoate
To a cooled (0° C.) solution of the mixture of the lactones prepared in Step A of Example 13 (916 mg) in MeOH (20 c.c.) and THF (10 c.c.) was added NaOMe (130 mg) followed 90 minutes later by N,N-dimethylacrylamide (300 mg) and this mixture was reacted for 2 hours at 0° C. It was then acidified with 1N HCl and extracted with ethyl acetate (3×25 c.c.); the organic layer was washed with brine, dried with Na 2 SO 4 and concentrated to yield a residue which was purified on silica gel to yield the title compound as an oil.
Analysis Calc'd: C, 63.13; H, 7.35; S, 10.87 Found: C, 62.86; H, 7.58; S, 10.83.
Step B: Preparation of βR*, γS* and βR*, γR* 4-((3-(4-acetyl-3-hydroxy-2-propylphenoxy)propyl)thio)-γ-((2-N,N-dimethylcarbonylethyl)thio)-β-methylbenzenebutanoic acid, sodium salt
To a solution of the ester obtained in the previous step (590 mg) in MeOH (10 c.c.) and H 2 O (2 c.c.) was added 2N NaOH (1.5 c.c.) and the mixture was reacted for 12 hours. It was then acidified and extracted with ethyl acetate (3×25 c.c.); the organic layer was washed with brine, dried with Na 2 SO 4 and concentrated to dryness. To the residue (512 mg) dissolved in EtOH (5 c.c.) and MeOH (5 c.c.) was added 1N NeOH (0.890 c.c.) and the obtained solution was evaporated to dryness in vacuo to yield the title compound as a foam.
Analysis Calc'd: C, 60.28; H, 6.75; S, 10.73. Found: C, 60.02; H, 6.75; S, 10.78. | Compounds having the formula: ##STR1## are antagonists of leukotrienes of C 4 , D 4 and E 4 , the slow reacting substance of anaphylaxis, and inhibitors of their biosynthesis. These compounds are useful as anti-asthmatic, anti-allergic, anti-inflammatory agents, anti-psoriatic agents, and cytoprotective agents. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Statement of the Technical Field
[0002] The inventive arrangements relate generally to transmission line stubs, and more particularly for transmission line stubs that can be dynamically tuned.
[0003] 2. Description of the Related Art
[0004] Transmission line stubs are commonly used in radio frequency (RF) circuits. For example, a resonant transmission line stub is sometimes said to be resonant at a particular frequency, meaning the line has impedance characteristics similar to a resonant circuit at that frequency, although resonant line characteristics are actually a function of voltage reflections, not circuit resonance. On printed circuit boards or substrates, resonant lines are typically implemented by creating a line with at least one port at the input and either an open-circuit or short-circuit to ground at the termination. The input impedance to an open or shorted resonant line is typically resistive when the length of the resonant line is an even or odd multiple of a quarter-wavelength of the operational frequency. That is, the input to the resonant line is at a position of voltage maxima or minima. When the input to the resonant line is at a position between the voltage maxima and minima points, the input impedance can have reactive components. Consequently, properly chosen transmission line stubs may be used as parallel-resonant, series-resonant, inductive, or capacitive circuits.
[0005] Transmission lines stubs in RF circuits are typically formed in one of three ways. One configuration known as microstrip, places the signal line on the top of a board surface. A second conductive layer, commonly referred to as a ground plane, is spaced apart from and below the signal line. A second type of configuration known as buried microstrip is similar except that the signal line is covered with a dielectric substrate material. In a third configuration known as stripline, the signal line is sandwiched between two electrically conductive (ground) planes. Other configurations, including waveguide stubs, are also known in the art.
[0006] Low permittivity printed circuit board materials are ordinarily selected for implementing RF circuit designs, including transmission line stubs. For example, polytetrafluoroethylene (PTFE) based composites such as RT/duroid® 6002 (permittivity of 2.94; loss tangent of 0.009) and RT/duroid® 5880 (permittivity of 2.2; loss tangent of 0.0007), both available from Rogers Microwave Products, Advanced Circuit Materials Division, 100 S. Roosevelt Ave, Chandler, Ariz. 85226 , are common board material choices.
[0007] Two important characteristics of dielectric materials are permittivity (sometimes called the relative permittivity or ε r ) and permeability (sometimes referred to as relative permeability or μ r ). The relative permittivity and permeability determine the propagation velocity of a signal, which is approximately inversely proportional to {square root}{square root over (με)}. The propagation velocity directly affects the electrical length of a transmission line and therefore the physical length of a transmission line stub.
[0008] Further, ignoring loss, the characteristic impedance of a transmission line, such as stripline or microstrip, is equal to {square root}{square root over (L l /C l )} where L l is the inductance per unit length and C l is the capacitance per unit length. The values of L l and C l are generally determined by the permittivity and the permeability of the dielectric material(s) used to separate the transmission line structures as well as the physical geometry and spacing of the line structures. Accordingly, the overall geometry of a stub will be highly dependent on the permittivity and permeability of the dielectric substrate.
[0009] The electrical characteristics of transmission line stubs generally cannot be modified once formed on an RF circuit board. This is not a problem where only a fixed frequency response is needed. The geometry of the transmission line can be readily designed and fabricated to achieve the proper characteristic impedance. When a variable frequency response is needed, however, use of a fixed length stub can be a problem.
[0010] A similar problem is encountered in RF circuit design with regard to optimization of circuit components for operation on different RF frequency bands. Line impedances and lengths that are optimized for a first RF frequency band may provide inferior performance when used for other bands, either due to impedance variations and/or variations in electrical length. Such limitations can limit the effective operational frequency range for a given RF system.
SUMMARY OF THE INVENTION
[0011] The present invention relates to a circuit for processing radio frequency signals. The circuit is a transmission line stub coupled to a fluidic dielectric and includes a composition processor for selectively varying a composition of the fluidic dielectric. Varying the fluid dielectric composition allows the electrical characteristics of the transmission line stub to be dynamically varied in response to a control signal.
[0012] The composition processor can selectively vary a permittivity and a permeability of the fluidic dielectric. Further, according to one aspect of the invention, the composition processor can vary the permittivity and the permeability concurrently in response to the control signal.
[0013] The electrical characteristics that can be varied with the fluid dielectric include, but are not limited to, an electrical length of the stub, a characteristic impedance of the stub, and a frequency response of the stub. The transmission line stub itself can be electrically shorted to ground or electrically open with respect to ground.
[0014] According to another aspect of the the transmission line stub is also coupled to a solid dielectric. For example, the solid dielectric can be a circuit board upon which the stub is formed. A cavity can be disposed within the dielectric circuit board substrate, and the fluidic dielectric can be disposed within the cavity.
[0015] According to one aspect, the invention can also include a component mixer. The component mixer can be arranged for dynamcially mixing a plurality of component parts of the fluidic dielectric responsive to the control signal to form the fluidic dielectric. The component parts can be selected from a low permittivity, low permeability component, a high permittivity, low permeability component, and a high permittivity, high permeability component. The composition processor further can include one or more proportional valves, one or more mixing pumps, and at least one conduit. The composition processor selectively mixes the plurality of component parts of the fluidic dielectric and transfers the fluidic dielectric to a cavity where the fluidic dielectric is coupled to the transmission line stub. According to another aspect of the invention, the composition processor can also include a component part separator adapted for separating the component parts of the fluidic dielectric for subsequent reuse.
[0016] According to one aspect, the fluidic dielectric can be comprised of an industrial solvent that has a suspension of magnetic particles contained therein. The magnetic particles can be formed of a material selected from the group consisting of ferrite, metallic salts, and organo-metallic particles. For example, the fluidic dielectric can be between about 50% to 90% magnetic particles by weight.
[0017] The invention can also include a method for dynamically controlling a frequency response of a transmission line stub. The method can include the steps of coupling the transmission line stub to a fluidic dielectric and, in response to a control signal, selectively varying a composition of the fluidic dielectric. The method permits dynamic changes to be performed relative to an electrical characteristic of the transmission line stub. The composition of the fluidic dielectric can be varied so as to modify a permittivity and a permeability of the fluidic dielectric. According to one aspect of the invention, this step can include varying the permittivity and the permeability concurrently in response to the control signal. The result is a corresponding variation in an electrical length, a characteristic impedance, and a frequency response, of the transmission line stub.
[0018] The method can also include the step of electrically shorting one end of the transmission line stub to a ground potential or forming an open circuit at one end of the transmission line stub. According to another aspect, the method can include the step of also coupling the transmission line stub to a solid dielectric. For example, this can include selecting the solid dielectric to be a circuit board upon which the stub is formed. In that case, the method can also advantageously include step of disposing the fluid dielectric in a cavity within the dielectric circuit board substrate.
[0019] According to yet another aspect, the method can include selecting a component part of the fluid dielectric from the group consisting of a low permittivity, low permeability component, a high permittivity, low permeability component, and a high permittivity, high permeability component. These components can be selectively mixed and communicated from respective fluid reservoirs to a cavity where the fluidic dielectric is coupled to the transmission line stub. Notably, the method can also include the step of separating the component parts of the fluidic dielectric for subsequent reuse.
[0020] Finally, the method can also include the step of selecting the fluidic dielectric to be an industrial solvent, either with or without a suspension of magnetic particles contained therein. If magnetic particles are used, the invention can further include the step of selecting the magnetic particles from the group consisting of ferrite, metallic salts, and organo-metallic particles. This step can include selecting a ratio of the component parts so that the fluid dielectric contains between about 50% to 90% magnetic particles by weight.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a block diagram useful for understanding the transmission line stub of the invention.
[0022] [0022]FIG. 2 is a flow chart that is useful for understanding the process of the invention.
[0023] [0023]FIG. 3 a is a cross-sectional view of the transmission line structure in FIG. 1, taken along line 3 - 3
[0024] [0024]FIG. 3 b is a cross-sectional view of an alternative embodiment of a transmission line structure of FIG. 1 taken along line 3 - 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] [0025]FIG. 1 is a conceptual diagram that is useful for understanding the tunable transmission line stub system of the present invention. The tunable transmission line stub system 100 includes a conductive RF transmission line stub 110 at least partially coupled to a fluidic dielectric 108 . In most instances, the stub 110 will be coupled to a larger circuit by associated transmission line circuitry. In FIG. 1, such circuitry is illustrated by a first transmission line 107 and a second transmission line 111 . Those skilled in the art will appreciate that these transmission lines are merely shown by way of example and are not intended to limit the scope of the invention. Instead, any suitable input and output circuitry can be provided for communicating signals to and from the stub 110 .
[0026] The fluidic dielectric 108 is preferably constrained within a cavity region 109 that is generally positioned relative to the RF transmission line stub 110 so as to be electrically and magnetically coupled thereto. It should be understood that while the RF transmission line stub 110 is shown in FIG. 1 as a conductor suspended within a dielectric layers 102 , 142 over a ground plane 140 , the invention is not so limited. Other transmission line structures can also be used to form the stub and such structures are within the scope of the invention provided that the stub is coupled to a fluid dielectric as described herein.
[0027] A composition processor 101 is preferably provided for changing a composition of the fluidic dielectric 108 to vary its permittivity. A controller 136 controls the composition processor for selectively varying the permittivity of the fluidic dielectric 108 in response to a control signal 137 received on control line 138 . The composition processor 101 is also adapted for changing a composition of the fluidic dielectric 108 to vary its permeability. According to a preferred embodiment, the controller 136 can cause the composition processor 101 to selectively vary the permittivity and the permeability of the fluidic dielectric concurrently in response to the control signal. Thus, the controller can vary the frequency response of the stub in accordance with an input control signal 137 by effectively vary the inductance and capacitance per unit length of the stub. According to a preferred embodiment, the composition processor also includes separator units 130 , 132 for separating out component parts of the fluidic dielectric so that they can be subsequently refused. The composition of the fluidic dielectric, the dynamic mixing process, and the component part separation process shall now be discussed in further detail.
[0028] Composition of Fluidic Dielectric
[0029] The fluidic dielectric can be comprised of several component parts that can be mixed together to produce a desired permeability and permittivity required for a particular stub electrical response. In this regard, it will be readily appreciated that fluid miscibility and particle suspension are key considerations to ensure proper mixing. Another key consideration is the relative ease by which the component parts can be subsequently separated from one another. The ability to separate the component parts is important when the stub frequency response requirements change. Specifically, this feature ensures that the component parts can be subsequently re-mixed in a different proportion to form a new fluidic dielectric.
[0030] The resultant mixture comprising the fluidic dielectric also preferably has a relatively low loss tangent to minimize the amount of RF energy lost in the stub 110 . However, devices with higher insertion loss may be acceptable in some instances so this may not be a critical factor. Also, the components of the fluidic dielectric must be capable of providing the proper permittivity and permeability. Aside from the foregoing constraints, there are relatively few limits on the range of component parts that can be used to form the fluidic dielectric. Accordingly, those skilled in the art will recognize that the examples of component parts, mixing methods and separation methods as shall be disclosed herein are merely by way of example and are not intended to limit in any way the scope of the invention.
[0031] Also, the component materials are described herein as being mixed in order to produce the fluidic dielectric. However, it should be noted that the invention is not so limited. Instead, it should be recognized that the composition of the fluidic dielectric could be modified in other ways. For example, the component parts could be selected to chemically react with one another in such a way as to produce the fluidic dielectric with the desired values of permittivity and or permeability. All such techniques will be understood to be included to the extent that it is stated that the composition of the fluidic dielectric is changed.
[0032] A nominal value of permittivity (ε r ) for fluids is approximately 2.0. However, the component parts for the fluidic dielectric can include fluids with extreme values of permittivity. Consequently, a mixture of such component parts can be used to produce a wide range of intermediate permittivity values. For example, component fluids could be selected with permittivity values of approximately 2.0 and about 58 to produce a fluidic dielectric with a permittivity anywhere within that range after mixing. Dielectric particle suspensions can also be used to increase permittivity.
[0033] According to a preferred embodiment, the component parts of the fluidic dielectric can be selected to include a low permittivity, low permeability component and a high permittivity, high permeability component. These two components can be mixed as needed for increasing permittivity while maintaining a relatively constant ratio of permittivity to permeability. A third component part of the fluidic dielectric can include a high permittivity, low permeability component for allowing adjustment of the permittivity of the fluidic dielectric independent of the permeability.
[0034] High levels of magnetic permeability are commonly observed in magnetic metals such as Fe and Co. For example, solid alloys of these materials can exhibit levels of μ r in excess of one thousand. By comparison, the permeability of fluids is nominally about 1.0 and they generally do not exhibit high levels of permeability. However, high permeability can be achieved in a fluid by introducing metal particles/elements to the fluid. For example typical magnetic fluids comprise suspensions of ferro-magnetic particles in a conventional industrial solvent such as water, toluene, mineral oil, silicone, and so on. Other types of magnetic particles include metallic salts, organo-metallic compounds, and other derivatives, although Fe and Co particles are most common. The size of the magnetic particles found in such systems is known to vary to some extent. However, particles sizes in the range of 1 nm to 20 μm are common. The composition of particles can be varied as necessary to achieve the required range of permeability in the final mixed fluidic dielectric after mixing. However, magnetic fluid compositions are typically between about 50% to 90% particles by weight. Increasing the number of particles will generally increase the permeability.
[0035] An example of a set of component parts that could be used to produce a fluidic dielectric as described herein would include oil (low permittivity, low permeability), a solvent (high permittivity, low permeability) and a magnetic fluid, such as combination of an oil and a ferrite (low permittivity and high permeability). A hydrocarbon dielectric oil such as Vacuum Pump Oil MSDS-12602 could be used to realize a low permittivity, low permeability fluid, low electrical loss fluid. A low permittivity, high permeability fluid may be realized by mixing same hydrocarbon fluid with magnetic particles such as magnetite manufactured by FerroTec Corporation of Nashua, N.H., or iron-nickel metal powders manufactured by Lord Corporation of Cary, N.C. for use in ferrofluids and magnetoresrictive (MR) fluids. Additional ingredients such as surfactants may be included to promote uniform dispersion of the particle. Fluids containing electrically conductive magnetic particles require a mix ratio low enough to ensure that no electrical path can be created in the mixture.
[0036] Solvents such as formamide inherently posses a relatively high permittivity and therefore can be used as the high permittivity component for the invention. Permittivity of other types of fluid can also be increased by adding high permittivity powders such as barium titanate manufactured by Ferro Corporation of Cleveland, Ohio. For broadband applications, the fluids would not have significant resonances over the frequency band of interest.
[0037] Processing of Fluidic Dielectric for Mixing/Unmixing of Components
[0038] Referring again to FIG. 1, the composition processor 101 can be comprised of a plurality of fluid reservoirs containing component parts of fluidic dielectric 108 . These can include a first fluid reservoir 122 for a low permittivity, low permeability component of the fluidic dielectric, a second fluid reservoir 124 for a high permittivity, low permeability component of the fluidic dielectric, and a third fluid reservoir 126 for a high permittivity, high permeability component of the fluidic dielectric. Those skilled in the art will appreciate that other combinations of component parts may also be suitable and the invention is not intended to be limited to the specific combination of component parts described herein.
[0039] A cooperating set of proportional valves 134 , mixing pumps 120 , 121 , and connecting conduits 135 can be provided as shown in FIG. 1 for selectively mixing and communicating the components of the fluidic dielectric 108 from the fluid reservoirs 122 , 124 , 126 to cavity 109 . The composition processor also serves to separate out the component parts of fluidic dielectric 108 so that they can be subsequently re-used to form the fluidic dielectric with different permittivity and/or permeability values. All of the various operating functions of the composition processor can be controlled by controller 136 . The operation of the composition processor shall now be described in greater detail with reference to FIG. 1 and the flowchart shown in FIG. 2.
[0040] The process can begin in step 202 of FIG. 1, with controller 136 checking to see if an updated control signal 137 has been received on a control signal input line 138 . If so, then the controller 136 continues on to step 204 to determine an updated permittivity value for producing the stub frequency response indicated by the control signal. The updated permittivity value necessary for achieving the indicated stub frequency response can be determined using a look-up table. Alternatively, the updated permittivity value can be calculated directly using equations well known to those skilled in the art for calculating capacitance per unit length. In step 206 , the controller can determine an updated permeability value required for achieving the desired inductance per unit length for achieving the indicated frequency response for transmission line stub 110 .
[0041] In step 208 , the controller 136 causes the composition processor 101 to begin mixing two or more component parts in a proportion to form fluidic dielectric that has the updated permittivity and permeability values determined earlier. This mixing process can be accomplished by any suitable means. For example, in FIG. 1 a set of proportional valves 134 , conduits 135 , and mixing pump 120 are used to mix component parts from reservoirs 122 , 124 , 126 appropriate to achieve the desired updated permeability and permittivity.
[0042] In step 210 , the controller causes the newly mixed fluidic dielectric 108 to be circulated into the cavity 109 through a second mixing pump 121 . In step 212 , the controller checks one or more sensors 116 , 118 to determine if the fluidic dielectric being circulated through the cavity 109 has the proper values of permeability and permittivity. Sensors 116 are preferably inductive type sensors capable of measuring permeability. Sensors 118 are preferably capacitive type sensors capable of measuring permittivity. The sensors can be located as shown, at the input to mixing pump 121 . Sensors 116 , 118 can also be positioned within solid dielectric substrate 102 to measure the permeability and permittivity of the fluidic dielectric passing through input conduit 113 and output conduit 114 . Note that it is desirable to have a second set of sensors 116 , 118 at or near the cavity 109 so that the controller can determine when the fluidic dielectric with updated permittivity and permeability values has completely replaced any previously used fluidic dielectric that may have been present in the cavity 109 .
[0043] In step 214 , the controller 136 compares the measured permeability to the desired updated permeability value determined in step 206 . If the fluidic dielectric does not have the proper updated permeability value, the controller 136 can cause additional amounts of high permeability component part to be added to the mix from reservoir 126 and continues circulating the modified fluidic dielectric 108 to the cavity 109 .
[0044] If the fluidic dielectric 108 is determined to have the proper level of permeability in step 214 , then the process continues on to step 218 where the measured permittivity value from step 212 is compared to the desired updated permittivity value from step 204 . If the updated permittivity value has not been achieved, then high or low permittivity component parts are added as necessary in step 210 and the modified fluid is circulated to the cavity 109 . If both the permittivity and permeability passing into and out of the cavity 109 are the proper value, the system can stop circulating the fluidic dielectric and the system returns to step 202 to wait for the next updated control signal.
[0045] Significantly, when updated fluidic dielectric is required, any existing fluidic dielectric can be circulated out of the cavity 109 . Any existing fluidic dielectric not having the proper permeability and/or permittivity can be deposited in a collection reservoir 128 . The fluidic dielectric deposited in the collection reservoir can thereafter be re-used directly as a fourth fluid by mixing with the first, second, and third fluids or separated out into its component parts in separator units 130 , 132 so that it may be re-used at a later time to produce additional fluidic dielectric. The aforementioned approach includes a method for sensing the properties of the collected fluid mixture to allow the fluid processor to appropriately mix the desired composition, and thereby, allowing a reduced volume of separation processing to be required.
[0046] According to a preferred embodiment, the component parts of the fluidic dielectric 108 can be selected to include a first fluid made of a high permittivity solvent completely miscible with a second fluid made of a low permittivity oil that has a significantly different boiling point. A third fluid component can be comprised a ferrite particle suspension in a low permittivity oil identical to the first fluid such that the first and second fluids do not form azeotropes. Given the foregoing, the following process may be used to separate the component parts.
[0047] A first stage separation process in separator unit 130 would utilize distillation to selectively remove the first fluid from the mixture by the controlled application of heat thereby evaporating the first fluid, transporting the gas phase to a physically separate condensing surface whose temperature is maintained below the boiling point of the first fluid, and collecting the liquid condensate for transfer to the first fluid reservoir 122 . A second stage process in separator unit 132 would introduce the mixture, free of the first fluid, into a chamber that includes an electromagnet that can be selectively energized to attract and hold the paramagnetic particles while allowing the pure second fluid to pass which is then diverted to the second fluid reservoir 124 . Upon de-energizing the electromagnet, the third fluid would be recovered by allowing the previously trapped magnetic particles to combine with the fluid exiting the first stage which is then diverted to the third fluid reservoir 126 .
[0048] Those skilled in the art will recognize that the specific process used to separate the component parts from one another will depend largely upon the properties of materials that are selected and the invention. Accordingly, the invention is not intended to be limited to the particular process outlined above.
[0049] RF Unit Structure, Materials and Fabrication
[0050] [0050]FIG. 3 a is a cross-sectional view of one embodiment of the transmission line structure in FIG. 1, taken along line 3 - 3 , that is useful for understanding the invention. As illustrated therein, cavity 109 can be formed in solid dielectric layer 102 and continued in solid dielectric layer 142 so that the fluidic dielectric is closely coupled to transmission line stub 110 on all sides of conductor. The transmission line stub 110 is suspended within the cavity 109 as shown. A ground plane 140 is disposed below the conductor forming the transmission line stub 110 . The ground plane is located between solid dielectric layer 102 and base substrate 144 .
[0051] [0051]FIG. 3 b is a cross-sectional view showing an alternative transmission line stub 110 ′ for a delay line in which the cavity structure 109 ′ extends on only one side of the conductor 111 ′ and the conductor 111 ′ is partially coupled to the solid dielectric layer 142 ′.
[0052] At this point it should be noted that while the embodiment of the invention in FIG. 1 is shown essentially in the form of a buried microstrip construction, the invention herein is not intended to be so limited. Instead, the invention can be implemented using any type of transmission line by replacing at least a portion of a conventional solid dielectric material that is normally coupled to the transmission line with a fluidic dielectric as described herein. For example, and without limitation, the invention can be implemented in transmission line configurations including conventional waveguides, stripline, microstrip, coaxial lines, and embedded coplanar waveguides. All such structures are intended to be within the scope of the invention.
[0053] According to one aspect of the invention, the solid dielectric layers 102 , 142 , 144 can be formed from a ceramic material. For example, the solid dielectric substrate can be formed from a low temperature co-fired ceramic (LTCC). Processing and fabrication of RF circuits on LTCC is well known to those skilled in the art. LTCC is particularly well suited for the present application because of its compatibility and resistance to attack from a wide range of fluids. The material also has superior properties of wetability and absorption as compared to other types of solid dielectric material. These factors, plus LTCC's proven suitability for manufacturing miniaturized RF circuits, make it a natural choice for use in the present invention.
[0054] While the preferred embodiments of the invention have been illustrated and described, it will be clear that the invention is not so limited. Numerous modifications, changes, variations, substitutions and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present invention as described in the claims. | A circuit for processing radio frequency signals. The circuit is a transmission line stub ( 110 ) coupled to a fluidic dielectric ( 108 ) and includes a composition processor ( 101 ) for selectively varying a composition of the fluidic dielectric. Varying the fluid dielectric composition allows the electrical characteristics of the transmission line stub ( 110 ) to be dynamically varied in response to a control signal 137 . The electrical characteristics that can be varied with the fluid dielectric include, but are not limited to, an electrical length of the stub, a characteristic impedance of the stub, and a frequency response of the stub. The transmission line stub ( 110 ) can be electrically shorted to ground or electrically open with respect to ground. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of and priority from U.S. Provisional Patent Application Serial No. 60/387,185, entitled System and Method for Hydrogen-Rich Selective Oxidation, filed Jun. 6, 2002 which is incorporated herein by reference in it's entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to semiconductor fabrication. More particularly, the present invention relates to a system and method for selective oxidation of device features on semiconductors or integrated circuits in a hydrogen rich environment.
BACKGROUND OF THE INVENTION
[0003] Fabrication of semiconductor devices or integrated circuits requires many complex steps. Heat treatment is an important step in the fabrication of semiconductor devices and is used to carry out a variety of processes such as thermal annealing and thermal oxidation, among many other processes.
[0004] As well known in the art, semiconductor devices are made of a number of conductive and insulating features on a semiconductor substrate. Devices such as gate electrodes comprised of a gate stack including layers of materials such as polysilicon, dielectric, and metals are commonly used. For semiconductor devices having a critical geometry requirement of less than 130 nm, the polysilicon layer may be strapped over the top by a metal silicide layer. However, it has been found that the circuit performance of such a device is limited due to resistance of the device to device interconnect lines. To reduce the resistance of these interconnect lines, it has been proposed in the industry to replace the metal silicide layer and to fabricate the interconnect lines of polysilicon strapped over the top by a barrier layer and then a metal layer which exhibits a lower resistance than the metal silicide layer, as illustrated in FIG. 1.
[0005] Plasma etch processing is typically used to define the gate device. The plasma etch step leaves a roughened edge on the polysilicon layer and produces plasma induced damage near the gate dielectric layer at the bottom of the polysilicon layer. Such damage may cause device failure or degraded performance. Methods have been developed in an attempt to minimize such failure or degraded performance. Methods have been developed in an attempt to minimize such damage, and have included an oxidation step to form a thin oxide layer of approximately 5 to 15 nm thick on the sidewall of the polysilicon layer to repair the plasma damage caused in the plasma step.
[0006] It has been found however, that during this oxidation step used to repair the plasma damage, the oxygen-rich environment exposes the metal layer to attack and the oxidant can destroy the metal layer. To address this problem, selective oxidation processes have been investigated.
[0007] In one prior art approach, selective oxidation of gate electrodes having polysilicon and tungsten metal structures has been performed in single wafer reactors using a catalytic reactor which reacts hydrogen and oxygen to form partial pressure of water vapor in the reactor ambient. Such an approach suffers from disadvantages however, such as high cost of the catalytic reactor and low throughput (less than approximately 10 wafers per hour achievable by such a single wafer system).
[0008] Batch furnace systems have long been employed to carry out annealing processes in the fabrication of semiconductor wafers. Many batch annealing processes are carried out in a hydrogen environment (hydrogen anneal). In most annealing processes, hydrogen is diluted with nitrogen, and safety features such gas ratio interlocks are used to control the hydrogen to concentrations below the explosive or flammability limit. However, for some process applications annealing in an atmosphere of up to 100% hydrogen is required. Systems of this type incorporate use of circuits that force a timed nitrogen purge of the reactor or tube prior to the flow of hydrogen gas, and an automated post purge of nitrogen applied upon the termination of the flow of hydrogen gas. While this approach is useful, improvements are needed. Accordingly, improved systems and methods for selectively oxidizing one material with respect to another in the fabrication of semiconductor devices is desired.
OBJECTS AND SUMMARY OF THE INVENTION
[0009] It is a general object of the present invention to provide a system and method for selective oxidation of device features on semiconductors or integrated circuits in a hydrogen rich environment. In another aspect the present invention provides a system and method for selectively oxidizing one material with respect to another material on a semiconductor substrate or wafer, such as oxidizing polysilicon without oxidizing metal layers such as tungsten that are also present on the substrate.
[0010] In a further aspect, the present invention provides a hydrogen-rich oxidation system and method for performing selective oxidation in a batch thermal processing system in which safety features are included to avoid the dangers to personnel and equipment that are inherent in working with hydrogen-rich atmospheres.
[0011] In one aspect, the present invention provides a method of selectively oxidizing one material with respect to another material formed on one or more semiconductor substrates, comprising contacting the one or more substrates in a process chamber with an environment comprising approximately 10% to 30% steam and the balance hydrogen, at a temperature in the range of approximately 700 to 850° C. to form an oxide layer selectively on the one material.
[0012] In another embodiment present invention provides a system that includes a processing chamber. The processing chamber accommodates one or more substrates and is provided with a controllable gas flow system that supplies any or all of hydrogen, oxygen, nitrogen, or inert gases. A hydrogen-rich atmosphere is supplied to the processing chamber via a torch chamber. In the torch chamber, oxygen gas is reacted with hydrogen to produce steam. The substrate is selectively oxidized under the resulting steam and hydrogen ambient atmosphere. To facilitate safe operation of this system under hydrogen-rich conditions, a series of interlocks and dilution flow features are provided. A flame sensor is provided in the torch chamber to verify combustion of the oxygen-hydrogen mixture prior to its introduction to the processing chamber. A failure to detect ignition triggers an interruption of processing and inert gas is conveyed to the chamber at a high flow rate (also referred to as inert gas dilution flow) to dissipate potentially explosive concentrations of hydrogen. Likewise, a system power failure also triggers high flow rate inert gas dilution of the system. Downstream of the processing chamber, a “burn box” is provided to function as a hydrogen afterburner that destroys unreacted hydrogen that passes the processing chamber and torch without reacting. Additional interlocks are provided that interrupt hydrogen flow and/or trigger inert gas dilution if the system fails one or more leak and pressurization tests.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Additional objects and advantages of the invention will become apparent in reading the detailed description of the invention and the claims and with reference to the figures, in which:
[0014] [0014]FIG. 1 is a cross-sectional view of a partially fabricated semiconductor device showing a gate electrode stack structure.
[0015] [0015]FIG. 2 is a cross-sectional view of a partially fabricated semiconductor device showing a gate electrode stack structure which has been selectively oxidized according to one embodiment of the present invention.
[0016] [0016]FIG. 3 is a schematic diagram of a selective oxidation system according to one embodiment of the present invention.
[0017] [0017]FIGS. 4A and 4B are a flow chart illustrating one embodiment of the method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention provides a system and method for selective oxidation of device features on semiconducts or integrated circuits in a hydrogen rich environment. More specifically, in one embodiment, one material is selectively oxidized with respect to another material, both materials being present on a semiconductor substrate or wafer.
[0019] Referring to FIG. 2, a partially fabricated semiconductor device is shown. In this example a gate electrode stack 5 having side wall 6 is formed on a substrate as illustrated. Specifically the gate electrode is comprised of a substrate with a dielectric layer formed thereon. In this example the dielectric layer is formed of silicon dioxide. A polysilicon layer is formed atop the dielectric layer. A barrier layer, in this example a tungsten nitride material (WN) is formed atop the polysilicon layer. A metal layer is formed atop the barrier WN layer, and the metal layer is then capped. In this example the metal layer is formed of tungsten (W) and capped with silicon nitride (SiN).
[0020] Of particular advantage, the present invention provides for selectively oxidizing one layer or material in the gate stack with respect to another layer or material in the gate stack. Specifically, the side wall 6 region at the polysilicon layer is oxidized with a layer 7 of silicon dioxide, while the metal layer is not oxidized. This promotes lowering of the resistance of the device without damaging the metal layers in the device.
[0021] According to the present invention selective oxidation is carried out in a hydrogen rich environment. In general, semiconductor wafers are placed in a thermal processing chamber 12 (shown in FIG. 3 and described in detail below). A hydrogen rich environment is created in the chamber 12 , and this environment may be up to 100% hydrogen. Oxidation is carried out by exposing the wafers to steam in the hydrogen rich environment. In one embodiment steam is present in the chamber at a concentration in the range of approximately 10% to 30% with the balance being hydrogen.
[0022] The steam is created by reaction of hydrogen and oxygen in the presence of a flame in a torch chamber (creating a pyrogenic steam generator).
[0023] In one embodiment, the system of the present invention provides a torch with the hydrogen and oxygen supply inlets interchanged. In addition, the torch includes a flame sensor. The furnace is fitted with a “burn-box” in which unreacted hydrogen is combusted. Finally a series of safety interlocks are added to enhance safe operation of the system.
[0024] Generally, in one embodiment the system 10 of the present invention as shown in FIG. 3 includes a thermal processing or furnace chamber 12 (also referred to as a tube or process tube) equipped with a pressure differential sensor 14 ; a hydrogen burn box 16 equipped with a pressure differential photohelix 18 ; an exhaust tube 20 leading from the burn box to the facility exhaust; a torch 22 including an oxygen gas inlet 24 , a hydrogen gas inlet 26 (each oxygen and hydrogen inlets being coupled to respective gas cabinets, not shown), and a UV flame sensor 28 . Sealed tubing is provided as appropriate such as leading from nitrogen, hydrogen, and oxygen gas supplies to corresponding gas inlets; and sealed tubing and appropriate check valves and filters are provided between the torch and the furnace chamber, and between the furnace chamber and the burn box.
[0025] As illustrated in FIG. 3, the thermal processing chamber 12 is generically shown, and it should be understood by those of ordinary skill in the art that other configurations of thermal processing systems may be used. One example of a suitable processing chamber, among many others, is described in U.S. Pat. No. 6,005,225, which is incorporated herein by reference in its entirety.
[0026] In general, the current invention provides a hydrogen/oxygen pyrogenic steam generator that can turn on and off in a hydrogen rich ambient to provide a means of water vapor generation controlled by a process recipe, a system to measure the leak integrity of the seals of the process chamber and interlocks not part of the user controlled recipe to prevent hydrogen flow until that leak integrity test is passed, and a safety interlock system that automatically activates a means of extracting unreacted hydrogen from the tube and diluting it with nitrogen to below hazardous levels in the event of an electrical power failure. Also provided is a method and system for detecting the presence of a hydrogen flame in the hydrogen-rich atmosphere of the torch.
[0027] The system of the present invention provides a pyrogenic steam generator by way of the torch chamber that can be turned on and off in a hydrogen rich ambient atmosphere to provide a controllable source of high purity water vapor. In contrast to prior art systems that generate water vapor by combusting hydrogen under lean (oxygen-rich) conditions, The system of the present invention provides a high concentration of hydrogen to a hydrogen-oxygen torch and then controls oxygen flow to the combustion region to produce a small flame that generates water vapor.
[0028] In another embodiment of the present invention, a hydrogen/oxygen pyrogenic steam generator that can turn on and off in a hydrogen rich ambient to provide a means of water vapor generation controlled by a process recipe is provided.
[0029] A further embodiment of the present invention provides a system to measure the leak integrity of the seals of the process chamber and interlocks to prevent hydrogen flow until that leak integrity test is passed.
[0030] Yet another embodiment of the present invention provides a system that automatically activates in case of an electrical power failure during hydrogen processing to provide a means of extracting the unreacted hydrogen from the processing tube and diluting it with nitrogen to below hazardous levels. This safety tube purge and abatement system operates even in the absence of electrical power.
[0031] To create an oxidizing atmosphere to oxidize polysilicon without oxidizing layers of metals such as tungsten on the semiconductor substrate, the resultant flame of the present invention is much smaller and less intense than those normally produced by a standard hydrogen torch. As such, prior art systems are inadequate to verify combustion and provide feedback to a system controller that uncombusted hydrogen is not flowing freely into areas of the system in which is might form an explosive mixture. The present invention employs a sensitive sensor located closer to the torch combustion region. Its output is directly fed back to the system process controller as an interlock that if triggered will cause hydrogen flow to be shut off and high flow rate dilution with an inert gas such as nitrogen to be initiated.
[0032] In one embodiment the method of the present invention includes the following steps as illustrated in FIGS. 4A and 4B to selectively oxidize device features on one or more wafers or substrates loaded in a wafer support such as a boat or cassette (not shown). The boat is loaded with wafers in a nitrogen ambient under the process chamber 12 as shown in step 110 . An idling temperature of approximately 300-600° C. is established in the processing tube with nitrogen flowing at step 112 . The nitrogen gas flow is sufficient to purge oxygen and other contaminants from the process chamber. In one embodiment, the nitrogen flow is approximately 10 standard liters per minute (slm). The oxygen concentration in the chamber is checked at step 114 , and once the ambient atmosphere in the chamber is less than approximately 5 ppm oxygen, the boat supporting the wafers is inserted into the chamber 12 and the door is closed at step 116 . With the chamber door closed at step 118 , a test is executed to establish that the system is sealed with no major leaks such as, for example, would occur if the torch were disconnected. Once the door is closed, a nitrogen gas pre-purge is run through the processing chamber for approximately 10 minutes at step 120 . Then at step 122 hydrogen gas flows to the chamber is begun at approximately 10 to 20 slm and the chamber temperature is ramped to 800° C. at step 124 . After the temperature has stabilized with hydrogen flowing, oxygen gas flow to the torch is begun at step 128 . If the flame is not detected by the torch sensor 28 within a programmed period of time, the oxygen gas flow is stopped to avoid formation of a potentially explosive mixture on the processing chamber at step 128 . Steam created by the reaction of hydrogen with oxygen in a concentration of approximately 10% to 30% steam with the balance hydrogen flows through the processing chamber and selectively oxidizes polysilicon without oxidizing metals such as tungsten metal formed on top of the polysilicon material at step 130 . At the end of the selective oxidation step, the oxygen flow is shut off to terminate the generation of steam in step 132 . At step 134 hydrogen gas continues to flow into the processing chamber while the temperature is ramped down. Once the temperature at which the boat is to be removed from the processing chamber is reached, the tube 12 is post-purged with nitrogen gas at step 136 . The boat is pulled into a nitrogen ambient area under the tube for unloading of the wafers at step 138 .
[0033] When the boat is pushed into the chamber 12 , and the temperature in the process chamber is ramped up and stabilized at a temperature of 700 to 850° C. under a flow of nitrogen gas, and hydrogen flow is initiated during temperature stabilization; then a low flow rate of oxygen is initiated through the gas injector of the external torch 22 . A small flame is formed that can preferably be detected by an optical sensor as a safety interlock to verify that the reaction of oxygen with hydrogen to form steam is in process.
[0034] To avoid oxidation of tungsten or other metal layers in the wafers, it is essential that no free oxygen be introduced into the process tube, and it is preferable that the partial fraction of the steam generated by reaction of the oxygen with the hydrogen be maintained at less than approximately 20%, with hydrogen comprising the balance of the atmosphere in the chamber.
[0035] The polysilicon material on the wafer is allowed to oxidize until a surface oxide layer of 5 to 15 nm has developed. Under the high hydrogen ambient in the presence of steam but without any free oxygen the tungsten metal is not oxidized. The process is terminated by switching off the oxygen gas flow, purging the tube of steam using hydrogen, switching to nitrogen and ramping temperature down to the value (typically 600° C.) used for push and pull of the boat containing the wafer batch load. It is important that the ambient environment in the chamber and under the chamber be maintained at less than approximately 1 ppm oxygen until the wafers have cooled to below 200° C.
[0036] Referring more specifically to FIG. 3 which shows a schematic diagram of one embodiment of the present invention, the following detailed description is provided. It should be understood by those of ordinary still in the art that other specific configuration and programmable logic routes and alarms may be employed within the scope of the teaching of the present invention. This specific description is provided for illustration and is not intended to limit the scope of the invention. The gas flow schematic and interlock system 30 , including associated valves, controller and the like, is generally shown in FIG. 3. A field programmable gate array (FPGA, not shown) is a programmable integrated circuit device that can be used to program various outputs based on combinations of inputs. Programming of FPGAs is carried out by methods well known in the art. In the exemplary embodiment of the present invention, these inputs comprise valve commands from recipe control and alarm inputs from the system. FPGA outputs include qualified valve outputs to operate valves and qualified alarm outputs to the operating system. Safety of the system depends on the safety logic programmed into the FPGA and the redundant relay interlocks. A redundant relay interlock is provided as a the backup interlock system comprised of relay logic, employed in parallel with the FPGA. Its function is to interrupt power to selected solenoids in the event of a failure in the primary interlock system (FPGA and related electronics).
[0037] Hardware circuitry and firmware on the LCA board monitor for faults including whether the gas interface sub-system power supplies are out of tolerance, load faults in the programmable logic array configuration, detection of programmable logic array configuration corruption by the micro-controller auditor firmware, and general faults triggered by a process controller watchdog and a micro-controller Xilinx watchdog (Subsystem failure). These faults shut off power to hazardous gas valves and turn on an audible alarm as long as the condition exists. When the fault is cleared the gas valves will turn back on. These fault conditions are not latched.
[0038] In general, gas valves or automatic valves are valves located downstream from their associated mass flow controllers (MFCs). They are automatically given an ON command when a non-zero set point is sent to the MFC and they are automatically given an OFF command when a zero setpoint is sent to the associated MFC. As shown in FIG. 3, valves are identified with the same ID number as the associated MFC (for example, Valve 1 corresponds to MFC 1 , Valve 2 corresponds to MFC 2 , etc.). However, the ability of these valves to actually turn ON or OFF is individually controlled by interlock logic programmed within the FPGA.
[0039] Process valves or non-automatic valves generally control the process. This group includes all other valves in the gas system. They must be given an ON command via recipe control from the FPGA. However, like the automatic valves, the ability of these valves to actually turn ON or OFF is individually controlled by interlock logic programmed within the FPGA.
[0040] A gas system disabled (GSD) state occurs when power to selected gas valve solenoids and process control valve solenoids is removed. This is designed to be a safe state. A user interface is provided in this exemplary embodiment to indicate this state via sets of relay contacts. Certain alarms cause the system to enter this state. Once the tool enters this state it will remain in this state until the alarm causing the GSD has been cleared and the operator resets the system.
[0041] A valve is defined to be ‘ON’ if gas can flow through the valve. In the case of a normally open (N.O.) valve, the valve is ‘ON’ when the valve does not have power. Each valve in the gas system is controlled by a signal from the FPGA. Signals generated by the recipe are sent to the FPGA. The FPGA processes the signal by internal programmed logic. If interlock conditions are met, the FPGA outputs a signal to a valve driver to control the valve. Redundant shutoff is provided to selected valves by relay logic. There are four relay loops on the valve driver board that can be programmed to shut off selected valves. These loops are designated “A, B, C, and D”. In addition to the four relay loops on the valve driver board a non-interruptible fifth loop (E) is provided for those valves that do not require relay interruption of power.
[0042] When certain interlocks programmed in the FPGA device are violated the FPGA places the system in a latched GSD State. Upon entering this state, an audible alarm is sounded that may be silenced via a push-button switch located on the rear of the main unit, labeled “SILENCE ALARM”, or at the front panel by clicking the mouse on a software-displayed button on the CRT. The indicator in the “SILENCE ALARM” switch is then turned ON to indicate that the alarm has been silenced. Once the alarm-causing condition has been cleared, the system must be manually reset via a lighted “RESET GAS SYSTEM DISABLE” push-button switch also located on the rear of the main. In this exemplary embodiment unless otherwise specified, the following alarms always cause the tool to enter the GSD State: Gas Cabinet Exhaust Fault (Alarm 5 ), Element Exhaust Fault (Alarm 8 ), Cabinet Over Temperature (Alarm 10 ), Burn-off Exhaust Fault (Alarm 11 ), Gas Cabinet Door Open (Alarm 14 ), Element Removal (Alarm 33 ), External System Disable Request (Alarm 37 ), Nitrogen Pressure Low (Alarm 28 —if hydrogen is flowing). These alarms are discussed in greater detail in the succeeding paragraphs. Of course, other configuration and alarms may be employed within the scope of the invention.
[0043] Certain critical alarms are used to actuate relays as well as inputs to the FPGA. If one of these alarms become active, the associated relay de-energizes removing power from the selected valves to provide redundant shutoff. Most alarms that cause the FPGA to go into the GSD state are backed up by relays. Unless otherwise specified, the following GSD alarms are backed up by a hardware relay: Gas Cabinet Exhaust Fault (Alarm 5 ), Element Exhaust Fault (Alarm 8 ), Scavenger Exhaust Fault (Alarm 11 ), Gas Cabinet Door Open (Alarm 14 ), and Element Removal (Alarm 33 ). Unless otherwise specified, the Process Door Open (Alarm 6 ) and AC Power Fault (Alarm 32 ) alarms shut off the power to System Disable Valves by relay action and by FPGA logic without causing GSD State. The Element Door Open (Alarm 59 ) and Gas System Watchdog (Alarm 38 ) alarms interrupt power to System Disable Valves by relay action only.
[0044] All valves that enable a process gas considered hazardous to personnel or equipment are considered System Disable Valves. In this exemplary embodiment of the present invention, the following valves are Gas System Disable Valves: High Hydrogen (Valve 2 ), Low Hydrogen (Valve 4 ), Hydrogen Enable (Valve 12 ), Hydrogen Manifold Purge (Valve 9 —Normally Open Valve), Oxygen (Valve 3 ), and Oxygen Manifold Purge (Valve 11 —Normally Open Valve).
[0045] When a power monitor relay de-energizes due to the system losing AC Power, a power fail signal (Alarm 47 ) is sent to the Process Controller. This same Power Fail signal also triggers an approximately 30-second delay circuit. After the 30-second delay circuit has timed out an AC power fault (Alarm 32 ) is generated. Alarm 32 starts an approximately 120-second timer. During this approximately 120-second period, the system operating on uninterruptible power supply power saves critical data before going into a controlled shutdown. After the approximately 120-second timer times out, an EPO signal is generated and all power to the system is removed. However, should AC Power come “back up” before Alarm 32 becomes active, the system will not go into the EPO condition. In that case processing will continue as before power loss.
[0046] Logic within the FPGA provides a run-time signal to drive a gas hour meter for monitoring the primary process gas flow. In this system the process gas monitored is hydrogen (H2). The following conditions send a signal to the GHM:
[0047] High H2 (Valve 2 ) or Low H2 (Valve 4 ) and H2 Enable (Valve 12 ) must be on.
[0048] Two automatic nitrogen gas purges are included in this exemplary embodiment. A system disable or power down purge occurs if the system enters the system disable state or if system power is lost. A timed pre-processing purge occurs if hydrogen flow is enabled (Valve 12 ) and a timed post-processing purge occurs if hydrogen processing is interrupted for any reason. The hydrogen manifold is purged via ultra high purity nitrogen (Normally Open Valves 9 and 11 ) through a 10 slm flow restrictor. A purge of the hydrogen manifold by the two nitrogen valves described above begins immediately upon entering the gas system disabled state and continues unabated until the system is manually reset. At that time, when the system is reset, Valves 9 and 11 are energized into their normal non-flow states, ending the purge. This purge will occur in every case of Gas System Disabled state except that caused by N2 Pressure Low Alarm 28 as described below. If system power is lost, the normally open purge valves will open and the H2 manifold will purge indefinitely.
[0049] A timed pre-processing and post-processing inert gas purge is initiated at the beginning and end of a Gas System Disabled state caused by nitrogen Pressure Low (Alarm 28 ), while hydrogen gas is flowing. Additionally, these purges are initiated upon enabling hydrogen flow through Valve 12 . Purges are also commanded whenever hydrogen gas flow is interrupted for any reason during hydrogen processing. During timed pre-processing and post-processing purges, Alarm 36 (Elevator Disabled) is activated to disable the elevator mechanism. Alarm 19 (Pre/Post Purge). A status indicator will also be sent to the Process Controller. Purge valves 9 and 11 are de-energized to their flow states and a countdown of approximately 10 minutes starts. If, after the purge begins, and before it completes, a low nitrogen pressure alarm (Alarm 28 ) occurs, the purge countdown is suspended on each occurrence until the nitrogen pressure returns to a non-alarm level, and won't complete until a cumulative approximately 10 minutes of nitrogen purging has taken place. Alarm 19 will indicate constantly from the time that purge starts until the purge is completely finished, and the elevator will be disabled by Alarm 36 (Elevator Disabled). At the completion of pre-processing and post-processing purges and after the system disable alarm is reset, both Valves 9 and 11 are energized into their normal non-flow states.
[0050] The system includes a hydrogen burn box 16 that must be on when hydrogen gas is flowing. In the exemplary embodiment, the burn box contains dual igniters (igniter 31 and igniter # 2 ) that are powered from 120 volts AC and act as an “afterburner” to combust unreacted hydrogen before it is vented to the exhaust system. The main igniter (igniter # 1 ) is turned on by logic in the FPGA when the pre-processing purge begins and remains on until after the post-processing purge has completed. The burn box is also equipped with a redundant stand-by igniter (igniter # 2 ) which is activated if the igniter # 1 fails. Circuits in the burn box perform the switch over if this fault condition is detected. Valve 18 output is assigned as the bum box ON command. This valve can be turned on from the recipe for maintenance purposes. However if the ON command is generated from FPGA safety logic the recipe cannot turn off the burn box. Two Alarm outputs from the burn box report the integrity of the igniters. Alarm 12 indicates igniter # 1 is open and igniter # 2 is active. Alarm 13 indicates igniter # 2 is open and the burn box can no longer burn hydrogen. Alarm 13 aborts the hydrogen process and starts the post-processing purge.
[0051] Preferably, a pressure differential photohelix 16 located near the process tube monitors the pressure difference between the inside of the process chamber 12 and the outside pressure. Before hydrogen gas can flow, a leak test is preformed to check the integrity of the tube seal. In one example an automatic leak test is performed by logic in the FPGA upon closing of the process door. The operator initiates an automatic leak test by activating Valve 16 from the operator recipe if the tool is not processing or purging and the process door is closed. Automatic leak testing is performed by first opening Valve 27 for approximately 10 seconds to relieve any pressure in the tube. Then, Valve 16 is opened to enable the differential pressure sensor. The chamber exhaust flow is sealed off by closing Valves 26 and 27 . Next, Valve 10 is opened to allow nitrogen gas to flow to the chamber at the rate of approximately 1 slm through needle valve MV 10 . When a preset upper differential limit is reached as evidenced by Alarm 25 becoming active, Valve 10 is closed to stop the nitrogen gas flow. If Alarm 25 does not activate within approximately 3 minutes, the leak test fails and Alarm 7 is activated. The pressure differential is monitored for approximately 3 minutes. If the differential pressure stays above the preset lower limit, the test is passed. If the test fails, Alarm 7 is activated and remains on until the door is opened, the leak repaired and a retest of the door seal passes. At the end of the leak test, Valve 27 opens for approximately 10 seconds to equalize pressure in the processing chamber or tube. After the equalization period, Valve 16 closes, thus sealing off the differential pressure sensor.
[0052] In the exemplary embodiment, the temperature of the torch 22 must be greater than 750° C. before oxygen gas can flow. Alarm 1 (Torch Temperature Below 750° C.) functions as an oxygen process scenario start-up alarm only, and as such, has no effect once oxygen gas is flowing; the alarm then being “masked” (transparent to system operation) by FPGA logic. The torch temperature must remain in the range of approximately 350° C. to 900° C. while oxygen gas is flowing, otherwise oxygen gas flow will be turned off. Alarm 2 (Torch Temperature Between 350 and 900° C.) is a “masked” alarm. It is not be passed to the Process Controller for status, nor is it used for interlocks by the FPGA, unless oxygen and hydrogen gases are flowing. Once the alarm occurs, it is latched within the FPGA until a zero setpoint command is sent to the oxygen MFC.
[0053] In one exemplary embodiment, the flame detector 28 at the torch must detect a flame within 15 seconds after oxygen gas begins flowing, or else oxygen gas flow is forced off. Any loss of flame after initial ignition will cause an immediate activation of Alarm 3 (Flame Detect), shutting off oxygen flow as well. Alarm 3 is a “masked” alarm; meaning that it is not passed to the Process Controller for status, nor is it used for interlocks by the FPGA, unless oxygen and hydrogen gases are flowing. Once the alarm occurs, it is latched within the FPGA until a zero setpoint command is sent to the oxygen MFC.
[0054] Alarm 4 (Hydrogen/Oxygen ratio Less than 2.15) is activated if the ratio of hydrogen flow to oxygen flow is less than approximately 2.15:1. Alarm 4 is a “masked” alarm; meaning that it is not passed to the Process Controller for status, nor is it used for interlocks by the FPGA, unless oxygen and hydrogen gases are flowing. Once the alarm occurs, it is latched within the FPGA until a zero set point command is sent to the oxygen MFC.
[0055] Loss of gas cabinet exhaust for approximately 10 seconds as monitored by a photohelic sensor causes Alarm 5 (Gas Cabinet Exhaust Fault) to be generated. This alarm shuts off process gas flows and causes the system to enter the latched gas system disabled state.
[0056] Several alarms provide input to the FPGA. Alarm 6 (Process Door Open) becomes active when the process chamber door is open. If the chamber leak test described above is failed, Alarm 7 (Leak Test Failure) is activated. Detection of a fault in the facility exhaust triggers Alarm 8 (Facility Exhaust Faut) which is a GSD alarm backed up by a relay. Loss of element exhaust for approximately 10 seconds as monitored by the aforementioned photohelic sensor causes activation of Alarm 8 . This alarm shuts off process gas flow and causes the system to enter the latched gas system disable state. This alarm also turns on the nitrogen dilution valve (Valve 25 ) if hydrogen flow is on or if the tool is in the purge mode. Once facility exhaust is restored and Alarm 8 is deactivated, Valve 25 turns off, stopping the nitrogen dilution flow. The tool remains in the GSD state until the operator resets the tool. Detection of hydrogen gas by a sensor causes Alarm 9 (Hydrogen Leak Detect) to become active. This alarm shuts off hydrogen and oxygen gas flows. Three hydrogen sensors are located in the gas cabinet, above the torch and in the upper cabinet. These sensors are configured to generate Alarm 9 if any sensor detects hydrogen. These sensors are set to detect 25% of the lower explosive limit for hydrogen. If a temperature sensor in the top of the main cabinet detects a temperature greater than approximately 62° C., Alarm 10 (Cabinet Over Temperature) is activated. This alarm shuts off process gas flow and causes the system to enter the latched Gas System Disable State. Loss of burn-off exhaust for approximately 10 or more seconds as monitored by the aforementioned photohelic sensor generates Alarm 11 (Burn-Off Exhaust Fault). This alarm shuts off process gas flow and causes the system to enter the Gas System Disable State. Alarm 12 (Burn-Off Igniter # 1 Fault) becomes active if igniter # 1 opens. If this alarm is activated before hydrogen processing is initiated, hydrogen flow through Valve 2 is inhibited. If Alarm 12 becomes active after hydrogen processing has begun, hydrogen flow is not affected. Under this condition, the alarm is merely advisory. The alarm is masked until approximately 5 seconds after initial turn on of the bum box. Once active, Alarm 12 remains on until the hydrogen enable valve (Valve 12 ) is commanded off by recipe.
[0057] Alarm 13 (Burn-Off Igniter # 2 Fault) becomes active if igniter # 2 opens. This alarm aborts hydrogen processing and starts a timed post-processing purge with nitrogen gas. This alarm is masked for approximately 5 seconds after Alarm 12 becomes active to allow for igniter switch over and heat up. Once active, Alarm 13 remains on until the hydrogen enable valve (Valve 12 ) is commanded off by the recipe. When the gas cabinet door is open Alarm 14 (Gas Cabinet Door Open) becomes active. This alarm shuts off process gas flows and causes the system to enter the latched Gas System Disable State. Alarm 16 (Low Water Flow) occurs if the water flow falls below the preset minimum flow rate. This alarm is advisory only and is not used to interlock valves. Alarm 18 (Nitrogen Dilution Pressure Low) is active if the facility environmental nitrogen source pressure measured by PT 10 is below approximately 60 psig. Alarm 18 is used as an hydrogen process scenario start-up alarm only. Once hydrogen gas is flowing the alarm is then advisory only. Alarm 19 (Timed Pre/Post Purge) occurs if the system goes into a timed automatic purge as described above. This alarm remains on until a cumulative approximately 10 minutes of purging with nitrogen gas has completed. This alarm triggers Alarm 36 which disables the elevator. It also forces valves 9 , 11 and 27 ‘ON’ in addition to forcing on the burn box valve (Valve 18 ).
[0058] If the system goes into the gas disabled state, Alarm 20 (Gas System Disable) becomes active. Alarm 21 (Leak Test) becomes active during the Leak Test and remains on until Leak Test has completed. It is an advisory alarm only. Other masked and/or advisory alarms are discussed below. Alarm 22 (MFM 10 (N2) FLOW<1 slm) becomes active if Valve 10 is on and the nitrogen gas flow through the loop is less than 1 slm. It is a masked advisory alarm. Alarm 24 (Burn Off IR Sensor Fault) is also masked. It becomes active if the temperature of the hydrogen burn-off igniters falls below the preset limit. This alarm is masked until 10 seconds after the burn off is commanded on. If while the process door is closed the differential pressure between the process chamber and the outside exceeds the preset upper limit Alarm 25 (Differential Pressure High) is activated. If this alarm occurs all gas flow into the tube is shut off to prevent over-pressuring the tube. Alarm 26 (High Hydrogen Flow) occurs if hydrogen gas flow via MFC 2 exceeds 90% of full scale flow. Alarm 26 is a “masked” alarm. It is passed to the Process Controller for status, nor will it be used for interlocks by the FPGA, unless hydrogen gas is flowing. This alarm is advisory only and is not used to interlock valves. Alarm 27 (Pneumatic Pressure Low) becomes active if the pneumatic pressure is less than 60-psig+5 psig as measured by a pressure switch in the pneumatic line.
[0059] Alarm 28 (Nitrogen Pressure Low) is a conditional alarm that becomes active if the nitrogen gas line purge pressure is below 10-psig-+5 psig as measured by pressure transducer PT 1 . If hydrogen gas is flowing or if the system is purging at the time this alarm becomes active, the system enters the GSD state. At that time all process gases are shut off and the elevator is disabled. Alarm 29 (Hydrogen Pressure High) becomes active if hydrogen pressure is more than 60 psig as measured by pressure transducer PT 2 . This alarm aborts hydrogen processing.
[0060] Alarm 30 (Oxygen Pressure Low) becomes active if oxygen pressure is less than 12 psig as measured by pressure transducer PT 3 . Alarm 32 (AC Power Fault) is activated when AC input power is lost for more than approximately 30 seconds+5 seconds. This alarm shuts off process gas flows and seals off tube. Alarm 33 (Element Removal) is a GSD alarm backed up by a relay that is activated when the chamber is moved from its normal processing position. This alarm shuts off process gas flows and causes the system to enter the gas system disable state.
[0061] Alarm 34 (Hydrogen Flowing) is an advisory alarm activated when hydrogen is flowing through MFC 2 . This alarm is advisory only and is not used to interlock valves. Alarm 35 (Torch Shield Open) becomes active if the torch shield is open. Alarm 36 (Elevator Disable) is a reporting alarm only with no interlocks and is generated by the logic within the FPGA when hydrogen gas is flowing and/or during the timed nitrogen pre-processing and post-processing purges. Alarm 37 (External Gas System Disable Request) is a GSD Alarm generated by the operator and routed to the tool via the operator I/O panel. This alarm shuts off process gas flows and causes the system to enter the latched gas system disable State as defined above. It functions as a manual override for emergency shutdown of the system by the operator.
[0062] A gas system watchdog circuit (Alarm 38 ) located on the LCA board monitors the integrity of the process controller. This circuit monitors a periodic signal sent by the process controller. If the circuit fails to receive this signal within approximately 10 seconds, a watchdog alarm is generated. This alarm disables a relay and shuts off GSD valves. This alarm is not latched.
[0063] Finally, Alarm 59 (Element Door Open) becomes active when the heater door is opened. This alarm disables a relay and shuts off GSD valves. This alarm is not latched.
EXPERIMENTAL
[0064] For initial process testing, the flame detection feature of the standard oxidation system was bypassed and door sealing was verified by manual inspection and use of a portable handheld hydrogen monitor. This testing revealed the need for a method to verify chamber sealing before hydrogen is turned on. In addition, a required safety feature to be added was identified: in the event of a power outage, the system should purge the tubing and chamber of hydrogen to avoid the possibility of formation of an explosive mixture. Finally, tests showed that the small flame generated by the low process oxygen flow was not detected by the standard thermal oxidation flame sensor and a change was needed to enable flame detection to be used as a system safety interlock in the selective oxidation process.
[0065] The solutions developed for these three design issues are novel features which contribute to system safety for the hydrogen rich oxidation system and are described in greater detail below. The exhaust line from the tube is equipped with a valve. Upon sensing the closure of the process tube door, the firmware initiates an automated sequence in which the exhaust line valve is closed to prevent outflow of gas. Then valves controlling a flow of nitrogen into the tube through a fixed orifice restrictor are opened until the internal pressure is sensed to have reached a certain level. Next, the nitrogen valves are closed and a timed test period is begun. The pressure is monitored in the tube during the test period to verify that it remains above a lower threshold pressure throughout the test period. The time and lower pressure level are selected to detect leaks from seals or damaged parts. This period is typically 30 seconds, but other periods are acceptable. Hydrogen flow to the process chamber is enabled only upon passing of this pressure test.
[0066] In the case of a power failure, the exhaust valve from the tube is closed and a valve opened to a bypass which is connected by a “Tee” to a source of high flow nitrogen. The high flow nitrogen dilutes the hydrogen and steam in the tube to concentrations below the flammability limits (<4% H2) and the mixed gas (forming gas) is exhausted into the process gas exhaust duct supplied by the building in which the system is installed. This prevents accumulation of hydrogen at potentially flammable or even explosive levels if a system power failure occurs.
[0067] The standard flame detector is sensitive to UV radiation coming from an area approximately 2 inches downstream of the tip of the gas injector. By modification of the water cooled housing, the mounting angle of the UV detector was changed so it sensed the area nearer the tip of the injector and became usable for the selective oxidation process which only produces a small flame size.
[0068] As taught by the foregoing description and examples, a system and method of selectively oxidizing semiconductor wafers and other substrates in a hydrogen-rich atmosphere is provided by the present invention. The foregoing description of specific embodiments and examples of the invention have been presented for the purpose of illustration and description, and although the invention has been illustrated by certain of the preceding examples, it is not to be construed as being limited thereby. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications, embodiments, and variations are possible in light of the above teaching. It is intended that the scope of the invention encompass the generic area as herein disclosed, and by the claims appended hereto and their equivalents. | The present invention relates generally to semiconductor fabrication. More particularly, the present invention relates to system and method of selectively oxidizing one material with respect to another material formed on a semiconductor substrate. A hydrogen-rich oxidation system for performing the process are provided in which innovative safety features are included to avoid the dangers to personnel and equipment that are inherent in working with hydrogen-rich atmospheres. | 7 |
TECHNICAL FIELD
The invention relates generally to a fuel shut oil valve and method of assembling the valve.
BACKGROUND OF THE ART
Gas turbine engines typically include a fuel shut-off mechanism to be triggered in the unlikely event of a shaft shear event. The clearance between the trigger of the fuel shut-off mechanism and the triggering component must be very accurately controlled so that the shut-off mechanism performs predictably and as required. Often, the trigger clearance is small—the clearance accuracy required is often within the range of the tolerance stack-up on the engine, and therefore the trigger is typically intentionally oversized, and must undergo a custom grinding operation during assembly to ensure the required triggering clearance, which introduces delay into assembly processes. Any grinding error further delays engine assembly. Customization and rework add unwanted cost and time to assembly. Accordingly, there is a need to provide improvements in gas turbine fuel shut-off mechanisms.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a specific protocol for the assembly of a fuel shut off adjustable pin valve for use in a turbo fan engine.
In one aspect, the present invention provides a method for adjusting the fuel shut off valve in a turbo fan engine, said engine having an exhaust casing surrounding a low pressure turbine, said method comprising: providing a pin valve assembly; providing a support for said pin valve assembly; mounting said pin valve assembly into said support; mounting said assembly and support within said exhaust casing; rotating said pin to determine the extent of resistance to movement; fixedly securing said assembly within said casing; connecting lever means to said support for said pin assembly with a predetermined torque; connecting actuation means to said lever means for selectively actuating said lever means; and determining connected components are secured within said casing.
In another aspect, the present invention provides a method for adjusting the axial gap between low pressure turbine and a pin valve fuel shut off assembly in a turbo fan engine, comprising; measuring said axial gap; rotating said pin valve within a support therefore to adjust said pin to a predetermined position; and securing said pin into said predetermined position.
In a further aspect of the present invention, there is provided a method of mounting a fuel shut-off valve assembly in a gas turbine engine, the engine having an exhaust case support, member, comprising: providing a fuel shut-off assembly having a seal means, pin means, support means, lever means and cable means mounted within an exhaust case; determining a proper height for the pin means when the assembly is mounted to the engine to ensure function of the fuel shut off assembly; determining seating of the pin means within the support means; and mounting the exhaust case to the engine.
Further details of these and other aspects of the present invention will be apparent from the detailed description and figures included below.
DESCRIPTION OF THE DRAWINGS
Reference is now made to the accompanying figures depicting aspects of the present, invention, in which:
FIG. 1 is a schematic cross-sectional view of a turbofan bypass gas turbine engine, showing an exemplary application of the present invention;
FIG. 2 is a partially cut away exploded view of an engine casing from a turbo fan engine illustrating a fuel supply shut off assembly;
FIG. 3A is a side elevational view of the exhaust casing illustrating the fuel supply shut off lever in situ;
FIG. 3B is an enlarged view of the section indicated in FIG. 3A ;
FIG. 3C is a view of the assembly in the direction of arrow “A” shown in FIG. 3A ;
FIG. 4A is a view similar to FIG. 3A with the actuation cable connected to the lever;
FIG. 4B is a view similar to FIG. 3B showing an enlarged area and the position of the cable relative to the lever;
FIG. 4C is a view in the direction A of FIG. 3A ;
FIG. 4D is an enlarged view of the area denoted in FIG. 4A ;
FIG. 5 is a perspective of a partially cut away view of the exhaust casing illustrating some of the components in their respective positions;
FIG. 5A is a partially cut away view illustrating the positioning of the fuel shut off arrangement in position amongst the wiring and other components associated with the exhaust casing;
FIG. 6 is a partially cut away cross section of the engine casing of the present invention;
FIG. 7 is an enlarged section of the circled section in FIG. 6 ;
FIG. 8 is a side cross sectional view of the engine casing illustrating further details concerning the fuel shut-off pin assembly.
FIG. 9 is an enlarged view of the area circled in FIG. 8 ;
FIG. 10 is a further view of the engine casing; and
FIG. 11 is a view taken from the direction of the arrow in FIG. 10 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , a turbofan gas turbine engine incorporating an embodiment of the present invention is presented as an example of the application of the present invention, and includes a housing 10 ′, a core casing 13 ′, a low pressure spool assembly seen generally at 12 ′ which includes a shaft 15 ′ interconnecting a fan assembly 14 ′, a low pressure compressor 16 ′ and a low pressure turbine assembly 18 ′, and a high pressure spool assembly seen generally at 20 ′ which includes a shaft at 25 ′ interconnecting a high pressure compressor assembly 22 ′ and a high pressure turbine assembly 24 ′. The core casing 13 ′ surrounds the low and high pressure spool assemblies 12 ′ and 20 ′ in order to define a main fluid path (not indicated) therethrough. In the main fluid path there are provided a combustion section 26 ′ having a combustor 28 ′ therein. Pressurized air provided by the high pressure compressor assembly 22 ′ through a diffuser 30 ′ enters the combustion section 26 ′ for combustion taking place in the combustor 28 ′. Numeral 10 generally denotes the location for the arrangement of the present invention.
FIG. 2 illustrates the rear of the turbine exhaust case, 10 with the exhaust cone removed therefrom in order to reveal the parts of the system with reference to the assembly pattern. The pin valve assembly is generally denoted by numeral 12 and includes a pin valve 14 . The pin valve 14 is screwed into a flange head 16 and then unscrewed approximately for five threads. The sub-assembly of 10 , 14 and flange 16 is then subsequently positioned within support 18 . A seal 20 is inserted into the pin valve 14 up to the point of the back surface of support 18 . The seal 20 is then discarded once positioning has been effected. Once formed, the so formed assembly is inserted in to the turbine exhaust case 10 as is shown in the Figure with parts removed for clarity.
Within the casing 10 , there is provided mounts 22 , which mounts 22 receive the support 18 . Support 18 is fixedly secured to mounts 22 by fasteners 24 . Antiseize compound is applied to the threads of fasteners 24 . Each fastener then is fixedly secured at a predetermined force, a predetermined torque between 20 pound inches and 26 pound inches in a specific sequence. The sequence involves torquing each fastener alternately in increments of 5 pound inches up to 20-26 pound inches.
During the installation procedure it is important, to ensure that the pin 14 remains movable and to this end, the pin must prevent at least some resistance to movement. This is confirmed by rotating the pin in seal 20 by a quarter of a turn. If no resistance is experienced the pin 14 is removed from support 18 and the seal 20 is replaced. In order to ensure positive engagement, fasteners 24 may also include a locking device, such as locking washers 26 .
Referring to FIGS. 3A , B and C, shown are a variety of views of the exhaust case. FIG. 3A illustrates a partially cut away side elevational view. FIG. 3B illustrates an enlarged view of the circular area noted in FIG. 3A . FIG. 3C is a front view looking in the direction of arrow “A” of FIG. 3A . In the above mentioned illustrations, a lever 28 is provided and is mounted to support 18 and more specifically, between lateral supports 30 of support 18 .
A nut and bolt 32 , 34 , respectively extend through registering apertures within support 18 to receive lever 28 . Antiseize compound is applied to the threads of the bolt and subsequent torquing of the system is performed between 27 and 30 pound inches. Once fastened, lever 28 is checked for free and clear movement without any binding by applying hand force. This also ensures the full seating of pin 14 .
Referring to the sequence of FIGS. 4A through 4D , shown are various views similar to those in respect to FIGS. 3A , 3 B and 3 C where the actuation device is provided for lever 28 . FIG. 4A illustrates the overall arrangement where lever 28 is connected to a shut off cable assembly, globally denoted by numeral 36 . One end of the cable, 38 is fastened adjacent to the terminal end of lever 28 . The fastening may be achieved by a ball connector 40 secured in position by a suitable retainer, an example of which is a cotter pin 42 . The opposed end of cable 38 terminates at a retaining flange 44 generally associated with the turbine exhaust casing 10 . In the mounting procedure, the arrangement includes a washer and nut combination 46 , 48 . The nut is turned under a predetermined amount of pressure and particularly torqued between 14 and 16 pound inches.
The cable jacket 50 then extends along the body as is typical in turbo fan engines.
Referring to FIGS. 5 and 5A , shown in the first instance is the rear of the turbo fen exhaust casing 10 partially cut away to reveal the disposition of the lever and other components discussed herein previously. The cut away section FIG. 5A clearly illustrates the disposition of the lever within the casing once the arrangement is assembled as has been discussed.
As further steps in the method, once the arrangement is assembled at this stage it is important to ensure that all components are correctly installed and locked. To this end, the cotter pin 42 must be confirmed to be correctly installed and locked into position. It is also at this point that confirmation is made as to whether the nut 32 and bolt 30 of the lever 28 are firmly secured and that the ancillary wiring globally denoted by numeral 52 is securely clamped and secured.
Finally, once an inspection has been conducted and each of the components is not only functioning properly, but also secured where appropriate and movable where appropriate the sequencing with respect to FIG. 5 and FIG. 6 can be effected.
Referring now to FIGS. 6 and 7 , the engine 10 is, in a further embodiment of the method according to the present invention rotated to record the dimension indicated in FIG. 7 by numeral 60 . This dimension is a measurement from the turbine support case flange, globally denoted by numeral 62 to the bearing locator bolt 64 . This measurement is used to then calculate required pin valve 14 height.
A pulling tool 66 is connected to the pin valve 14 to ensure that the pin is fully seated against its support (numeral designations required for this aspect).
The valve 14 is adjusted by rotation to the proper height in relation to the exhaust case flange 62 .
As shown in FIGS. 10 and 11 , once the pin has been adjusted, it is important to ensure that the pin remains in this position. Accordingly, as shown in FIG. 11 , a washer lock 68 is positioned on to the support flange 62 and secured there with retaining ring 70 as illustrated in FIG. 11 .
The case is then installed on engine in a known manner.
The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without department from the scope of the invention disclosed. Still other modifications which fail within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims. | A protocol for assembling a fuel shut off pin valve assembly for a turbo fan engine. The protocol outlines a specific sequence of events in order to ensure failsafe incorporation of a fuel shut off valve assembly within the low pressure turbine area and specifically within the engine casing of the turbo fan. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to waterborne curing compositions for electrodeposition and radiation curing and to processes for manufacturing such compositions. The compositions are particularly suitable for formulation of water-dilutable primers and one-coat paints which can be deposited cathodically and cured by radiation, more in particular UV radiation.
BACKGROUND
[0002] The application of a coating by means of electrodeposition is known. Electrodeposition is a known coating method which comprises dipping an electrically conductive material to be coated into a suspension of a charged film-forming material dispersed in water, and subjecting the conductive material to electrocoagulation by the passage of electric current through the suspension, and carrying out a baking treatment of the conductive material coated with the electrocoagulation.
[0003] Electrodeposition has major advantages in that the loss of coating material is low; the process is easily automated and controlled thereby reducing labor costs; a variety of materials to be coated can be treated simultaneously; uniform film formation is possible in the inside and edge of the materials to be coated; and coating materials have good adhesiveness to the materials to be coated. Waterborne coating materials have an improved ecological profile and are preferred in view of environmental pollution and disaster prevention.
[0004] The actual coating process usually involves submerging the part to be coated into a container which holds the coating bath or solution and applying direct current electricity through the bath using electrodes. Typically voltages of 25-400 volts DC are used. The object to be coated is one of the electrodes, and a set of “counter-electrodes” are used to complete the circuit.
[0005] After deposition, the object is normally rinsed to remove the undeposited bath. The rinse is followed by a baking or curing process. This will crosslink the polymer and allows the coating to flow out and become smooth and continuous.
[0006] The process is useful for applying materials to any electrically conductive surface. Consequently cationic electrodeposition is widely employed as coating method in the car industry as a coating method for car bodies. However for heat-sensitive materials such as metalised plastics, coating compositions with a thermosetting temperature above 100° C. cannot be used.
[0007] In order to solve this problem, there is a method for coating materials using ultraviolet radiation. This method employs coating compositions with radiation curable, preferably UV curable or electron beam curable, oligomers, monomers, photo polymerization initiators, radical inhibitors. In these solventless coating materials, the reactive monomer is used for diluting other components in place of an organic solvent and thus becomes part of the cross-linked polymer network after radical polymerization. Cured coating film produced from this type of coating material is very hard, but fragile and less adhesive to the base material, which is particularly problematic on a smooth surfaced base material.
[0008] Coating compositions have been described which contain both electrodepositable and radiation curable properties. A problem however is that the energy curable part has poor solubility in water. It is therefore problematic to obtain a composition with good dispersibility.
[0009] U.S. Pat. No. 6,232,364 discloses the use of two or more carefully selected species of photo initiators in order to prevent this phenomenon. However this selection process is tedious. A more robust and less critical method is sought for.
[0010] There remains a need in the art for improved coating compositions, especially for heat sensitive materials, and for their manufacturing processes.
[0011] The present invention aims to resolve at least some of the problems mentioned above. The invention thereto aims to provide coating compositions for electrodeposition and radiation curing with high reactivity, low tackiness, good adhesion, high anticorrosion, and high gloss. It is a further object of the invention that the coating compositions are suitable for coating heat-sensitive materials such as plastics.
SUMMARY OF THE INVENTION
[0012] The present invention provides compositions for low temperature radiation curable electro-deposition with improved dispersibility, and a process for manufacturing the compositions.
[0013] In particular, the invention in a first aspect provides a radiation curable electrodepositable coating composition (a)+(b), comprising an aqueous dispersion of:
(i) a dispersing polymer (a) consisting essentially of an at least partially neutralized (meth)acrylic modified amine epoxy adduct, and (ii) an ethylenically unsaturated compound (b), and (iii) optionally a photo initiator (c).
[0017] In a second aspect, the invention provides a process for the preparation of a non-aqueous water-dilutable composition (AB)+(b) for the preparation of an aqueous coating composition (a)+(b) which can be deposited cathodically and is curable by radiation, comprising the steps of:
bringing an ethylenically unsaturated compound (b) together with a (meth)acrylic modified amine epoxy adduct material (AB) comprising 20-95 wt %, preferably 50-95 wt %, more preferably 70-95 wt % (meth)acrylic monomer content based on the total monomer content of (AB) with an amine number of 20-150 mg KOH/g in a non-aqueous water-dilutable solvent (d), optionally adding a photo initiator (c1), using an amount from 20 to 80 wt % of compound (AB) and from 80 to 20 wt % of compound (b), expressed relative to the total weight of the compounds (AB) and (b), wherein the (meth)acrylic modified amine epoxy adduct material (AB) is preferably prepared as follows based on an epoxy resin-amine adduct (A) and a (meth)acrylate copolymer (B): (A) 3 to 50%, preferably 3 to 30%, by weight, based on the solids, of a basic adduct of epoxy resins,
which has an amine number of 50 to 170 mg KOH/g and is present, preferably as a 10 to 40% strength by weight solution, in a non-aqueous, preferably, water-dilutable solvent which is inert to the reaction (component A), and
(B) 50 to 97%, preferably 70 to 97%, by weight of a monomer mixture which comprises
(Ba) 7 to 20% by weight of esters of (meth)acrylic acid which contain secondary or tertiary amino groups, (Bb) 15 to 30% by weight of monoesters of (meth)acrylic acid with diols, which contain alkylene radicals having 2 to 6 carbon atoms and/or oxyalkylene radicals having 4 to 12 carbon atoms, (Bc) 50 to 78% by weight of (meth)acrylic acid alkyl esters, the alkyl radicals of which contain 1 to 18 carbon atoms, and (Bd) up to 10% by weight of aromatic vinyl monomers (component B),
are subjected to free radical polymerization, and the combination (AB) thus obtained is at least partially neutralized thereby providing (a), with the provisos that component (AB) has an amine number of 20-150 mg KOH/g, preferably of 30 to 90 mg KOH/g and a hydroxyl number of 80 to 150 mg KOH/g, and that the sums of the percentage figures of components (A) and (B), respectively (Ba) to (Bd), are in each case 100.
[0034] In a third aspect, the invention provides a process for the preparation of an aqueous coating composition (a)+(b) which can be deposited cathodically and cured by ultraviolet radiation, comprising the steps of:
preparing a non-aqueous water-dilutable composition (AB)+(b) according to an embodiment of the process previously described, optionally adding a photo initiator (c2), which can be the same or different from the photo initiator (c1) added to prepare the water-dilutable composition (AB)+(b), at least partially neutralizing the amino groups of (AB), preferably using an acid, thereby providing (a), diluting the combination (a)+(b) thus obtained with deionized water to a solids content suitable for further processing.
[0039] In a fourth aspect, the invention provides compositions prepared according to a process of the invention.
[0040] In a final aspect, the invention provides uses of an inventive composition for coating metallic materials, metal plated materials and electrically conductive plastic materials as well as to a process for coating metallic materials, metal plated materials and electrically conductive plastic materials wherein a coating is formed on said material by electrodeposition in a bath containing a composition according to the invention, the coated material is withdrawn from the bath, optionally rinsed with water or a solvent, optionally dried at a temperature of preferably from 60 to 100° C., and then further submitted to radiation curing.
[0041] Preferred embodiments are as specified in the dependent claims.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.
[0043] As used herein, the following terms have the following meanings:
[0044] “A”, “an”, and “the” as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, “a compartment” refers to one or more than one compartment.
[0045] “About” as used herein referring to a measurable value such as a parameter, an amount, a temporal duration, and the like, is meant to encompass variations of +/−20% or less, preferably +/−10% or less, more preferably +/−5% or less, even more preferably +/−1% or less, and still more preferably +/−0.1% or less of and from the specified value, in so far such variations are appropriate to perform in the disclosed invention. However, it is to be understood that the value to which the modifier “about” refers is itself also specifically disclosed.
[0046] “Comprise,” “comprising,” and “comprises” and “comprised of” as used herein are synonymous with “include”, “including”, “includes” or “contain”, “containing”, “contains” and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, features, element, members, steps, known in the art or disclosed therein.
[0047] The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within that range, as well as the recited endpoints.
[0048] By the term “aqueous” as used herein, is meant that the solvent used in the composition is mainly water. Hence, “aqueous” and “water-based” may be considered synonyms. Water-based formulations generally have the advantage that they require little or no organic solvent fraction. Note that water is not considered a solvent in the present application. It is considered the dispersing phase.
[0049] The inventors have found a resin combination wherein a water dispersible cationic component acts as dispersing polymer for a second radiation curable component. In addition, the resulting composition was found to have a decreased dependence on the presence of a photo initiator.
[0050] In particular, the present invention provides in a first aspect, a radiation curable electrodepositable coating composition, comprising an aqueous dispersion of: (i) a dispersing polymer (a) consisting essentially of an at least partially neutralized (meth)acrylic modified amine epoxy adduct, and (ii) an ethylenically unsaturated compound (b). The combination presented above has the advantage that the dispersibility of (b) in water is improved in the presence of compound (a).
[0051] By (meth)acrylic modified amine epoxy adduct is understood in the present invention a blend and/or the reaction product of an amine epoxy adduct with at least one (meth)acrylic (co)polymer which is obtained by polymerizing at least one (meth)acrylic monomer which in the presence of the amine epoxy adduct to form an (meth)acrylic (co)polymer.
[0052] In the present invention, the term “(meth)acryl” is to be understood as to encompass both acryl and methacryl compounds or derivatives as well as mixtures thereof.
[0053] By amine epoxy adduct is understood in the present invention the reaction product of at least one epoxy compound comprising at least two epoxy groups with at least one amine compound comprising at least one amine group.
[0054] In order to be able to act as a dispersing polymer, the (meth)acrylic modified amine epoxy adduct comprises at least one functional group which enables to obtain a dispersion in water. Such functional groups are well known in the art. In case of cationic electrodeposition coating compositions, this functional group is a moiety that is or is able to form a cationic group upon dispersion in water, optionally after neutralization with an acid.
[0055] In a preferred embodiment the radiation curable electrodepositable coating composition, comprises an aqueous dispersion of: (i) a dispersing polymer (a) consisting essentially of an at least partially neutralized (meth)acrylic modified amine epoxy adduct comprising 20-95 wt % (meth)acrylic monomer content based on the total monomer content of (a) with an amine number of 20-150 mg KOH/g, and (ii) an ethylenically unsaturated compound (b).
[0056] In a preferred embodiment, the amine number of the dispersing polymer is 30-140 mg KOH/g, more preferably 40-120 mg KOH/g. In a preferred embodiment, the at least partially neutralized (meth)acrylic modified amine epoxy adduct comprises 50-95 wt % polymer derived from (meth)acrylic monomer based on the total monomer content of (a).
[0057] In a preferred embodiment the dispersion comprising (a), (b) and optionally (c1) and (c2), has a particle size of below 250 nm, preferably below 200 nm, more preferably below 180 nm. In another preferred embodiment the dispersion has a particle size above 50 nm, preferably above 100 nm.
[0058] More preferably above 140 nm, even more preferably above 145 nm, most preferably above 150 nm. In a most preferred embodiment the dispersion has a particle size between 50 nm and 250 nm, preferably between 100 nm and 230 nm, more preferably between 150 nm and 200 nm, most preferably between 155 and 180 nm.
[0059] By the term “particle size” as used herein, is meant the average mean particle size d50 as measured on the aqueous dispersion with a Malvern Zetasizer.
[0060] The presence of a photo initiator (c) in the composition is optional. It was found that the composition does not require an initiator to be present in order to obtain curing. This is of interest as prior art disclosures, such as U.S. Pat. No. 6,232,364, have shown that the presence and selection of suitable initiators for the compositions described therein is essential to obtaining a good curing. Hence, a composition according to the invention provides for a less critical, more robust composition for use in a coating process.
[0061] The polymerization reaction induced by radiation chemistry or curing is preferably carried out by means of radiation with a wavelength of less than 400 nm, such as UV, electron, X- or gamma rays. UV radiation is particularly preferred, the curing with UV radiation often being initiated in the presence of photo initiators.
[0062] The photo-initiator encompasses any molecule capable to initiate a radical poly-addition reaction of the (meth)acrylate-functional components by the action of light.
[0063] In a preferred embodiment, said photo initiator is selected from the list of a benzophenone; 1-hydroxy-cyclohexyl phenyl ketone; 2,4,6-trimethyl benzophenone; 3,3-dimethyl-4-methoxy-benzophenone; benzyl dimethyl ketal; oligo (2-hydrox-2-methyl-1-(4-(1-methyl-vinyl)phenyl)propanone; 2,2-dimethoxy-1,2-diphenylethan-1-one; 2-hydroxy-2-methyl-1-phenylpropan-1-one; bis (2,4,6-trimethylbenzoyl)pheny phosphine oxide; 2,4-diethylthioxanthoine; ethyl p-dimethylaminobenzoate; isoamyl p-dimethylaminobenzoate; bis (n 5 -2,4-cyclopentadien-1-yl)-bis(2,6-difluoro-3-(1H-pyrrol-1-yl)-phenyl) titanium or mixtures thereof. In a more preferred embodiment, said photo initiator is selected from the list of a benzophenone and 1-hydroxy-cyclohexyl phenyl ketone, or mixtures thereof. Mixtures can provide eutectic compositions that are advantageously liquid at room temperature.
[0064] The photoinitiator (c1) or (c2) can be added to the composition comprising (b) before the dispersion in water and before or after the neutralization in order to form (a) and (b). The photoinitiator (c1) or (c2) is preferably added after the neutralization, more preferably just before the use of the composition for coating substrates.
[0065] In a preferred embodiment, an amount from 20 to 80 wt % of compound (a) and from 80 to 20 wt % of compound (b), expressed relative to the total weight of the compounds (a) and (b) is used. When the amount of (a) is increased above 70 wt %, crosslinking goes down. In a more preferred embodiment, an amount from 30 to 70 wt % of compound (a) and from 70 to 30 wt % of compound (b), expressed relative to the total weight of the compounds (a) and (b) is used. In a most preferred embodiment, an amount from 40 to 60 wt % of compound (a) and from 60 to 40 wt % of compound (b), expressed relative to the total weight of the compounds (a) and (b) is used.
[0066] In a preferred embodiment, compound (a) comprises epoxy resin-amine adducts (component A) and (meth)acrylate copolymers (component B), more specifically 3 to 50% by weight, more preferably 3 to 30% by weight, of (A) and 50 to 97% by weight, more preferably 70 to 97% by weight, of (B), expressed as % by weight of the solids content provided by (A) and (B).
[0067] In a preferred embodiment, compound (a) is obtainable from a process wherein 50 to 97%, more preferably 70 to 97%, by weight of (meth)acrylic monomers are subjected to free radical polymerization in the presence of 3 to 50%, more preferably 3 to 30%, by weight of an epoxy resin-amine adduct (component A) in order to form (meth)acrylic modified amine epoxy adduct (AB) comprising a blend and/or the reaction product of (meth)acrylate copolymer (component B) and component A. The sum of the percentages of the (meth)acrylic monomers forming component (B) and component (A) are 100.
[0068] Said epoxy resin-amine adduct (A) is preferably a basic amine epoxy adduct of epoxy resins, which contains at least one amino group per molecule and has an amine number of 50 to 170 mg KOH/g, preferably 90 to 130 mg KOH/g.
[0069] In a preferred embodiment of this component A at least 5% by weight, preferably 10 to 20% by weight, of aliphatic moieties, are present, preferably as end or side chains, which have 7 to 18 carbon atoms and are identical to the aliphatic moieties likewise present in component (B).
[0070] In a preferred embodiment of a composition according to the invention, components (A) and (B) in each case comprise at least 5% by weight of identical aliphatic moieties having 7 to 18 carbon atoms. Due to the presence of a content of identical aliphatic moieties having 7 to 18 carbon atoms in each of components (A) and (B), and the resulting compatibility, the properties of the baked films based on the products prepared according to the invention, can be optimized. These properties may include degree of gloss, UV resistance, weathering resistance, washing agent resistance and corrosion resistance.
[0071] The C7-C18 aliphatic moieties are preferably introduced into component (A) by using alkylamines, such as 2-ethylhexylamine or stearylamine, and/or by reaction of corresponding alkyl glycidyl ethers and/or alkyl glycidyl esters with primary and/or secondary amino groups of epoxy resin-amine adducts. The aliphatic moieties can also be incorporated by reaction of diisocyanates which are semi-blocked or half-blocked by fatty alcohols and/or fatty amines with hydroxyl and/or amino groups of the epoxy resin-amine adducts. There is furthermore the possibility of introducing fatty alcohols or fatty acids into component (A) by esterification, or of reacting alkyl glycidyl ethers and/or alkyl glycidyl esters with carboxyl groups. Compounds which carry corresponding side chains, such as are described, for example, in U.S. Pat. No. 4,992,516, can also be used to lengthen aromatic epoxy resins. Epoxy resin-amine adducts based on aromatic and aliphatic diepoxy resins or other epoxide compounds, and modifications thereof, are described in the literature.
[0072] A solution of component (A) in a solvent which is inert in the subsequent polymerization but which is preferably water-dilutable, such as in alkanols, glycol ethers or glycol esters, serves as the reaction medium for the preparation of component (B). By the term water-dilutable is meant to designate in the present invention a solvent that permits to form a homogeneous, single phase mixture when the compound is mixed with water over a concentration range of at least 30% of water in the total mass of water and the solvent.
[0073] In this preparation, a monomer mixture which comprises (Ba) 7 to 20% by weight of esters of (meth)acrylic acid which contain secondary or tertiary amino groups; preferably tertiary amino groups, (Bb) 15 to 30% by weight of monoesters of (meth)acrylic acid with diols, which contain alkylene radicals having 2 to 6 carbon atoms and/or oxyalkylene radicals having 4 to 12 carbon atoms, (Bc) 50 to 78% by weight of (meth)acrylic acid alkyl esters, the alkyl radicals of which contain 1 to 18 carbon atoms, and (Bd) up to 10% by weight of aromatic vinyl monomers, preferably styrene, wherein the sum of the percentage figures of (Ba) to (Bd) must be 100, is subjected to free radical polymerization in the solution of component (A) in a known manner.
[0074] According to the invention, the reaction mixture (AB) of components (A) and (B) consists of 3 to 50% by weight, preferably of 3 to 30% by weight, more preferably 5 to 20% by weight, based on the solids, of component (A) and 50 to 97% by weight, preferably 70 to 97% by weight, more preferably 80 to 95% by weight, of component (B), wherein the sum of the percentage figures of (A) and (B) must likewise be 100.
[0075] The starting substances are furthermore chosen in a ratio of amounts such that the components (AB) have an amine number of 20 to 150 mg KOH/g, preferably 30 to 90 mg KOH/g, more preferably 40 to 70 mg KOH/g; and a hydroxyl number of 80 to 150 mg KOH/g.
[0076] N-monoalkyl- and/or N-dialkyl-aminoalkyl (meth)acrylates and/or the corresponding N-alkanol compounds are preferably employed as monomers (Ba) which contain nitrogen groups. If other such monomers are used, the desired profile of properties in respect to yellowing, adhesive strength, elasticity of the films must be taken into account.
[0077] When choosing the monomers of group (Bb) and (Bc), it may be necessary to take into account the preferred requirement according to the invention that the monomer mixture preferably has a composition such that at least 5% by weight, preferably 10 to 20% by weight, of aliphatic moieties having 7 to 18 carbon atoms which are identical to the radicals present in component (A) are present. This embodiment has the advantage that improved dispersibility is provided.
[0078] In a preferred embodiment, component (AB) has been subjected to partial neutralization of the amino groups with an acid before mixing with component (b) to provide (a). Said acid is preferably selected from the list formic acid, acetic acid, lactic acid, or mixtures thereof. The addition of more water, apart from its introduction for the neutralization of the amino groups, is avoided in view of the poor water solubility of the component (b).
[0079] Therefore, in a more preferred embodiment, component (AB) is subjected to at least partial neutralization of the amino groups with an acid only after mixing with component (b) to provide (a)+(b).
[0080] Prior to mixing of (AB) with (b), some of the auxiliary solvent employed may be removed first. In case an auxiliary solvent is used which is incompatible with water, such as ketones or aromatics, it needs to be removed first prior to adding water.
[0081] The non-aqueous water-dilutable compositions obtainable as described above are then used for the preparation of aqueous coating compositions.
[0082] The at least partially neutralized (meth)acrylic modified amine epoxy adduct material (a), present in a non-aqueous water dilutable solvent (d) is brought together with an ethylenically unsaturated compound (b) using an amount from 20 to 80 wt % of compound (a) and from 80 to 20 wt % of compound (b), expressed relative to the total weight of the compounds (a) and (b). Optionally a photo initiator (c) is added. In a preferred embodiment an amount of 30 to 70 wt % of compound (a) and from 70 to 30 wt % of compound (b); more preferably an amount of from 40 to 60 wt % (a) and from 60 to 40 wt %; most preferably an amount of 50 wt % (a) and 50 wt % of (b) is used, expressed relative to the total weight of the compounds (a) and (b).
[0083] In the context of the present invention a wide variety of ethylenically unsaturated compounds (b) can be used. Typically they are (meth)acrylated compounds. Often these compounds (b) have a weight average molecular weight ranging 200-20000 Daltons, preferably 300-5000 Daltons, more preferably 400-4000 Daltons, most preferably 500-2000 Daltons.
[0084] In general, the amount of (meth)acrylic functionality of compounds (b) is between 1 and 10 meq/g, typically between 5 and 10 meq/g, most typically between 7 and 10 meq/g.
[0085] In a preferred embodiment of a composition according to the invention, (b) is selected from one or more of urethane (meth)acrylate(s) (b1), polyester (meth)acrylate(s) (b2), polyepoxy (meth)acrylate(s) (b3), polycarbonate (meth)acrylate(s) (b4), polyether (meth)acrylate(s) (b5), and polyacrylic (meth)acrylate(s) (b6); preferably urethane (meth)acrylate(s) (b1), polyester (meth)acrylate(s) (b2) and/or polyepoxy (meth)acrylate(s) (b3).
[0086] In a preferred embodiment of a composition according to the invention, (b) is a urethane (meth)acrylate (b1) that are generally based on an aliphatic or an aromatic polyisocyanate, possibly a mixture of both. Urethane (meth) acrylates and in particular urethane acrylates are preferred as they give good adhesion in different substrates and provide good corrosion resistance. Urethane acrylates offer a higher (meth)acrylate functionality with a good balance of properties in the cured film as well as the beneficial presence of urethane hard segments prone to coating reinforcement by hydrogen bonding.
[0087] Urethane (meth)acrylates (b1) typically are obtained from the reaction of at least one polyisocyanate (i), at least one polymerizable ethylenically unsaturated compound (ii) containing at least one reactive group capable to react with isocyanate groups, and optionally at least one other compound (iii) that contains at least one reactive group capable to react with isocyanate groups. By “other” is meant that compounds (iii) are different from compounds (ii). The “reactive groups capable to react with isocyanate groups” are usually hydroxyl groups; amino groups and/or thiol groups can also be used to provide additional urea and thio-urea functions.
[0088] By a polyisocyanate (i) is meant to designate a compound containing at least two isocyanate groups. Typically the polyisocyanate contains not more than six isocyanate groups, more preferably not more than three isocyanate groups. Most typically it is a diisocyanate. The polyisocyanate is generally selected from aliphatic, cycloaliphatic, aromatic and/or heterocyclic polyisocyanates, or combinations thereof. Most typically (cyclo)aliphatic and/or aromatic polyisocyanates are used.
[0089] Examples of aliphatic and cycloaliphatic polyisocyanates that may be used are: 1,6-diisocyanatohexane (HDI), 1,1′-methylene bis[4-isocyanatocyclohexane] (H12MDI), 5-isocyanato-1-isocyanatomethyl-1,3,3-trimethylcyclohexane (isophorone diisocyanate, IPDI). Aliphatic polyisocyanates containing more than two isocyanate groups are for example the derivatives of above mentioned diisocyanates like 1,6-diisocyanatohexane biuret and trimer. Examples of aromatic polyisocyanates that may be used are 1,4-diisocyanatobenzene (BDI), 2,4-diisocyanatotoluene (TDI), 1,1′-methylenebis[4-isocyanatobenzene] (MDI), xylilene diisocyanate (XDI), tetramethylxylilene diisocyanate (TMXDI), 1,5-naphtalene diisocyanate (NDI), tolidine diisocyanate (TODI) and p-phenylene diisocyanate (PPDI).
[0090] The amount of polyisocyanate compound (i) used for the synthesis of the urethane (meth)acrylate (b1) is generally in the range of from 10 to 70 percent by weight (wt %), preferably from 15 to 60 wt % and more preferably from 20 to 50 wt %. Weight percentages are herein relative to the total weight of compounds used to prepare urethane (meth)acrylates (b1).
[0091] Compounds (ii) typically are (meth)acrylated compounds. Most often they are (meth)acrylated compounds containing essentially one reactive group capable to react with isocyanate groups. Such compounds typically comprise at least one unsaturated function such as acrylic or methacrylic groups and one nucleophilic function capable of reacting with isocyanate. This can be a hydroxyl, amino and/or thiol group, but typically is a hydroxyl group.
[0092] Typically compounds (ii) are hydroxyl functional (meth)acrylates and more in particular (meth)acryloyl mono-hydroxy compounds, or compounds comprising one hydroxyl group and one or more (meth)acryloyl groups. Acrylates are particularly preferred.
[0093] Suitable are for instance the esterification products of aliphatic and/or aromatic polyols with (meth)acrylic acid having a residual average hydroxyl functionality of about 1.
[0094] Examples of suitable hydroxyl functional (meth)acrylates (ii) include but are not limited to hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, hydroxybutyl (meth)acrylate, polyethyleneoxide mono(meth)acrylate, polypropyleneoxide mono(meth)acrylate, or any of those hydroxylated monomers further reacted with lactones or lactides which add to these hydroxyls in a ring-opening reaction.
[0095] Suitable are also the esterification products of aliphatic and/or aromatic polyols with (meth)acrylic acid having a residual average hydroxyl functionality of about 1 or higher. The partial esterification products of (meth)acrylic acid with tri-, tetra-, penta- or hexahydric polyols or mixtures thereof are preferred but it is also possible to use reaction products of such polyols with ethylene oxide and/or propylene oxide or mixtures thereof, or the reaction products of such polyols with lactones or lactides which add to these polyols in a ring-opening reaction until the desired residual hydroxyl functionality is reached. It is known to those skilled in the art that the (meth)acrylation of polyols proceeds to a mixture of (meth)acrylate components and that an easy and suitable way to characterize the mixture is by measuring its hydroxyl value (mg KOH/g). Suitable compounds (ii) are for instance the (meth)acrylic esters of linear and branched polyols in which at least one hydroxy functionality remains free. Particularly preferred are compounds comprising at least two (meth)acryl functions such as glycerol diacrylate, trimethylolpropane diacrylate, pentaerythritol triacrylate, ditrimethylolpropane triacrylate, dipentaerythritol pentaacrylate and their (poly)ethoxylated and/or (poly)propoxylated equivalents. Particularly preferred are pentaerythritol triacrylate (PETIA), a mixture containing essentially pentaerythritol diacrylate, pentaerythritol triacrylate and pentaerythritol tetraacrylate and a dipentaerythrytol hydroxypentaacrylate (DPHA), a mixture containing essentially dipentaerythritol tetraacrylate, dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate.
[0096] Also suitable are C1-4 hydroxyalkyl(meth)acrylate-((poly)lactone)t compounds, wherein t is an integer of from 1 to 10, preferably from 1 to 5. Preferably the (poly)lactone is a (poly)caprolactone. Examples of useful compounds in this category are Tone M100 (Dow Chemicals) and/or Bisomer PEMCURE 12A (Cognis). Other examples of suitable compounds (ii) are C1-4 hydroxyalkyl(meth)acrylate-((poly)lactide)n compounds, wherein n is an integer between 1 and 10, preferably n is between 1 and 5 and most preferably n is between 2 and 4.
[0097] Also suitable are the reaction products of (meth)acrylic acid with aliphatic, cycloaliphatic or aromatic compounds that bear an epoxy functionality and that, optionally, further bear at least one (meth)acrylic functionality. It is also possible to use compounds obtained from the reaction of an aliphatic, cycloaliphatic or aromatic compound containing at least one carboxylic acid with another compound bearing an epoxy functionality and at least one (meth)acrylic functionality. Particularly suitable is the reaction of the glycidyl ester of a C9-C11 versatic acid with (meth)acrylic acid.
[0098] From the above in particular poly(meth)acryloyl mono-hydroxy compounds, or compounds comprising one hydroxyl group and two or more (meth)acryloyl groups are preferred.
[0099] The amount of compounds (ii) used for the synthesis of the urethane (meth)acrylate (b1) is generally in the range of from 10 to 90 wt %, preferably from 40 to 85 wt % and more preferably from 50 to 80 wt %. Weight percentages are herein relative to the total weight of compounds used to prepare urethane (meth)acrylates (b1).
[0100] Optionally, other hydroxyl functional compounds (iii) can be used for preparing urethane (meth)acrylates (b1) of the invention. Compounds (iii) typically are polyols and more in particular diols. In general compounds (iii) are saturated polyols.
[0101] By polyol (iii) is meant to designate an organic compound comprising at least two hydroxyl groups. The polyol (iii) can be selected from low molecular weight polyols having a number average weight of less than 300, preferably less than 200 Daltons; from high molecular weight polyols having a number average molecular weight of at least 300, preferably at least 400, more preferably at least 500 Daltons; or from any mixtures thereof. The high molecular weight polyol (iii) preferably has a number average molecular weight of at most 5000, preferably at most 2000, more preferably at most 1000 Daltons.
[0102] Examples of suitable low molecular weight compounds (iii) include compounds like aliphatic or cycloaliphatic polyols such as ethyleneglycol (EG), propyleneglycol (PG), cyclohexane dimethanol (CHDM), glycerol (GLY), trimethylolpropane (TMP), ditrimethylolpropane (di-TMP), pentaerythrytol (PENTA), dipentaerythritol (di-PENTA), or any other renewable polyols like fatty dimer diols, and the like.
[0103] Examples of high molecular weight polyols (iii) are polyester polyols, polyether polyols, polycarbonate polyols, polybutadiene polyols, polyacrylate polyols and silicone polyols, as well as combinations thereof. Preferred are polyester polyols, polycarbonate polyols and/or polyether polyols, having a molecular weight above 500 Daltons. Particularly preferred are polyhydroxylated polyester polyols. Examples of such compounds are well known in the art.
[0104] Where present, compounds (iii) are generally used in an amount from 1 to 95 wt %, preferably from 2 to 20 wt % more preferably from 3 to 10 wt %, and most preferably from 5 to 10 wt %. Weight percentages are herein relative to the total weight of compounds used to prepare urethane (meth)acrylates (b1).
[0105] In an embodiment of the invention, urethane (meth)acrylates are prepared from compounds (i), (ii) and the optional compound (iii) as identified above. Typically the sum of the weight percentages of compounds (i), (ii) and (iii) equals 100%. In an embodiment of the invention compounds (iii) are used to prepare urethane (meth)acrylates (b11) of the invention. In yet another embodiment of the invention, no compounds (iii) are used to prepare compounds (b1) according to the invention. Especially preferred are urethane (meth)acrylates (b12) that are obtained from the reaction of at least one polyisocyanate (i) and at least one polymerizable ethylenically unsaturated compound (ii) containing at least one reactive group capable to react with isocyanate groups as described above. Most typically urethane (meth)acrylates (b12) are the reaction product of a polyisocyanate (i) and an active hydroxyl-containing ethylenically-unsaturated compound (ii) having acrylate or methacrylate unsaturation. Typically the sum of the weight percentages of compounds (i) and (ii) herein equals 100%.
[0106] Typically urethane (meth)acrylates (b1) that are used in the invention have a molecular weight MW of between 400 and 20000 Daltons. Usually the MW is at most 5000 Daltons, typically at most 2000 Daltons, and most typically at most 1000 Daltons. Molecular weights can be measured by gel permeation chromatography using polystyrene standards but most typically they are calculated from the target molecule. Optionally urethane (meth)acrylates (b1) of the invention can have residual amounts of hydroxyl functions. In general the residual amount of hydroxyl functions is between 0 and 5 meq/g. Typically the residual amount of hydroxyl functions is at most 3 meq/g, more typically at most 1 meq/g. In a particular embodiment of the invention no residual hydroxyl functions are present. In general, the amount of (meth)acrylic functionality of (b) is between 1 and 10 meq/g, typically between 5 and 10 meq/g, most typically between 7 and 10 meq/g.
[0107] Examples of suitable urethane (meth)acrylates (b1) are those commercialized as EBECRYL® 1290, EBECRYL® 220, EBECRYL® 270, EBECRYL® 264, EBECRYL® 294/25HD, EBECRYL® 4883, EBECRYL® 5129 and EBECRYL® 8210. These urethane (meth)acrylates can be diluted in a reactive diluent or be used in combination with other (meth)acrylated compounds.
[0108] In another preferred embodiment of a composition according to the invention, (b) is selected from one or more polyester (meth)acrylate(s) (b2). This selection has the advantage that an improved film smoothness or flow is provided.
[0109] Polyester (meth)acrylates (b2) used in the invention typically are obtained from the reaction of at least one polyol (iii) and at least one ethylenically unsaturated carboxylic acid (iv) or a suitable equivalent. Examples of suitable compounds (iv) include (meth)acrylic acid, β-carboxyethyl(meth)acrylate, crotonic acid, iso-crotonic acid, maleic acid, fumaric acid, itaconic acid, citraconic acid, 3-(meth)acrylamido-3-methylbutanoic acid, 10-(meth)acrylamido-undecanoic acid, 2-(meth)acrylamido-2-hydroxyacetic acid, vinyl acetic acid and/or allyl acetic acid. Acrylic acid and methacrylic acid, used alone or in combination, are preferred.
[0110] Suitable polyester (meth)acrylates (b2) are for instance aliphatic or aromatic polyhydric polyols which have been totally esterified with (meth)acrylic acid and may contain a residual hydroxyl functionality in the molecule; an easy and suitable way to characterize the product is thus by measuring its hydroxyl value (mgKOH/g). Suitable are the partial or total esterification products of (meth)acrylic acid with di-, tri-, tetra-, penta- and/or hexahydric polyols and mixtures thereof. It is also possible to use reaction products of such polyols with ethylene oxide and/or propylene oxide or mixtures thereof, or reaction products of such polyols with lactones and lactides, which add to these polyols in a ring-opening reaction. Examples of poly-unsaturated compounds from this category are dipropyleneglycol di-acrylate, trimethylolpropane tri-acrylate, glycerol tri-acrylate, pentaerythritol tetra-acrylate, di-trimethylolpropane tetra-acrylate, di-pentaerythritol hexa-acrylate and their (poly)ethoxylated and/or (poly)propoxylated equivalents, as well as mixtures thereof. Partial acrylation products from these examples are also considered.
[0111] Polyester (meth)acrylates (b2) with a higher molecular weight, e.g. a MW above 500 Daltons, preferably above 750 Daltons, more preferably above 1000 Daltons, can also be obtained by reacting a hydroxyl group-containing polyester with (meth)acrylic acid, or by reacting a carboxylic acid group-containing polyester with a hydroxyalkyl (meth)acrylate such as for example 2-hydroxyethyl acrylate, 2- or 3-hydroxypropyl acrylate, etc., or with glycidyl (meth)acrylate. The polyester backbone can be obtained in a conventional manner by polycondensation of at least one mono- and/or polyhydroxy alcohol, such as ethylene glycol, propylene glycol, butanediol, neopentyl glycol, hexanediol, trimethylolpropane, bisphenol A, pentaerythritol, etc., or/and the ethoxylates and/or propoxylates thereof, with at least one mono- and/or polycarboxylic acid such as adipic acid, phthalic acid, isophthalic acid, terephthalic acid, trimellitic acid, etc. By using unsaturated compounds for the polyester synthesis, such as for example fumaric acid, maleic acid, itaconic acid, etc., polyesters bearing both (meth)acrylic and ethylenic unsaturations in the polymer chain, can be obtained. In addition polylactones and/or polylactides can be used as polyester backbone. For example poly(E-caprolactone) obtained by ring-opening polymerization of ε-caprolactone, optionally in the presence of one or more polyhydroxy alcohol, can be used. In a particular embodiment of the invention the polyester (meth)acrylate (b2) is an alkyd, more in particular is a (meth)acrylated alkyd. In another embodiment of the invention the polyester (meth)acrylate (b2) is not an alkyd, more in particular is not a (meth)acrylated alkyd. By using an alkyd structure, it is possible to encompass its typical coating features like glossy finishes together with an increased content of renewable raw materials (fatty acids).
[0112] Typically polyester (meth)acrylates (b2) have a molecular weight MW of between 200 and 20000 Daltons. Usually the MW is at most 5000 Daltons, typically at most 1000 Daltons, most typically at most 500 Daltons.
[0113] Suitable polyester acrylates (b2) are for instance those commercialized as EBECRYL®800, EBECRYL®830 and EBECRYL®884.
[0114] In another preferred embodiment of a composition according to the invention, (b) is selected from one or more polyepoxy (meth)acrylate(s) (b3). This selection has the advantage that corrosion resistance is improved.
[0115] Polyepoxy (meth)acrylates (b3) that are used in the invention can be obtained from the reaction of (meth)acrylic acid, or the like as described above, with polyepoxides, i.e. compounds comprising at least two epoxide functions. The polyepoxides are generally chosen from glycidyl ethers of aromatic or aliphatic alcohols, polyols and from cycloaliphatic polyepoxides. Preferred epoxides are diglycidylethers of aromatic, aliphatic and/or cycloaliphatic diols, such as diglycidyl ether of bisphenol-A, diglycidyl ether of bisphenol-F, diglycidylether of poly(ethylene oxide-co-propylene oxide), diglycidylether of polypropylene oxide, diglycidylether of hexanediol, diglycidylether of pentanediol, diglycidylether of butanediol. Particularly preferred is diglycidyl ether of bisphenol-A. Also epoxidized unsaturated fatty acid triglycerides or epoxidized novolacs can be used. Examples include epoxidized soya oil, epoxidized castor oil, epoxidized linseed oil and the like.
[0116] Polyether (meth)acrylates (b4) that are used in the invention can be prepared by esterification of hydroxyfunctional polyethers with an ethylenically unsaturated carboxylic acid like (meth)acrylic acid. For more examples—see compounds (iv) above. The polyether can be a random or a bloc copolymer (usually dibloc or tribloc).
[0117] Hydroxyfunctional polyethers are obtained by ring-opening homo- or copolymerization of cyclic ethers such as tetrahydrofuran, ethylene oxide and/or propylene oxide or can be prepared by reacting polyhydroxy alcohols with ethylene and/or propylene oxide. Polycarbonate (meth)acrylates (b5) that are used in the invention can be prepared by esterification of hydroxyfunctional polycarbonates with an ethylenically unsaturated carboxylic acid like (meth)acrylic acid like. For more examples—see compounds (iv) above.
[0118] Poly(meth)acrylic (meth)acrylates (b6) that are used in this invention can be prepared by the radical polymerization of (meth)acrylic monomers in the presence of thermal radical initiators, transfer agents and optional solvents; a chemical functionality is introduced on the acrylic backbone to ensure the subsequent grafting with suitable mono- or poly-(meth)acrylated compounds. For example, the (meth)acrylic oligomer bears carboxylic acid functionality and is grafted with glycidyl (meth)acrylate (or vice versa). Suitable (meth)acrylated (meth)acrylics of this type are commercialized as EBECRYL®1200.
[0119] In one particular embodiment, compositions of the invention comprise at least one urethane (meth)acrylate (b1) as described above, and optionally at least one polyester (meth)acrylate (b2) as described above.
[0120] In another particular embodiment, compositions of the invention comprise at least one polyester (meth)acrylate (b2) as described above.
[0121] In yet another particular embodiment, compositions of the invention comprise at least one urethane (meth)acrylate (b1) and at least one polyester (meth)acrylate, more in particular at least one polyester (meth)acrylate (b2) as described above.
[0122] In an embodiment of the invention, compositions of the invention comprise two or more different compounds (b), that typically are selected from two or more of the group of urethane (meth)acrylates (b1), polyester (meth)acrylates (b2), polyepoxy (meth)acrylates (b3), polyether (meth)acrylates (b4), polycarbonate (meth)acrylates (b5) and/or poly(meth)acrylic (meth)acrylates (b6) as described above. Possibly two urethane (meth)acrylates (b1) of a different type are present.
[0123] In a preferred embodiment of a composition of the invention, the amount of (meth)acrylate functionality expressed on the whole solid composition (a) and (b) is 0.2 to 8 meq/q, more preferably 0.3 to 7 meq/q, even more preferably 0.4 to 6 meq/q, most preferably 0.5 to 5 meq/g.
[0124] The mixture of (a) and (b) is optionally mixed with one or more photo initiators (c2), at times after removal of some of the auxiliary solvent employed and/or after partial neutralization of the amino groups with acids, preferably with formic, acetic or lactic acid. Said photo initiator (c2) can be the same or different from the photo initiator (c1). Examples of suitable photo initiators are Irgacure® 500 and Irgacure 819DW, Esacure KIP EM, Esacure DP 250.
[0125] Amino groups of (a) and possibly of (b) are typically protonated with an acid. Said acid is preferably selected from the list formic acid, acetic acid, lactic acid, or mixtures thereof.
[0126] In a preferred embodiment of a process according to the invention, the (meth)acrylic modified amine epoxy adduct material (a) is prepared as follows based on an epoxy resin-amine adduct (A) and a (meth)acrylate copolymer (B):
[0127] (A) 3 to 30% by weight, based on the solids, of a basic adduct of epoxy resins, which has an amine number of 50 to 170 mg KOH/g and is preferably present as a 10 to 40% strength by weight solution in a (preferably water-dilutable) solvent which is inert to the reaction (component A), and
[0128] (B) 70 to 97% by weight of a monomer mixture which comprises
(Ba) 7 to 20% by weight of esters of (meth)acrylic acid which contain secondary or tertiary amino groups, preferably tertiary amino groups, (Bb) 15 to 30% by weight of monoesters of (meth)acrylic acid with diols, which contain alkylene radicals having 2 to 6 carbon atoms and/or oxyalkylene radicals having 4 to 12 carbon atoms, (Bc) 50 to 78% by weight of (meth)acrylic acid alkyl esters, the alkyl radicals of which contain 1 to 18 carbon atoms, and (Bd) up to 10% by weight of aromatic vinyl monomers (component B), are subjected to free radical polymerization to provide (AB), and the thus obtained (AB) is at least partially neutralized to provide (a)
with the provisos that component (AB) has an amine number of 30 to 90 mg KOH/g and a hydroxyl number of 80 to 150 mg KOH/g, and that the sums of the percentage figures of components (A) and (B), respectively (Ba) to (Bd), are in each case 100.
[0134] In a preferred embodiment the components (A) and (B) in each case comprise at least 5% by weight of identical aliphatic moieties having 7 to 18 carbon atoms.
[0135] In a preferred embodiment of a process of the invention, N-monoalkyl- or N-dialkyl-aminoalkyl (meth)acrylates or the corresponding N-alkanol compounds are employed as component (Bb).
[0136] In a preferred embodiment of a process of the invention, component (A) is present in an amount of from 5 to 20% by weight and has an amine number of 90 to 130 mg KOH/g, component (B) is present at from 80 to 95% by weight, and the amine number of component (AB) is from 40 to 70 mg KOH/g.
[0137] The component (AB) can be partially neutralized to provide (a) before or after mixing with component (b). An aqueous coating composition can be obtained by either in a first step at least partially neutralizing (AB) to provide (a) and to mix it with (b); or alternatively to first mix (AB) with (b) and then at least partially neutralizing (AB) to provide (a). Preferably only the amount of water required for neutralization of the cationic groups with an acid is used.
[0138] This coating composition is finally diluted, in a known manner, with deionized water to a solids content suitable for further processing. The subsequent process steps for the preparation of coatings are known to one skilled in the art.
[0139] It is possible to use the composition as such; alternatively any solvent present in the composition may be removed.
[0140] Additives usually used in coating compositions such as flow modifiers or leveling agents and pigments may be added to the composition.
[0141] Optionally further components can be added to the aqueous coating compositions of the invention. For further improvement of corrosion resistance of cationic electrodeposition (CED) applied coatings, reaction products of bismuth oxide with alkyl sulfonic acid, lactic acid or dimethylol propionic acid can be used.
[0142] If the substrate is not heat sensitive then a dual cure is possible. For that purpose crosslinking components (C) can be added. Components (C) are typically hydrophilic or hydrophobic crosslinking agents which effect curing by transesterification, transetherification or transurethanization, of the coating films which are deposited. Suitable external crosslinking components (C) are (blocked) polyisocyanates and/or amino resins (brand name Cymel®).
[0143] Optionally a co-solvent can be added that preferentially is chosen from oxygen containing types such as dipropylene glycol methyl ether (Dowanol™ DPM*) and/or diethylene glycol methyl ether (Dowanol™ DM*) (*available from Dow Chemical Company).
[0144] The coating composition according to an embodiment of the invention can advantageously be used to be deposited cathodically and cured by ultraviolet radiation. They are particularly suitable for low temperature coating of temperature sensitive materials such as plastics.
[0145] The composition and process according to the present invention are advantageous in that they are able to provide dispersions with low volatile organic content (VOC), a high solids content, a low viscosity, a low particle size, an excellent stability and a low film formation temperature. Typically compositions of the invention are characterized by one or more of the following:
a solid content between 25 wt % and 45 wt %, preferably between 30 wt % and 45 wt %, most preferably between 35 and 45 wt %, a Brookfield viscosity between 20 and 2000 mPa·s, preferably between 20 and 1000 mPa·s, most preferably between 20 and 500 mPa·s, a pH between 1 and 9, preferably between 3 and 7, most preferably between 4 and 6, a mean particle size between 20 and 200 nm, most preferably between 50 and 100 nm, a minimum film formation temperature below 20° C., preferably below 10° C., most preferably below 0° C.
[0151] The coating composition according to the invention can be applied via standard application techniques well known in the art including spraying, dipping, and rolling. The coating composition can be further diluted with water.
[0152] The coating compositions according to the invention are particularly suitable for cationic electrodeposition applications, followed by radiation curing.
[0153] The coating compositions are characterized by a higher reactivity and a better compatibility over the compositions know in the art. The coating compositions according to the invention permit to obtain coatings with good mechanical properties as well as an increased adhesion and corrosion resistance.
EXAMPLES
Examples 1-4, Comparative Examples CE1-CE4
Preparation of an Amine Epoxy Adduct (A)
[0154] Step I: 103 g of diethylenetriamine were reacted for 4 hours at 60° C. with 577 g 2-ethylhexylglycidether in 170 g methoxypropanol. Then a mixture of 190 g bisphenol A-diglycidylether and 48 g methoxypropanol were added within 2 hours at 60° C. and reacted at this temperature for 3 hours. The solids content of the resulting intermediate was 80%.
[0155] Step II: 652 g of the epoxy amine adduct intermediate prepared as described above were reacted with 570 g of a bisphenol A diglycidylether, 77 g 2-ethylhexylamine and 162 g methoxypropanol at 60° C., until all primary NH groups were reacted. Then 1330 g of a 75% solution of bisphenol A diglycidylether in methoxypropanol and 189 g diethanolamine were added, until all NH groups were reacted.
[0156] In a last step, 78 g N,N-diethylaminopropylamine were added and reacted at 120° C. until all epoxy groups had reacted. The epoxy determination can be carried out using ISO 3001. The product thus obtained was diluted with methoxypropanol to a solids content of 65%.
Preparation of Acryl Modified Epoxy Amine Adduct (AB)
[0157] 308 parts of the amine epoxy adduct prepared as described above and 444 parts of methoxypropanol were mixed and warmed up to 85° C. Over 4 hours, a mixture consisting of 84 parts dimethylaminoethylmethacrylate, 159 parts 2-hydroxyethylmethacrylate, 306 parts of n-butylmethacrylate, 106 parts methylmethacrylate, 145 parts 2-ethylhexylacrylate, 24 parts of azobisisobutyronitrile and 2 parts of dodecylmercaptane were added over 4 hours. Then the temperature was raised to 90° C. and kept for 2 hours. Then 10 more parts of azobisisobutyronitrile were added and the reaction mass was kept at 90° C., until the content of free monomers was below 0.5%; measurable by gas chromatography. The resulting acryl modified epoxy amine adduct is a acrylic modified epoxy-amine adduct with 20% epoxy-amine and 80% acrylic modification.
Urethane Acrylates (b)
[0158] (b1) Ebecryl®220 which is an Allnex proprietary urethane acrylated based on aromatic polyisocyanate.
(b2) Ebecryl®1290 which is an Allnex proprietary urethane acrylated based on aliphatic polyisocyanate.
UV Curable Electrodeposition Coating Compositions
Example 1 (1.1 and 1.2)
[0159] 740 parts (AB) and 320 parts (b1) corresponding with a solids ratio (AB) to (b) of 60:40 were neutralized with 48 parts of acetic acid 30% in water to provide a mixture (a1)+(b1). Then portions of water were added at 50° C. under stirring with a shear rate of about 140 per seconds, until a solids content of 40% by weight was reached.
[0160] The particle size as measured with a Malvern Zetasizer was 175 nm. The product obtained is denominated as 1.1. The 40% solution was diluted further to 15% with water (denominated 1.2).
Example 2 (2.1 and 2.2)
[0161] To samples of the dispersion prepared as described above without initiator (1.1 and 1.2), 32 g of a photo initiator Irgacure® 500 was added. The samples with solids content of respectively 40% and 15% are denominated as 2.1 and 2.2.
Example 3 (3.1 and 3.2)
[0162] 370 parts (AB) and 560 parts (b2) corresponding with a solids ratio (AB):(b2) of 30:70 are neutralized with 50 parts of lactic acid 30% in water. Then portions of water are added at 50° C. under stirring with a shear rate of 140 per seconds, until a solids content of 40% is reached. The dilution to 15% solids content was performed as in Experiments 1 and 2. The products obtained, without photo initiator are named 3.1 and 3.2.
Example 4 (4.1 and 4.2)
[0163] To samples obtained under experiment 3, 32 g of a photo initiator Irgacure®500 was added. The resulting samples are named 4.1 and 4.2.
Comparative Experiments (CE1-CE4)
[0164] A composition was prepared according to example 1 of U.S. Pat. No. 6,232,364 B1, with and without initiator. Samples CE1 and CE3 stand for a 40 wt % solids sample, respectively without and with photo initiator. Samples CE2 and CE4 stand for a 15 wt % solids sample, respectively without and with photo initiator.
[0165] In a four-necked flask equipped with a stirrer, condenser, thermometer and dropping funnel at each neck were placed 200 g of the trimer (isocyanurate) of hexamethylene diisocyanate and 135 g of xylene. A mixture of 116 g of 2-hydroxyethyl acrylate; 0.46 g of dibutyltin dilaurate as a catalyst and 0.1 g of methoquinone as a polymerizing inhibitor was dropwise added through the dropping funnel with stirring over 10 minutes at a fixed rate. The mixture was further stirred for 90 minutes, with keeping the temperature at 40° C. or lower, to give an intended acrylate solution. The completion of the reaction of the isocyanate group was confirmed by disappearance of the peak at 2270 cm −1 by infrared absorption spectra.
[0166] To 300 g of isopropyl alcohol as a solvent were added 40 g of dimethylaminoethyl methacrylate, 100 g of 2-hydroxyethyl methacrylate, 90 g of 2-ethylhexyl acrylate, 50 g of n-butyl methacrylate and 145 g of methyl methacrylate, and 75 g of styrene. Then, the combination photopolymeriation initiators namely, 1 g of 1-hydroxy-cyclohexyl phenyl ketone and 4 g of 2-hydroxy-2-methyl-1-phenylpropan-1-one were added for those samples comprising a photo initiator (samples CE3 and CE4).
[0167] The resulting mixture was placed in a 4-necked flask equipped with a stirrer and so on in the same way as described in the first paragraph and warmed up with stirring. After starting of flux, an equal amount of the mixture of the same component was drop wise added through the dropping funnel homogeneously over 90 minutes, and the mixture was stirred at 85° C. for 4 hours to give a solution of the copolymer resin having the cationic electrodeposition property. The average molecular weight of this copolymer was 26000, which was confirmed by GPC.
[0168] The copolymer solution (91 g) prepared as described in the previous paragraph was neutralized with 1.9 g of lactic acid. There was added the acrylate solution (71.4 g) prepared in accordance with the first paragraph and 1 g of 2-hydroxy-2-methylpropiophenone as a photopolymerization initiator with stirring. Then, the mixture was made to 1 liter in total by addition of ion-exchange water with stirring to give the ultraviolet curable coating composition for cationic electrodeposition.
Performance Tests
[0169] The 40% coating compositions (1.1, 2.1, 3.1, 4.1, CE1 and CE3) were tested as follows: a drawdown on glass with a wet film thickness of 300 μm was predried for 5 minutes at 90° C. and then UV cured (Hg-lamp with standard conditions: 120 W/cm and a speed of 5 m/min) to give a dry film thickness of 80 μm. The film is tackfree and has a pendulum hardness of 25 s. The adhesion on glass was very good.
[0170] The 15% solutions (1.2, 2.2, 3.2, 4.2, CE2 and CE4) were deposited by cationic electrodeposition at 100 V for 2 minutes on Zn phosphate panels. The electrodeposited film was predried at 90° C. and UV cured under the same conditions as in the drawdown test. The adhesion, as measured by a crosscut test, was excellent (value o); the coated panels were tested in the salt spray chamber following ASTM-B 117-64. This gave a delamination of 3 mm after 500 hours.
[0000]
TABLE 1
Performance tests on different substrates
Salt spray test
Solids
Pendulum
Metal
500 h,
Initiator
content
Particle size
hardness
Glass
adhesion,
delamination
Example
(Y/N)
(%)
Coatings application
(nm)
(s)
adhesion
cross cut
(mm)
1.1
N
40
drawdown (glass)
175
25
Good
1.2
N
15
electrodeposition (steel panels)
170
0-1
3
2.1
Y
40
drawdown (glass)
160
140
Good
2.2
Y
15
electrodeposition (steel panels)
165
0
1
3.1
N
40
drawdown (glass)
150
20
Good
3.2
N
15
electrodeposition (steel panels)
150
0
4
4.1
Y
40
drawdown (glass)
155
130
Good
4.2
Y
15
electrodeposition (steel panels)
155
0
2
CE1
N
40
drawdown (glass)
140
sticky
No
CE2
N
15
electrodeposition (steel panels)
140
None
Full
delamination
CE3
Y
40
drawdown (glass)
140
90
Medium
CE4
Y
15
electrodeposition (steel panels)
140
1
25
Examples 5-6 and Comparative Examples CE5 and CE6
[0171] Example 5 is the 40% dispersion of Example 1; i.e. without photo initiator.
[0172] Example 6 is the 40% dispersion of Example 5, to which 32 g of a photo initiator Irgacure® 500 was added.
[0173] These compositions were compared to a composition prepared according to example 1 of U.S. Pat. No. 6,232,364 B1 as previously described. The composition obtained, with initiator, is referred to as comparative example 5, abbreviated CE5.
[0174] Comparative composition CE6 is based on the non modified pure amino epoxy adduct (A) as described in example 1 (first part):
[0175] 740 g of the amine epoxy product (A) and 320 parts of (b2) corresponding to a solids ration of A to (b2) of 60:40 were neutralized with 48 parts of acetic acid 30% in water to provide a mixture. Then portions of water were added at 50° C. under stirring with a shear rate of about 140 per seconds, until a solids content of 40% by weight was reached. The particle size as measured with a Malvern Zetasizer was 195 nm. The 40% solution was diluted further to 15% with water.
[0176] To the sample as described above, 32 g of photo initiator Irgacure® 500 was added.
[0177] Performance tests were conducted on coatings obtained from the above described compositions. The pendulum hardness on a glass plate was tested. Corrosion resistance was tested according to ASTM B 117 for a coating deposited on Zn phosphate steel and on blank steel, 15 μm dry film thickness. The results were as summarized in Table 2.
[0000]
TABLE 2
Performance tests on different substrates
Test
Ex 5
Ex 6
CE5
CE6
Appearance
good
good
good
good
Uniformity
good
good
good
Good
Pendulum hardness
25
150
90
70
on glass plate (s)
Corrosion resistance
360
500
120
240
Zn phosphate steel (h)
Corrosion resistance
120
120
24
24
Zn blank steel (h)
Example 7
7.1 Alternative Modified Epoxy Resin-Amine Adducts
7.1.1 Preparation of Modifiers Carrying Aliphatic Groups (V1 to V3)
[0178] Modifier (V1): 577 g (3.1 mol) of 2-ethylhexyl glycidyl ether are added to a solution of 103 g (1 mol) of diethylenetriamine and 170 g of methoxypropanol at 60° C. in the course of 2 hours, and the mixture is reacted. A mixture of 190 g of a bisphenol A epoxy resin (epoxide equivalent weight of the epoxy resin (EEW) of about 190) and 48 g of methoxypropanol is then added at 60° C. in the course of 2 hours. The solid resin content is 80% by weight.
[0179] Modifier (V2): 1010 g (3.1 mol) of stearyl glycidyl ether in 129 g of methoxypropanol are added to a solution of 103 g (1 mol) of diethylenetriamine and 150 g of methoxypropanol at 60° C. in the course of 2 hours. A mixture of 190 g of a bisphenol A epoxy resin (EEW 190) and 48 g of methoxypropanol is then added at 60° C. in the course of 2 hours. The solid resin content is 80% by weight.
[0180] Modifier (V3): 372 g (2 mol) of ethylhexyl glycidyl ether are added to a solution of 104 g (1 mol) of aminoethylethanolamine and 119 g of methoxypropanol at 60° C. in the course of 2 hours. The solid resin content is 80% by weight.
7.1.2. Preparation of Further Components (A): (A1) to (A4)
[0181] Component (A1): 652 g (0.6 mol) of modifier (V1), 80% strength, 570 g of a bisphenol A diepoxy resin (EEW 190), 77 g (0.6 mol) of 2-ethylhexylamine and 162 g of methoxypropanol are reacted at 60° C. in a first reaction stage in a suitable reaction vessel until the NH-functionality has been converted completely. 1357 g (2 mol) of a 70% strength solution of a bisphenol A diepoxy resin (EEW 475) in methoxypropanol and 189 g (1.8 mol) of diethanolamine are then added, and the mixture is again reacted until the NH-functionality has been converted. In a third reaction stage, the remaining oxirane groups are reacted with 78 g (1.66 mol) of N,N-diethylaminopropylamine at 60° C. for 2 hours, at 90° C. for a further hour and at 120° C. for a further 3 hours, and the mixture is diluted with methoxypropanol to a solid resin content of 65% by weight.
[0182] Components (A2) to (A4): Components (A2) to (A4) are prepared in the same manner as in (A1) from the data summarized in Table 3. In the case of component (A3), reaction stage 4 is carried out such that after reaction stage 3, methoxypropanol and a polyoxypropylene glycol diglycidyl ether (EEW 200, commercial name DER® 736, Dow Chemical) are added at 120° C. and this temperature is maintained for 3 to 5 hours.
[0183] Component (A5): 500 g of a bisphenol A diepoxy resin (EEW about 500) are dissolved in 214 g of methoxypropanol and reacted with 83 g (0.3 mol) of a half-ester of phthalic anhydride and 2-ethylhexanol at 110 DEG C. in the presence of 0.5 g of triethylamine as a catalyst, to an acid number of less than 3 mg KOH/g. 120 g (0.4 mol) of an NH-functional oxazolidine of aminoethylethanolamine, 2-ethylhexyl acrylate and formaldehyde, and 26 g (0.2 mol) of diethylaminopropylamine are then added, and the batch is reacted at 80° C. The batch is diluted with 181 parts of methoxypropanol to a solid resin content of 70% by weight.
[0184] The parameters for all the products (A1) to (A5) are summarized in Table 4.
7.2. Preparation of Further Components (AB): AB1 to AB10
[0185] Component (AB1): 308 parts of component (A1), 65% strength, and 444 parts of methoxypropanol are heated to 85° C. in a reaction vessel which is suitable for free radical polymerization and is equipped with a stirrer, reflux condenser, feed vessel, nitrogen flushing and temperature measurement. A mixture of 84 parts of dimethylaminoethyl methacrylate, 159 parts of 2-hydroxyethyl methacrylate, 306 parts of n-butyl methacrylate, 106 parts of methyl methacrylate, 145 parts of 2-ethylhexyl acrylate, 24 parts of azobisisobutyronitrile and 2 parts of tert-dodecylmercaptan is then added uniformly in the course of 4 hours. The temperature is then increased to 90° C. and kept at this value for 2 hours. After addition of a further 10 parts of azobisisobutyronitrile, the batch is kept at 90° C. for a further 3 hours, to a degree of polymerization of at least 99.5%.
[0186] Further components (AB2 to AB10) are prepared according to the proportions shown in Table 5 in the same manner. The parameters for all the products are also summarized in Table 5. Explanation of the abbreviations in Table 5:
[0000] DAMA dimethylaminoethyl methacrylate
BAMA N-tert-butylaminoethyl methacrylate
HEMA 2-hydroxyethyl methacrylate
HEA 2-hydroxyethyl acrylate
HBA 4-hydroxyethyl acrylate
TGMA tripropylene glycol methacrylate
MMA methyl methacrylate
BMA n-butyl methacrylate
BA n-butyl acrylate
EHA 2-ethylhexyl acrylate
SMA stearyl methacrylate
ST styrene
DDM tert-dodecylmercapto (regulator)
AIBN azobisisobutyronitrile (starter)
[0000]
TABLE 3
Preparation of additional components (A)
Component
A1
A2
A3
A4
Stage 1
V1 solution
652
652
325
—
(80% strength in MP)
V2 solution
—
—
—
489
(80% strength in MP)
Epoxy resin EEW 190
570
722
380
570
2-Ethylhexylamine
77
122
65
—
Stearylamine
—
—
—
202
Methoxypropanol (MP)
162
455
237
193
Stage 2
Epoxy resin EEW 475
1330
1837
1647
1330
(75% strength in MP)
Methoxypropanol
—
268
223
—
V3 solution
—
952
536
—
(80% strength in MP)
Monoethanolamine
—
—
68
—
Diethanolamine
189
—
—
189
Stage 3
N,N-Diethylaminopropylamine
78
143
78
78
Methoxypropanol
—
61
33
—
Stage 4
Epoxy resin EEW 200
—
—
132
—
Methoxypropanol
—
—
57
—
[0000]
TABLE 4
Parameters for components (A1) to (A5)
Component
A1
A2
A3
A4
A5
Solid resin content (% by weight)
65
65
70
65
70
Amine number (mg KOH/g of solid
124
125
112
107
92
resin)
Hydroxyl number (mg KOH/g of
257
214
220
228
77
solid resin)
% by weight of ethylhexyl radicals
11.0
18.6
14.5
—
10.8
% by weight of stearyl radicals
—
—
—
18.5
—
[0000]
TABLE 5
Recipes for further preparations of components (AB)
AB1
AB2
AB3
AB4
AB5
AB6
AB7
AB8
AB9
AB10
(A1) (65%)
308
77
—
—
—
—
154
—
—
—
(A2) (65%)
—
—
154
462
—
—
—
—
—
(A3) (70%)
—
—
—
—
143
214
—
—
—
—
(A4) (65%)
—
—
—
—
—
—
—
154
77
—
(A5) (70%)
—
—
—
—
—
—
—
—
—
214
Methoxypropanol
444
—
501
280
515
—
503
501
532
491
Butoxyethanol
—
530
—
—
—
489
—
—
—
—
DAMA
84
—
80
112
67
107
73
—
115
98
BAMA
—
180
—
—
—
—
—
140
—
—
HEMA
159
250
—
—
200
235
—
—
240
205
HEA
—
—
—
168
—
—
228
—
—
—
HBA
—
—
154
—
—
—
—
205
—
—
TGMA
—
—
—
—
70
—
—
—
—
—
MMA
106
—
300
130
248
—
249
—
260
180
BMA
306
280
—
160
100
263
250
295
—
200
BA
—
—
100
—
—
—
—
—
230
—
EHA
145
200
266
130
215
185
100
—
—
167
SMA
—
—
—
—
—
—
—
180
105
—
ST
—
40
—
—
—
60
—
80
—
—
DDM
2
3
2
—
2
3
—
2
3
2
AIBN
24
32
28
35
34
27
34
30
35
28
Parameters
Amine number
55
60
41
77
35
55
38
53
46
49
(mg KOH/g)
Hydroxyl number
119
120
81
145
113
134
136
103
115
100
(mg KOH/g)
Solid resin content
65
65
65
70
65
65
65
65
65
65
(%)
Content of 2-
11.1
12.9
18.2
11.4
14.7
13.4
6.1
—
—
10.3
Ethylhexyl radicals in
the acrylate portion
(% by weight)
Content of stearyl
—
—
—
—
—
—
—
13.5
7.9
—
radicals in the
acrylate portion (%
by weight)
[0187] The combination of those components AB1 to AB10 provide similar results when combined with the ethylenically unsaturated compounds (b) as described here above. | The present invention relates to waterborne curing compositions for electrodeposition and radiation curing and processes to obtain such compositions. The compositions are characterized in that an ethylenically unsaturated compound (b), is dispersed in an aqueous solution by an at least partially neutralized (meth)acrylic modified amine epoxy adduct. The compositions of the invention are particularly suitable for coating metallic materials and temperature sensitive materials such as electrically conductive plastic materials. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of U.S. NonProvisional patent application Ser. No. 10/790,170 filed Mar. 1, 2004, now pending; which claims the benefit of and is a Continuation of Ser. No. 09/814,678 filed Mar. 21, 2001, now abandoned.
FIELD OF THE INVENTION
[0002] The methods and devices described below relate to the fields of treatment of migraines and/or headaches and noninvasive electrical stimulation of an acupuncture point.
BACKGROUND OF THE INVENTION
[0003] A headache is pain that occurs in the tissues covering the brain, the attaching structures at the base of the brain, and the muscles and blood vessels around the scalp, face, and neck. The three most common headaches are tension, migraine, and cluster. Tension headaches are the most common and cluster headaches affect only about one-percent of the population, mostly males. The exact mechanism for each type of headache is not known. Some experts theorize that they all occur from the same mechanism.
[0004] Migraines are divided into two types, the common migraine and the classical migraine. The difference between the common and the classical migraine is whether or not the patient experiences the migraine aura prior to experiencing the headache. The migraine aura is a composite of possible symptoms, namely, visual disturbances, light sensitivity, speech difficulty, tingling of the face or hands, and confusion. The common migraine is not preceded by an aura, while the classical migraine is preceded by an aura.
[0005] Research scientists are unclear about the precise cause of migraine headaches. There seems to be a consensus, however, that the key element is blood flow changes in the brain. One theory states that the nervous system responds to a trigger such as stress by creating a spasm in the nerve-rich arteries at the base of the brain. The spasm close down or constricts several arteries supplying blood to the brain, including the scalp artery and the carotid arteries. As these arteries constrict, the flow of blood to the brain is reduced. At the same time, platelets clump together, this process is believed to cause the release of serotonin. Serotonin acts as a powerful constrictor of arteries, thus further reducing the blood supply to the brain. This reduction in blood flow is likely the cause of the migraine aura.
[0006] The reduced blood flow decreases the brain's supply of oxygen. Reacting to the reduced blood supply, certain other arteries within the brain dilate in an attempt to increase the blood supply and thus the oxygen levels in the brain. The dilation spreads and finally affects the carotid and scalp arteries. The dilation of these arteries triggers the release of pain-producing prostagladins. Prostagladins cause inflammation and swelling. Other substances which increase sensitivity to pain are also released. The circulation of these chemicals and the dilation of the scalp arteries stimulate the pain-sensitive nociceptors. The result, a throbbing headache.
[0007] Acupuncture has long been used in the treatment of migraines and/or headaches. In accordance with well-known acupuncture standards, several acupuncture points are simultaneously stimulated to achieve the therapeutic goal. As taught in The Basics of Acupuncture by Stux and Pomeranz, Springer-Verlag, New York, pp. 237-238, 1995, the specific acupuncture points being used to treat the migraine or headache depends upon the where the patient is experiencing pain.
[0008] If the pain is along the gallbladder channel, then ten acupuncture points are stimulated: the top of the head (Du 20 Baihui), the forehead (GB.14 Yangbai), behind the ear (GB.20 Fengchi), above the ear (GB.8 Shuaigu), dorsal-side of lower arm (SJ.5 Waiguan), top of the hand between the thumb and index finger (LI.4 Hegu) , the toe (GB.41 Linqi), the ankle (GB.37 Guangming), top of the foot (St.44 Neiting), and the foot (Liv.3 Taichong). If the pain is in the area of the temple, then the top of the head (Du 20 Baihui), near the top of the head (St.8 Touwei), the temple (GB.4 Hanyan), top of the hand between the thumb and index finger (LI.4 Hegu)˜the elbow (LI.11 Quchi), top of the foot (St.44 Neiting), and the shin (St.36 Zusanli) are stimulated. If the pain is along the urinary bladder channel, then the top of the head (Du 20 Baihui), eyebrow (UB.2 Zanzhu), back of the neck (UB.10 Tianshu), the side of the hand near the pinkie finger (SI.3 Houxi), top of the hand between the thumb and index finger (LI.4 Hegu), the ankle (UB.60 Kunlun), and the little toe (UB.67 Zhiyin) are stimulated. If the pain is in the area of vertex Du 20 Baihui, then the top of the head (Du 20 Baihui), top of the head (Ex.6 Sishencong), the abdomen (Liv.14 Qimen), top of hand between the thumb and index finger (LI.4 Hegu) , dorsal-side of lower arm (SJ.6 Zhigou), the foot (Liv.3 Taichong), top of the foot (Liv.2 Xingjian), and the calf (GB.34 Yanlingquan) are stimulated. All the acupuncture points listed for each area of pain are stimulated simultaneously to obtain results.
[0009] Bertolucci, Nausea Control Device, U.S. Pat. No. 4,981,146, Jan. 1, 1991, describes a nausea control device in the form of a watch-like housing attachable to the human wrist by an adjustable attachment band. The device uses non-invasive nerve stimulation whereby electricity is passed through two electrodes to stimulate nerves located on the ventral side of the wrist (this anatomical position is sometimes referred to as the palmar side of the wrist). The treatment provided by the device is sometimes referred to as electro-acupuncture which is a form of acupuncture, and the ventral site of application is referred to in the acupuncture art as the P6 point, pericardium 6 point, or master point of the pericardium meridian (sometimes referred to as the vascular meridian). A primary object of the invention is to provide a non-chemical, non-invasive, painless and inexpensive method of alleviating nausea. It is also portable, self-contained and convenient to the patient. Electrical pulse repetition rate of approximately 70 pulses per second, and a pulse width of 80 microseconds has been found to provide effective relief of nausea in a patient. Our currently preferred electrical pulse pattern comprises about 350 microsecond pulse width at about 31 pulses per second at power levels of about 10-35 milli-amps peak pulse height. Thus a wide range of pulse patterns may be used in noninvasive nerve stimulation devices.
[0010] We have discovered that using noninvasive electrical stimulation of the P6 or Neiguan point of the pericardium meridian relieves migraines and/or headaches.
SUMMARY OF INVENTION
[0011] The method described below employs use of the device described in Bertolucci, Nausea Control Device, U.S. Pat. No. 4,981,146 (Jan. 1, 1991), and similar devices, for the relief and alleviation of migraines and/or headaches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates placement of an electro-acupuncture device over the P6 acupuncture point on the human wrist.
[0013] FIG. 2 illustrates a stimulation waveform for stimulating the wrist in accomplishing the treatment.
[0014] FIG. 3 illustrates an individual pulse of the stimulation waveform.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Use of our ReliefBand® NST™ device for the approved treatment of nausea has revealed that the treatment also relieves migraines and/or headaches. Significant reduction in migraines and/or headaches has been observed when electrostimulation is provided to the P6 point on the wrist. The ReliefBand® NST™ is a wristwatch like device worn on the wrist and energized to provide electrical stimulation to the wrists. The ReliefBand® NST™ non-invasive nerve stimulation device 1 is secured with strap 2 to the ventral side of the wrist 3 such that the pair of electrodes 4 are disposed over the median nerve 5 (indicated by the phantom line) in contact with the skin in the vicinity of the p 6 acupuncture point. The electrodes are on the underside of the housing 6 , the required battery and control electronics are housed within the housing, and input mechanisms are located on the outer face of the housing. The electrodes stimulate the median nerve and collateral or associated nerve structures.
[0016] FIG. 2 shows the preferred waveform. The overall waveform comprises a series of bipolar trapezoidal waveforms which make low frequency pulses 11 . The waveform is initiated at low power levels of about 1 to 2 volts and ramps up over a period of about 1 second to a maximum level of 10-20 volts, and is maintained for about 2 seconds, and then ramps down over a period of about 1 second to low power levels of about 1 to 2 volts. The individual pulses 12 are separated by about 32 milliseconds (msec) (measured peak to peak), and last about 350 microseconds (μsec). The individual pulses alternate between negative and positive pulses, and are said to constitute a bipolar waveform. The individual pulses are illustrated in FIG. 3 , in which the time scale is enlarged to show the detail. The individual pulse 12 is made of a sharply vertical spike which decays exponentially over a period of about 350 μsec, thus comprising a basically vertical leading edge 13 and an exponentially decaying trailing edge 14 to each individual pulse. The following pulse will be shaped the same, except that it will be of negative voltage. The exponential nature of the individual pulse decay maximizes the high frequency components in the signal. These high frequency components contribute to a lessening of the skin impedance, in particular the capacitive components. This contributes to a higher level of current able to enter the deeper tissues. The power levels may be adjusted up or down to intensify the therapeutic effect of the device or lessen the sensation causes by the device, according to the preferences of individual users. The pulse rate within the waveform may be increased or decreased also.
[0017] To use the device to alleviate migraines and/or headaches, the user merely secures the housing over the inner surface of the wrist and straps it on like a wristwatch. This places the electrodes over the P6 acupuncture point, in electrical contact with the skin overlying the median nerve. The user then turns the device on, adjusts it to a comfortable power level, and allows stimulation to continue for a few minutes, for example 5-10 minutes to achieve relief. The device may be applied intermittently, once every hour or so, or continuously. The device provides electrical current and voltage to the electrodes which stimulates the P6 acupuncture point. While less convenient, the methods may be accomplished with electro-acupuncture needles or electrodes handled individually by an acupuncturist.
[0018] While the devices and methods have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the inventions. Other embodiments and configurations may be devised without departing from the spirit of the inventions and the scope of the appended claims. | A device for providing noninvasive electrical stimulation of a single acupuncture site for treatment of migraines and/or headaches is disclosed. | 0 |
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
This invention relates to a vacuum bonded non-woven batt. The batt is characterized by having a relatively high density which renders it suitable for uses such as mattresses, furniture upholstery and similar applications where substantial density and resistance against compression is desired, together with substantial resilience which will return the batt to its shape and thickness after compression for an indefinite number of cycles.
There are a number of advantages to be achieved by construction of batts for use as mattresses and upholstery from synthetic, staple fiber material. Such fibers are inherently lightweight and therefore easy to ship, store and manipulate during fabrication. These fibers are also generally less moisture absorbent than natural fibers such as cotton, or cellulosic based synthetic fibers such as rayon. Therefore, products made from these fibers can be maintained in a more hygienic condition and dried with much less expenditure of energy. Many such fibers also tend to melt and drip rather than burn. While some of these fibers give off toxic fumes, the escape of such fumes can be avoided or minimized by encapsulating the batt in a fire retardant or relatively air impermeable casing. In contrast, fibers such as cotton burn rapidly at high heat and generate dense smoke.
However, synthetic staple fibers also present certain processing difficulties which have heretofore made the construction of a relatively dense non-woven batt from synthetic staple fibers difficult and in some cases impractical. For example, the resiliency inherent in synthetic fibers such as nylon and polyester is caused by the plastic memory which is set into the fiber during manufacture. By plastic memory is meant simply the tendency of a fiber to return to a given shape upon release of an externally applied force. Unless the plastic memory is altered by either elevated temperature or stress beyond the tolerance of the fiber, the plastic memory lasts essentially throughout the life of the fiber. This makes formation of a batt by compressing a much thicker, less dense batt very difficult because of the tendency of the fibers to rebound to their original shape. Such fiber batts can be maintained in a compressed state, but this has sometimes involved the encapsulation of the batt in a cover or container. All of these methods create other problems such as unevenness and eventual deterioration of the batt due to fiber shifting, breakage and breakdown of the mechanical structure which maintains the compressed batt.
Not only are the batts themselves subject to numerous disadvantages, but the manufacturing processes known in the prior art are deficient in numerous respects. For example, insofar as is known all processes compress the batt into its desired density by use of engaging members such as rollers or plates on both sides of the batt. In effect, the batt is heated simultaneously from both sides to the point where its elastic memory is relaxed. However, the batt must then be removed from the rollers, plates or the like which have held the batt in its compressed state. Even with the use of TFE or other similarly coated rollers or plates, sticking is a common problem. In addition, even heating is inherently difficult to obtain since the fibers in contact with the heated metal surfaces are heated almost instantly whereas fibers in the interior of the batt are heated at a much slower rate. If the rollers between which the batt is traveling are heated to the extent necessary to completely relax the plastic memory of the fibers on the interior of the batt, quite often the fibers in intimate contact with the rollers will melt completely or disintegrate. If the rollers are cooled to avoid complete melting of the fibers on the outer surface of the batt, the interior fibers are not heated sufficiently to reset their plastic memory. In this event, the outer fibers are constantly being pushed against from the interior by fibers whose plastic memory is constantly attempting to cause the fibers to reassume their original shape. Attempts to correct this problem have included varying the percentage of fibers having relatively different melting temperatures through the cross-section of the batt or providing fibers on the interior of the batt having a relatively lower temperature at which the elastic memory is relaxed.
SUMMARY OF THE INVENTION
Therefore, it is an object of the invention to provide a vacuum bonded non-woven batt.
It is another object of the present invention to provide a vacuum bonded non-woven batt wherein the fibers of the batt are evenly fused together from the side to the other by heated air.
It is another object of the present invention to provide a vacuum bonded non-woven batt having an even distribution of first and second constituent fibers throughout the batt.
It is yet another object of the invention to provide a vacuum bonded non-woven batt wherein the desired density and thickness of the batt can be maintained without physically compressing the batt between rollers, plates or the like during manufacture.
These and other objects and advantages of the present invention are achieved by providing a dense, resilient, non-woven staple polymer fiber batt comprised either of at least one relatively thick web or a plurality of overlayed, relatively thin webs. In each case, the web or webs comprise at least first and second staple polymer fiber constituents blended to form a homogeneous intermixture of the fibers. The first fiber constituent has a relatively low predetermined melting temperature and the second fiber constituent has a relatively high predetermined melting temperature. The fibers of the first fiber constituent are fused by heat to themselves and to the fibers of the second fiber constituent to intimately interconnect and fuse the fibers within the web layers and each of the web layers to adjacent web layers while the web layers are in a vacuum-compressed state. The heat is sufficient to melt the fibers of the first fiber constituent but not high enough to melt the fibers of the second fiber constituent. Upon cooling, the fibers of the first fiber constituent retain a plastic memory of the batt in its compressed state to hold the web layer or layers at the compressed thickness of the batt. The fibers of the second fiber constituent retain the plastic memory of the fibers in their non-compressed state and thereby provide substantial resilience to the batt in counteracting compressive forces exerted on the batt by the fibers of the first fiber constituent.
In accordance with one embodiment of the invention, the first and second fiber constituents each comprise polyester. The relatively low melting temperature of the first polyester fiber constituent is in the range of from 240° to 300° F. (115°-149° C.).
Also according to a preferred embodiment, the fiber batt has a density before compression of approximately 4 ounces per cubic foot (4 kg/cm) and a density after compression of approximately 20 ounces per cubic foot (20 kg/cm).
According to the same embodiment, the fiber batt may have a fiber mixture wherein the relatively low melting temperature fiber constituent comprises 15 percent by weight of the fiber batt and the other fiber constituent comprises 85 percent by weight of the fiber batt.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the description of the invention proceeds when taken in conjunction with the following drawings, in which:
FIG. 1 is a block diagram of a method according to which a fiber batt according to the present invention is constructed;
FIG. 2 is a perspective view of a multilayer web structure in its uncompressed state;
FIG. 3 is a fragmentary side elevational view of an apparatus according to which a fiber batt according to the present invention is constructed;
FIG. 4 is a fragmentary end elevational view showing one of the rotating drums shown in FIG. 3 with associated drive and vacuum components;
FIG. 5 is a schematic view of the two drums shown in FIGS. 3 and 4 in a given intermediate spaced-apart relation;
FIG. 6 is a view similar to FIG. 5 showing the two drums in a closer spaced-apart configuration for producing a relatively thinner batt;
FIG. 7 is a view similar to FIG. 5 showing the two drums in a relatively further spaced-apart configuration for producing a relatively thicker batt;
FIG. 8 is an enlarged, fragmentary perspective view showing the perforated surface of one of the drums with the vacuum-compressed multilayer web structure in position thereon;
FIG. 9 is a perspective view of a batt according to the invention;
FIG. 10 is a perspective view of a batt in the form of a mattress with mattress cover thereon in accordance with the present invention; and
FIG. 11 is a magnified section in a single plane of the fiber structure of a batt according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now specifically to the drawings, a block diagram of the method according to which a batt according to the invention is constructed is shown in FIG. 1. The method begins by opening and blending suitable staple fibers. The stable fibers to be used are chosen from the group defined as thermoplastic polymer fibers such as nylon and polyester. Of course, other thermoplastic fibers can be used depending upon the precise processing limitations imposed and the nature of the compressed batt which is desired at the end of the process. For purposes of this application, the batt is constructed of 85 percent Type 430 15 denier, 3 inch (7.6 cm) staple polyester and 15 percent Type 410 8 denier 2 inch (5 cm) staple polyester, both manufactured by Eastman Fibers. The Type 430 polyester is a conventional polyester fiber which has a melting temperature of approximately 480° F. (294° C.). As used in the specification and claims, this fiber is referred to as having a relatively high predetermined melting temperature as compared with the Type 410 low melt polyester which has a melting temperature of approximately 300° (149° C.).
Low melt polyester of the type referred to above has a melting temperature of approximately 300° F. (149° C.), but begins to soften and become tacky at approximately 240° to 260° F. (115°-127° C.).
As used in this application, however, the term melting does not refer to the actual transformation of the solid polyester into liquid form. Rather, it refers to a gradual transformation of the fiber over range of temperatures within which the polyester becomes sufficiently soft and tacky to cling to other fibers within which it comes in contact, including other fibers having its same characteristics and, as described above, adjacent polyester fibers having a higher melting temperature. It is an inherent characteristic of thermoplastic fibers such as polyester and nylon, that they become sticky and tacky when melted, as that term is used in this application. Also, thermoplastic fibers lose their "plastic memory" when thus heated. The process and apparatus described in this application take advantage of these two simultaneous occurrences by softening and releasing the plastic memory in the fibers having the relatively low melting temperature and causing these fibers to fuse to themselves and to the other polyester fibers in the mat which have not melted and which have not lost their plastic memory.
The opened and blended fiber intermixture is conveyed to a web forming machine such as a garnet machine or other type of web forming machine. As illustrated in this application, the thickness of a single web formed in the web formation step will be approximately 1/2 to 3/4 of one inch (1.3-1.9 cm) thick, with a square foot (0.09 m 2 ) piece of the web weighing approximately 1/3 of an ounce (8.5 gm). However, an air laying machine, such as a Rando webber can be used to form a thick, single layer web structure. Further discussion relates to the multilayer web structure formed by a garnet machine.
Once formed, the web is formed into a multilayer web structure by means of an apparatus which festoons multiple thicknesses of the web onto a moving slat conveyor in progressive overlapping relationship. The number of layers which make up the multilayer web structure is determined by the speed of the slat conveyor in relation to the speed at which successive layers of the web are layered on top of each other. In the examples disclosed below, the number of single webs which make up a multilayer web structure range between 6 and 28, with the speed of the apron conveyor ranging between 27 feet per minute (8.2 m/min) and 6 feet per minute (1.82 m/min). See FIG. 2.
Once the multilayer web structure is formed, it is moved successively onto first and second rotating drums where the web structure batt is simultaneously compressed by vacuum and heated so that the relatively low melting point polyester melts (softens) to the extent necessary to fuse to itself and to the other polyester fibers having a relatively higher melting point. The structure is cooled to reset the plastic memory of the relatively low melting point polyester to form a batt having a density and thickness substantially the same as when the batt was compressed and heated on the rotating drums. See FIG. 9.
Then, as desired, the batt may be covered with a suitable cover such as mattress ticking or upholstery to form a very dense and resilient cushion-like material. See FIG. 10.
The resulting construction offers substantial advantages over materials of equivalent density such as polyurethane foam. The resulting cushions or mattresses are usable in environments such as aircraft and prisons where a relatively high degree of fire retardency and relatively low output of toxic fumes is desired. Polyester is particularly desirable from this standpoint, since it does not flash-burn and is self-extinguishing. When fully melted to liquid state, polyester drops off when exposed to flame or rolls, with a black, waxy edge forming along the effected area. By enclosing the entire batt within a cover, a much safer product than either foam or cotton is achieved.
Referring now to FIG. 3, an apparatus 10 according to the invention by which the method described above may be carried out is shown. Apparatus 10 includes a large substantially rectangular sheet metal housing 11, the upper extent of which comprises an air recirculation chamber. A one million BTU (252,000 kg-cal) gas furnace 13 is positioned in the lower portion of housing 11. Upward movement of the heated air from gas furnace 13 through the housing provides the heat necessary to soften and melt the polyester.
Two counter-rotating drums 15 and 16, respectively, are positioned in the central portion of housing 11. Drum 15 is positioned adjacent an inlet 17 through which the multilayer web structure W is fed. The web structure is delivered from the upstream processes described above by means of a feed apron 18 through inlet 17. Drum 15 is approximately 55 inches (140 cm) in diameter and is perforated with a multiplicity of holes 20 (see FIG. 8) in the surface to permit the flow of heated air.
In the embodiment illustrated in this application, the drum has thirty holes per square inch (4.7 per sq.cm) with each hole 20 having a diameter of three thirty-seconds of an inch (2.4 mm).
A suction fan 21 preferably having a diameter of 42 inches (107 cm) is positioned in communication with the interior of drum 15. As is also shown by continued reference to FIG. 3, the lower one half of the circumference of drum 15 is shielded by an imperforate baffle 22 so positioned inside drum 15 that suction-creating air flow is forced to enter drum 15 through the holes 20 in the upper half.
Drum 15 is also mounted for lateral sliding movement relative to drum 16 by means of a shaft 23 mounted in a collar 24 having an elongate opening 25. Once adjusted, shaft 23 can be locked in any given position within collar 24 by any conventional means such as a locking pillow block or the like. (Not shown).
Drum 16 is mounted immediately downstream from drum 15 in housing 11. Drum 16 includes a ventilation fan 27, also having a diameter of 42 inches (107 cm). Note that fans 21 and 27 are shown in FIG. 3 in reduced size for clarity. An imperforate baffle 28 positioned inside drum 16 and enclosing the upper half of the circumference of drum 16 forces suction creating air flow to flow through the holes 20 in the lower half of the drum surface.
Preferably, the drum 16 contains the same number and size holes 20 as described above with reference to drum 15. The exiting batt is simultaneously cooled and carried away from housing 11 by a feed apron 30.
Both drums are ventilated and driven in the manner shown in FIG. 4. As is shown specifically with reference to drum 15, fan 21 recirculates heated air back to the ventilation chamber of 12 of housing 11 by means of a recirculating conduit 33. Drum 15 is driven in a conventional manner by means of an electric motor 35 connected by suitable drive belting 36 to a drive pulley 37.
Referring again to FIG. 3, multilayer web structure W in uncompressed form enters housing 11 through inlet 17. Suction applied through the holes 20 in drum 15 immediately force the web structure W tightly down onto the rotating surface of drum 15 and by air flow through the holes 20 and through the porous web structure. As is apparent, the extent to which compression takes place at this point can be controlled by the suction exerted through drum 15 by fan 21. The air temperature is approximately 325° F. (163° C.).
By continued reference to FIG. 3, it is seen that one side of the mat is in contact with drum 15 along its upper surface. At a point between drum 15 and drum 16, the web is transferred to drum 16 so that the other side of the web is in contact with the surface of drum 16 and the surface which was previously in contact with drum 15 is now spaced-apart from the surface of drum 16. In effect, a reverse flow of air is created. It has been found that an extraordinarily uniform degree of heating takes place by doing this. Therefore, the polyester fibers having a relatively low melting temperature can be melted throughout the thickness of the web without any melting of the polyester fibers having the relatively high melting temperature.
In order to maintain constant vacuum pressure on the web throughout the housing, it is important that intimate contact between the web structure and either drum 15 or 16 be maintained at all times. To do this, it is important that a gap not be created at the point of transfer of the web structure between drum 15 and drum 16. For example, if the space between the adjacent surfaces of drum 15 and 16 was 5 inches (12.7 cm) and the thickness of the web being transferred at that point was only 3 inches (7.6 cm), a relatively thin length of drum surface on both drums 15 and 16 would be exposed to the free flow of air therethrough. The unrestricted flow of air could damage the web structure. Furthermore, vacuum would not be exerted on the web for a portion of the distance between drum 15 and 16, thereby allowing the polyester fibers having the relatively high melting temperature and which still retain their plastic memory to begin to resume their uncompressed state. This would cause undesirable movement between the softened low melt polyester fibers and the adjacent polyester fibers having the higher melting temperature. Therefore, shaft 23 is adjusted in opening 24 as is illustrated in FIGS. 5, 6 and 7. The adjustment is made according to the thickness of the web being processed so that the distance between adjacent surfaces of drum 15 and 16 very closely approximate the thickness of the web in its compressed state as it is transferred from drum 15 to drum 16.
Assuming a web thickness of 4 inches (10 cm) in its compressed state on drum 15, the distance between adjacent surfaces of drums 15 and 16 in FIG. 5 would be 4 inches (10 cm). To manufacture a web having less thickness, drums 15 and 16 would be moved closer together by sliding shaft 23 forward in opening 24 so that, for example, the distance between drums 15 and 16 would be 2 inches (5 cm) when processing a 2 inch (5 cm) web. Conversely, to process a thicker web, shaft 23 would be moved rearwardly in opening 24 thereby moving drum 15 away from drum 16 so that, again, the thickness of the distance between adjacent surfaces of drums 15 and 16 closely approximates the thickness of the web in its compressed state. It is important to note that the web structure is not being compressed by the adjacent drum surfaces at this point. Compression continues to occur only because of vacuum pressure.
As noted above, a wide variety of high density batts can be created by altering the manufacturing of variables in many different ways. In the table that follows, only a few of the many possible processing combinations are illustrated. In the following examples, note the dramatic increase in air flow consistent with the decrease in the input web thickness even though lower fan rpms are needed.
TABLE I__________________________________________________________________________ FINISHEDFINISHED PRODUCT INPUT WEB NO. TOTAL FANPRODUCT DENSITY THICKNESS THICKNESS OF CAPACITY FAN APRON SPEED AIR TEMP.oz/ft.sup.3 & (kg/m.sup.3) inches (cm) inches (cm) LAYERS CFM (M.sup.3 /sec) RPM ft/min (m/min) °F. (°C.)__________________________________________________________________________ 22.2 4.4 (11) 20 (51) 28 5,000 (2.36) 800 6.0 (1.82) 325 (163)24 3.5 (8.9) 18.5 (47) 26 4,800 (2.26) 850 6.5 (1.98) "20 3.0 (7.6) 13.5 (34) 18 7,500 (3.54) 700 9.0 (2.74) "19 2.0 (5.1) 9.0 (23) 12 8,000 (3.78) 600 13.0 (3.96) "20 1.0 (2.5) 5.0 (13) 6 10,000 (4.72) 550 27.0 (8.2) "__________________________________________________________________________
Once the batt leaves housing 11 it cools very rapidly into a dense batt having the same thickness as when processed in housing 11. Cooling resets the plastic memory of the low melt polyester fibers, fusing the low melt polyester fibers to themselves and also to the fibers having the relatively higher melting temperature. Because of the compression created by the vacuum, many fibers from adjacent web layers fuse to each other. The result is a homogeneous structure which, from visual observation, does not appear to have been constructed from a plurality of thinner layers. (See FIG. 9). The batt processed on the apparatus and according to the method described above therefore has fibers with plastic memories set at two different temperatures. The plastic memory of the low melting point fibers act as springs to pull the batt into a compressed state. The plastic memory of the fibers having the higher melting temperature urge the batt to expand but are prevented from doing so by the low melt fibers. The result is a batt which, while being held in a relatively dense, compressed state nevertheless has considerable resiliency.
A vacuum bonded non-woven batt is described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment according to the present invention is provided for the purpose of illustration only and not for the purpose of limitation--the invention being defined by the claims. | A dense, resilient, non-woven staple polymer fiber batt is formed of either of a plurality of overlayed, relatively thin webs or at least one relatively thick web. The web or webs comprise at least first and second staple polymer fiber constituents blended to form a homogenous mixture. The first fiber constituent has a relatively low melting temperature and the second fiber constituent has a relatively high melting temperature. The fibers of the first fiber constituent are fused by heat to themselves and to fibers of a second fiber constituent to interconnect the fibers while in a vacuum-compressed state. The heat is sufficient to melt the fibers of the first fiber constituent but not high enough to melt the fibers of the second fiber constituent. Therefore, the fibers of the first fiber constituent retain a plastic memory of the batt in its compressed state to hold the interconnected web layers together at the compressed thickness of the batt, and the fibers of the second fiber constituent retain the plastic memory of the fibers in their non-compressed state to provide substantial resilience. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to toilet seat covers, and more particularly pertains to a new and improved automated toilet seat cover wherein the same is provided with a housing centrally positioned between opposed ends of a toilet seat selectively actuatable to present successive covering to the associated toilet seat.
2. Description of the Prior Art
The use of various automated toilet seat covers for effecting sanitary usage of the associated toilet seat is known in the prior art Heretofore the apparatus utilized in the prior art has been of a relatively cumbersome and expansive organization. Examples of prior art automated toilet seat covers may be found in examples such as U.S. Pat. No. 4,662,009 to Hefty wherein a detection system to check to see that a length of hose shaped foil is dispensed about an associated toilet seat in one seat length increments. The Hefty patent utilizes a plurality of spaced motors positioned in general alignment relative to one another to dispense and retract the foil associated with the toilet seat.
U.S. Pat. No. 4,297,750 to Lutz sets forth a housing including a roll of perforated toilet seat covers for positioning over a forwardly oriented toilet seat.
U.S. Pat. No. 8,271,792 to Tromp sets forth a toilet seat covering arrangement wherein a plurality of seat cushions including webs of paper mechanically drawn over the associated toilet seat driven by the swinging movement of the seat. The Tromp patent is typical of the prior art and the associated awkward use of spaced rolls for dispensing seat covering means.
U.S. Pat. No. 2,491,187 to Knoetzsch sets forth a toilet seat protector arrangement wherein pivotment of levering arrangements associated with the toilet seat effects dispensing of covering material to an associated toilet seat and as in the previously noted Tromp patent, is of a cumbersome and awkward arrangement in association with a toilet seat.
U.S. Pat. No. 3,961,386 to Beno sets forth an apparatus for positioning an endless sheet overlying a toilet seat including a plurality of housings positioned exteriorly of opposed sides of the associated commode to present a new toilet seat cover to an associated toilet seat.
As such, it may be appreciated that there is a continuing need for a new and improved automated toilet seat cover apparatus which addresses both the problems of compactness of organization and effectiveness in operation, and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of automated toilet seat cover apparatus now present in the prior art, the present invention provides an automated toilet seat cover apparatus wherein the same is compactly efficiently positioned within a modular housing between opposed terminal ends of an associated toilet seat. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved automated toilet seat cover apparatus which has all the advantages of the prior art automated toilet seat cover apparatus and none of the disadvantages.
To attain this, the present invention comprises an automated toilet seat cover apparatus wherein the same includes a plurality of spaced parallel rolls positioned within a modular housing with an associated drive motor therebetween. An actuating gear on the drive motor cooperates with driven gears on the spaced rolls to simultaneously dispense and retract associated covering material. An axially extending wheel extends exteriorly and in axial alignment with the motorized gear for manual actuation of the apparatus. The toilet seat is provided with a plurality of hinges secured to "U" shaped brackets extending from forward surfaces proximate the terminal ends of the toilet seat rearwardly in axial alignment with one another and a hinge mounting the housing.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved automated toilet seat cover apparatus which has all the advantages of the prior art automated toilet seat cover apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved automated toilet seat cover apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved automated toilet seat cover apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved automated toilet seat cover apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such automated toilet seat cover apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved automated toilet seat cover apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new and improved automated toilet seat cover apparatus wherein the same is compactly oriented between spaced terminal ends of an associated toilet seat to dispense and retract covering material about the toilet seat.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of the instant invention.
FIG. 2 is a top orthographic view of the instant invention.
FIG. 3 is a frontal orthographic view taken in elevation of the instant invention.
FIG. 4 is an isometric illustration, somewhat expanded, of the modular housing positioned between opposed terminal ends of an associated toilet seat lid.
FIG. 5 is an orthographic bottom plan view of the instant invention.
FIG. 6 is an orthographic side view taken in elevation of the housing of the instant invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 6 thereof, a new and improved automated toilet seat cover apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, it will be noted that the automated toilet seat cover apparatus 10 essentially comprises a toilet seat 12 in combination with a commode 11. The toilet seat 12 is formed with spaced first and second terminal ends positioned rearwardly about the central opening of the commode with a housing 15 fixedly positioned therebetween.
The housing 15 is formed with a base 16 defining a compartment therewithin with an overlying pivotally mounted lid 17 with a first hinge 18 pivotally mounting a rearward edge of the base 16 to a top surface of the commode 11. A spring 19 is positioned between the base 16 and the top surface of the commode 11 to normally bias the housing 15 and associated toilet seat 12 upwardly at an angle relative to the top surface of the commode 11. A latch 20 normally secures the lid 17 relative to the base 16 and enables selective access to the interior compartment defined interiorly of the housing 15 to enable replenishment of the tubing utilized by the interiorly positioned retraction and dispensing rolls 24 and 25 respectively. The base 16 of the housing 15 is formed with pairs of aligned recessed slots 21 formed in communication with the upper edge of the base 16 to receive respective spaced first and second axles 22 and 28 of the respective retraction and dispensing rolls 24 and 25. The rolls 24 and 25 are in paralleled spaced alignment to each other, and wherein the rearward ends of the respective first and second axles 22 and 28 are provided with first and second driven gears 26 and 27. The parallel spaced alignment of the rolls 24 and 25 is significant to enable a single central drive gear 28 to operate simultaneously both driven gears 26 and 27. The central drive gear 28 is operative by means of a motor 81 provided with an outwardly extending motor axle 30. The motor axle 30 extends exteriorly of the base 16 and associated housing 15 and terminates with a manual over-ride wheel 29 whereupon a malfunction of the motor 31 enables manual turning of the serrated circumferential surface of the wheel 29 to enable actuation of the retraction and dispensing rolls 24 and 25 respectively.
The dispensing roll 25 is defined by a roll of tubular covering material 32 and is delivered to envelop the toilet seat 12 originating at the second end 14 through a dispensing slot 17a formed in a side wall of the lid 17. Similarly, a receiving slot (not shown) of parallel construction to the dispensing slot 17a receives the terminal end of the tubular covering 32 for securement about the retraction roll 24. To assist in securement initially of the forward terminal end of the tubular covering 32, a plurality of projecting tape ends 32a are formed at the forward terminal end of the tubular covering 32 for securement initially about the retraction roll 24 to secure that end to the associated roll. The tubular covering 32 is formed with a slit 33 positioned in alignment with the interior circumferential edge of the seat in alignment with a plurality of first and second "U" shaped brackets 34 and 35 formed with a first short leg extending orthogonally outwardly of the interior circumferential edge of the seat 12 with an intermediate base portion extending downwardly orthogonally relative to the first leg with a longer leg extending rearwardly underlying each respective surface adjacent the ends 13 and 14 of the seat 12 and are each respectively formed with a hinge defined by a second hinge 36 of the "U" shaped bracket 34, and a third hinge 37 formed at a rearward terminal end of the second "U" shaped bracket 35. It should be noted that the first hinge 18, the second hinge 36, and the third hinge 37 are each in alignment along a hinge access 38 to enable unencumbered pivotment of the seat 12 with respect to the commode 11. First and second "U" shaped brackets 34 and 35 are integrally secured together in association with the housing 15 by a link 40 integrally joining the first and second " U" shaped brackets together and integrally secured to the bottom surface of the base 16 to enable unitary pivotment of the housing 16 and the toilet seat 12. An actuator button 39 is positioned through-extending a top surface of the lid 17 to energize the associated motor 31 in a conventional manner to direct a desired amount of covering about the seat 12. The motor 31 may receive power through a conventional battery pack (not shown) or through the use of a direct current transformer, as is conventional in the application of power to direct current motors of this class.
The upward bias of the housing 15 in association with the toilet seat 12 by the spring 19, as noted earlier, spaces the toilet seat 12 above the top surface of the commode 11 and lifts the associated forward ribs 12a, mounted to the lid 12, slightly above the top surface of the commode 11 to eliminate friction and resistance that would normally be effected by the positioning of the ribs 12a upon the top surface of the commode 11.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above description, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | An automated toilet seat cover is provided wherein a plurality of spaced parallel rolls are rotatably mounted within the housing positioned between rearwardmost ends of a toilet seat. The rolls are provided with rearwardly extending axles with gears secured thereon for cooperation with a medially positioned selectively actuatable motor for simultaneously dispensing and reeling in a tubular seat cover for overlying securement of the toilet seat. The motor is provided with a rearwardly extending axle positioned exteriorly of the housing with a manually rotatable wheel for manual actuation of the plurality of rolls. | 0 |
This invention relates to the construction of automobile seats, and is directed particularly to the manner of attachment of a headrest to the frame of an automobile seat.
BACKGROUND TO THE INVENTION
The headrest on an automobile seat is often made adjustable as to height. One common way in which the headrest is mounted on the seat in a way that permits height adjustment is for the headrest to be provided with two downwardly extending pegs, and the pegs engage sockets secured into the frame of the seat. Detent means are usually provided which interact between the pegs and the sockets, whereby the headrest may be set, by the occupant of the vehicle, at one of a number of pre-set heights.
The socket in which the peg is received comprises a metal tube. A plastic liner may be provided in the tube, to act as a bearing material for the peg. In the conventional system, the tube is welded to a bracket, and the bracket is welded to a frame piece of the seat. This manner of attachment, though secure enough (because it has to be secure by regulation), unfortunately is expensive as to the labour time and the materials needed to make it that secure. Any securement system that involves welding tends to be labour-intensive and therefore expensive, besides being difficult to inspect and test. A welded system generally has to be over-engineered.
Also, welding does not lead to high accuracy. The need for accuracy of placement of the headrest on the seat is not high, although the accuracy of the spacing of the pegs and their sockets cannot be too far out; the conventional welded-on system is just about at the limit for accuracy for welding, which means that, when welding is used as the basis of the attachment method, skilled care has to be taken, which in turn does nothing to ease the cost problem.
The invention is aimed at providing a manner of securing a headrest support tube into a seat frame, in a manner that eases some of the compromises that have had to be resorted to in the conventional systems.
Typically, the operations carried out in a conventional seat manufactory include welding, bending of frame pieces, securing components together, and assembly, all of which tend to have a higher labour content. It is an aim of the headrest support system as described herein, to minimise the labour content of the task of attaching the support tubes to the seat frame piece.
Support tubes for headrests are conventionally attached to the seat frame piece by welding a bracket onto the frame piece, and then welding the tube to the bracket. Sometimes, the tube is pressed into holes in the welded-on bracket; but welding is nearly always resorted to, to assure that the tube remains in position on the bracket. Of course, the tubes can be attached securely enough, but the conventional costs of ensuring that security are high.
GENERAL FEATURES OF THE INVENTION
The invention lies in the manner of attaching the headrest-support-tube. First, the headrest-support-tube is provided with a first ring, in which the metal of the headrest-support-tube is expanded radially outwards. The headrest-support-tube is assembled into a hole in the web of the seat-frame-piece, with the first ring abutting against the web.
The frame-piece, with the headrest-support-tube resting therein, is placed in the die of a punch and die set, with the first ring in the die. The punch then is brought down over the other end of the headrest-support-tube, and a second ring is formed on the other side of the web. When the punch is withdrawn, the web lies gripped between the two rings. Usually, another headrest-support-tube is inserted into the frame-piece, in a similar manner. Then, the seat-frame piece is assembled into a seat, and finally the pegs of the headrest are inserted into the headrest-support-tubes.
THE PRIOR ART
As mentioned, headrest-support tubes are attached to the seat-frame-piece by welding. Sometimes, designers have specified intermediate brackets, rather than just welding the tube to the frame piece.
Techniques for mounting a tube into a through-hole in a piece of sheet metal are commonplace, per se. The broad range of options available include bulk-head fittings generally. Such fittings have included cases where a first bead is provided on the tube on one side of the sheet, then a second bead is swaged into the tube after the tube has been inserted into the through-hole. The technique is commonly known as lock-beading.
In cases where bulk-head fittings are being designed, a common requirement is that the fitting be air- or liquid-tight. It is recognised that the lock-beading technique is not suitable for such cases. It is recognised that lock-beading is highly suitable for cases where mechanical integrity is paramount, rather than sealing. It is also recognised that lock-beading is highly suitable for cases where access to the beads is only to be had from an axial direction, such as a case where flat-access to the through-hole is denied because the through-hole is surrounded by raised flanges.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
By way of further explanation of the invention, exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a diagram of an automobile seat frame, shown partly in cross-section, carrying a headrest which is mounted in a manner in accordance with the invention;
FIG. 2 is a view of some of the components that support the headrest, shown at a preliminary stage of manufacture;
FIG. 3 is a view of a punch and die set-up, which is used at a stage in the manufacture of one of the headrest supports;
FIG. 4 is a view corresponding to FIG. 3 of another stage during manufacture;
FIG. 5 is a cross-section of the headrest mounting support, shown at a later stage;
FIGS. 6a, 6b, 6c are cross-sections of a tooling arrangement for forming a metal tube locally into an I-section beam;
FIGS. 7a, 7c are views on the line 7--7 of FIG. 6a, corresponding to the conditions shown in FIGS. 6a and 6c respectively;
FIGS. 8a, 8b are cross-sections of a hole-punching arrangement, for making a through-hole in the web of the I-beam produced as in FIG. 6c;
FIG. 9 is a view of a headrest-support-tube, shown prior to final forming;
FIGS. 10a, 10b, 10c are cross-sections of a tooling arrangement for ring-bead-locking the headrest-support-tube of FIG. 9 into the through-hole in the web of the I-beam.
The apparatuses shown in the accompanying drawings and described below are examples which embody the invention. It should be noted that the scope of the invention is defined by the accompanying claims, and not necessarily by specific features of exemplary embodiments.
FIG. 1 shows an automobile seat 20, having a seat frame piece 23. In this case, the seat frame piece 23 made from a length of extruded I-section aluminum. The seat frame piece is bent generally into an inverted U-shape, as shown, in which the horizontal rail 24 of the U-shape forms the horizontal top rail of the seat.
The headrest 25 of the seat 20 is formed with two pegs 26, which protrude downwards, as shown. The pegs engage into support tubes 27, which are integral with the frame of the seat. The support tubes 27 are fixed firmly to the horizontal rail 24, and in fact the support tubes pass through holes 28 in the web 29 of the I-section that forms the rail 24 (see FIG. 2).
The invention is concerned with the manner of attaching the support tubes 27 into the holes 28 in the web 29 of the I-section. Usually, headrests are adjustable as to vertical position, and the adjustment is effected by moving the headrest, with its two pegs 26, vertically up or down within the tubes 27.
The designer can provide a plastic sleeve 30, which is inserted into the support tube to provide a bearing for guiding the pegs for up/down adjustment movement. The designer can provide the pegs with detents (not shown), which interact with the plastic sleeves 30, or with the tubes 27, in order to define some vertical positions to which the headrest might be set. It is usually necessary to align the plastic sleeve orientationally with respect to the tube, and the plastic sleeve can be moulded with a tongue for engagement with a notch 32 (FIG. 5) in the tube, for this purpose.
In order to manufacture the seat frame, with the headrest support tubes 27 attached, first the tubes are formed with a single first swaged-out ring 34. The tube in this state is as shown in FIG. 2.
The swaged-out ring 34 is formed by pressing the ends of a plain length of tubing axially, and confining the walls thereof everywhere but at the place where the ring is to be formed. It may be noted that this first operation is carried out on the tube when only the tube itself is present, i.e in the absence of any other components. The operation of forming the first ring is of low labour content, and can be easily automated.
The job of attaching the tube 27, with its first swaged-out ring 34, into the hole 28 in the web 29 of the I-section, can also be fully automated, as can the job of swaging the first ring into the tube. This may be compared with the job of welding a bracket onto the frame piece, and then locating a tube into holes in the bracket, and then welding the tube to the bracket, in which the labour content is inevitably high.
FIG. 3 shows the tube 27, with its first swaged-out ring 34, resting in a die 35. The seat frame piece 23 has been placed over the tube 27, with the web 29 resting against the first ring 34. A punch 36 is advanced, and a hole 37 in the punch slides over the upper portion of the tube 27. When the end of the hole 38 bottoms against the end 39 of the tube 27, further movement of the punch causes the upper portion of the tube to be compressed. A recess 40 in the punch allows the metal of the tube to expand outwards, in response to the axial force, with the result that the action of the punch causes a second ring 42 to be formed in the tube.
FIG. 4 shows the situation when the punch and die are (almost) closed fully together. It will be seen from FIG. 4 that the web 29 is not contacted by either the die 35 or the punch 36 during the operation of swaging out the second ring 42. At the very end of the operation, the designer might provide that the web is in fact subjected to a squeeze between the punch and die, as a coining phase to ensure everything is straight; but in general, throughout the pressing stages indicated in FIGS. 3 and 4, the web 29 floats. As the pressing operation is nearing completion, the press forces also act on the first ring 34, and cause that to be consolidated and even coined.
The hole 28 in the frame piece is a clearance fit over the diameter of the tube 27, and so the frame-piece is not held in position, during the FIG. 4 operation, by being held by a tight fit on the tube 27. Therefore, the frame-piece 23 does need to be held--at least loosely--to prevent tipping thereof. However, that kind of holding is simple enough--at least when compared with securing the components in welding jigs.
It is important, during the FIG. 4 pressing operation, that the web 29 remain resting in close touching contact with the first ring 34. In an automated system, the designer should ensure that the components are presented properly to each other for the operation. Seat-frame-pieces can include bends and twists, and be of an awkward shape, but the designer can provide the holding-clamps etc to accommodate whatever shape the seat-frame-pieces are in. The designer can decide whether to insert the head-rest-support-tubes into the seat-frame-piece before or after the seat-frame-piece is bent and twisted to its final shape.
The designer should ensure that, whatever the configuration of the components, the web can and does rest properly (i.e in firm abutment) against the first ring during the operation of pressing the second ring: if there were to be some clearance between the web and the first ring during pressing, the final joint would be significantly less tight and secure. The ideal is that the web should be under some degree of residual compression after the punch and die have separated, even if only slightly, and that can only happen if the web remains cleanly in abutment against the first ring throughout the pressing operation.
In an alternative, the die and punch set may be arranged with a subsidiary actuable member, which loads the web tightly against the first ring while the forming of the second ring is taking place.
It is important also that the clearance between the hole 28 in the web and the diameter of the tube 27 be taken up during the pressing operation. The force that causes the metal of the tube to swell out to form the second ring 42, of course also causes the metal to swell out to fill the clearance at the hole 28. Generally, the filling of the hole 28 is so good that any crannies. etc caused by burrs or other malformations arising from the punching of the hole 28, are filled completely and tightly.
The manner as described above of attaching the headrest support tubes to the seat frame provides a very secure attachment, which is amply able to accommodate the forces and abusive forces encountered in automotive seating equipment. The material costs are somewhat reduced, and the labour costs are very much reduced, as compared with what has to be done in the conventional tasks of welding the tubes to the frames.
It is conventional for the frames of automobile seats to be made from steel tubing. The head-rest-support-posts can be attached into a tubular-steel seat-frame in the manner as will now be described.
FIGS. 6a, 6b, 6c are views directed axially along the length of the seat-frame-tube 50, and show three stages in the preparation of the seat-frame-tube. FIGS. 7a, 7c are views corresponding to FIGS. 6a, 6c in the direction of arrows 7--7 of FIG. 6a.
In FIG. 6a, the seat-frame-tube 50 has been gripped on its outside diameter between two dies 52x, 52y. The dies are dimensioned to grip the seat-frame-tube at two spaced locations 53, 54. The dies 52x, 52y are shaped so as not to directly grip the seat-frame-tube 50 in the recess 55 between the locations 53, 54.
Once the dies 52x, 52y are in contact, and the seat-frame-tube 50 is firmly held, the two formers 56x, 56y are advanced. At first, the seat-frame-tube 50 is flattened, as shown in FIG. 6b. As the upper and lower zones 57x, 57y of the tube walls are forced together, the left and right side-zones 58L, 58R are forced apart, and these zones of the walls come into contact with the sides 59L, 59R of the recess 55.
The formers 56x, 56y are advanced until they bottom against the two thicknesses of the wall-zones 57x, 57y, as shown in FIGS. 6c, 7c. The wall-zones 58L, 58R are formed to the shape as shown by virtue of their confinement by the sides 59L, 59R of the recess 55. It will be noted that this manner of forming the seat-frame-tube produces a localised shape which is similar to that of an I-beam. The web 60 of the I-beam shape is derived from the wall-zones 57x, 57y, and the flanges 62L, 62R of the I-beam are derived from the folded wall-zones 58L, 58R.
It is noted that the seat-frame-tube 50 is not simply squashed flat. The operations as described produce a configuration that is much stronger and more rigid than a flattened tube. The flanges 62L, 62R, being tall (i.e the height of the flanges is equal to several thicknesses of the walls of the tube), are crucial to the rigidity of the tube against bending forces, which of course is an important consideration in a seat frame.
A hole 63 for receiving the head-rest-support-tube is punched in the web 60 of the seat-frame-tube, in the manner as shown in FIGS. 8a, 8b. A die-button 64 is brought into contact with one side of the web 60. A punch 65, carried in a stripper 67, is advanced, and pierces the hole 63 in the web. The die-button 64 and the stripper 67 are dimensioned to hold the web 60 to its desired shape during the disruption caused by the punching operation and subsequent stripping of the web from the punch 65.
The head-rest-support-tube 68 that is to be secured into the hole 63 in the web 60 is shown in FIG. 9. The head-rest-support-tube 68 is of steel, and includes an upper section 69, in which is cut a notch 70, a first ring-bead 72, and a lower section 73, the bottom section 74 of which is swaged down to a slightly smaller diameter than the rest of the head-rest-support-tube. The inside diameter of the bottom section 74 is dimensioned to be a tight location-fit on the peg 26 of the head-rest, and the reduced outside diameter of the bottom section 74 ensures an easy placement of the head-rest-support-tube 68 into the hole 63 in the web 60 of the seat-frame-tube 50.
The manner of installing the head-rest-support-tube 68 into the hole 63 is illustrated in FIGS. 10a, 10b, 10c. The head-rest-support-tube is first positioned into a punch unit 75. The top end 76 of the head-rest-support-tube abuts against a shoulder 78 of the punch 79, and the already-formed first ring-bead 72 abuts against the bottom face of the punch-holder 80.
As shown in FIG. 10b, the head-rest-support-tube passes through the hole 63, and the tapered bottom end of the head-rest-support-tube enters the recess 82 in the die 83. As the punch 75 and die 83 approach, the bottom end of the head-rest-support-tube abuts against the bottom of the recess 82. From then on, further approaching movement of the punch and die are reacted as an axially-directed compressive force on the head-rest-support-tube. The compressive force is enough to cause the walls of the head-rest-support-tube to buckle outwards, whereby the second ring-bead 84 is formed. Approaching movement of the punch and die continues until the condition of FIG. 10c is reached.
The punch and die are then withdrawn, and the seat-frame-tube 50, with the head-rest-support-tube 68 now firmly attached, can be transferred to the next stage in the manufacture of the seat.
The manner of attaching the head-rest-support-tube into the seat-frame-tube ensures that the web 60 is structurally unitary with the head-rest-support-tube. The first and second ring-beads 72, 84 grip the web between them, providing a secure base for resisting abusive forces from any direction, which might tend to disrupt the attachment.
By forcing the punch unit 75 and the die 83 hard together (FIG. 10c) the amount of spring-back upon release can be made very small, whereby the compressive grip on the web is still firmly present upon release.
The head-rest-support-tube might be subjected to forces tending to rotate it, during use of the automobile, and it is important that rotation forces are resisted. If rotation of the head-rest-support-tube were to be permitted, the movement might cause the attachment to rattle or work loose. Accordingly, the designer might prefer to make the hole 63 in the web slightly non-circular. In fact, given the fact that the hole occupies a large area of the tube, it is all too easy for the hole 63 to be non-circular in any event. The operation of forming the second ring-bead 84, however, ensures that the head-rest-support-tube adapts itself completely to whatever out-of-roundness there might be in the hole 63, which helps to ensure freedom from rotation of the head-rest-support-tube.
The attachment system as described is very strong, as compared with the conventional welded construction, but apart from that clear advantage, the attachment system provides excellent and repeatable accuracy. Now that accuracy of alignment of the two head-rest-support-tubes can be relied upon, the design of the head-rest detents can be free of the compromises needed with the conventional welded attachment; designing a detent is a matter of making sure the force to move the head-rest pegs against the detent is neither too light nor too heavy, and the more accurately the components can be positioned, the easier it is to ensure the correct force.
Not only is the attachment system as described very strong, and accurate, but the system also lends itself to full automation. The attachment system is in keeping with the kinds of operations that have to be carried out on seat-frame-tubes, such as bending, piercing, etc, and the machinery for automating such operations is already commonplace. The similarity of those frame-tube operations with the operations required in the attachment system will be clear: the dis-similarity of the frame-tube operations with the conventional welding attachment system, is even more clear.
"The expressions upper, lower, horizontal, vertical, etc, as used in this specification, should not be interpreted to mean that the invention only applies when the actual physical components used in operating the invention are orientated in only that way. Rather, the expressions should be taken as referring to those directions when the components are represented on paper, which is oriented accordingly." | The headrest support tubes are secured to the seat frame member not by the usual welding, but by gripping the web of the member between two rings or lock-beads swaged into the metal of the tube. The first ring is swaged-out by compressing the tube. The tube, with the one ring, is then assembled into a through-hole in the web of the frame member. Then, the second ring is swaged into the metal of the tube, on the other side of the web, and the web lies gripped between the rings. The seat frame member may be an I-section extrusion, or a round tube with localised squeezed-flat areas, flanked by flanges. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a coupling device to be arranged between an output shaft of an electric motor and an input shaft of a reducing gear for driving a screen or a leaf that is part of closing, solar protection or projection equipment. The invention also relates to home automation equipment comprising, inter alia, such a coupling device.
According to the present invention, a screen comprises a movable part consisting of a sliding panel or a set of strips which is moved, generally by rolling, between a raised position, wherein it leaves an opening clear, and a lowered position, wherein it shuts off said opening. Such a screen may be a rolling shutter or door. The screen may also be a blind for solar protection, for example a terrace blind or a Venetian blind. A screen may also be a screen used for image projection, notably in video format. According to the invention, a leaf is a part of closing device, such as a door leaf of a gate or a shutter hinged about a vertical axis on the edge of a window.
2. Brief Discussion of the Related Art
The use of an electric motor associated with a reducing gear for driving the rolling shaft of the flexible sliding panel of a rolling shutter or blind is known. These devices are frequently integrated within a so-called tubular actuator which is inserted inside a rolling tube and which is rigidly connected thereto by means of a wheel. The coupling between the output shaft of the motor and the input shaft of the reducing gear is sometimes difficult since each of these devices is equipped with bearings supporting the respective shafts thereof, which are not necessarily aligned or even parallel. This gives rise to noise from running the actuator, and premature wear of the reducing gear, at least in some configurations.
One solution incorporating a universal joint on one of the shafts may be envisaged. However, it is relatively expensive and complex to implement, while only allowing misalignment of the axes of the shafts to be coupled to a limited extent.
Moreover, U.S. Pat. No. 2,011,147 discloses the use of an assembly of mutually movable parts, for rotatably securing coupling elements each provided with a hub and a broadened cross-section. The three-part assembly comprises two lateral parts each interacting with a coupling element and a central part. The manufacture of this device is complex and costly. Moreover, the transmission of the torque between a coupling element and an associated lateral part is based on the engagement of ribs in grooves, with merely axial relative movement capability. The parts of the three-part assembly and the coupling elements are complex and thus need to be produced with precision and assembled with care, which increases the cost of the system according to the prior art.
Similar problems are encountered with the device known from FR-A-970 629.
SUMMARY OF THE INVENTION
The invention is more particularly intended to remedy these drawbacks by proposing a new coupling device that is simple to manufacture and use and reliable over time, while being suitable for integration in home automation equipment.
For this purpose, the invention relates to a coupling device between an output shaft and an input shaft, such as an output shaft of an electric motor and an input shaft of a reducing gear of an actuator for driving a screen or a leaf that is part of home automation equipment for closing, solar protection or projection. This device includes a first member which is rotatably secured, or suitable for being rotatably secured, to the output shaft, and which is provided with at least one longitudinal outer groove, and a second member which is rotatably secured, or suitable for being rotatably secured, to the input shaft, and which is provided with at least one longitudinal outer groove. According to the invention, this device further includes an element for rotatably coupling the first and second members together, which has, on at least one surface thereof, at least two series of lugs projecting from said surface, wherein the lugs are inserted into the longitudinal outer groove of the first member and the longitudinal outer groove of the second member, respectively.
According to the invention, a coupling element such as a sleeve or a plate is an integral or multi-part part which, once manufactured, is rigid, enabling effective transmission of a drive torque.
By means of the invention, it is possible to provide, in a compact space, effective coupling between the output shaft and the input shaft, the manufacture and/or assembly of the two series of projecting lugs being simple to carry out. The use of a coupling element, such as a sleeve or a plate, and not of three mutually movable parts, ensures effective torque transmission. Furthermore, the lugs offer movement capabilities in a plurality of directions in relation to the longitudinal outer grooves of the first and second members. This makes it possible to simplify this coupling element and these members.
According to advantageous, but optional, aspects of the invention, such a device may incorporate one or a plurality of the following features in any technically feasible combination thereof:
The coupling element is a sleeve in the internal volume whereof the first and second members are inserted at least partially and the lugs of the two series of lugs project from an inner radial surface of said sleeve. The coupling element is a plate arranged between the first and second members, along an axis of rotation of one of these members, and the lugs of the two series of lugs project from two axial surfaces of this plate, in two opposite directions parallel to the axis of rotation. Each lug includes a spherical section head projecting from the surface of the coupling element. Each first and second member is provided with a plurality of longitudinal outer grooves, whereas the coupling element is equipped with a plurality of lugs, equal in number to the sum of the numbers of longitudinal outer grooves of the first and second members, with a first series of lugs situated in the vicinity of a first axial end of the coupling element and each respectively inserted into one of the longitudinal outer grooves of the first member and a second series of lugs situated in the vicinity of a second axial end of the coupling element, opposite the first axial end, each respectively inserted into one of the longitudinal outer grooves of the second member. The longitudinal outer grooves and the lugs are regularly distributed, respectively about the longitudinal and central axes of the first and second members and the coupling element. The lugs of the second series are offset, angularly about a longitudinal and central axis of the coupling element, in relation to the lugs of the first series. The angular offset between two lugs respectively belonging to the first and second series has a value equal to half the value of the angular offset between two lugs of the same series. The lugs of the two series are aligned in directions parallel to a central axis of the coupling element. Each of the first and second members is provided with three longitudinal outer grooves distributed at 120° about a central axis of this member and the coupling element is equipped with two series of three lugs, the lugs of each series being distributed at 120° about a longitudinal and central axis of the coupling element. The coupling element is provided, on at least one angular sector situated between two lugs of the same series, with a recess. The first and second members are identical parts mounted on the output shaft, on one hand, and on the input shaft, on the other. The lugs are parts mounted on the coupling element and locked thereon in rotation, by means of wedging, crimping or engaging shapes. In this case, it may be envisaged that the coupling element is provided with axial grooves each suitable for slidably receiving a lug anchoring shank and each bordered by a space for receiving an end heel of the anchoring shank. Alternatively, the coupling element is provided with housings for receiving and locking lug anchoring shanks. The lugs are integral with the coupling element. If the coupling element is a plate, an axial surface of the first member, the second member or the plate is provided with a portion projecting in a direction parallel to a central axis of the plate, this projecting portion bearing on an axial surface of the plate, of the first member or the second member.
The invention also relates to home automation equipment including a leaf, a closing or solar protection screen or a projection screen, and a coupling device as mentioned above, inserted between an output shaft, particularly of an electric motor, and an input shaft, particularly of a reducing gear for driving the leaf or screen.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention will be understood more clearly and further advantages thereof will emerge more specifically in the light of the following description of the first embodiments of a coupling device and equipment according to the principle thereof, given as examples and with reference to the appended figures wherein:
FIG. 1 is a schematic illustration of closing equipment according to the invention,
FIG. 2 is an exploded perspective view of a coupling device used in the equipment in FIG. 1 ,
FIG. 3 is a section on a larger scale along the line III-III in FIG. 1 ,
FIG. 4 is a view similar to FIG. 2 for a coupling device according to a second embodiment of the invention,
FIG. 5 is a section similar to FIG. 3 for the embodiment in FIG. 4 ,
FIG. 6 is a view similar to FIG. 2 for a coupling device according to a third embodiment of the invention,
FIG. 7 is a section similar to FIG. 3 for the embodiment in FIG. 6 ,
FIG. 8 is an exploded perspective view of a sleeve belonging to a coupling device according to a fourth embodiment of the invention, and
FIG. 9 is an exploded perspective view of a coupling device according to a fifth embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 represents a tubular actuator 100 suitable for rotating a rolling tube 1 whereon a sliding panel 2 for closing off an opening O can be rolled. The tube 1 is rotated by the actuator 100 about a rotational axis X-X which is arranged horizontally in the upper part of the opening. The opening O is, for example, provided in the walls of a building. The actuator 100 , the tube 1 and the sliding panel 2 thus form a motor-driven rolling shutter.
The actuator 100 includes a fixed cylindrical tube 101 wherein a gear motor 102 , including an electric motor 103 and a reducing gear 104 , is mounted. The output shaft of the motor 103 is referenced 105 and the input shaft of the reducing gear 104 is referenced 106 .
The output shaft 107 of the reducing gear 104 projects at one end 101 A of the fixed tube 101 and actuates a wheel 3 rotatably secured to the tube 1 .
The rolling tube 1 then rotates about the axis X-X and the fixed tube 101 by means to two pin joints. A ring-bearing 4 , mounted on the outer periphery of the tube 101 , in the vicinity of the end 101 B thereof opposite the end 101 A, acts as the first pin joint. The second pin joint is fitted at the other end of the tube 1 and cannot be seen in FIG. 1 .
The actuator 100 also includes an attachment part 108 projecting at the end 101 B of the tube 101 and is suitable for attaching the actuator 100 on a frame 5 of the building containing the opening O. This attachment part 108 is further suitable for closing off the tube 101 , and for supporting a control module 109 of the power supply of the motor 103 . This control module is powered by a mains cable 6 .
A coupling device 200 arranged between shafts 105 and 106 is suitable for transmitting the output torque from the motor 103 to the reducing gear 104 . The longitudinal and central axis of the shaft 105 is referenced X 105 . The longitudinal and central axis of the shaft 106 is referenced X 106 . In theory, these axes are parallel, aligned with each other and merged with the axis X-X. In practice, this is not necessarily the case, the axes X 105 and X 106 may be parallel, but not merged, or sequent, according to the manufacturing tolerances of the constituent elements of the actuator 100 and the quality of the assembly thereof. The device 200 is suitable for adapting to these alignment defects.
During the operation of the actuator 100 , the gear motor 102 rotates the shaft 7 which, in turn, rotates the tube 1 via the wheel 3 . In the gear motor 102 , the drive torque of the shaft 107 is transmitted from the shaft 105 to the shaft 106 , by means of the device 200 .
As seen more particularly in FIGS. 2 and 3 , the device 200 includes a first end piece 201 made of sintered metal provided with a central bore hole 2011 centred on a longitudinal axis X 201 of the end piece 201 . The outer radial surface 2012 of the end piece 201 is cylindrical with a circular cross-section centred on the axis X 201 . It is provided with three longitudinal outer grooves 2013 regularly distributed about the axis X 201 , i.e. mutually forming an angle of 120° about the axis X 201 . The grooves 2013 open onto an end of the first end piece 201 and may be described as longitudinal, in that the larger dimension thereof is parallel to the axis X 201 .
The device 200 also includes a second end piece 202 also made of sintered metal and which is provided with a central bore hole 2021 centred on a longitudinal axis X 202 of the end piece 202 . The outer radial surface 2022 of the end piece 202 is cylindrical with a circular cross-section centred on the axis X 202 , except at the three longitudinal outer through grooves 2023 , the larger dimension whereof is parallel to the axis X 202 and which are distributed, in the surface 2022 , at 120° about the axis X 202 .
The respective dimensions of the bore holes 2011 and 2021 are provided to enable force fitting of the end pieces 201 and 202 respectively on the shaft 105 and on the shaft 106 . When these end pieces are fitted in this way, they are rotatably secured to said shafts and the axes X 105 and X 201 , on one hand, and X 106 and X 202 , on the other, merge.
Producing the end pieces 201 and 202 in sintered metal is suitable for obtaining parts wherein the geometry is well controlled, which are resistant and with a particularly attractive cost price. They may then be clamp-fitted onto the shafts. Alternatively, according to the torques involved, these end pieces may also be produced by machining or injection moulding, from plastics or zamak. They are then mounted onto grooved shafts for example for the rotatable securing thereof.
The coupling device 200 also includes a sleeve 203 acting as a coupling element between the end pieces 201 and 202 , which has a circular cross-section and extends about a longitudinal and central axis X 203 . The inner radial surface of the sleeve is referenced 2031 and the outer radial surface is referenced 2032 . The internal volume of the sleeve 203 is referenced V 203 , this volume being radially externally bordered by the surface 2031 . The sleeve 203 is equipped with six lugs 204 respectively projecting from the surface 2031 and towards the axis X 203 in the volume V 203 , respectively in the vicinity of a first axial end surface 2034 of the sleeve 203 and a second axial end surface 2035 of this sleeve, opposite the first.
The parts 203 and 204 are preferentially obtained by machining or injection moulding of plastic or zamak.
The sleeve 203 is provided, in the vicinity of the end surface 2034 thereof, with three slots 2036 bordered by a rabbet 2036 A on the side of the surface 2032 and which pass through the sleeve 203 , from the surface 2031 towards the surface 2032 , radially in relation to the axis X 203 . The slots 2036 open onto the surface 2034 and have a decreasing width, measured in an orthoradial direction in relation to the axis X 203 , on moving away from the end surface 2034 .
Moreover, each lug 204 includes a head 2041 protruding from the surface 2031 towards the axis X 203 , and an anchoring shank 2042 inserted into a slot 2036 . The head 2041 of each lug is a spherical segment. Opposite the head 2041 thereof, each lug 204 has a circular heel 2043 , greater in diameter than the minimum width of a slot 2036 , in the part thereof furthest from the end surface 2034 , but less than the minimum width of a rabbet 2036 A. It is thus possible to hold a lug 204 in position in each slot 2036 , each lug being secured, in a parallel direction in relation to a central axis X 204 of the anchoring shank 2042 , by engaging the head 2041 with the surface 2031 , on an inner side of the sleeve 203 , and engaging the heel 2043 with the rabbet 2036 A, on the outer side of the sleeve. Advantageously, the heels 2043 do not protrude from the outer surface 2032 of the sleeve.
The lugs 204 are distributed in a first series S 1 of three regularly distributed lugs 204 , at 120° about the axis X 203 and close to the end surface 2034 , insofar as they are received in slots 2036 opening onto this end surface. Three further lugs 204 form a second series S 2 which is close to the second end surface 2035 . They are arranged in slots 2036 opening onto this surface and regularly distributed, at 120°, about the axis X 203 . The offset angle, about the axis X 203 , of the axes X 204 of two lugs 204 of the first series S 1 is referenced a. This angle equals 120° and it has the same value as the offset angle β, about the axis X 203 , of the axes X 204 of two lugs of the second series S 2 .
The lugs 204 of the first series S 1 and the lugs 204 of the second series are arranged on either side of a median plane P M of the sleeve, this plane being perpendicular to the axis X 203 and equidistant from the surfaces 2034 and 2035 . The distance d 1 between the series of lugs S 1 and S 2 , measured parallel to the axis X 203 , may be optimised: the longer this is, the less sliding is required between each lug 204 and each groove 2013 or 2023 , favouring enhanced accounting for shaft misalignment.
The lugs 204 are identical. The maximum diameter of the heads 2041 which are circular and centred on the axes X 204 of the various lugs is referenced D 204 . The widths of the grooves 2013 and 2023 measured along orthoradial directions in relation to the axes X 201 and X 202 , respectively, are referenced I 2013 and I 2023 . The diameter D 204 is chosen to be slightly less than the widths I 2013 and I 2023 which are identical, to enable sliding and guidance of the heads 2041 in the grooves 2013 and 2023 .
In this way, in the assembled configuration of the device 200 , as shown in FIG. 3 , it is possible to insert the end pieces 201 and 202 into the volume 203 by placing the heads 2041 of the lugs 204 of the series S 1 in the grooves 2013 of the first end piece 201 , while the heads 2041 of the lugs 204 of the series S 2 are placed in the grooves 2023 of the second end piece 202 .
A torque C about the axis X 201 may thus be transmitted from the end piece 201 to the sleeve 203 , by engaging the lugs 204 of the series S 1 with the grooves 2013 , and from the sleeve 203 to the end piece 202 by engaging the lugs 204 of the series S 2 with the grooves 2023 .
It is noted that, between two lugs 204 of the series S 1 , the sleeve 203 is provided with first recesses 2037 suitable for lightening same and opening onto the end surface 2034 . Similarly, further recesses 2037 are provided between two lugs 204 of the series S 2 and open onto the end surface 2035 .
As seen in FIG. 3 , the first recesses 2037 extend over an angular sector between two lugs 204 of the series S 1 . Similarly, the further recesses 2037 extend over an angular sector between two lugs of the series S 2 . These recesses extend from a surface 2034 or 2035 to beyond the axes X 204 , along the axis X 203 .
Moreover, the lugs 204 of the series S 1 are angularly offset in relation to the lugs 204 of the series S 2 by an angle γ equal to 60°, i.e. half the angle α. An angular offset, regardless of the offset angle, may be suitable for simplifying the manufacture of the sleeve 203 . Alternatively, it is possible to keep the lugs of the series S 1 and S 2 aligned.
The device 200 is suitable for effective torque transmission between the end pieces 201 and 202 , while the axes X 201 and X 202 thereof may not be aligned. Indeed, the heads 2041 of the lugs 204 inserted into the grooves 2013 and 2023 are suitable for slight axial movement in the grooves 2013 and 2023 of the end pieces 201 and 202 . This relative movement is suitable for offsetting an alignment defect of these axes when rotating the shafts 105 and 106 whereon the end pieces 201 and 202 are mounted, respectively.
In the second to fifth embodiments of the invention shown in FIGS. 4 to 7 , the elements equivalent to those of the first embodiment bear the same references. Hereinafter, only the aspects whereby these embodiments differ from the first are described.
In the embodiment shown in FIGS. 4 and 5 , the shanks 2042 of the lugs 204 are devoid of heels and are received in corresponding bore holes 2038 of the sleeve 203 wherein they are force-fitted. This assembly is sturdier than that of the first embodiment.
In the third embodiment shown in FIGS. 6 and 7 , the lugs 204 and the sleeve 203 are integral. In this embodiment, the offset by the angle γ, about the axis X 203 , between the lugs 204 of the series S 1 and the lugs 204 of the series S 2 enables the manufacture of the sleeve 203 by sintering, without using complex slide moulds.
In FIG. 8 , only the sleeve 203 of a coupling device according to a fourth embodiment of the invention is shown. The end pieces of this device are identical to those of the first embodiment. The sleeve 203 is in two parts, in that it is formed by assembling two identical integral parts 203 A and 203 B. Each of the parts 203 A and 203 B includes a series of three lugs 204 , the series S 1 of the lugs 204 of the part 203 A being shown in FIG. 8 , whereas only one of the lugs 204 of the series S 2 of the part 203 B is seen in this figure.
Each part 203 A and 203 is provided with a tab 2051 projecting from an end surface 2052 oriented towards the other part. Each tab 2051 is provided with a central opening 2053 for receiving a cog 2054 arranged at the centre of a groove 2055 provided in the outer surface 2032 A or 2032 B of each part 203 A or 203 B. From the end surface 2052 of each part 203 A or 203 B, two tabs 2056 extend, intended to be inserted into slots 2057 of a corresponding shape provided on the inner surface 2031 A or 2031 B of the part 203 A or 203 B in question.
In this way, the sleeve 203 is formed by aligning the parts 203 A and 203 B on the axis X 203 of the sleeve, by placing the end surfaces 2052 thereof opposite each other, approaching the parts 203 A and 203 B by translation along the axis X 203 and by inserting the tab 2051 of each part into the groove 2055 of the other part until the cog 2054 of the other part enters the opening 2053 of each tab. This approaching movement is represented by the arrows FA and FB in FIG. 8 .
During the approach, the tabs 2056 of one part 203 A or 203 B are inserted into the slots 2057 of the other part, and vice versa.
The geometry of the parts 203 A and 203 B is chosen so that, when they are assembled to form the sleeve 203 together, the series S 1 and S 2 of lugs 204 thereof are angularly offset by an angle γ, for example equal to 60°.
This embodiment is particularly suitable for small-diameter coupling devices intended to be integrated in actuators less than 30 mm, for example equal to 25 or 28 mm, in diameter. Indeed, the parts 203 A and 203 B may be moulded relatively easily, more easily than the integral sleeve according to the third embodiment in the case of a small-diameter sleeve.
In the fifth embodiment shown in FIG. 9 , the two end pieces 201 and 202 of a device 200 according to the invention are respectively provided with three grooves 2013 and 2023 distributed at 120° about a central axis X 201 or X 202 of the end piece 201 or 202 in question.
These end pieces 201 and 202 engage with a plate 203 which is also part of the device 200 , suitable for the rotatable coupling of the end pieces 201 and 202 and which is centred on an axis X 203 which is generally parallel to the axes X 201 and X 202 in the configuration for use. The plate 203 is arranged between the end pieces 201 and 202 , along one of the axes X 201 and X 202 .
The plate 203 includes two axial surfaces 2039 A and 2039 B which are perpendicular to the axis X 203 and generally in the shape of a disk. These surfaces form the axial ends of the central part of the plate 203 .
From the surface 2039 A, three lugs 204 extend, forming a first series S 1 of lugs each intended to be inserted into a groove 2013 of the end piece 201 .
Each lug 204 of this series of lugs extends along a direction D 204 parallel to the axis X 203 and moving away from the surface 2039 A.
Each lug 2041 includes a shank 2042 and a head 2041 forming the end thereof opposite the surface 2039 A which is in the shape of a spherical segment. The inner and outer radial surfaces of the head 2041 of a lug 204 are truncated to extend from the inner and outer radial surfaces of the shank 2042 thereof. Moreover, the end surface of a head 2041 is also truncated, restricting the length thereof, measured parallel to the direction d 204 or the axis X 203 .
The surface 2039 B of the plate 203 is also provided with three lugs 204 of which two can be seen in FIG. 9 and which have substantially the same geometry as the lugs 204 of the first series of lugs, except that they each extend along a direction D′ 204 parallel to the axis X 203 and oriented in the opposite direction in relation to a direction D 104 . In other words, the lugs 204 of the second series S 2 extend, in relation to a defined disk-shaped central portion 2039 C, axially along the axis X 203 , between the surfaces 2039 A and 2039 B, in an opposite direction in relation to the lugs 204 of the first series S 1 .
The lugs 204 of each series S 1 and S 2 are distributed at 120° about the axis X 203 and the lugs of the two series are arranged extending from each other. In other words, the lugs 204 of the two series S 1 and S 2 are aligned along the directions D 204 and D′ 204 which are parallel to the axis X 203 .
Alternatively, the lugs of the series S 1 and S 2 may be angularly offset about the axis X 203 .
Moreover, the axial surface 2024 of the end piece 202 which is perpendicular to the axis X 202 and oriented towards the plate 203 is provided with a portion 2025 projecting parallel with the axis X 203 and in the shape of a spherical segment. This portion 2025 bears against the surface 2039 B in the assembled configuration of the coupling device 200 . Similarly, the axial surface 2014 of the end piece 201 which is perpendicular to the axis X 201 and oriented towards the plate 203 is equipped with a convex projecting portion, in the shape of a spherical segment, which is not shown in FIG. 9 but which bears against the surface 2039 A of the plate 203 . These projecting portions in the shape of a spherical segment provided on the input and output end pieces 201 and 202 , respectively, are suitable for reinforcing the coupling since they create a tangential contact point between the parts 201 and 203 , on one hand, and 202 and 203 , on the other. This contact point is active in all the configurations of the device 200 , including when the axes X 201 and X 202 are not aligned. This contact point is suitable for limiting parasitic friction at the interface between the parts 201 , 202 and 203 .
Alternatively, only one of the end pieces 201 and 202 is equipped with such a projecting portion 2025 or equivalent. According to a further alternative embodiment, a projecting portion comparable to the portion 2025 is provided on one of the surfaces 2039 A and 2039 B or on these two surfaces. In this case, the surfaces 2014 and 2024 are devoid thereof.
According to a further alternative embodiment, the plate 203 is not in axial contact with the end pieces 201 and 202 at the surfaces 2014 , 2024 , 2039 A and 2039 B. In this case, it is not necessary to provide an equivalent projecting portion similar to the portions 2025 on these surfaces.
In the various embodiments, the sleeve or the plate 203 may be made of synthetic material, particularly thermoplastic.
According to one alternative embodiment of the invention not shown, the end pieces 201 and 202 may be replaced by the ends of the shafts 105 and 106 which are then machined to form the grooves 2013 and 2023 . These ends then form members rotatably secured to these shafts, according to the invention.
According to a further alternative embodiment also not shown, the end pieces 201 and 202 may be identical and provided with a staged central bore hole suitable for the assembly thereof on shafts of two different diameters. In this case, the longitudinal outer grooves thereof open at both ends thereof. It is then necessary to provide further means, not shown, to axially fix the sleeve of the first four embodiments on the shaft thereof. Indeed, this sleeve, in the examples described, is axially fixed by means of the lugs to the blind bottom of the grooves.
The invention is described hereinafter in the context of use with a rolling shutter provided with a flexible sliding panel. It is also applicable with further types of shutters or blinds and with an image projection screen. The invention is also applicable for operating a leaf, such as a gate leaf or a shutter hinged about a vertical axis in the vicinity of a passage opening, such as a door or a window.
Regardless of the embodiment or alternative embodiment envisaged, the coupling element 203 is rigid when used in the device 200 , enabling effective torque transmission between the end pieces 201 and 202 . Due to the engagement of the lugs 204 with the grooves 2013 and 2023 , there is movement capability in a plurality of directions, at the interface between the parts 201 and 203 , on one hand, 202 and 203 , on the other, without requiring the use of a complex structure of multiple parts.
The technical features of the embodiments and alternative embodiments envisaged above may be combined together. | A coupling device installed between an output shaft of an electric motor and an input shaft of a reducing gear of an actuator for driving a screen or a hatch that is part of home-automation equipment for closure, solar protection, or projection and which includes a first member rotatably secured to the output shaft, and which is provided with at least one longitudinal outer groove, and a second member rotatably secured to the input shaft, and which is provided with at least one longitudinal outer groove and wherein the coupling device further includes an element for coupling the first and second members together in rotation, and which has, on at least one surface thereof, at least two series of lugs which project from the at least one surface, wherein the lugs are inserted into the longitudinal outer groove of the first member and the longitudinal outer groove of the second member, respectively. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to an automatic sewing machine, and in particular to the operation control thereof.
With the rapid progress of electronics technology in recent years, operations in a sewing machine such as sewing operation, speed control operation of a drive motor (electric motor), etc., have become to be placed under detailed processing control employing electronic controlling circuits, which has enabled a sewing machine to carry out many complicated operations and to have many improved functions. An enumeration of the functions newly developed includes: a function of arresting the needle at an upper position above the bed, a function of shifting the needle to a lower position for arresting the same there, a function of stopping the electric motor, in case of an emergency, by means of pressing a button other than the main button for the ordinary starting and stopping the electric motor, and a function of effectively selecting a desired stitch pattern from among a lot of stitch patterns by utilizing as few selecting buttons as possible, etc. Because these functions must be realized by the operator, by means of handling an operable means corresponding to each related function, so that the number of operable means is inevitably increased accompanied by the increasing number of the functions. Those operable means have to be usually arranged on a handy place for the operator, that is to say, on the front side of the machine facing to him or her, and this place is generally a limited and rather small one, being already occupied by the main button for the electric motor, a display panel for indicating a plurality of stitch patterns, selecting buttons for selecting a stitch pattern, etc., leaving little space to be spared. Arranging many kinds of operable means on the limited front side space detracts from the appearance of a sewing machine and likely to degrade the easiness of the operation (operability) of the machine. Each of the operable means has to be connected to an electronic controlling circuit respectively for being checked of its operation state, resulting in increase of the number of connecting lines, which naturally invites difficulty of wiring and sometimes mis-connecting of electric wiring. The reliability of sewing machines have been lowered by those troublesome problems.
SUMMARY OF THE INVENTION
An object of the invention is to provide a sewing machine wherein as few numbers of operating means as possible are capable of effectively performing as many of functions as possible.
Another object of this invention is to provide a sewing machine wherein one operating means is capable of selectively letting the needle arrest at a predetermined position or having a specific stitch pattern formed depending on the length of a time duration of the operation.
Still another object of this invention is to provide a sewing machine wherein a forthcoming operation can be varied depending not only on the length of the time duration of operation of the operating means but also on the state of the machine which can be in either a stopped or in an operation.
A further object of this invention is to provide a sewing machine excellent in operability and reliability.
For attaining the objects a sewing machine in accordance with this invention is provided with discriminating means for discriminating the length of the time duration of operation of an operable means.
In an instance where the present invention is applied, for example, to a sewing machine having stitch forming instrumentalities including an endwise reciprocative needle and a work feeding mechanism for transporting a workpiece to be sewn in timed relation with a reciprocal movement of the needle, drive means for imparting a reciprocal movement to the needle to produce a specific stitch pattern with the stitch forming instrumentalities, and needle positioning means for moving the needle to arrive at at least one predetermined position and arresting the needle thereat, the sewing machine may be provided with an operable means disposed on the front side of the machine; detecting means for determining whether the operation time when the operable means is operated is within a predetermined time or not; and control means for selectively actuating the drive means and the needle positioning means according to the discrimination.
In a sewing machine with such a structure the operable means is capable of selectively letting the needle arrest at a predetermined position or having a specific stitch pattern formed depending on the length of a time duration of the operation.
The control means preferably actuates the needle positioning means when the operation time is within the predetermined time and actuates the drive means when the operation time is beyond the predetermined time, and the drive means will preferably keep on imparting a reciprocal movement to the needle during the operation of the operable means after the control means actuates the drive means.
In a further improved sewing machine state detecting means for discriminating whether the machine is in a stationary state or in an operational state is disposed, in addition to the above-mentioned time detecting means for discriminating the length of the operation time of the operable means. A combined discrimination of the length of the operation time and the operational state of the machine enables the forthcoming operation of the machine to be changed according to the resultant information of that discrimination.
When this invention is applied to a sewing machine which is provided with an operable button for carrying out a specific stitching such as non-ravel stitching or seaming which has a predetermined stitch pattern for forming a straight stitch in a reverse feeding direction before and after the formation of a desired stitch pattern, the sewing machine can be operated in various modes as stated hereunder.
When this operable button is operated for a short time while the machine is in stoppage state, the arrested position of the needle is shifted (or switched). That is to say, the needle placed at the upper position above the bed is shifted to the lower position beneath the bed, and vice versa, the needle at the lower position is shifted to the upper position. When this operable button is operated for a long time while the sewing machine is stopped, the electric motor is driven at a low speed to allow the performance of the specific stitching; by the release of the operable button the stitching operation is interrupted to settle the needle at the upper position.
When on the other hand the operable button is operated for a short time while the machine is in operation, the electric motor is stopped instantly stopping the sewing operation of the machine. It means that the rotation of parts of the machine can be stopped in an emergency by a button other than the main button which effects ordinary starting and stopping of the machine. This is very effective as a safety measure of the sewing machine itself. When the operable button is operated for a long time while the machine is in operaton, a specific stitching such as non-ravel stitching can be formed following the formation of a desired stitch pattern during the operation time of the operable button. Releasing of the operable button settles the needle at the upper position to terminate the specific stitching.
In a sewing machine according to this invention, one operable means makes the machine perform plural kinds of operations. It allows the sewing mahine to have more functions without detracting from the appearance thereof. It makes it possible for the operator to eliminate a selective operation from plural operable means. It has become unnecessary, in addition, to dispose as many operable means as the number of different operations. The decrease of the number of operable means results in decreasing of the connection wiring between the operable means and the controlling system of the machine, diminishing the trouble occurrence such as faulty connection of the wiring. In addition, the operational state of the operable means can be easily detected and controlled by the electronic controlling circuit of the machine, because the circuit is suitable to discriminate and determine the operational state, not in amount of sewing but in the length of the operation time. This invention will surely contribute to the improvement and enlargement of the functions of the sewing machine a great deal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general perspective view of a sewing machine in which this invention is incorporated;
FIG. 2 is a general block chart of an electric controlling system of the above-mentioned sewing machine;
FIG. 3 is a timing diagram for explaining the operation of the above-mentioned sewing machine;
FIG. 4 is a circuit diagram for showing the detail of the operation controlling circuit for the electric motor;
FIG. 5 is a flow chart for explaining the operation of the electric controlling circuit of a first embodiment of this invention; and
FIG. 6 is another flow chart for showing only the different part from that in FIG. 5 in order to explain the operation of the electric controlling circuit of a second embodiment of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention is applied to a sewing machine wherein a plurality kind of predetermined stitch patterns, for example 16 kinds, can be selectively formed. A frame 1 of the machine is provided with a bracket arm 2 which is cantilevered over a bed. The bracket arm 2 has a top cover 3 which is provided with a laterally elongated display panel 4 on its side wall portion facing the operator. On the display panel 4 indicia 5 for designating respective stitch pattern of the 16 kinds are laterally arranged side by side. Above each of the indicia 5 are arranged light emitting diodes (LED) 6. In the rightwardly biased part of the display panel 4 a first and a second select buttons, 7, 8 are disposed. A needle 9 is attached to a needle bar such that it is allowed vertically reciprocating movement interlocked with a main shaft (not show) and also laterally oscillating movement by means of a bight control device (not shown). A presser 10 is attached to a presser bar 11 disposed behind the needle 9 in a vertically movable manner, and a feed dog 12 feeds a work fabric in an adapted timing with the vertically reciprocating movement of the needle 9. The work fabric is controlled of its feeding direction and feeding amount by means of a not-shown feed control device. A main button 13 for the starting and stopping of the machine is disposed at a leftwardly biased portion on the front side of the bracket arm 2; just beneath the main button 13 an operable button 14 is disposed for carrying out a non-ravel stitching having a predetermined stitch pattern for forming a straight stitch in a reverse feeding direction.
A motor control circuit 60 for controlling the rotation of an electric motor 15 for driving the main shaft of the machine will be described hereunder with reference to FIG. 4. A semiconductor member 18 for surge suppression is connected between two of alternating current source terminals 16, 17, to each of which is respectively connected one end of a choke coil 20, 21. Between each one terminal of the both terminals of the choke coils 20, 21 is respectively connected a capacitor 22 and another capacitor 23. Those choke coils 20, 21 and capacitors 22, 23 constitute a noise filter 19; and diodes 24, 25 and silicon controlled rectifiers (thyristor) 26, 27 constitute a bridge circuit for full wave rectifying of an alternating voltage. An anode of one diode 24 and a cathode of the other diode 25 are connected to the other end of the choke coil 21; and an anode of one thyristor 26 and a cathode of the other thyristor 27 are respectively connected to the other end of the choke coil 20. Each cathode of the diode 24 and the thyristor 26 is connected to a positive source line 28 and each anode of the diode 25 and the thyristor 27 is connected to a negative source line 29. A transformer 30 is for supplying firing pulse to the thyristors 26, 27, and between input terminals 31, 31 of the primary winding 30a of the transformer 30 a pulse signal from the later described input-output device is given. A secondary winding 30b of the transformer 30 is connected between the gate and the cathode of the thyristor 26, and another secondary winding 30c of the same is connected between the gate and the cathode of the thyristor 27. A resistor 32 and a capacitor 33 are respectively connected in parallel to the secondary winding 30b, and a resistor 34 and a capacitor 35 are respectively connected in parallel to the secondary winding 30c. A terminal 15a of the electric motor 15 is, via a diode 36 for preventing a reverse current flow, connected to the positive source line 28, and the other terminal 15b of the electric motor 15 is connected to the negative source line 29. Between the terminals 15a and 15b of the electric motor 15 is connected a semiconductor member 37 for surge suppression. A thyristor 38 is for braking the electric motor 15, the anode of which is connected, via a resistor 39, to the terminal 15a, and the cathode is connected, via a diode 40 (for preventing reverse current flow), to the terminal 15b. A pulse-transformer 41 is for firing the thyristor 38, and between input terminals 42, 42 of the primary winding 41a of the same is imparted a pulse signal from the later described input-output device. The secondary winding 41b of the pulse-transformer 41 is connected at one end to the thyristor 38 and at the other end to the negative source line 29. A resistor 43 is connected between the gate and cathode of the thyristor 38 and a capacitor 44 is connected in parallel to the secondary winding 41b.
FIG. 2 shows a block diagram of an electric control apparatus 45, in which a read only memory 47 (ROM) memorizes permanently fixed information such as stitch pattern information and speed-setting information, etc., for selectively giving the fixed information to the central processor unit 46(CPU), and a random access memory 48 (RAM) memorizes processed information from the central processor unit 46 and information showing the operational state of the machine. An input-output device 49 gives input information to the central processor unit 46 and also gives the processed information from the central processor unit 46 to the actual operational part of the machine. Each operation of both memories 47, 48 and the input-output device 49 is controlled according to the program illustrated in the later described flow chart. The motor control circuit 60 is for, upon receiving drive information and brake information coming from the input-output device 49, driving (including the speed-setting) and braking (including the needle positioning) the electric motor 15. A rotation detector 50 is provided for detecting the number of rotation of the electric motor 15, which detector is constituted of, for example, a tachogenerator directly connected to the main shaft (not shown). Obtained information regarding the starting and stopping as well as the number of rotation of the electric motor 15 will be given to the input-output device 49.
A position detector 51 for detecting the needle position and a generator 52 for generating a timing signal generate, as shown in FIG. 3, a needle position signal Sa and a timing signal Sb for giving them to the input-output device 49. In FIG. 3 a base line c designates the bed surface on which the work fabric is laid, a curve d designates a locus of movement of the tip of the needle 9, and the abscissa is a time axis T. The needle position signal Sa is an electric signal which falls, when the needle 9 has passed the highest possible point (top) and slightly descended, from high level to low level, and rises, when the needle 9 has reached a point slightly before the lowest possible point (bottom), from low level to high level. And the timing signal Sb is an electric signal which falls, from high level to low level, when the needle 9 has slightly risen from the bed surface (designated by the base line c) and rises, from low level to high level, when the needle 9 has slightly descended from the bed surface. A normal open switch interlocked with the operable button 14 is provided with a pair of fixed contact pieces 14a, 14b and a movable contact piece 14c; the fixed contact piece 14a is grounded and the fixed contact piece 14b is connected, via resistor 53, to a positive source terminal 54. While the operable button 14 is in non-operation the fixed contact piece 14b is in a high level state, and when the operable button 14 is operated by depressing to make the movable contact piece 14c connect the pair of fixed contact pieces 14a, 14b, the fixed contact piece 14b is changed to low level, and the voltage varying of this fixed contact piece 14b is imparted as an electric signal to the input-output device 49. A stitch forming system 55 is composed of the bight control device which is driven in accordance with the output information from the input-output device 49 for laterally oscillating the needle 9 and the feed control device for controlling the feed amount and the feed direction of the work fabric.
With reference to the flow chart of FIG. 5, the way of controlling a portion which directly relates to this invention is to be described hereunder. For the purpose of better understanding of the explanation numerical signs will be alloted to the flow chart, and the signs on the flow chart are tabulated hereunder:
______________________________________TABLE OF THE SIGNS ON THE FLOW CHARTPro-cess Symbols Brief Description______________________________________P1 PWR ON Power source onP2 NEEDLE UP? Is the needle at upper position?P3 NP MERY RT Reset NP memoryP4 NP MERY ST Set NP memoryP5 LS MERY RT Reset LS memoryP6 MTR ROT? Is the motor in rotation?P7 NP MERY ST Set NP memoryP8 OPBTN ON? Is the operable button on?P9 0.25s TMR ST Set the 0.25 sec. timerP10 TMR OVR? Is the timer's operation over?P11 OPBTN ON? Is the operable button on?P12 100 CMD Output the 100 r.p.m. commandP13 RVm ≦ 200 Is the number of rotaton of motor not more than 200 r.p.m.?P14 0.1s TMR Set 0.1 sec. timerP15 TMR OVR? Is the timer's operation over?P16 NP MERY ST? Is NP memory set?P17 NP SL UP? Has the needle position signal Sa risen?P18 NP MERY ST Set NP memoryP19 FPLS STP Stop the supply of firing pulse signalP20 0.006s TMR ST Set the 6 milli sec. timerP21 TMR OVR? Is the timer's operation over?P22 MTR BRK Apply braking to the motorP23 NP SL DWN? Has the needle position signal fallen?P24 NP MERY RT Reset NP memoryP25 100 CMD Output the 100 r.p.m. commandP26 NP MERY ST Set NP memoryP27 LSINF OUT Output the information for non- ravel stitchingP28 LS MERY ST Set LS memoryP29 SLTPTN FORM Form a selected stitch pattern other than non-ravel stitchingP30 SLTPTN FORM Form a selected stitch pattern other than non-ravel stitchingP31 LS MERY ST? Is LS memory set?P32 SLTPTN FORM Form a selected stitch pattern other than non-ravel stitchingP33 LS MERY ST? Is LS memory set?P34 SLTPTN FORM Form a selected stitch pattern other than non-ravel stitchingP35 LS MERY ST? Is LS memory set?P36 SLTPTN FORM Form a selected stitch pattern other than non-ravel stitchingP37 LSINF OUT Output the information for non-ravel stitchingP38 LSINF OUT Output the information for non-ravel stitchingP39 LSINF OUT Output the informaton for non-ravel stitchingP5' LS MERY RT Reset LS memoryP6' MTR ROT? Is motor in rotation?P7' NP MERY ST Set NP memoryP8' OPBTN ON? Is the operable button on?P8" OPBTN ON? Is the operable button on?P9' 0.25s TMR ST Set the 0.25 sec. timerP10' TMR OVR? Is the timer's operation over?P29' SLTPTN FORM Form a selected stitch pattern other than non-ravel stitchingP30' SLTPTN FORM Form a selected stitch pattern other than non-ravel stitching______________________________________
When, to begin with, the operator puts the power source ON (P1), a descrimination process (P2) is performed for determining whether the needle position is up or not by an output from the generator 52; if the output from the generator 52 is then in low level and the needle 9 is positioned above the bed (YES) will come out, and if the output from the generator 52 is in high level and the needle 9 is positioned below the bed (NO) will come out. In case of (YES) the program is advanced to a reset step (P3) of NP memory (needle position memory) for resetting NP memory in the random access memory 48; in case of (NO) to a set step (P4) of NP memory for setting NP memory in the random access memory 48. When either the reset step (P3) of NP memory or the set step of NP memory is over the program will be advanced to a reset step (P5) of LS memory (non-ravel stitching memory) for resetting LS memory in the random access memory 48. Another discrimination process (P6) is then executed for discriminating whether the motor 15 is in rotation or not by an output signal from the rotation detector 50. If the motor is in rotation (YES) will come out and otherwise (NO) will come out. (YES) advances the program to a set step (P7) of NP memory for setting NP memory in the random access memory 48 and further advances to a discrimination process (P8) for discriminating whether a switch interlocked with the operable button 14 is ON or not; (NO) result of the discrimination process (P6) advances the program directly from the discrimination process (P6) to the discrimination process (P8) without carrying out the set step (P7) of NP memory.
Now the explantion will be proceeded to a case wherein when the operator put the power source ON the needle 9 is at the upper position and then the operable button 14 is depressed for a short period of time within 0.25 sec. In this instance, the electric motor 15 is stationary when the operable button 14 is depressed because of the main button 13 being not operated after the putting ON (switching on) the power source (P1). When the power source is put ON (P1) the discrimination process (P2) shows (YES) discrimination because of the upper position of the needle 9 for resetting NP memory by the reset step (P3) and the discrimination process (P6) shows (NO) discrimination because of the stopping of the electric motor 15 without advancing to the reset step (P7) of NP memory; and then the discrimination process (P8) executes a discrimination of (YES) for advancing to a set step (P9) of 0.25 sec. timer. The program will further advance soon after the setting of the set step (P9) of the 0.25 sec. timer to a discrimination process (P10), which performs a discrimination whether the time measuring operation of the timer, a time measuring means, is over or not. The 0.25 sec. passes after the setting of the timer (YES) comes out, until then the discrimination being (NO). Upon descriminating (YES) in the discrimination process (P10) the program will be advanced to a discrimination process (P11) for discriminating whether the operable button 14 is ON or not. When it is affirmative (YES) will come out; when it is OFF the discrimination will be (NO). The program is, however, further advanced, after showing the (NO) discrimination in the discrimination process (P11) to a 100 r.p.m. setting step (P12) of the electric motor 15 because the operable button 14 was depressed only for a short period of time. In this step (P12) information setting the electric motor 15 at 100 r.p.m. is read out from the read only memory 47 by the central processor unit 46 for giving a suitable firing pulse to that speed, via the input-output device 49, in between the input terminals 31, 31 of the motor control circuit 60, and in turn rotating the electric motor 15. Following this step (P12) a discrimination process (P13) is ececuted for discriminating whether the number of rotation of the electric motor 15 is not more than 200 r.p.m. or not. In this process (P13) a comparison between the information from the rotation detector 50 and the rotational speed information from the read only memory 47 is made in the central processor unit 46. As a result of the comparison, rotational speed of the motor 15 not more than 200 r.p.m. gives (YES) discrimination, and not less than 200 r.p.m. gives (NO) discrimination. this discrimination process (P13) is immediately executed when the electric motor 15 is set in the step (P12) at 100 r.p.m. for being started, so the result will be (YES). The program will be advanced to a setting step (P14) of a 0.1 sec. timer followed by transferring to a discrimination process (P15) for discriminating whether the time measuring operation is over or not. If the 0.1 sec. timer is terminated (YES) discrimination will come out to advance in turn to a discrimination process (P16), wherein discrimination is performed in respect of discriminating whether NP memory is set or not. The NP memory is already reset in the reset step (P3), so (NO) discrimination comes out in this discrimination process (P16) for being advanced to a discrimination process (P17), wherein discrimination is performed for discriminating whether a needle-position signal Sa has risen or not. If the needle-position signal Sa from the position detector 51 rises (YES) discrimination will come out to advance the program to a set step (P18) of NP memory to in turn set NP memory in the random access memory 48. Upon the setting of NP memory the program will be immediately advanced to a process (P19) for stopping the supply of firing pulse in between the input terminals of the motor control circuit 60. After having finished the process (P19) the program will be advanced to a set step (P20) of a 6 milli sec. timer in order to set the same for being further transferred to a discrimination process (P21) wherein discrimination is performed regarding whether the time counting operation has finished or not. While the timer is working (not yet finished) (NO) discrimination will come out for maintaining the discrimination process (P21) for some more time. When the timer has finished its operation the discrimination process (P21) will turn to (YES) for being transferred to a braking process (P22) of the electric motor 15, wherein a firing pulse is given in between the input terminals 42, 42 of the motor control circuit 60 with a result of turning the thyristor 38 ON. So a short circuit will arise between the terminals 15a and 15b of the electric motor 15 through the resistor 39, the thyristor 38, and diode 40 for carrying out a dynamic braking, which brings about a stoppage of the electic motor 15, with the needle 9 being shifted from the upper position to the lower position.
Another case, in which the needle 9 is positioned down when the operator has put the power source ON and afterwards the operable button 14 is depressed for a short time less than 0.25 sec., will be described next. The discrimination process (P2) shows, in this instance, (NO) discrimination, so NP memory in the random access memory 48 is set by the set step (P4). Thereafter the same process from (P5) to (P15) as in the previous case will be followed in the order, finally reaching the discrimination process (P16). As NP memory is already set in the set step (P4), (YES) discrimination will naturally come out in the discrimination process (P16) for being advanced to a discrimination process (P23), wherein discrimination is performed for discriminating whether the needle position signal Sa has fallen or not. When the needle-position signal Sa from the position detector 51 falls (YES) discrimination will come out for being advanced to a reset step (P24) of NP memory. NP memory in the random access memory 48 is consequently reset. Processing from (P19) to (P22) will be followed as in the previous case after the finish of the reset step (P24). The electric motor 15 will be stopped in a state wherein the needle 9 has been shifted from the lower position to the upper position.
As can be understood from the detailed description set out above, when the operable button 14 is put ON again for a short period of time less than 0.25 sec., after the needle 9 has been shifted from the upper position to the lower position, all the processes as far as the discrimination process (P16) are executed similarly to the previous description, and the processes from the discrimination process (P23) to the braking process (P22) of the motor 15 will be advanced due to the (YES) discrimination in the discrimination process (P16), because the NP memory is already set in the previous operation of the set step (P18). The electric motor 15 is consequently stopped in a state where the needle 9 has been returned from the lower position to the upper position. When the operable button 14 is again put ON for a short period of time less than 0.25 sec., while the needle 9 is at the upper position, processes as far as the discrimination process (P16) are performed in the same way as previously mentioned and (NO) discrimination will come out in the discrimination process (P16), because of the already setting of NP memory in the reset step (P24) in the previous operation, for performing the processes or steps from (P17) to (P22). The electric motor 15 is stopped in a state where the needle 9 has been shifted from the upper position to the lower position.
The description now turns to an instance where the operable button 14 is put ON for a long period of time not less than 0.25 sec. while the electric motor 15 is stopped (stationary). The processes as far as the discrimination process (P11) are carried out just in the same manner as the foregoing description. As the operable button 14 is maintained ON even after the 0.25 sec. has elapsed, (YES) discrimination will come out from the discrimination process (P11); a 100 r.p.m. set step (P25), an NP memory set step (P26), a non-ravel stitching information output process (P27), and an LS memory set step (P28) are carried out in the order. In the 100 r.p.m. set step (P25) a responding firing pulse to that speed is supplied, in the similar manner as in the above-mentioned step (P12), in between the input terminals 31, 31 of the motor control circuit 60 for starting the electric motor 15; in the NP memory set step (P26) an NP memory in the random access memory 48 is set; in the non-ravel stitching information output process (P27) information for the non-ravel stitching is synchronously read out with the reciprocation of the needle 9 from the read only memory 47 by the central processor unit 46 for outputting the information, via the input-output device 49, to the stitch forming system 55; and in the LS memory set step (P28) the LS memory in the random access memory 48 is set. When the step (P28) is finished the program is advanced again to the discrimination process (P11) for repeatedly performing each step and process from the discrimination process (P11) to the step (P28), while operable button 14 is maintained ON and performing the non-ravel stitching in accordance with the information produced in the process (P27). When the operable button 14 is released of depression to become OFF after the non-ravel stitching has been performed for a corresponding time of that button depression the discrimination result of the discrimination process (P11) will be (NO) for advancing the program to the process (P12), and each step and process from the process (P12) to the discrimination process (P16) is carried out in the same order as mentioned above. The discrimination result in the discrimination process (P16) will be (YES), because of the NP memory being set in the step (P26), for performing each step and process from the discrimination process (P23) to the process (P22) in the same manner as mentioned above. The electric motor 15 is therefore stopped when the needle 9 has reached the upper position.
For forming various stitch patterns, on the other hand, the first select button 7 or the second select button 8 is operated ON to light desired one of the LEDs 6 positioned right above the indicia 5 representing desired stitch patterns, then a pattern code signal representing the desired stitch pattern is input as a commanding signal, via the input-output device 49, to the central processor unit 46. When the main button 13 is depressed ON after having finished the non-ravel stitching, etc., a command for starting the electric motor 15 is input, via the input-output device 49, to the central processor unit 46, whereby a firing pulse is supplied from the central processor unit 46, via the input-output device 49, in between the input terminals 31, 31 of the motor control circuit 60 for starting the electric motor 15. In this situation the central processor unit 46 makes an (YES) discrimination in the discrimination process (P6) of the flow chart, because of the electric motor 15 being in rotation, and a (NO) discrimination in the discrimination process (P8), because of the operable button 14 not being ON, for performing a stitch pattern forming process other than the non-ravel stitching (P29). In the process (P29) the central processor unit 46 selectively reads out the information from the read only memory 47 for forming a stitch pattern corresponding to an indicium 5 indicated by the LED 6 for giving the information to the stitch forming system 55. The machine is therefore held in a state wherein the selected stitch pattern other than the non-ravel stitching is formed. And while the selected stitch pattern is formed in this manner the central processor unit 46 circulates each of the steps and the processes (P5), (P6), (P7), (P8), and (P29) in every one reciprocation of the needle 9. And the electric motor 15 can be driven at any desired speed by a speed setting apparatus which is operated by an operator, being usually so set as to be driven at a speed not less than 200 r.p.m.
Next a case, wherein the operable button 14 is turned ON for a short period of time within 0.25 sec., while a selected stitch pattern other than the non-ravel stitching is formed, will be described. The moment when the operable button 14 is turned ON the discrimination result of the discrimination process (P8) will be (YES) to carry out the step (P9) and the discrimination process (P10) in the order. As the discrimination process (P10) keeps the (NO) discrimination for the period of 0.25 sec. until the timer terminates the measuring operation, for allowing based on this discrimination result to continuously execute a process (P30) of forming a stitch pattern other than the non-ravel stitching which has been previously selected by the operator. When the discrimination result in the discrimination process (P10) is turned to (YES) due to the termination of the timer's operation, the program is advanced in the same manner stated above to the discrimination process (P11), wherein (NO) discrimination is made, owing to a turning ON of the operable button 14 only for a short period of time, for being advanced after the performance of the process (P12) to the discrimination process (P13). The electric motor 15 which had been rotated at a speed not less than 200 r.p.m. until immediate before the advancement to the step (P12) needs a certain time duration due to its inherent inertia before it is decelerated down to 100 r.p.m. set in the step (P12). (NO) discrimination in the discrimination process (P13) advances the program to the discrimination process (P31) for discriminating whether the LS memory is set or not. Then the LS memory is maintained in a reset state by the above-mentioned step (P5), (NO) discrimination comes out to advance the program to the stitch pattern forming process (P32) other than the non-ravel stitching for continuing the formation of the stitch pattern selected by the operator. When the rotation speed of the electric motor 15 is decelerated down to less than 200 r.p.m. (YES) discrimination comes out in the discrimination process (P13) for advancing the program to the step (P14) in order to set a 0.1 sec. timer. The program advances further to the discrimination process (P15). During the time until the termination of the 0.1 sec. timer the rotation speed of the electric motor 15 comes down from 200 r.p.m. to 100 r.p.m., the set speed. As the discrimination in the discrimination process (P15) keeps (NO) until the timer terminates, the program is advanced to a discrimination process (P33) for discriminating again whether the LS memory is set or not. The then coming out (NO) discrimination advances the program, just like in the case of the discrimination process (P31), to a stitch pattern forming process (P34) other than the non-ravel stitching in order to further continue the formation of the selected stitch pattern. (YES) discrimination in the discrimination process (P15) due to the termination of the timer moves the program to the discrimination process (P16), which makes (YES) discrimination, because of the NP memory being set in the above-mentioned step (P7), to advance the program to the discrimination process (P23). (NO) discrimination continues until the needle-position signal falls in this process (P23), so the program advances to a discrimination process (P35) for discriminating again whether the LS memory is set or not. (NO) discrimination in this process (P35) advances the program to a stitch pattern forming process (P36) other than the non-ravel stitching for continuously forming the selected stitch pattern until the needle-position signal falls. When the discrimination result of the discrimination process (P23) turns to (YES) due to the falling of the needle-position signal, each step and process from the step (P24) to the process (P22) is performed to stop the electric motor 15, with the needle being maintained at the upper position.
A case wherein the operable button 14 is depressed ON for a long period of time not less than 0.25 sec. while the machine is forming a selected stitch pattern other than the non-ravel stitching is to be described hereunder.
Turning ON of the operable button 14 causes performance of each process as far as the discrimination process (P11), similarly to a case wherein the operable button 14 is depressed for a short period of time within 0.25 sec. while a selected stitch pattern is formed as stated above. (YES) discrimination comes out in the discrimination process (P11), just like in the above description, for performing each process between the step (P25) and the step (P28) in order to carry out the non-ravel stitching. Releasing depression of the operable button 14 for turning OFF after having formed the non-ravel stitching for a desired period of time by the operator makes the discrimination result in the discrimination process (P11) (NO), which advances the program, via the step (P12), to the discrimination process (P13). If the rotation speed of the electric motor 15 is then above 200 r.p.m., the discrimination result of the discrimination process (P13) turns out (NO) for advancing the program to the discrimination process (P31), where (YES) discrimination will be given, because of the LS memory being set in the above-mentioned step (P28) to advance the program to a non-ravel stitching information outputting process (P37). As the non-ravel stitching information is given in this process (P37), just like in the above-mentioned process (P27), to the stitch forming system 55 synchronously with the reciprocation of the needle 9, the non-ravel stitching can be continuously formed. Besides, in a case where the electric motor 15 is rotated at a speed less than 200 r.p.m. due to a relatively long operation of the forming of non-ravel stitching by the depression of the operable button 14, the discrimination process (P13) gives (YES) discrimination. With a turning of the discrimination result of the discrimination process (P13) to (YES), the program is promoted, via the step (P14), to the discrimination process (P15) for maintaining (NO) discrimination in the discrimination process (P15) until the 0.1 sec. timer terminates the measuring operation, so the program advances to the discrimination process (P33) so long as the discrimination result of the discrimination process (P15) keeps on (NO) discrimination, which causes the program to advance, with the discrimination process (P33) producing (YES) discrimination because of the LS memory being already set, to a non-ravel stitching information output process (P38) for continuing, just similarly to the above-mentioned process (P37), formation of the stitches for the non-ravel stitching. When the discrimination process (P15) gives (YES) discrimination due to termination of the timer's operation, the discrimination result of the discrimination process (P16) turns to (YES) due to the setting of the NP memory in the above-mentioned step (P26) for advancing the program to the discrimination process (P23). As the discrimination keeps (NO) in this process (P23) until the needle-position signal falls, the program continues to advance to the discrimination process (P35). As the discrimination result of the discrimination process (P35) is (YES), because of the LS memory being set as stated above, a non-ravel stitching information output process (P39) is carried out for continuously forming stitches for non-ravel stitching, similarly to the statement in the above description, until the fall of the needle-position signal. When the needle position signal falls the discrimination process (P23) gives (YES) discrimination to cause each of the steps and processes between (P24) and (P22) to be carried out; and the electric motor 15 is stopped, with the needle 9 being maintained at the upper position. Performance of the process (P22) successively causes performance of the step (P5), which brings about a resetting of the LS memory which has been set in the step (P28).
In the embodiment the needle 9 can be altered its position, when the operable button 14 is turned ON for a short period of time while the electric motor 15 is stationary, so that it is shifted downwards when it is in the upper position and upwards when it is in the lower postion respectively; when the operable button 14 is turned ON for a long period of time while the electric motor 15 is stationary, stitches for the non-ravel seaming are formed so long as the operable button 14 is ON, and when it is turned OFF the non-ravel stitching is terminated, with the needle 9 being arrested at the upper position. When the operable button 14 is turned ON for a short period of time while a selected stitch pattern other than the non-ravel stitching is being formed, with the electric motor 15 being in rotation, the rotation of the motor 15 is gently decelerated to arrest the needle 9 at the upper position and then the motor 15 is stopped with the termination of forming of the selected stitch pattern; when the operable button 14 is turned ON for a long period of time while a selected stitch pattern other than the non-ravel stitching is being formed, with the electric motor 15 being in rotation, the rotation of the motor 15 is gently decelerated to shift the machine operation to the formation of stitches for the non-ravel stitching, which is continued so long as the operable button is kept ON. And when the operable button 14 is turned OFF the needle 9 is arrested at the upper position.
In this embodiment above described, in case of an ON operation of the operable button 14 while a selected stitch pattern other than the non-ravel stitching is formed, a formation of stitches for the non-ravel stitching and an arresting of the needle 9 at the upper position will be selectively carried out depending on the length of the operation time duration of the operable button 14, but it is of course permissible to change the program such that an ON operation of the operable button 14 during the formation of the selected stitch pattern causes an instantaneous switching over to the formation of the non-ravel stitching irrespective of the length of the operation time duration. In this instance, the function of the operable button 14 can be changed by means of substituting the processes indicated in FIG. 6 with solid lines for the processes from the step (P5) to the process (P10) in FIG. 5. | A sewing machine wherein a single operable button is capable of selectively performing a plurality of actions depending on the length of duration of the operation time. The machine is provided with a needle positioning device for arresting the needle at a certain predetermined position and a stitch forming system for forming a specific stitch pattern, and either of the two is actuated according to the length of duration of the operation time of the operable button. Furthermore, a forthcoming action of the machine can be varied in response not only to the length of duration of the operation time mentioned above but also to the state of the machine which can be in operation or stationary. The machine is thereby capable of performing a plurality of different actions by means of fewer operable buttons. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a semiconductor apparatus and a production method thereof. Especially, it relates to a semiconductor apparatus and the production method suitable for a device for electric power.
[0003] 2. Description of the Related Art
[0004] The semiconductor module indicated in the circuit as shown in FIGS. 1 and 2 has been conventionally known. FIG. 1 shows a semiconductor module 100 (so-called 2 in 1) such that two MOSFETs (Metal Oxide Semiconductor Field Effect Transistors) 101 are mounted on one insulation substrate. FIG. 2 shows a semiconductor module 200 (so-called 6 in 1) such that six MOSFETs 201 are mounted on one insulation substrate. These semiconductor modules 100 and 200 configure the arm of an inverter apparatus for driving a motor. The semiconductor module 100 is configured in such a way that two MOSFETs 101 are connected in series. Also, the semiconductor module 200 is configured in such a way that three circuits obtained by serially connecting MOSFETs 201 are connected in parallel.
[0005] In the semiconductor module provided with such a semiconductor element (semiconductor switching element) like the above-mentioned conventional MOSFET, only a product provided with an arm configuration can be used so that the use application of this product is limited. Also, in the case where the above-mentioned semiconductor modules are connected in parallel to be used, the derating of an allowable current capacity should be increased, thereby generating many wastes.
[0006] Furthermore, an IGBT (Insulated Gate Bipolar Transistor) semiconductor module obtained by connecting a plurality of IGBT semiconductor elements via an emitter terminal external connection part, a collector terminal external connection part and a gate terminal external connection part has been known. In addition, an inverter apparatus that uses this IGBT semiconductor module has been known. In this inverter apparatus, these two IGBT semiconductor modules are connected in series. In this series connection, wiring connection using bus bar wiring, etc. is used. This IGBT semiconductor module is obtained by connecting in parallel a plurality of, that is, at least two or more IGBT semiconductor elements in an inside thereof (for example, refer to a patent literature 1).
[0007] Consequently, it is necessary to produce at least several IGBT semiconductor elements even in the case where a semiconductor module with a small current capacity is produced. Therefore, there is a problem such that the production cost of the semiconductor module with a small current capacity becomes comparatively expensive. In addition, there arises a problem when the product is downsized.
[0008] [Patent literature 1] Japanese Patent Laid-open Application Publication No. 10-84077.
SUMMARY OF THE INVENTION
[0009] In the present invention, the use application of a semiconductor module is increased by connecting in parallel and/or in series semiconductor elements in a semiconductor module.
[0010] When a semiconductor apparatus is produced using the semiconductor module on which a plurality of semiconductor elements are mounted, the semiconductor elements in the semiconductor module can be connected in parallel and/or in series, which is the main characteristic of the present invention.
[0011] The present invention aims at offering a semiconductor apparatus comprising a semiconductor module having a plurality of semiconductor elements and an external connection terminal for externally connecting electrodes of the semiconductor elements in the semiconductor module. Furthermore, this semiconductor apparatus is characterized in that the semiconductor elements in each semiconductor module are connected in parallel and/or in series via an external connection terminal.
[0012] The external connection terminal is characterized in that it comprises a first external connection terminal for externally connecting first electrodes of the semiconductor elements and a second external connection terminal for externally connecting second electrodes of the semiconductor elements.
[0013] The external connection terminal is characterized in that it comprises a third external connection terminal for externally connecting a first electrode of the semiconductor element and a second electrode of another semiconductor element.
[0014] The present invention is characterized in that by externally connecting electrodes of semiconductor elements in two or more semiconductor modules via an external connection terminal, a semiconductor apparatus is produced in such a way that semiconductor elements in the semiconductor modules are connected in parallel and/or in series.
[0015] The present invention is characterized in that first electrodes of the semiconductor elements are externally connected via a first external connection terminal and second electrodes of the semiconductor elements are externally connected via a second external connection terminal.
[0016] The first external connection terminal is characterized in that it is mounted on a surface of the semiconductor module, an insulation part is mounted on the first external connection terminal and the second external connection terminal is mounted at an upper part of the insulation part and on a surface of the semiconductor module.
[0017] It is characterized in that the first electrode of the semiconductor element and the second electrode of another semiconductor element are connected via the third external connection terminal.
[0018] According to the production method of a semiconductor apparatus of the present invention, a semiconductor apparatus of the present invention with the above-mentioned operation and effect can be produced.
[0019] The present invention offers a semiconductor apparatus characterized in that this apparatus comprises first and second semiconductor modules each having at least one semiconductor element; a case for storing the first and second semiconductor modules; and a plurality of terminal conductors for deriving a main electrode of each semiconductor module to an outside of the case so that the terminal conductors of the first semiconductor module and the second semiconductor module can be connected in parallel and/or in series via an external connection terminal.
[0020] The external connection terminal is characterized in that it comprises the first external connection terminal for externally connecting terminal conductors of the first electrodes of each semiconductor module and the second external connection terminal for externally connecting terminal conductors of the second electrodes of each semiconductor module.
[0021] The external connection terminal is characterized in that it comprises the third external connection terminal for externally connecting the terminal conductor of the first electrode of the first semiconductor module to the terminal conductor of the second electrode of the second semiconductor module.
[0022] Consequently, the present invention can offer circuits in which modules are connected via various external connection terminals that implement the parallel connection and series connection of semiconductor elements, as one package of semiconductor apparatuses. In addition, in a circuit, etc. in which semiconductor elements are connected in parallel, the derating of an electric characteristic such as an allowable current capacity can be decreased by matching electric characteristics of semiconductor elements in the respective semiconductor modules. Furthermore, since only an optional number of the semiconductor elements can be connected in parallel via an external connection terminal, one package of products of many kinds can be offered as one package of semiconductor apparatuses. Accordingly, the production cost of those products can be reduced by the mass-production effect.
[0023] According to the present invention, semiconductor elements in a semiconductor module are configured to be externally connected via an external connection terminal (output to a motor) so that the semiconductor elements are externally connected to the 2 in 1. Therefore, the thus-connected module can be used as one MOS module.
[0024] According to the present invention, the semiconductor modules each having at least one semiconductor element are connected in parallel and/or in series via an external connection terminal to be offered as one package of products. Therefore, a variety of products can be provided as a package of semiconductor apparatuses. In addition, the component (the semiconductor module) can be standardized in each product so that the production cost of each product can be reduced by the mass-production effect. Furthermore, in a product such that semiconductor elements in a plurality of semiconductor modules are connected in parallel via an external connection element, the derating of the electric characteristic of an allowable current, etc. can be reduced in comparison with the conventional product such that individual semiconductor packaged products are connected in parallel. Furthermore, a package of downsized products with different maximum allowable currents can be widely produced so that an abundant product lineup can be offered to a user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 shows a circuit of a conventional MOS module;
[0026] FIG. 2 shows a circuit of another conventional MOS module;
[0027] FIG. 3 is a top view of a semiconductor apparatus substrate;
[0028] FIG. 4 ( a ) shows the circuit of a MOS module part 12 and ( b ) shows the circuit of a MOS module part 14 ;
[0029] FIG. 5 is a top view of the semiconductor apparatus that is produced by externally connecting two MOS module parts on the semiconductor apparatus substrate;
[0030] FIG. 6 is a circuit diagram of a semiconductor apparatus of the preferred embodiment 1;
[0031] FIG. 7 is a top view of the semiconductor apparatus that is produced from the substrate of a semiconductor apparatus in such a way that an insulation part is provided between a positive electrode external connection terminal and a negative electrode external connection terminal (preferred embodiment 2);
[0032] FIG. 8 is a cross-section view of the semiconductor apparatus of the preferred embodiment 2 along the line A-A′ in FIG. 7 ;
[0033] FIG. 9 is a top view of another semiconductor apparatus that is produced by externally connecting two MOS module parts on the semiconductor apparatus substrate (preferred embodiment 3); and
[0034] FIG. 10 is a circuit diagram of a semiconductor apparatus of the preferred embodiment 3;
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] The following is the detailed explanation of the preferred embodiments of the present invention in reference to the drawings.
[0036] FIG. 3 shows a preferred embodiment before a semiconductor apparatus of the preferred embodiment of the present invention is externally connected. The semiconductor apparatus shown in FIG. 3 is called a semiconductor apparatus substrate 10 for convenience.
[0037] A case 11 is provided with a MOS module part 12 (first MOS module part) and a MOS module part 14 (second MOS module part)
[0038] FIGS. 4 ( a ) and ( b ) are the circuit diagrams of the MOS module part 12 and the MOS module part 14 , respectively. As shown in FIGS. 4 ( a ) and ( b ), each of the MOS module parts 12 and 14 is provided with enhancement-shaped MOSFETs (hereinafter, refer to n-MOSFET) 13 (first semiconductor module) and 15 (second semiconductor module) of an n channel in the case 11 .
[0039] As shown in FIGS. 3 and 4 , the MOS module part 12 is provided with a terminal conductor 16 to be connected to a drain electrode (D) regarding the n-MOSFET 13 and terminal conductors 17 - 1 and 17 - 2 to be connected to a source electrode (S). The MOS module part 14 is provided with terminal conductors 18 - 1 and 18 - 2 to be connected to a drain electrode (D) regarding the n-MOSFET 15 and a terminal conductor 19 to be connected to a source electrode (S). The terminal conductors 16 , 17 - 1 , 17 - 2 , 18 - 1 , 18 - 2 and 19 extend to the outside of the case 11 and they are orthogonally bent at the outside of the case 11 . Each of the MOS module parts 12 and 14 is provided with a gate electrode (G) which is not shown in FIG. 3 but shown in FIGS. 4 ( a ) and ( b ).
[0040] Meanwhile, the semiconductor apparatus substrate 10 that is shown in FIG. 3 is only an example. In the present invention, therefore, the arrangement and the number of terminal conductors that are connected to the drain electrode on a semiconductor apparatus substrate and the terminal conductors that are connected to a source electrode are not limited. In addition, each electrode and terminal conductors can be configured to be integrated.
Preferred Embodiment 1
[0041] FIG. 5 shows the method of producing a semiconductor apparatus in which the n-MOSFETs 13 and 15 of each of the MOS module part 12 and the MOS module part 14 are connected in parallel by externally connecting the MOS module 12 and the MOS module 14 of the semiconductor substrate 10 of FIG. 3 via external connection terminals 22 , 24 .
[0042] In the semiconductor apparatus 20 that is shown in FIG. 5 , the terminal conductor 16 that is connected to a drain electrode of the MOS module part 12 is externally connected to the terminal conductors 18 - 1 and 18 - 2 that are connected to the first and second drain electrodes of the MOS module part 14 via a positive electrode external connection terminal 22 . At the same time, the terminal conductors 17 - 1 and 17 - 2 that are connected to the first and second source electrodes of the MOS module part 12 and the terminal conductor 19 that is connected to the source electrode of the MOS module part 14 are connected via a negative electrode external connection terminal 24 .
[0043] FIG. 6 shows the circuit of a semiconductor apparatus 20 produced by externally connecting module parts via such external connection terminals 22 and 24 . The semiconductor apparatus 20 is a circuit in which n-MOSFETs 13 and 15 are connected in parallel via external connection terminals 22 , 24 .
[0044] In this way, the semiconductor apparatus 20 with the current capacity rating twice that of the n-MOSFETs 13 and 15 of each of the MOS module parts 12 and 14 can be produced by externally connecting the MOS module parts 12 and 14 .
[0045] Furthermore, the derating that is usually required can be reduced by making the electric characteristics of the n-MOSFETs 13 and 15 in each of the MOS module parts 12 and 14 approximately the same.
Preferred Embodiment 2
[0046] FIG. 7 shows another semiconductor apparatus produced from the semiconductor apparatus substrate 10 of FIG. 3 . A semiconductor apparatus 30 that is shown in FIG. 7 is the same as the semiconductor apparatus 20 of the preferred embodiment 1 in circuit and external connection configurations. In this apparatus 30 , however, an external connection terminal 32 includes a rectangle electric conductor flat plate that covers the conductor terminals 16 , 17 - 1 , 17 - 2 , 18 - 1 , 18 - 2 and 19 while an external connection terminal 34 includes a hexagon electric conductor flat plate that covers conductor terminals 17 - 1 , 17 - 2 and 19 . By providing an insulation part (sheet, etc.) between the positive electrode connection terminal 32 and the negative electrode external connection terminal 34 , this apparatus 30 can reduce inductance and further decrease derating in comparison with the semiconductor apparatus 20 .
[0047] FIG. 8 is the partial cross-section view of a periphery part of the terminal conductor 17 - 2 along the line A-A′ of the semiconductor apparatus 30 that is shown in FIG. 7 .
[0048] As shown in FIG. 8 , the negative electrode external connection terminal 34 is provided on the surfaces of the MOS module parts 12 and 14 (not drawn in FIG. 8 ) like the shape shown in the top view of FIG. 7 and a sheet-shaped insulation part 36 is further provided so as to cover whole the negative electrode external connection terminal 34 . In addition, a positive electrode external connection terminal 32 is provided on the insulation part 36 . The positive electrode external connection terminal 32 is provided in the shape as shown on the top view of FIG. 7 . Therefore, a part of the positive electrode external connection terminal 32 is provided on the surfaces of the MOS module parts 12 and 14 . At this time, the insulation part 36 is provided in order that the positive electrode external connection terminal 32 and the negative electrode external connection terminal 34 do not contact to each other.
[0049] Each of the semiconductor apparatuses 20 and 30 of the above-mentioned preferred embodiments 1 and 2 has the circuit configuration such that two semiconductor elements are connected in parallel. The circuit configuration of the semiconductor apparatus of the present invention is not limited to this configuration and the number of the semiconductor elements that are connected in parallel can be optional.
Preferred Embodiment 3
[0050] FIG. 9 shows still another semiconductor apparatus produced from the semiconductor apparatus substrate 10 of FIG. 3 .
[0051] A semiconductor apparatus 40 is configured in such a way that the MOS module parts 12 and 14 are externally connected via an intermediate external connection terminal 48 in addition to the positive electrode external connection terminal 42 and the negative electrode external connection terminal 44 . FIG. 10 is the circuit diagram of the semiconductor apparatus 40 .
[0052] In the semiconductor apparatus 40 , the terminal conductor 17 - 1 that is connected to the first source electrode of the n-MOSFET 13 of the MOS module part 12 is externally connected to the terminal conductor 18 - 2 that is connected to the second drain electrode of the n-MOSFET 15 of the MOS module part 14 , via the intermediate external connection terminal 48 . Meanwhile, the positive electrode external connection terminal 42 for the terminal conductor 16 that is connected to the drain electrode of the n-MOSFET 13 of the MOS module part 12 and the negative electrode external connection terminal 44 for the terminal conductor 19 that is connected to the source electrode of the n-MOSFET 15 of the MOS module part 14 are used for, for example, the series connection between module parts.
[0053] By externally connecting the semiconductor apparatus substrate 10 , the n-MOSFET 13 of the MOS module part 12 and the n-MOSFET 15 of the MOS module part 14 are serially connected. Then, a semiconductor apparatus 40 of an arm configuration is produced by externally connecting modules via an external terminal. In this semiconductor apparatus 40 , two n-MOSFETs 13 and 15 are serially connected. In the present invention, however, the number of n-MOSFETs that are serially connected is not limited and the number is optional.
[0054] In the present invention, not only a circuit in which n-MOSFETs are connected in parallel like the semiconductor apparatuses 20 and 30 of the preferred embodiments 1 and 2 but also a circuit in which n-MOSFETs are connected in series like the semiconductor apparatus 40 of the preferred embodiment 3 can be configured. In addition, it is possible to produce the semiconductor apparatus 20 or the semiconductor apparatus 30 and the semiconductor apparatus 40 as one package of semiconductor apparatuses. Therefore, in the present invention, it is possible to produce as one package of semiconductor apparatuses a circuit in which n-MOSFETs are connected in parallel and in series.
[0055] Meanwhile, the semiconductor apparatus of each preferred embodiment uses the semiconductor module that is provided with an n-MOSFET as a semiconductor element. The semiconductor module that is used in the present invention can be provided with a semiconductor element other than an n-MOSFET. The semiconductor element of the present invention may include, for example, an FET, an IGBT, an SIT (Static Induction Transistor) such as a p-MOSFET, a CMOS-FET (Complementary Metal Oxide Semiconductor FET), etc., a transistor such as a bipolar transistor and a thyristor etc., such as a GTO (Gate Turn-off Thyristor).
[0056] Meanwhile, the number of the semiconductor elements that are mounted on the semiconductor module is not limited to one and an optional number can be adopted. Furthermore, the numbers of the respective semiconductor elements that are mounted on all the semiconductor modules need not be the same so that the numbers of semiconductor elements mounted on the respective semiconductor modules can be different. In addition, the types of the semiconductor elements that are mounted on the respective semiconductor modules can be different. | A semiconductor apparatus is characterized in that it comprises a semiconductor module having a plurality of semiconductor elements and an external connection terminal for externally connecting electrodes of the semiconductor elements in the semiconductor module, wherein the semiconductor elements in each semiconductor module are connected in parallel and/or in series via the external connection terminal. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to apparatus for measuring ligamentous insufficiency in the knee to enable a physican to provide a diagnosis of injury and evaluation of different treatment methods. In the past, abnormal motion between the tibia and the femur was detected by a physican by manipulation of the leg by hand. Often the motion of a leg with a ligament tear is subtle and difficult to compare with the patient's uninjured leg. Because even a normal knee may have a substantial motion, it is desirable to quantitatively measure the displacement to allow an accurate comparison between the patient's normal and injured knees to determine the extent of injury.
While an electromechanical instrument has been devised for measuring the anterior drawer in the legs of normal volunteers and patients with known anterior cruciate deficits in a clinical research study, the device has certain disadvantages. The instrument is expensive and bulky and is not autoclavable to allow for its use in the operating room. Also the instrument is primarily restricted to the 20° anterior drawer (Lachman) test.
The apparatus of this invention is autoclavable and is designed for use in both the 20° anterior draw and 90° anterior draw tests and without refitting is designed for use in measuring posterior excursions. It is believed that measurement of both anterior and posterior excursions provides the physician with the maximum useful data for proper diagnosis and treatment.
SUMMARY OF THE INVENTION
The sagittal knee test apparatus of this invention is devised to accurately measure displacements in the knee particularly for determining and treating ligamentous insufficiencies. The apparatus includes a leg support frame having an adjustment mechanism for disposing the legs of a patient at a select test angle. The leg support frame includes ankle straps and thigh straps for securing the patient's legs to the frame at two fixed points which permit displacements at the knee to be measured in reference to these fixed points.
Operating in conjunction with the leg support frame is an instrument bridge having two mounts positioned against the tibia and secured thereto by legs straps. The instrument bridge, is displaced from and aligned along the length of the tibia with a telescoping end with an indicator positionable over the patella. The indicator comprises a spring-loaded plunger with an end button that is pressed against the patella. The indicator detects and records displacements at the end of the bridge with respect to the patella.
To induce these displacements, a push-pull load applicator is used. The preferred load applicator comprises a crooked hand probe with a spring scale to register the force of push or pull applied to the anterior or posterior of the lower leg proximate the knee. An electronic pressure sensitive transducer can be substituted for the spring indicator if an electronic or electronically displayed reading is desired. The applied force from the load applicator displaces the tibia relative to the femur. As the patella is assumed to move in unison with the femur, the plunger, which is in contact with the patella, is displaced with respect to the end of the bridge which is in contact with the tibia. The displacement is transmitted to the indicator for both a posterior and anterior thrust such that the sagittal component of knee laxity is accurately measured. The indicator for simplicity is mechanical. However an equivalent electronic display and/or displacement measuring means may be used.
The load applicator is an independent device from the instrument bridge and can be used alone by the physican for preliminary diagnostics where a definite applied force is desired, but an accurate measurement is not required. Similarly, the instrument bridge can be used in conjunction with some other means of applying a displacement force that is not the same in construction as that described as a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the leg support component of the saggital knee test apparatus.
FIG. 2 is a side elevational view of the three component knee test apparatus in a demonstrated use.
FIG. 3 is a cross sectional view of the measuring device component taken on the lines 3--3 in FIG. 2.
FIG. 4 is a partial cross sectional view of the leg support component taken on the lines 4--4 in FIG. 2.
FIG. 5 is an enlarged side elevational view, partially in cross section, of the measuring device component.
FIG. 6 is a partial cross sectional view taken on the lines 6--6 in FIG. 5.
FIG. 7 is a cross sectional view of the force application component of the knee test apparatus.
FIG. 8 is a view of the indicator taken on the lines 8--8 in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, in particular to FIGS. 1,2,3, and 7, the sagittal knee test apparatus comprises three components, a leg support 12, a measurement device 14 and a force applicator 16. The apparatus is shown in use with a physican 18 and patient 20 illustrated in part in phantom, in FIG. 2.
The leg support 12 comprises a base pad 22, which is placed on an examining table. The base pad 22 has a leg support frame 24 connected to a coupling plate 26 at the front of the pad 22 by an adjustment clamp 28. The leg support frame 24 has a central support arm 30 and a telescoping T-member 31 at the distal end of the support arm 30 for support of the legs at the ankles. Angular disposition of the support arm 30 relative to the base pad 22 is obtained by loosening the clamping screw 32 and rotating the support arm 30 to the position desired. The toothed clamp faces 34 insure that the position is accurately selected and maintained without slippage. In the standard tests for knee laxity, two positions are used, a 20° flexion for the Lachman Test and a 90° flexion for the Drawer Sign Test. The former 20° position is optimal for testing a suspected anterior cruciate ligament tear, and the latter 90° position is optimal for testing a suspected posterior cruciate ligament tear. These two positions are indicated by markings 36 on the adjustment clamp 28.
The telescoping T-member 31 at the end of the support arm is extendable to accomodate different patients with different length legs. The crosspiece 38 on the T-member is positioned to contact the back of the ankle at a location above the heel where the heel tendon joins the calf muscle. The position is fixed by insertion of a threaded clamp 40 which engages the neck piece 44 of the T-member 31 as shown in FIG. 4. In addition to a proper positioning mechanism, the crosspiece 38 preferably includes padded sleeves 46 to assure a maximum degree of comfort during the test period.
Since the ankle contact at the crosspiece 38 of the T-member 31 is essentially the pivot point for inducing deflection of the tibia at the knee, to accomplish both anterior and posterior tests, thigh straps 47 and ankle straps 48 are necessary to maintain the position of the lower legs, particularly during the anterior test where a force is applied against the back of the leg below the knee. The thigh straps 47 and ankle straps 48 loop through retainer hooks 49 on the base pad 22 and overlap to engage a hook and mat coupling means 51.
The force is applied with a push-pull force applicator 16. The applicator has a handle 50 with a hand grip 52 and a spring scale 54 with a compression spring 56 and slide collar 58 with an engagement screw 60 for engaging the spring 56 at a selected position for a desired force. Projecting from the handle 50 is a hook shaped probe 62 having a transverse pressure bar 64. The probe 62 slidably extends into the handle 50 and is locked to the slide collar 58 by the engagement screw 60. A rubberlike contact pad 66 is mounted on the pressure bar 64. The contact pad has a convex surface for contacting the back of the leg during a leg pull for anterior tests, and a concave surface for contacting the front of the leg during a leg push for posterior tests. Since excursions of the tibia at its connection with the femur are being measured, the force is applied against the tibia just below the knee.
The movement of the tibia relative to the femur is measured and recorded by the measurement device 14, which comprises an instrument bridge 68 and supported displacement instrument 69, shown also in FIGS. 5 and 6. The instrument bridge is constructed with a mounting support 70 proximate the knee and a mounting support 72 distally displaced from the knee and an interconnecting tube 88. The mounting supports 70 and 72 include a shallow V-shaped contact pad 74 having a projecting post 76 with a clamp stud 77. A double clamp 78 engaging the clamp stud 77 at one end and the tube 88 at the other end, utilizes a center mounted clamp screw 79 to secure the supports to the elongated tube. The contact pad 74 rests against the anterior of the tibia and is strapped thereto by an elastic strap 82 having strap holes 84 through which a pin 86 is inserted to hold the end of a strap wrapped around the patient's leg. The tube 88 is substantially aligned with the tibia by the supports to permit a telescoping rod 90, projecting from a rod clamp 91, to position the displacement instrument 69 over the patient's patella.
The displacement instrument 69 is constructed with a rod-like plunger 92 reciprocally slidable in a plunger barrel 94 that is fastened perpendicularly to the end of the rod 90 by a yoke fastener 96. The plunger barrel contains a spring 97, to spring load the plunder 92 to lightly press a flat button 98 at the end of the plunger, against the patella. Connected to the barrel by a fastener 100 is a scale card 102 having an incremental millimeter scale.
The plunger projects from each end of the barrel, and carries two slide indicators 104 and 106 to record the relative displacement of the plunger, which is in contact with the patella, with the barrel, which is in contact with the tibia.
At the start of a test, the two indicators are positioned against the respective ends of the barrel indicating zero displacement.
In a posterior force test, the tibia is pushed causing the barrel to shorten the distance between the barrel and the patella button. The lower indicator 106 is pushed down the plunger until maximum displacement is reached. When the force against the tibia is relaxed, the barrel retracts leaving the indicator on the plunger to record the displacement. The indicator remains at its displaced position by friction engagement of a shoe 108 that is biased by a spring 110 contained in a hole, capped by a set screw 112. A pointer 114 on the indicator 106 points to the scale marking 116 on the card to indicate the displacement that occurred.
Similarly, in an anterior force test, the tibia is pulled causing the barrel to rise on the plunger carrying the top indicator 104 upward. When the force is relaxed the indicator remains on the plunger at the point of maximum displacement. When a test is repeated, the pertinent indicator, or both indicators are returned to a zero start position.
Because simple mechanical parts are utilized the entire apparatus can be sterilized in an autoclave. The elements are easily disassembled for repair or packing, and are simple in construction and operation. The modular construction permits easily observable confirmation of results and permits recognition of equipment malfunction or dislocation that would impair the accuracy of the results.
The apparatus is designed for use with patients having a variety of different physical builds, and provides for adjustment of the apparatus to conform to the patient. Further, the force applicator is adjustable to permit the application of measurement forces other than a 20 lb standard test force, which has been shown to be inadequate to produce maximum displacement for certain larger patients.
While in the foregoing embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention. | Apparatus for measuring ligamentous insufficiency in the knee, the apparatus including a leg support having an adjustment mechanism for disposing the legs at a select test angle and having straps securing the ankles and the thighs to the leg support; an instrument bridge having mounting supports for mounting the bridge to the tibia, the bridge having at one end an indicator with a patella contact for measuring displacements of the patella and femur relative to the tibia; and a push-pull force applicator for applying posterior and anterior forces to the lower leg to induce sagittal excursions. | 0 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to the field of electrical connections and more specifically to electrical connections formed in or associated with textile materials.
BACKGROUND OF THE INVENTION
[0002] Applications for electronic circuits include connecting electronic circuits to conductors within textile materials. Textile materials, such as commonly available fabrics, are able to include electronic circuits for a variety of purposes. One such application includes “wearable electronics” whereby electronic circuits are attached to or embedded into clothing. These electronic circuits can be connected to conductive threads woven into the cloth of the clothing to provide electrical interfaces between those electronic circuits and other components, such as switches or other input/output devices.
[0003] An obstacle to the cost effective construction of such wearable electronic circuits is that it is difficult to connect the electronic components, such as integrated circuits, to conductive threads sewn into the textile garment. Conductive threads create efficient “wearable wires,” but connecting these wires to devices has been difficult to do in an efficient and cost effective manner that is sufficiently robust to withstand being worn and washed. Solutions that use solder and/or printed circuit boards further complicate and restrict the design and construction of low-cost and practical clothing.
[0004] Therefore a need exists to overcome the problems with the prior art as discussed above.
SUMMARY OF THE INVENTION
[0005] In accordance with an exemplary embodiment of the present invention, an electronic circuit module arrangement has an electronic circuit module with at least one connection point and a carrier that is sewn through by forming perforations in the carrier during a passing of a thread through the carrier. The electronic circuit module arrangement further has at least one connection areas where each of the at least one connection areas is in mechanical contact with the carrier and in electrical coupling with the at least one connection point.
[0006] In accordance with another aspect of the present invention, an electrical circuit connection has a carrier that is sewn through. The electrical circuit connection further has at least one connection areas where each of the at least one connection areas is in mechanical contact with the carrier. The electrical circuit connection also has a textile material with at least one interwoven conductive thread that is a part of the textile material. The electrical connection further has at least one conductive stitching where each of the at least one conductive stitching consists of conductive material and is, for example, woven, knitted, and/or stitched through the carrier and the textile material so as to form an electrical connection between one of the at least one connection areas and one of the at least one interwoven conductive thread.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention.
[0008] FIG. 1 illustrates an unattached carrier 100 prior to attachment to a textile material, according to an exemplary embodiment of the present invention.
[0009] FIG. 2 illustrates an attached sewn-through carrier 200 according to an exemplary embodiment of the present invention.
[0010] FIG. 3 illustrates an unattached hole-connection carrier 300 according to an exemplary alternative embodiment of the present invention.
[0011] FIG. 4 illustrates an attached hole-connection carrier 400 according to the alternative exemplary embodiment of the present invention.
[0012] FIG. 5 illustrates a processing flow diagram for implementing a method for connecting two electrical circuits in accordance with the present invention.
DETAILED DESCRIPTION
[0013] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms as described in the non-limiting exemplary embodiments of FIGS. 1 through 4 . Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention.
[0014] The terms “a” or “an”, as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language). The term coupled, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. The term woven, as used herein, is defined to include but is not limited to woven, knitted, stitched, or embroidered.
[0015] FIG. 1 illustrates an unattached carrier 100 prior to attachment to a textile material, according to an exemplary embodiment of the present invention. The exemplary unattached carrier 100 illustrates a textile material 130 with four conductive threads interwoven therein. A first conductive thread 102 , a second conductive thread 104 , a third conductive thread 106 and a fourth conductive thread 108 are interwoven conductive threads that are a part of the textile material shown in this example. Further embodiments of the present invention incorporate textile material with only one interwoven conductive thread or any number of interwoven conductive threads that are used to convey electrical power and/or signals to a circuit, as is described below.
[0016] The textile material 130 of the exemplary embodiment is a conventional material made of any of the numerous materials adapted for fabrics. It is clear that any suitable material is able to be used in embodiments of the present invention. Textile materials can be woven from, for example and without limitation, cotton, polyester, wool, and other such materials. Interwoven conductive threads, such as the first conductive thread 102 , are formed in an exemplary embodiment of carbon fiber. Further embodiments include interwoven conductive threads that include copper, silver and/or gold conductors. Such threads are able to be solid or stranded metallic threads or cloth insulating threads that include intermixed conductive materials to form a conductive circuit path. These interwoven conductive threads are able to be accurately woven into textile material by, for example, conventional or modified embroidery machines. Interwoven conductive threads woven into the textile material 130 are able to have an insulating coating or be uninsulated. Some embodiments that use uninsulated conductive threads (i.e., lacking an insulating cover), such as the first conductive thread 102 , use the textile material 130 as a liner that is either sandwiched between two or more other layers of textile material or that is a backing for a single layer of material that forms an outer layer of an article.
[0017] The unattached carrier 100 further illustrates a circuit arrangement and assembly 134 that includes a carrier 132 and a circuit element 128 . Circuit element 128 in this exemplary embodiment is an electronic circuit formed on a single silicon integrated circuit die. This circuit element 128 of the exemplary embodiment is itself an unpackaged integrated circuit die that is not encapsulated in an insulating material. Further embodiments include encapsulated electronic circuit elements, such as silicone integrated circuits encapsulated in epoxy. Further embodiments include electronic circuits that consist of several integrated circuits, discrete components, and/or other electronic circuit elements. The electronic circuits in some embodiments of the present invention are attached to the carrier 132 .
[0018] The circuit element 128 of the exemplary embodiment has a number of electrical connection points 136 , as is known by ordinary practitioners in the relevant arts. Each of the electrical connection points 136 in the exemplary embodiment forms a separate electrical connection to the electronic circuitry within the circuit element 128 and has a wire bond connected thereto, such as a first wire bond 118 , a second wire bond 120 , a third wire bond 122 and a fourth wire bond 124 . Each of the wire bonds are connected to a corresponding connection area. The connection areas in the exemplary embodiment are conductive traces deposited on either surface of carrier 132 and are therefore in physical contact with the carrier 132 . The wire bonds place the corresponding connection point ( 136 ) in electrical coupling with a corresponding connection area of the electronic circuit arrangement. The unattached carrier 100 includes of a first conductive trace 110 , a second conductive trace 112 , a third conductive trace 114 , and a fourth conductive trace 116 that are each a connection area. Further embodiments of the present invention use different techniques, such as conductive epoxy, solders, ultrasonic bonding of bumps and other known techniques for direct chip attachment, to electrically connect the electrical connection points 136 on the electronic circuit 128 to the plated traces. It is to be noted that plated traces are able to be made of any conductive trace material. These traces can be plated, etched conductive materials, sputtered, printed, or formed by other means to create an electrically defined conductor. The connection areas in further embodiments of the present invention are embedded into, and therefore in contact with, the carrier of those embodiments, and electrical connections to these connection areas are made by sewing conductive thread through that carrier where the connection areas are located.
[0019] Carrier 132 of the exemplary embodiment is made of a thin, flexible substrate material. Carrier 132 of the exemplary embodiment is made of a Polyimide flexible circuit substrate. Further embodiments use carriers made of different materials, including but not limited to paper, Mylar, reinforced epoxy or other electrically based dielectric materials. Yet further embodiments use more rigid carriers, such as thin FR4 carriers. Carrier 132 of this exemplary embodiment is able to be sewn through by sewing a thread through the carrier material. When being sewn in such a manner, perforations are formed in the carrier 132 when the thread is passed through the carrier 132 . Such sewing is performed, for example, by common embroidery machines. Conductive threads are sewn through the carrier 132 to form electrical connections, as is described below, and conductive or non-conductive thread are able to be sewn through the carrier 132 to provide physical attachment of the carrier 132 , as well as the circuit assembly 134 , to a textile material 130 .
[0020] The textile material 130 of the exemplary embodiment has a substrate area 140 that is formed on the surface or within the textile material. A substrate area 140 is used in some, but not all, embodiments of the present invention to provide a more physically stable area onto which the circuit assembly 134 is to be mounted. The substrate area 140 is generally placed in an area proximate, such as adjacent to, an area of the textile material where a carrier 132 is secured to the textile material 130 or a conductive stitching is woven through the carrier 132 and the textile material 130 , as is discussed in more detail below.
[0021] In further embodiments of the present invention, a substrate area 140 , which can be a plastic coated, fabric, impregnated fabric, or any other surface such as a label, patch, etc., formed on a surface of textile material 130 is itself used as a carrier that is similar to carrier 132 . Using substrate area 140 as a carrier allows further economization of costs and reduction of manufacturing complexity. Some embodiments that use a substrate area 140 as a carrier form connection areas, similar to the first plated trace 110 , onto the substrate area 140 by a metallization process, such as vacuum metallization. Further embodiments of the present invention fabricate carrier 132 directly onto the textile material 130 and do not have a separate substrate area 140 .
[0022] FIG. 2 illustrates an attached sewn-through carrier 200 according to an exemplary embodiment of the present invention. The attached sewn-through carrier 200 illustrates the configuration of the unattached carrier 100 after electrical connections are formed between the interwoven conductive threads, such as the first conductive thread 102 , and corresponding connection areas of the circuit assembly 134 . The conductive stitching includes a thread that consists entirely or in part of one or more conductive materials, is used in this exemplary embodiment to form these electrical connections. A first conductive stitching 202 connects the first conductive trace 110 and the first conductive thread 102 . The first conductive stitching 202 is a two string stitching as is commonly used for stitching in conventional fabrics. Further embodiments are able to use single thread or multiple thread conductive stitching to form conductive stitching. The first conductive stitching 202 of the exemplary embodiment uses carbon fiber that is sewn through both the carrier 132 and textile material 130 and positioned so as to be in conductive and physical contact with both the first conductive thread 102 and the first conductive trace 110 . This stitching thereby forms a conductive path and electrical connection between the first conductive thread 102 and the first conductive trace 110 .
[0023] Further embodiments utilize other conductive strings or wires to form conductive stitching. A second conductive stitching 204 similarly forms a conductive contact between the second conductive thread 104 and the second conductive contact 112 , thus creating a separate circuit between the electronic circuit 128 and conductive threads in the textile material 130 . A third conductive stitching 206 and a fourth conductive stitching 208 similarly form independent and electrically isolated contacts between their respective conductive threads and conductive contacts. In addition to the conductive stitching used to form electrical connections with the circuit assembly 134 , further stitching 210 , which can be formed with conductive or non-conductive thread, is able to be used to further mechanically secure the circuit assembly 134 , in particular the carrier 132 , to the textile material 130 .
[0024] FIG. 3 illustrates an unattached hole-connection carrier 300 according to an exemplary alternative embodiment of the present invention. The unattached hole-connection carrier 300 is similar to the unattached sewn-through connection carrier 100 with the exemption of the structure of the electrical connection between the conductive threads within textile material 330 and the electrical connection points 136 within the electronic circuit 128 . The connection points 136 in this alternative embodiment are connected to the conductive traces with via by wire bonds. Further embodiments connect the connection points to the plated traces with via by other means, such as conductive epoxy, solders, ultrasonic bonding of bumps and other techniques for direct chip attachment.
[0025] Each of the conductive traces with via, such as the first conducive trace with via 320 , consists of a first conductive trace 340 that is terminated with a pre-formed first conductive, through-hole via 310 that is within the connection area formed by the first conductive trace with via 320 . The first conductive trace 340 of the exemplary alternative embodiment is a conductive trace formed from copper or any conductive trace material, and can be formed as plated, etched conductive materials, sputtered, printed, or through any other technique to create an electrically defined conductor. The first conductive trace 340 is formed on the surface of carrier 332 and is therefore in physical contact with the carrier 332 . Further embodiments incorporate conductive traces that are formed within carrier 332 . The first conductive, through-hole via 310 of the exemplary embodiment is a pre-formed hole within the carrier 332 that is conductive along its walls, and on the top and bottom surfaces. Further embodiments of the present invention have only one of the top and bottom surfaces that consist of conductive material, while the other surface is non-conductive. The first conductive, through-hole via 310 of the exemplary embodiment has conductive pads attaching the hole on each surface of the carrier 332 . Further embodiments have conductive pads on only one surface. The conductive material of the through hole via structure on the surfaces and hole walls facilitates effective electrical connection to the plated trace by threads woven through the hole 310 .
[0026] The textile material 330 of the exemplary embodiment has conductive threads, such as the first conductive thread 102 , woven therein. The ends of the conductive threads are terminated with button holes, such as the first conductive thread 102 that is terminated with a first button hole 302 . Button holes in the exemplary embodiment are sewn into the textile material 330 with conductive thread that is in physical and conductive contact with one of the conductive threads woven into the textile material. The second conductive thread 104 similarly has a second button hole 304 . The third conductive thread 106 and the fourth conductive thread 108 also have third button hole 306 and a fourth button hole 308 , respectively.
[0027] FIG. 4 illustrates an attached hole-connection carrier 400 according to the alternative exemplary embodiment of the present invention. The attached hole-connection carrier 400 illustrates that conductive thread is sewn with a button stitch through the conductive, through-hole vias and the button holes so as to form an electrical connection from the conductive threads that are woven into the textile material 330 and the connection points 136 of the electronic circuit 128 . For example, a first button stitch 402 is sewn through by passing a thread through the pre-formed first button hole 302 and the first conductive, through-hole via 310 . The other conductive threads and conductive, through hole vias are physically and electrically connected with other button stitches. It is to be noted that each button stitch is physically isolated from other button stitches and forms a separate connection to a conductive thread woven into the textile material 330 . The button stitches are formed in the exemplary alternative embodiment from carbon thread using button stitching techniques that are familiar to ordinary practitioners in the relevant arts, such as tailoring. The exemplary alternative embodiment further incorporates physical stitching 420 , which can be made from conductive or non-conductive thread, to physically secure the carrier 332 to the textile material 330 .
[0028] FIG. 5 illustrates a processing flow diagram for implementing a method for connecting two electrical circuits in accordance with the present invention. The processing for this embodiment begins by providing, at step 502 , a carrier, such as carrier 132 , that is able to be sewn through. As discussed above, the carrier 132 has a number of connection areas, such as the first conductive trace 110 , that are in physical contact with the carrier. The processing then places, at step 504 , the carrier, such as carrier 132 , in proximity to a textile material, such as textile material 130 . As discussed above, the textile material has one or more interwoven conductive threads attached to the textile material. The processing then passes, at step 506 , conductive stitching, such as first conductive stitching 202 , through the carrier, such as carrier 132 , and the textile material, such as textile material 130 , so as to form an electrical connection between the connection areas and corresponding interwoven conductive thread. As discussed above, the conductive stitching comprises a conductive material. The processing then determines, at step 508 , if there are more electrical connections to form. If there are more electrical connections to form, the processing returns to passing, at step 506 , conductive stitching to form the next electrical connection. If there are no more electrical connections to form, the processing then terminates.
[0029] Although specific embodiments of the invention have been disclosed, those having ordinary skill in the art will understand that changes can be made to the specific embodiments without departing from the spirit and scope of the invention. The scope of the invention is not to be restricted, therefore, to the specific embodiments, and it is intended that the appended claims cover any and all such applications, modifications, and embodiments within the scope of the present invention. | A method and apparatus form electrical connections between electronic circuits and conductive threads ( 102, 104, 106, 108 ) that are interwoven into textile material ( 130 ). Electronic circuits ( 128 ), such as semiconductor dies, are connected to a carrier ( 132 ) and electrical connections ( 136 ) are made to conductive connection areas ( 110, 112, 114, 116 ) on the carrier ( 132 ). Conductive stitching ( 202, 204, 206, 208 ) provides electrical contacts for both the conductive connection areas ( 110, 112, 114, 116 ) on the carrier ( 132 ) and the conductive threads ( 102, 104, 106, 108 ) that are interwoven into the textile material ( 130 ). Optionally, a thin, flexible substrate material ( 132 ) is perforated during the stitching process. | 8 |
BACKGROUND
[0001] An inflatable apparatus is described and, more particularly, an apparatus comprising an inflatable frame assembly that is lightweight and, when operatively associated with a cover, provides shelter for one or more persons.
[0002] An inflatable shelter may comprise a plurality of pneumatic tubes and a cover for cooperatively supporting the shelter in an upright position. Each of the inflatable tubes is configured so that, with the addition of air, the tube is expanded into a frame member of the shelter. The deflated frame structure can be collapsed and rolled or compacted in any desired manner for transport.
[0003] Inflatable shelters are useful as tents for camping tents, which typically rely on rigid frame members or flexible fiberglass poles for support structure. The inflatable shelter substitutes inflatable pneumatic tubes for the rigid frame members and poles by providing a framework on which exterior fabric cover or a tent canopy is mounted.
[0004] There is a need for an improved inflatable frame assembly or structure comprising inflatable elements capable of supporting a covering material for providing shelter for one or more persons. The inflatable frame or structure should be quickly constructed by single person. Ideally, the inflatable frame or structure should be light weight and small volume when collapsed so as to be relatively easily transportable.
SUMMARY
[0005] An inflatable frame assembly comprises a plurality of inflatable tubular members elements having a longitudinal dimension. A first portion of the plurality of tubular members is connected in fluid communication end to end in a continuous relationship for defining a closed area. A second portion of the plurality of tubular members is connected in fluid communication at their ends with the first portion of the tubular members. The second portion of the tubular members forms uprights for suspending and supporting the first tubular members. A first inflating valve is disposed on at least one of the tubular members for introducing air for inflating the plurality of tubular members, wherein the plurality of tubular members are self-supporting when inflated and define a closed volume.
[0006] In one aspect, the tubular members extend substantially linearly when inflated and unconstrained, and the tubular members are collapsible without inflating fluid at a minimum pressure.
[0007] In a second aspect, the first portion of the plurality of tubular members is in a plane. The second plurality of tubular members may extend perpendicular to the plane.
[0008] In a third aspect, the closed area defined by the first portion of the plurality of tubular members is rectangular.
[0009] In another aspect, the inflatable frame assembly further comprises a removable cover. The cover may span between and extend over the closed area defined by the first plurality of tubular members for forming a shelter. Alternatively, the cover has a configuration corresponding to the closed volume for enclosing a top and sides of the closed volume and forming an enclosed shelter. The cover may comprise a flexible sheet material, wherein the flexible sheet material comprises a waterproof nylon fabric. At least one loop fastener may be provided along a periphery of at least one of the tubular members for fastening the cover so as to form a shelter. The cover may be detachably fastened to the at least one loop fastener, wherein the cover can be selectively removed.
[0010] In a further aspect, the inflatable frame assembly further comprises a plurality of selectively closable fluid passages in fluid communication between adjacent tubular members of the first plurality of tubular members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more complete understanding of the inflatable frame assembly, reference should now be had to the embodiments shown in the accompanying drawings and described below. In the drawings:
[0012] FIG. 1 is a perspective view of an embodiment of an inflatable frame assembly.
[0013] FIG. 2 is an exploded perspective of the inflatable frame assembly as shown in FIG. 1 .
[0014] FIG. 3 is a top plan view of the inflatable frame assembly as shown in FIG. 1
[0015] FIG. 4 is a side elevation view of the inflatable frame assembly as shown in FIG. 1
[0016] FIG. 5 is an end elevation view of the inflatable frame assembly as shown in FIG. 1
[0017] FIG. 6 is a cross-section view of an embodiment of an inflatable tubular member for use in the frame assembly as shown in FIG. 1 .
[0018] FIG. 7 is a close-up perspective view of an interior corner of the inflatable frame assembly as shown in FIG. 1 .
[0019] FIG. 8 is an exploded perspective view of the interior corner as shown in FIG. 7 .
[0020] FIG. 9 is a cross-section view of an embodiment of a fluid connector of the interior corner as shown in FIG. 7 .
[0021] FIG. 10 is an exploded perspective view of a pneumatic valve of the inflatable frame assembly as shown in FIG. 1 .
[0022] FIG. 11 is a cross-section view of the pneumatic valve as shown in FIG. 10 .
[0023] FIG. 12 is a close-up elevation view of an embodiment of a loop strap sewn onto the inflatable frame assembly as shown in FIG. 1 .
[0024] FIG. 13 is a front perspective view of the inflatable frame assembly as shown in FIG. 1 and further comprising a cover supported by the frame assembly.
DESCRIPTION
[0025] Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configuration shown in the FIGs. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise.
[0026] Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the several views, an inflatable frame assembly is shown in FIGS. 1-5 and generally designated at 20 . The frame assembly 20 comprises a plurality of hollow inflatable tubular members connected at their ends. In one embodiment, when the frame assembly 20 is inflated with air under pressure, the tubular members assume the position shown in FIG. 1 . The frame assembly 20 provides a support structure for receiving a cover or canopy (not shown) which serves as a means for partially or totally enclosing the frame assembly 20 and providing covered shelter to one or more persons. The covered shelter may be used as a housing, tent, sports enclosure, storage facility and the like.
[0027] The inflatable tubular members include a pair of upper side beams 22 which are of substantially equal length. The respective ends of the side beams 22 are interconnected by a pair of end beams 24 which are also of substantially equal length. The length of the end beams 24 is relatively shorter than the side beams 22 . The ends of the side beams 22 and the end beams 24 are adjoined at right angles such that each pair of the side beams 22 and the end beams 24 extend parallel to one another in respective spaced relation for defining a rectangular area.
[0028] Four inflatable tubular members 26 are connected at their ends at the corners of the adjoined side beams 22 and end beams 24 . The tubular members 26 extend downwardly from the corners and function as legs for supporting the interconnected side beams 22 and end beams 24 . The leg members 26 are of substantially equal length such that, when inflated, the side beams 22 and end beams 24 are in substantially the same plane. For example, when the leg members 26 extend substantially vertically, the side beams 22 and the end beams 24 extend substantially horizontally.
[0029] A transverse tubular member 28 extends between and interconnects the side beams 22 intermediate along their length. The transverse member 28 extends slightly upwardly to a peak 30 at its midpoint when inflated. This configuration of the transverse tubular member 28 resists buckling at the vertex when supporting the cover.
[0030] Each of the inflatable tubular members 22 , 24 , 26 , 28 comprises an outer flexible substantially non-resilient sleeve 32 and an inner resilient inflatable bladder 34 inside and extending substantially along the entire length of the sleeve 32 . As used herein, the phrase substantially non-resilient means that the corresponding material or fabric expands slightly under tension to an estimated five percent expansion when highly tensioned. A cross-section of an exemplary tubular member is shown in FIG. 6 , which depicts the sleeve layer 32 and the bladder layer 34 and shows slight spacing between the layers for ease of understanding of the view. It is understood that, when the inner bladder 34 is inflated, there is no spacing between the layers forming the tubular member, and the sleeve 32 and the bladder 34 are tightly engaged one to the other. In this configuration, the sleeve 32 constrains the expansion of the bladder 34 under high pneumatic pressure sufficient to maintain the desired configuration. This enables the air to be forced into the tubular members under considerable pressure to assure a rigid structure to the frame assembly 20 .
[0031] The outer sleeve 32 is formed from sheets of flexible fabric such as a coated or waterproof nylon cloth. Each sheet is substantially rectangular having a longitudinal dimension and a lateral dimension orthogonal to the longitudinal dimension. The linear edges of the sheet includes a substantially linear common seam inset from each side edge forming a flat side seam extending completely along each side edge. The thread used to form the edge seams may be mono-cord bonded polyester thread or other suitable thread as would be known to one skilled in the art to withstand the loading of the sleeves. It is understood that the tubular members may be vulcanized, glued or otherwise connected to one another by known means. The result is a sleeve 32 having a uniformly tubular or cylindrical shape, when unbent, of substantially constant diameter. Each tubular member may have a circumference of about six inches, for example, meaning a diameter of approximately two inches. The side beams 22 may be, for example, about eight feet long and the end beams 24 may be, for example, about four feet long.
[0032] The inner bladder 34 is formed as a continuous hollow rubber or plastic tube wherein the ends of the bladder are sealed so that the bladder 34 is airtight. One bladder is enclosed within each sleeve.
[0033] As shown in FIGS. 1-5 , an air hose 36 is mounted in fluid communication between the side beams 22 and the end beams 24 in each corner. An air hose 36 also extends between the transverse tubular member 36 and a side beam 22 . Referring to FIGS. 7-9 , the air hoses 36 are connected at their ends with air inlet discs 38 sealingly connected to the side beams 22 and end beams 24 or transverse member 36 , respectively. The inlet discs 38 include an inlet tube 40 configured to receive an end of the air hose 36 . The inlet disc 38 is connected through an opening in the sleeve 32 and the bladder 34 . The connection includes dual washers 42 glued to the bladder therebetween. The air hoses 36 and air inlet discs 38 function to render the tubular members in fluid communication forming a continuous air passage so that the inflation of one of the tubular members causes simultaneous inflation of all of the remaining tubular members in the frame assembly 20 so that the structure is self-erecting. All of the tubular members can be inflated or deflated from a single valve 50 . A pinch clip 44 is provided for closing an air hose 36 so that a bladder 34 of one of the tubular members may be separated from the remainder of the frame assembly 20 .
[0034] An air valve 50 is disposed in each of the legs 26 for providing an air passage for inflating and deflating the frame assembly 20 . It is advantageous to provide means for introducing air under pressure at more than a single point of the frame assembly 20 . Referring to FIGS. 10 and 11 , the air valve 50 is in fluid communication with the bladder 34 in the respective leg member 26 . The valve 50 is configured for connection to any suitable source of compressed air connected thereto. The valve 50 comprises an airtight screw cap 52 for closure.
[0035] Referring to FIG. 13 , the frame assembly 20 may be enclosed by a suitable cover 60 , which functions to form the walls and ceiling of a shelter enclosure. The cover 60 is configured to be reasonably taut over the frame assembly 20 while being supported in position by the longitudinal side beams 22 and transverse end beam 24 . The cover 60 may be formed as one-piece from thin plastic sheathing of the poly-ethylene or other synthetic resin families, canvas or other suitable material. The plastic sheathing is preferred because the plastic is thin and lightweight while having good tensile strength and is waterproof to maintain a dry interior. The material can be opaque so the interior will be invisible from the outside, although transparent material can be used where entrance of light is desirable. Alternatively, at least a portion of the cover 60 material may be a ventilating mesh which is used as a window while preventing insects from entering the enclosure. The cover material may have one or more vertical slits in the sheathing, which serves as a door, or be otherwise open-ended or open-sided or may be entirely open with merely a sun-shade covering the enclosure.
[0036] The cover 60 can be releasably secured to the tubular members of the frame assembly 20 . In one embodiment, shown in the FIG. 12 , the cover 60 may be retained on the frame assembly 20 with ties or retainer strips 54 sewed to the walls of the tubular members. Alternatively, the cover 60 may be fastened to the tubular members by means of grommets and turnbuckles or any other means for detachably fastening the cover to the tubular members of the frame assembly 20 . In another embodiment, hook-and-loop fasteners (not shown) may be disposed along the side beams 22 and end beams 24 whereby the cover can be selectively removed. It is understood that other means for fastening the cover 60 are possible so as to enable the cover to be applied to the frame assembly 20 when inflated or removed from the frame assembly 20 before deflating. The cover 60 can also be secured to frame assembly 20 permanently as by sewing.
[0037] In use, the frame assembly 20 is spread on the ground or other supporting base. A means for supplying air to the tubular members, such as an air pump, is connected to one of the air inlet valves 50 . Air is delivered to the tubular members via the valve 50 . The tubular members gradually fill and distend and separate from one another to assume their predetermined angular relations. Because the tubular members are all in fluid connection with one another via the air hoses 36 , the pump can inflate the entire frame assembly 20 upon introducing air at any one valve 50 .
[0038] A minimum pressurization goal is about 8 psi, but considerably higher pressures are contemplated. Pressurization of the tubular member should be sufficient to support a cover without any additional rigid support. Accordingly, the pneumatic tubular members allow for pressurization to high air pressures in the order of 45-110 pounds per square inch (psi). Inflation of the frame to its operating pressure of, for example, fifty-five psi will cause the surface of the tubular members to become smooth. When inflated to substantially 8 psi or more, buckling or bending of the tubular members at the vertex of a bend is inhibited. The frame assembly 20 will be sufficiently rigid so as to provide load support for, and tensioning of, the cover or other structure being supported. After the frame assembly 20 is fully inflated, the inflating pump is removed. Although air-inflated tubular members are described, it is to be understood that any gas or other fluid substance serving the purpose of air may be employed to inflate the tubular members.
[0039] The inflated frame assembly 20 may be anchored to the ground or other base to minimize the effect of wind lifting or upsetting the frame assembly or moving from a selected position.
[0040] In one embodiment, stakes (not shown) may pass through the loops formed by the retainer strips 54 receiving suitable hold-down strips 12 ( FIG. 12 ) and driven into the ground as is well-known manner of a tent.
[0041] When the frame assembly 20 is not in use, one of the valve caps 52 is opened to deflate the frame assembly 20 . The deflated frame assembly 20 is folded or rolled into a relatively small light mass for storage and shipment.
[0042] The inflatable frame assembly 20 has many advantages, including providing a lightweight portable shelter which can be erected in a minimum of time and by the use of an air pump for inflating the frame assembly 20 . The frame assembly 20 can be easily deflated for compact storage and transport.
[0043] The frame assembly 20 is for use in connection with tents or the like, although it is understood that the frame assembly 20 may be employed in various other structures or shelters and in combination with sport utility vehicles, boats, trailers, and other wheeled vehicles. Moreover, while the frame assembly 20 has been shown and described as generally rectangular, the tubular members may be arranged in a criss-cross pattern or circular formation to provide a round tent or any other arrangement for other possible form of tent or shelter.
[0044] Although the inflatable frame assembly has been shown and described in considerable detail with respect to a few exemplary embodiments thereof, it should be understood by those skilled in the art that we do not intend to limit the invention to the embodiments since various modifications, omissions and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages of the frame assembly, particularly in light of the foregoing teachings. Accordingly, we intend to cover all such modifications, omission, additions and equivalents as may be included within the spirit and scope of the description as defined by the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. | An inflatable frame assembly comprises a plurality of inflatable tubular members elements having a longitudinal dimension. A first portion of the plurality of tubular members is connected in fluid communication end to end in a continuous relationship for defining a closed area. A second portion of the plurality of tubular members is connected in fluid communication at their ends with the first portion of the tubular members. The second portion of the tubular members forms uprights for suspending and supporting the first tubular members. A first inflating valve is disposed on at least one of the tubular members for introducing air for inflating the plurality of tubular members, wherein the plurality of tubular members are self-supporting when inflated and define a closed volume. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. application Ser. No. 09/849,467 filed May 4, 2001, hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates transmissions of a land motor vehicle. In particular, the present invention relates to a field of friction clutch plates. More specifically, the present invention relates to a method of making adhesive bonded sintered friction plates using an intermetallic compound such as brass or bronze. Furthermore, the present invention provides a less expensive and more efficient method of bonding materials whose melting point is greater than 1220° F., such as aluminum.
BACKGROUND OF THE INVENTION
[0003] There are several known methods for the making of adhesive bonded sintered plates. However, the conventional methods lack the purpose that the present invention so readily provides. Furthermore, the prior art does not achieve the same results as the present invention does. The following is a discussion of such prior art and the reasons for the lack of complacency with the parameters that the present invention has.
[0004] U.S. Pat. No. 4,778,548 to Fox et al. teaches a bonding woven carbon fabric friction materials. This particular prior art discloses a porous, woven carbon fabric friction material that is bonded to a solid substrate, such as a conical transmission synchronizer, with a high temperature thermosetting adhesive, such as synthetic rubber-phenolic resin base adhesive. Prior to applying the adhesive, a thin layer of one surface of the friction material is removed such as by contacting the surface with a band-type sander, to break through the pyrolytic carbon coating on the substantial portion of the carbon fibers. The adhesive is applied to the abraded surface of the friction material and/or roughened surface on the solid substrate, the friction material is clamped to the solid substrate and thus-assembled parts are heated to at least substantially cure the adhesive. Improved bonds between the adhesive and friction material are produced and a tendency for the adhesive to “bleed through” the pores of the friction material and migrate to the friction surface during curing us significantly reduced. The present invention comprises a method of making adhesive bonded sintered metal plates. The process comprises the steps of cleaning metal cores, roughening the surface, where the adhesive would be applied, so that the surface would accept a thermosetting phenolic or epoxy adhesive. Then, placing sintered metal lining on one or both sides of the adhesive coated metal core and bonding the sintered linings under pressure (in the range of 25-1000 psi) and at a temperature (in the range 375-475 F). It is important that the material is bonded for at least 30 seconds. This particular method has an advantage over the previous prior art because it can be used for bonding of sintered parts with metals having melting temperatures greater than 1220 F, such as aluminum. The prior art in question does not allow for such bonding at specified ranges of temperature, time and pressure.
[0005] U.S. Pat. No. 5,199,540 to Fitzpatrick-Ellis et al. discloses a friction facing material and carrier assembly. This particular piece of prior art is designed to be used for a clutch driven plate. The assembly comprises two arrays, wherein a first and second arrays are secured, using an adhesive material bonds, to an axis of the clutch driven plate. The adhesive bond that secures the second array comprises an elastomeric material that provides a resilient cushioning relative to the carrier for the second array of friction material. The adhesive bond that secures the first array is axially thinner than the adhesive bond that secures the second array. The present invention is a method for making adhesive bonded sintered metal plates. The method comprises the steps of cleaning the metal cores and roughening the surface to which the thermosetting pheolic or epoxy adhesive would be applied; placing the sintered metal on one or both sides of the adhesive coated metal core and then bonding at a pressure range of 25-1000 psi at a temperature of 375-475 F for a period of at least 30 seconds.
[0006] U.S. Pat. No. 5,281,481 to Hayward teaches a method of manufacturing a composite friction element wherein a powdered solventless thermosetting adhesive is applied to a metal substrate and the product made from it. The metal substrate and thermosetting adhesive material are heated to allow the powdered solventless adhesive material to flow but not crosslink. A friction material is applied under the heat and pressure to the adhesive such that the adhesive material crosslinks and a composite element is formed. Furthermore, the adhesive material comprises a resin that contains at least one of the following: 0-70 weight percent range of bisphenol A epoxy resin, unmodified, 0-70 weight percent range of bisphenol A epoxy resin, modified with novolak epoxy, or 0-95 weight percent range of multifunctional epoxy O-cresol novolak resin, and 5-10 weight percent range of bisphenol A epoxy resin with a flow modifier comprising an acrylic acid butyl ester. The present invention is a method of bonding sintered plates using an adhesive. The present invention includes several steps including cleaning the metal core in preparation for application and then later on roughening the application surface so that it would be able to accept a thermosetting phenolic or epoxy adhesive. The present invention bonds the plates at a temperature of 375 F to 475 F at a pressure range of 25-1000 psi for a duration of at least 30 seconds. The present invention allows for bonding of sintered plates, where the metal core may be an aluminum, whose melting point is at 1220° F.
[0007] The discussed prior art presents a formidable database of information. However, this prior art does not attempt to solve the problems that the present invention is designed to answer. The present invention is a unique variation of a power anchor band that allows driving of a land motor vehicle under extreme operating conditions such as on rough surfaces or under racing conditions. Due to the specific qualities of the intermetallic compound that is used to manufacture the power band.
[0008] It should be clear to one skilled in the art, that the above discussed prior art is used for the purposes of illustration and should not be construed as limiting in any way, except for the prior art elements claimed in the above patents.
SUMMARY OF THE INVENTION
[0009] The present invention discloses a friction clutch plate for a transmission of a land motor vehicle comprising a metal core, an adhesive layer and a first sintered metal lining. The metal core has a first thickness with a top surface and a bottom surface. The adhesive layer has a second thickness and covers the entire top surface of said metal core. The first sintered metal lining has a third thickness and is formed from an intermetallic compound.
[0010] The first sintered metal lining covers the entire adhesive layer and is attached to the metal core via the top adhesive layer. This first sintered layer is used for a first specific function, whereby the intermetallic compound allows the first sintered lining to operate under extreme operating temperatures.
[0011] The friction clutch plate also may comprise a bottom adhesive layer and a second sintered metal lining. The bottom adhesive layer also covers the entire bottom surface of the metal core and has a substantially equal thickness to that of the top adhesive layer.
[0012] The second sintered metal lining is also substantially equal to the thickness of the first sintered metal lining. The second sintered metal lining is attached to the core via the bottom adhesive layer. The second sintered layer may be used for a second specific function.
[0013] The first sintered metal lining and second sintered metal lining also may have different compositions. With each compositions allowing the first sintered metal lining and the second sintered metal lining to perform different first and second specific functions, both of which may be under extreme operating conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The following description of preferred embodiment of the present invention will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the invention is not limited to the precise arrangements shown in which:
[0015] FIG. 1 presents a schematic illustration of the present invention's method steps.
[0016] FIG. 2 presents plain view of an outcome after steps of the method in the present invention are applied.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] In the following description, references to the drawings, certain terms are used for conciseness, clarity and comprehension. It is assumed by one skilled in the art that there are to be no unnecessary limitations implied from the references, besides the limitations imposed by the prior art, because such terms and references are used for descriptive purposes only and intended to be broadly construed. Furthermore, the description and the drawings are for illustrative purposes only and not to be construed as limited to the exact details shown, depicted, represented, or described.
[0018] Referring to FIG. 1 , the present invention's process is shown. The box labeled 10 indicates that before the process begins to produce the end result depicted in FIG. 2 the metal core 24 should be cleaned on any irregularities, such as corrosions, abrasions or accumulating dusts and other elements that may adversely affect the proper binding of adhesives to the metal core 24 . After the metal core 24 is cleaned, if it is necessary the surface of the metal core 24 may be roughened as indicated in the box labeled 12 , as shown in FIG. 2 . The roughening of the metal core 24 is performed so that the metal core 24 is better able to accept the adhesive 22 and 26 , as shown in FIG. 2 . When the thermosetting phenolic or epoxy adhesive 22 and/or 26 are applied to the metal core 24 under pressure and temperature, it is vital to the sintered plate 40 that all elements are well bound, otherwise the functionality and lifetime of the sintered plate 40 is greatly reduced. The roughening of step 12 assures such functionality and a longer lifespan of the sintered plate 40 .
[0019] Referring to FIG. 1 , the next step shown in box 14 is applying thermosetting phenolic or epoxy adhesive 22 and/or 26 to the metal core 24 , as shown in FIG. 2 . The thermosetting phenolic or epoxy adhesive 22 and/or 26 is applied so to prepare the sintered plate 40 and the metal core 24 for the receiving of the sintered metal linings 20 and/or 28 , respective of thermosetting phenolic or epoxy adhesive 22 and/or 26 . Furthermore, referring to FIG. 1 , boxes 16 and 18 describe the final steps of the present invention's method that it results in the sintered metal plate 40 depicted in FIG. 2 . Sintered metal lining 20 and/or 28 is respectively applied on top of adhesive layers 22 and/or 26 . (A sintered metal lining is, normally, a mixture of steel powders which are axially compacted in a pressing tool. The metal lining obtains its final strength, microstructure and hardness during a heat treatment in a protective atmosphere.)
[0020] In the preferred embodiment of the invention, the sintered metal lining 20 comprises an intermetallic compound such as a brass or bronze compound. For example, the sintered metal lining can be a mixture of brass and bronze powders along with other materials that are pressed and subsequently sintered in a protective atmosphere.
[0021] This allows the sinitered brass lining 20 to operate at much higher temperatures than ordinary sintered materials because the brass and/or bronze compounds form a special type of chemical compound, called an intermetallic compound. Intermetallic compounds do not separate by mere heating or cooling of the compound. Due this feature, the chemical compound has many advantages when used in devices such as a motor vehicle transmission or brake system that uses friction between objects to operate.
[0022] Normal operating friction causes a friction device to operate in controlled heat environments. However, under extreme driving conditions, such as racing or off-road use, the friction materials normally used for this type of environment begin to break down in extreme heat. But when a friction device utilizes brass and bronze under these extreme operating conditions, the brass and/or bronze sintered lining does not break down in the extreme heat and thereby provides increased stability and longevity for the friction device.
[0023] In the preferred embodiment of the present invention, a unique variation of a power anchor band that has intermetallic compound allows driving of a land motor vehicle on rough surfaces or under racing conditions. This is due to the specific qualities of the material that is used in manufacturing of the power band.
[0024] For background, to make a brass compound, Zinc (Zn) and Copper (Cu) are dissolved in one another to form a metallic solution. They, however, do not form a compound in the normal sense that we use the term “compound” meaning a definite molecular composition. That is, most metal alloys can be separated by purely physical processes, like heating and cooling the alloy (including melting). A chemical compound such as brass cannot be separated so easily because they do not have a fixed composition and thereby form an intermetallic compound.
[0025] Intermetallic compounds are formed by two metals that have great differences in their electronegativities and chemical properties. In many of these compounds there is an integral ratio between the sum of the number of valence electrons and the number of atoms. An intermetallic compound is a distinct material from any of the metals that comprise it and often having a completely new crystal structure.
[0026] This is opposed to alloys that correspond to a combination of two or more metals. Several types of alloys depend on the nature of the interaction of the two or more metals in the alloys. Many combinations of metals form liquid solutions when fused at high temperatures. Once they are cooled reverting to the solid state they may form a polyphase system, or they may remain in solution and are said to be a solid solution. The metals likely to form solid-solution alloys are those most similar to each other in electronegativity, atomic radii, and chemical properties. The structure of a solid-solution alloy is between the two extremes of order and disorder. In the molten state a high degree of disorder prevails. Upon solidification the random arrangement may be preserved or different degrees of order can appear as result of atoms finding more stable positions in the lattice structure. In turn, these alloys begin to break down at much lower temperatures than intermetallic compounds.
[0027] Referring to FIG. 1 , box 18 , the above-described application takes places under certain conditions to ensure proper binding of all layers, as shown in FIG. 2 . In one embodiment, the conditions that the binding of the sintered plates takes place are a pressure of 25 to 1000 psi that is applied to the plates. Such scale of pressure ensures proper binding of the components of the sintered plate 40 . Furthermore, in another embodiment, the process described in FIG. 1 may take place at a temperature in the range of 375 F to 475 F. Such temperature ensures that the different kinds of metals may be used for the sintered portion(s) 20 and/or 28 , as shown in FIG. 2 . Moreover, in yet another embodiment, the process of bonding the sintered plates 40 takes place for at least 30 seconds. Such a time interval is necessary for proper adhesion of phenolic or epoxy adhesives 22 and/or 24 , as shown in FIG. 2 , together with sintered plates layers 20 and/or 28 and the metal core layer 24 .
[0028] After steps 10 through 18 as shown in FIG. 1 have taken place, the sintered bonded plate 40 is a final result, as shown in FIG. 2 . The sintered plate 40 is shown to have a top face 30 and a bottom face 32 . In one embodiment, the sintered plate 40 may have both the top face 30 and the bottom face 32 . In another embodiment, the sintered plate 40 may have just the top face 30 . Depending on the purpose of use of the sintered plate 40 , the plate may have both the top and the bottom faces or just a single top face. The sintered plate 40 , as shown in FIG. 2 , has both the top and the bottom faces 30 and 32 , respectively.
[0029] Referring to FIG. 2 , the sintered plate 40 has a top sintered layer 20 and a bottom sintered layer 28 , wherein the top sintered layer 20 is located at the top of the top face 30 and the bottom sintered layer 28 is located at the bottom face 32 . The sintered plate 40 has a metal core layer 24 . The metal core layer 24 may be of variable thickness, depending on the application of the plate. Moreover, the metal core layer 24 may be fabricated from different metallic elements of variable strength, sturdiness and other characteristics. The metal core layer 24 and the sintered layers 20 and 28 are attached through a process defined in FIG. 1 , and by means of top adhesive layer 22 attaching top layer 20 and the metal core 24 and by means of bottom adhesive layer 26 attaching bottom layer 28 and the metal core 24 .
[0030] The layers 22 and 26 may be fabricated from a phenolic or epoxy adhesives or others that are well known in the art. The sintered layers 20 and 28 may be fabricated from a metal that is capable of performing a specific function that a user has in mind. However, it is vital to keep in mind that the process described in FIG. 1 and above is designed for metals that have a melting temperature, such as aluminum, of at least 450 F. The melting point of the metals used in the structure allows a greater flexibility in terms of variety of materials that the components of the sintered plate 40 may be chosen from. Furthermore, the present invention has another advantage that is closely tied with the subject matter sought to be patented, it is the cost of the making such plate. Because of the particular methods and materials used in the invention, the cost of manufacturing the present invention is significantly lower than of those prior art invention currently available.
[0031] In the foregoing description of the invention, reference to the drawings, certain terms, have been used for clarity, conciseness and comprehension. However, no unnecessary limitations are to be implied from or because of the terms used, beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Furthermore, the description and illustration of the invention are by way of example, and the scope of the invention is not limited to the exact details shown, represented, or described.
[0032] While the present invention has been described with reference to specific embodiments, it is understood that the invention is not limited but rather includes any and all changes and modifications thereto which would be apparent to those skilled in the art and which come within the spirit and scope of the appended claims. | The present invention is directed to a method of manufacturing of sintered bonded adhesive plates. The present invention comprises the steps of clearing the metal cores, applying thermosetting adhesives, such as phenolic or epoxy adhesives, to the core layer, then applying sintered layers on top of the adhesive layers and bonding said layers at a temperature in the range of 375-475 F, pressure in the range of 25-1000 psi and bonding such structure for at least 30 seconds. The metal core may be fabricated from metals whose melting point is at least 122° F., such as aluminum. The present invention presents a relatively inexpensive way of manufacturing sintered bonded adhesive plates. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 12/517,426, filed Jun. 3, 2009, which is a 371 National phase of PCT/EP2007/010394, filed Nov. 30, 2007, which claims the benefit of German Patent Application No. 102007003296.1, filed Jan. 23, 2007, all of which are incorporated herein by reference as if fully set forth.
BACKGROUND
[0002] The invention relates to a sanitary unit having a jet aerator which has an aerator housing which can be inserted into the water outlet of a sanitary outlet fitting and which, in its housing interior, has a jet splitter which separates the incoming water flow into a multiplicity of individual jets and downstream of which at the outflow side is positioned a mixing zone for aerating the individual jets, with at least one aerating duct which opens out in the mixing zone being provided, and also having a throttling or closing piece which, for throttling and/or selectively activating or deactivating the aerating function, can be varied in terms of its relative position with respect to the aerator housing.
[0003] Attachment units having jet aerators of said type are already known in a wide variety of embodiments. The already known jet aerators have an aerator housing which can be inserted into the water outlet of a sanitary outlet fitting. A jet splitter is provided in the housing interior of the aerator housing, which jet splitter may for example be embodied as a perforated plate or as a diffuser and separates the water flow flowing to the jet aerator into a multiplicity of individual jets. Positioned in the aerator housing downstream of the jet splitter at the outflow side is a mixing zone in which the individual jets are aerated before said jets are merged and formed again in downstream functional units of the jet aerator to form a homogeneous, sparkling, soft and non-sputtering overall jet. To be able to supply the required air to the mixing zone, at least one aerating duct is provided which may for example be formed by the annular chamber which is arranged between the outlet mouthpiece and the aerator housing and which leads to orifice openings in the aerator housing.
[0004] The aeration of the water jet flowing out of the outlet fitting, as is sought with the already known jet aerators, manifests itself in a multiplicity of air bubbles which cause the outflowing water jet to be made noticeably white in color. In some culture groups, however, only a clear, non-colored and therefore non-aerated water jet is tolerated as being fit for consumption. Furthermore, the aeration of the water jet may possibly increase the risk of germs being entrained in the water jet, for which reason such aeration of the water jet is in part also avoided in hospitals, for example. In such cases, jet regulators are used in which aeration of the water jet is not possible. Different jet regulator designs must therefore be produced and stocked according to the application and field of use.
[0005] DE-B1 107 607 already describes various embodiments of a device which serves to aerate water which emerges under pressure, in particular in domestic water lines. In the already known device, external air can freely enter below a perforated transverse wall, wherein the splitting of the water and the intimate mixture of said water with the air is performed by a sieve body which is dimensioned such that a coherent, air-bubble-laden water flow emerges from said sieve body. In the already known device, to influence the composition of the water-air mixture which is generated, and to also be able to activate or deactivate the aerating function if appropriate, the throughflow cross section of the perforated transverse wall and therefore the speed of the water flowing through the transverse wall and impinging on the sieve body can be regulated. In said already known device, however, it is disadvantageous that the aerating function is regulated only indirectly by means of a change in the throughflow speed or throughflow power of the water flowing to the mixing zone, and that other parameters of the outflowing water jet are also changed with the regulation of the aerating function. The handling of the already known device is thereby impeded considerably.
[0006] A device has also already been created in which, to generate aerated or non-aerated jets, sieves or sieve-free outlet openings can be selectively placed in the region below the transverse wall openings in which the external air can freely enter (cf. DE-B 1 184 706). Since sieves of said type can however retard the emerging water jet, other parameters of the emerging water jet are noticeably changed by means of the aerating function in said device too. Furthermore, said already known device does not permit continuously variable regulation of the aerating function.
[0007] DE 34 18 165 C2 has already disclosed a device having an aerating device for aerating the water jet emerging from a tap, which aerating device has a plurality of transverse walls arranged transversely with respect to the outflow direction of the water jet, wherein air can be supplied from the outside at least downstream of the first transverse wall. Here, the water quantity per unit time can be adjusted by rotating a spindle which projects out of the aerating device downstream. In the device already known from DE 34 18 165 C2, therefore, a water jet is generated which is variable in terms of its throughflow quantity but which is always aerated.
[0008] A jet aerator having an aerator housing is already known from US-A-2004/0199995. The already known jet aerator can be inserted with its aerator housing into the outlet-side end opening of a throttling or closing piece in such a way that the aerator housing can be gripped by a partial region, which projects out of the throttling or closing piece, and can be rotated in terms of its relative position with respect to the throttling or closing piece in such a way that the duct sections, which are provided firstly in the throttling or closing piece and secondly in the aerator housing, of the at least one aerating duct can be placed in order out of alignment, into an open and closed position respectively.
[0009] Since, in the jet aerator already known from US-A-2004/0199995, the aerating duct is aligned radially with respect to the longitudinal axis of the water outlet and since the throttling or closing piece forms the outflow-side outlet end region of the sanitary outlet fitting, the duct inlet, which is arranged on the outer periphery of the throttling or closing piece, of the aerating duct is always in the field of view of the user. However, since, at relatively low line pressures and low flow speeds, as regularly occur during the opening and closing of a fitting, the vacuum required for air induction in the mixing chamber below the jet splitter device is not yet generated, it is often the case that the throughflowing water can build up upstream of the insert parts which are positioned downstream of the aerator housing, and can flow into the region of the aerating duct. With increasing throughflow and increasing acceleration of the individual water jets in the jet splitter device, the vacuum required for air induction is duly generated, but the aerating duct is also still wetted, which can lead to accumulations of limescale in the case of lime-containing water, which limescale accumulations are firstly visible as undesired dirt in the region of the duct inlet, which is arranged at the outer peripheral side, of the aerating duct, and secondly causes the free duct cross section of the aerating duct to become progressively smaller until said aerating duct is completely contaminated with dirt and is unusable. Furthermore, in the jet aerator provided in US-A-2004/199995, the aerating duct can be hermetically sealed off with respect to the throttling or closing piece in order to reliably prevent an induction of air in the throttling or closed position. For this purpose, it is necessary for the seal, which surrounds the duct sections provided firstly in the throttling or closing piece and secondly in the aerator housing, to bear under preload against the throttling or closing piece, such that a rotational movement which is applied to the aerator housing relative to the throttling or closing piece is possible only with increased friction. As a result, there is the risk that, in the event of such a rotational movement being applied to the aerator housing, the throttling or closing piece can also be inadvertently detached from the outflow-side end of the outlet fitting. Furthermore, the attachment unit already known from US-A-2004/0199995 has the disadvantage that it is not compatible with commercially available jet aerators and can therefore be produced only with considerably increased production expenditure.
SUMMARY
[0010] It is therefore the object to create a sanitary unit of the type mentioned in the introduction having a jet aerator whose aerating function can be varied in a simple manner, which can be used in a correspondingly versatile manner and by means of which the disadvantages known from already known jet aerators can be avoided.
[0011] According to the appended proposal for a new application for protection, said object is now achieved according to the invention in that the jet aerator can be inserted into an outlet mouthpiece which can be mounted on the water outlet of the outlet fitting, in that the at least one aerating duct is provided, at least in sections, between the outlet mouthpiece and the aerator housing, in that the throttling or closing piece can be moved, by means of a rotational and/or sliding movement, between an open position, in which the at least one aerating duct is open, and a throttling or closed position, in which the at least one aerating duct is at least partially closed, and in that the throttling or closing piece, in the throttling or closed position, at least partially closes off the at least one aerating duct in the region of the at least one duct orifice, which leads to the mixing zone, of said aerating duct and/or in the region of the at least one duct inlet of said aerating duct.
[0012] Since the jet aerator of the attachment unit according to the invention is inserted into an outlet mouthpiece which can be mounted on the water outlet of the outlet fitting, it is possible to resort even to commercially available jet aerators. Since the at least one aerating duct is not arranged radially, and its duct opening therefore also need not have an attachment unit at the outer periphery, limescale accumulations which lie in the field of view of the user are prevented. Since the rotational and/or sliding movement required for the throttling and/or selective activation or deactivation of the aerating function is applied to the throttling or closing piece, and since the jet aerator is, in contrast, held in an outlet mouthpiece which can be mounted on the water outlet of the outlet fitting, an inadvertent detachment of the attachment unit composed of jet regulator, throttling or closing piece and outlet mouthpiece is prevented.
[0013] One particularly simple and nevertheless advantageous embodiment according to the invention provides that the throttling or closing piece is of sleeve-shaped design and engages around the aerator housing.
[0014] It is expedient if the throttling or closing piece is held in a rotatable and/or slidable manner on the aerator housing or on the outlet mouthpiece.
[0015] One embodiment of the invention provides that the throttling or closing piece can be latched, preferably in a detachable fashion, in its open position and/or in its throttling or closed position.
[0016] It may be expedient if the throttling or closing piece is connected to the outlet mouthpiece by means of a screw thread.
[0017] Another embodiment of the invention consists in that the throttling or closing piece carries an annular seal which, in the throttling or closed position of the throttling or closing piece, at least partially closes off the inlet opening of the aerating duct which is provided between the outlet mouthpiece and the aerator housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Further features according to the invention can be gathered from the following description of the figures and from the claims. The invention is described in more detail below on the basis of advantageous exemplary embodiments.
[0019] In the figures:
[0020] FIGS. 1 to 2 show a jet aerator in which an aerating duct which leads to a mixing zone in the aerator housing can be opened and closed off in the region of the inlet opening,
[0021] FIGS. 3 to 4 show a jet aerator in which the inlet opening of the aerating duct is delimited by a sealing surface on the aerator housing, which sealing surface interacts with a counterpart sealing surface on a throttling or closing piece which can be moved in the direction of the aerator housing,
[0022] FIGS. 5 to 6 show a jet aerator which can be inserted into an outlet mouthpiece which, instead of the internal thread provided in FIGS. 3 and 4 , has an external thread by means of which the outlet mouthpiece can be detachably mounted on a sanitary outlet fitting,
[0023] FIGS. 7 to 8 show a jet aerator in which a throttling or closing piece is guided in an axially movable manner, which throttling or closing piece, in its closed position, closes off the orifice openings, which lead to a mixing zone in the housing interior, of the aerating duct,
[0024] FIGS. 9 to 12 show a jet aerator in which the throttling or closing piece is held in a rotatable manner on the aerator housing and has, at the periphery, aerating openings which, in the open position of the closing piece, are aligned with orifice openings in the aerating housing, while the closing piece, in its closed position, closes off the orifice openings,
[0025] FIGS. 13 to 16 show a jet aerator whose throttling or closing piece has a rotary piece, which is held in a rotatable manner on the outlet mouthpiece, and a closure piece which is guided in an axially slidable manner on the aerator housing, wherein the rotary piece and the closure piece are connected to one another by means of a screw connection which converts a rotational movement at the rotary piece into an axial sliding movement of the closure piece,
[0026] FIGS. 17 to 19 show a jet aerator which is of substantially comparable design to FIGS. 13 to 16 , and
[0027] FIGS. 20 to 24 show a jet aerator whose throttling or closing piece is guided in an axially slidable manner on the aerator housing and, in its closed position, closes off the orifice openings on the aerator housing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] FIGS. 1 to 24 show a jet aerator in various embodiments 1 , 2 , 3 , 4 , 5 , 6 and 7 . The jet aerator 1 , 2 , 3 , 4 , 5 , 6 and 7 has an aerator housing 8 which can be mounted on the water outlet of a sanitary outlet fitting (not illustrated in any more detail here). For this purpose, an outlet mouthpiece 9 is provided which can be screwed with an external thread 10 or with an internal thread 11 to a counterpart thread provided on the water outlet of the outlet fitting, and into which the jet aerator 1 , 2 , 3 , 4 , 5 , 6 and 7 can be inserted from the inflow side of the outlet mouthpiece 9 up to an insertion stop.
[0029] The jet aerator 1 , 2 , 3 , 4 , 5 , 6 or 7 has, in the housing interior of its aerator housing 8 , a jet splitter 12 which separates the incoming water jet into a multiplicity of individual jets. Said jet splitter 12 may be designed as a perforated plate—in the present figures, however, the jet splitter 12 is embodied as a pot-shaped diffuser which, at the peripheral edge of its pot shape, has throughflow openings 13 arranged so as to be distributed at regular intervals in relation to one another. Positioned in the housing interior of the aerator housing 8 downstream of the jet splitter 12 at the outflow side is a mixing zone 14 in which the individual jets can be aerated before said jets are merged and formed in a downstream flow straightener which is preferably designed as a honeycomb-shaped perforated plate 15 , or if appropriate in further upstream functional units of the jet aerator 1 , 2 , 3 , 4 , 5 , 6 or 7 , to form a homogeneous, sparking, soft and non-sputtering water jet.
[0030] To be able to aerate the individual jets in the mixing zone 14 , an aerating duct 16 which is embodied as an annular chamber is provided between the outlet mouthpiece 9 and the aerator housing 8 , which aerating duct 16 opens out into a plurality of orifice openings 17 which are arranged in an encircling fashion on the housing periphery of the aerator housing 8 and which serve as a duct outlet. As a result of the constriction of the jet cross section in the region of the jet splitter 12 , and the resulting increase in speed of the individual jets in relation to the incoming water flow, a vacuum is generated in the mixing zone 14 , which vacuum causes air to be inducted via the aerating duct 16 .
[0031] From a comparison of FIGS. 1 to 24 , it is clear that the aerating function of the jet aerators 1 , 2 , 3 , 4 , 5 , 6 , 7 can be selectively activated or deactivated. For this purpose, a throttling or closing piece 18 is provided which can be moved, by means of a rotational and/or sliding movement, between an open position, in which the at least one aerating duct 16 is open, and a throttling or closed position, in which the at least one aerating duct 16 is closed. Since the aerating function can be varied in a continuous fashion in the exemplary embodiments 1 , 2 , 3 , 4 , 5 , 6 , 7 illustrated here, intermediate positions with a throttled aerating function in relation to the open position are also possible.
[0032] The throttling or closing piece 18 is of sleeve-shaped design and engages around the aerator housing 8 . While the throttling or closing piece 18 closes off the aerating duct 16 in the region of its at least one duct inlet 19 in the jet regulators 1 , 2 , 5 shown in FIGS. 1 to 6 and 13 to 16 , the throttling or closing piece 18 of the jet aerators 3 , 4 , 6 and 7 illustrated in the other figures blocks in the region of the at least one duct orifice, which leads to the mixing zone 14 , of said aerating duct 16 .
[0033] In the jet aerators 3 , 4 and 7 shown in FIGS. 7 to 12 and 20 to 24 , the throttling or closing piece 18 is held in a rotatable and/or slidable manner on the aerator housing 8 . In contrast, in the jet aerators 1 , 2 , 5 and 6 , the throttling or closing piece 18 is guided in a movable manner on the outlet mouthpiece 9 .
[0034] The throttling or closing piece 18 of the jet aerators 3 , 4 , 7 can be latched at least in the closed position in a detachable fashion.
[0035] In the jet aerators 1 , 2 illustrated in FIGS. 1 to 4 , the throttling or closing piece 18 is held on the outer periphery of the outlet mouthpiece 9 in a rotatably and axially adjustable manner by means of a screw thread 20 . Here, the throttling or closing piece 18 of the jet aerator 1 shown in FIGS. 1 and 2 has, on its inner periphery, an annular seal 21 which, in the closed position of the throttling or closing piece, closes off the duct inlet of the aerating duct 16 which is provided between the outlet mouthpiece 9 and aerator housing 8 .
[0036] The jet aerator 2 illustrated in FIGS. 3 and 4 has, on the outlet-side end edge region of its aerator housing 8 , an encircling sealing surface 22 which interacts with a counterpart sealing surface 23 on the throttling or closing piece 18 . As can be seen from the open position shown in FIG. 4 , the inlet opening 19 of the aerating duct 8 is bordered by the sealing surface 22 and the counterpart sealing surface 23 which has a corresponding chamfer with respect to the jet aerator longitudinal axis.
[0037] By means of a rotational movement applied to the throttling or closing piece 18 , the closing piece 18 is screwed to the outlet mouthpiece 9 in such a way that, in the closed position as per FIG. 3 , the sealing surface 22 acts on the counterpart sealing surface 23 in a sealing fashion. Here, the annular gap which is provided between the throttling or closing piece 18 on the one hand and the outlet mouthpiece 9 on the other hand is sealed off by means of an annular seal 24 which is held in an annular groove 25 on the outer periphery of the outlet mouthpiece 9 .
[0038] While the outlet mouthpiece 9 of the jet regulator 2 shown in FIGS. 3 and 4 can be fastened with an internal thread 11 to the water outlet of a sanitary outlet fitting, an external thread 10 is provided for this purpose in the jet aerator 2 shown in FIGS. 5 and 6 .
[0039] The aerator housing 8 of the jet aerator 3 shown in FIGS. 7 and 8 has, on its outflow-side housing peripheral edge, orifice openings 17 which can be closed off by means of a throttling or closing piece 18 which is guided in an axially slidable manner on the outer periphery of the aerator housing 8 . The throttling or closing piece 18 has corresponding passage openings 26 which, only in the open position shown in FIG. 8 , are aligned with the orifice openings 17 which lead to the mixing zone 14 . The throttling or closing piece 18 can be latched to the housing outer periphery of the jet aerator in a detachable fashion in the open position and in the closed position.
[0040] FIGS. 9 to 12 illustrate a jet aerator 4 which is of similar design but whose passage openings 26 can, by means of a rotational movement, be placed in alignment with the orifice openings on the aerator housing 8 . To be able to tangibly discern that the jet aerator 4 is in the open position shown in FIGS. 10 and 11 , corresponding latching means 27 , 28 are provided between the aerator housing 8 and the throttling or closing piece 18 , which latching means 27 , 28 latch in each case in the different open and closed positions.
[0041] The jet aerators 5 , 6 shown in FIGS. 13 to 19 have a two-part throttling or closing piece 18 with a rotary piece 29 which is held in a rotatable manner on the outlet mouthpiece 9 and with a closure piece 30 which is guided in an axially slidable manner on the jet aerator 5 , 6 . Here, the rotary piece 29 and the closure piece 30 are connected to one another by means of a screw connection 31 which converts a rotational movement of the rotary piece 29 into an axial sliding movement of the closure piece 30 . By means of a rotation applied to the rotary piece 29 , the closure piece 30 can be adjusted axially from the open position shown in FIGS. 13 and 15 into the closed position shown in FIG. 14 , until the counterpart sealing surface 23 which is provided on the inner periphery of the closure piece 30 acts on the sealing surface 22 , which is arranged on the outflow-side end edge region of the aerator housing 8 , in a sealing fashion.
[0042] A jet aerator 6 which is of comparable design is shown in FIGS. 17 to 19 . However, the jet aerator 6 has, on that side of the orifice openings 17 which faces toward the water outlet of the jet aerator 6 , a sealing surface 22 which projects in the manner of a bead and which interacts with the inflow-side end edge region, which has a corresponding chamfer, of the closure piece 30 , which end edge region forms the counterpart sealing surface 23 . FIG. 19 shows that the outer periphery of the rotary piece is of non-circular design in order that the user can grip the rotary piece in a rotationally fixed manner between the fingers.
[0043] The jet aerator 7 shown in FIGS. 20 to 24 has, on its aerator housing 8 , the axially slidably guided throttling or closing piece 18 which, in its open position according to FIG. 21 and in its closed position according to FIG. 20 , can latch in each case on the aerator housing 8 .
[0044] The jet aerators 1 , 2 , 3 , 4 , 5 , 6 , 7 have, at the inflow side, an ancillary sieve 34 which is intended to retain the dirt particles which are entrained in the water and to ensure the correct functioning of the jet aerator 1 , 2 , 3 , 4 , 5 , 6 , 7 . All the jet aerators 1 , 2 , 3 , 4 , 5 , 6 , 7 have an inflow-side sealing ring 37 which can be sealingly clamped between the jet aerators 1 , 2 , 3 , 4 , 5 , 6 , 7 and the adjacent end edge of the water outlet of the outlet fitting.
[0045] It can be seen in FIGS. 20 to 24 that a handle 36 projects on the outer end edge region of the throttling or closing piece 18 . Said handle 36 is integrally formed on the throttling or closing piece 18 and is formed by a wall section, which extends up to a longitudinal central plane, of the throttling or closing piece 18 , which wall section can be bent in the direction of the longitudinal central plane from the initial position or readiness position illustrated in FIGS. 20 and 21 into the use position shown in FIGS. 22 and 23 . In said use position, the throttling or closing piece 18 can be gripped by the handle 36 and moved in the desired rotational direction. To be able to better grip the handle 36 , said handle has a projection 35 which is preferably arranged centrally and projects outward beyond the outlet mouthpiece 9 . | A jet aerator ( 1 ) having an aerator housing ( 8 ) that can be installed in the water discharge of a sanitary outlet fitting, and having a jet splitter ( 12 ) in the interior of the housing, dividing the inflowing water flow into a plurality of individual jets, a mixing zone ( 14 ) being disposed downstream of the splitter for aerating the individual jets, wherein at least one aerator duct ( 16 ) is provided that ends in the mixing zone ( 14 ). The jet aerator has a throttle or closing piece ( 18 ) for reducing and/or optionally activating or deactivating the aerating function, the throttle or closing piece being displaceable between an open position opening the at least one aerating duct ( 16 ) and a throttle or closing position at least partially closing the at least one aerating duct ( 16 ) by a rotary and/or sliding movement. | 4 |
SUMMARY BACKGROUND OF THE INVENTION
The present invention relates to an electrical control system for providing remote steering for marine vehicles.
Boats, especially of the recreational type, are traditionally equipped with outboard motors, inboard motors and/or inboard-outboard motors. Steering is usually accomplished by pivoting the rudder or by pivoting the motor or the propeller drive of the motor with either of the latter two functioning as a steering rudder. Except for relatively small watercraft with relatively small sized outboard motors, a remote steering mechanism is frequently provided which permits steering movement of the motor, propeller drive unit, etc. to facilitate steering of the boat by the operator at a position remote from the rear (aft) of the boat. While some electrical, remote systems have been employed, traditionally remote steering has been accomplished by a cable or pair of cables which must be run from the steering wheel at or near the front (fore) of the boat to the motor or propeller drive at the back (aft) of the boat. While satisfactory steering can be achieved with cable systems, there are inherent problems with backlash by which the motor or propeller drive unit can oscillate. This oscillation can be severe enough to cause damage to the boat especially with larger motors and at higher speeds. In order to inhibit backlash, a pair of cables are used and are connected in a push-pull manner to opposite sides of the motor or drive unit. This results in a relatively costly assembly requiring balancing between the separate cables. In any event, whether single or dual cable systems are used, different cable lengths and connections are required for different boats of different sizes and different configurations.
In the present invention, remote steering is provided by an electrical system utilizing electronic controls to provide steering via an electric motor. The system is readily adaptable to boats of different sizes and different configurations since common major components can be used from one boat to the next with changes mainly in the length of the wiring harness. For example, the same major components of the remote system of the present invention can be used with outboard, inboard, and/or inboard-outboard motors varying in size and configuration in rating from around 15 horsepower to about 250 horsepower and with boats varying in size and configuration from runabouts to houseboats and cruisers.
In addition the system of the present invention can be provided as original equipment and can also readily be provided as a retrofit for existing boats using a cable system. In this regard, it should be noted that on most boats an industry standard guide tube is connected to the motor or drive unit and is used for the cable steering system. In the present invention, the steering apparatus has been specifically designed to function with the standard guide tube thus making it readily adaptable for use either as an original equipment option or as a retrofit for existing boats.
Thus it is an object of the present invention to provide a unique remote electrical steering system in which a generally common structure can be used for boats having a wide range of sizes and configurations.
It is another object of the present invention to provide a unique remote electrical steering system adapted to provide steering in conjunction with the standard guide tube used in cable steering systems.
It is another object of the present invention to provide a unique remote electrical steering system which is readily adaptable either as original equipment on new boats or as a retrofit for existing boats.
It is a general object of the present invention to provide a unique remote electrical steering system for boats.
Other objects, features, and advantages of the present invention will become apparent from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a pictorial view of one type of boat with the remote electrical steering system of the present invention generally shown and including a steering unit and a power unit;
FIG. 2 is an exploded pictorial view of the mechanical and electrical components of the steering unit of the remote electrical steering system of the present invention of FIG. 1;
FIG. 2A is a longitudinal, plan view of components of FIG. 2 shown assembled with some parts shown in section and others partially shown;
FIG. 3 is an exploded pictorial view of the mechanical and electrical components of the power unit of the remote electrical steering system of the present invention of FIG. 1;
FIG. 3A is a longitudinal, plan view of components of FIG. 3 shown assembled with some parts shown in section and others partially shown;
FIG. 4 is a block diagram of the electrical control circuit of the present invention including the circuits of the steering unit and power unit of FIG. 1;
FIG. 5 is an electrical schematic diagram of the electrical control circuit of the steering unit and power unit of the remote electrical control system of the present invention;
FIG. 5A is a pictorial view of the rudder position indicator of FIG. 5 for providing a visual indication to the vehicle operator of the steering orientation of the motor-rudder such as that of the boat of FIG. 1;
FIG. 6A is a pictorial view of the motor-rudder of FIG. 1 with a prior art cable steering system shown in a pre-assembled condition relative to the standard guide tube and with some portions shown broken away and others in section;
FIG. 6B is a pictorial view of the motor-rudder of FIG. 1 with the power unit, of the present invention, shown in a pre-assembled condition relative to the standard guide tube; and
FIG. 6C is a pictorial view similar to FIG. 6B showing the power unit of the present invention assembled to the motor-rudder via the standard guide tube.
DETAILED DESCRIPTION OF THE INVENTION
Looking now to FIG. 1, a boat 10 is shown to have a body or hull 12 and an outboard motor 14. Typically outboard motors such as motor 14 are secured to a transom structure 16 at the rear (aft) of the boat hull 12. The boat 10 is also shown to have its steering mechanism located at a typical driver location generally towards the front (fore) of the boat hull 12. In the present invention, a steering unit 18 is provided at a driver's compartment 20 and is manipulated by a typical steering wheel 22. The motor 14 is supported at the transom structure 16 for pivotal movement about an axis X which is generally transverse to the body or hull 12 whereby steering of the boat 10 is accomplished. In the present invention, a power unit 23 is secured to the transom structure 16 and is electrically connected to the steering unit 18 via an electrical control cable 24. Thus, as will be seen, the power unit 23 can be actuated in response to actuation of the steering unit 18 to provide the desired pivotal movement of motor 14 about transverse axis X whereby remote steering of the boat 10 can be achieved.
A. The Electrical Control And Power Circuit
The electrical control and power circuit for the system and hence the electrical interconnection between the steering unit 18 and power unit 23, whereby steering action of the motor 14 is accomplished, can be generally seen from the block diagram of FIG. 4.
In FIG. 4 the electrical circuitry of the steering unit 18 is generally indicated by the numeral 26 and includes a steering wheel position sensor 28. The steering wheel position sensor 28 functions to sense the rotational or angular position of the steering wheel 22 and to provide a signal having a magnitude indicative of that angular, rotational position from a predetermined neutral position. The electrical circuitry of the power unit 23 is generally indicated by the numeral 30 and includes a motor-rudder position sensor 32 which senses the pivotal or angular position of the motor 14 about pivot axis X and provides a signal having a magnitude indicative of that angular, pivotal position relative to a predetermined neutral position. The signal from the motor-rudder position sensor 32 is transmitted to a rudder position indicator circuit 33 of the circuitry 26 of the steering unit 18 and provides a visual display to the driver of the relative port or starboard angle of the motor 14 about pivot axis X relative to the neutral position.
The steering wheel position sensor 28 and motor-rudder position sensor 32 are connected to a motor controller circuit 34 which provides output control signals (GATE SIGNALS) when a predetermined relationship between the signals from the steering wheel position sensor 28 and motor-rudder position sensor 32 is detected. As will be seen this can be in the form of a difference in magnitude between the two sensor signals which difference can be considered as an error signal. This error signal will have a magnitude and a polarity indicative of the magnitude of the difference and direction of the difference, i.e. the signal from steering wheel sensor 28 is greater or less than the signal from the motor-rudder sensor 32. The polarity indication of the error signal in turn will determine the direction of rotation of the motor 14 to comply with the angular position of the steering wheel 22, as selected by the driver, relative to the angular position of the motor 14 about its pivot axis X.
The output control signal (GATE SIGNAL) from the motor controller circuit 34 is transmitted to a motor drive circuit 36 which includes a reversible, direct current (dc) permanent magnet motor 38 controlled by four switch circuits 40, 42, 44 and 46. The dc motor 38 will rotate either clockwise or counterclockwise depending upon the polarity of the error signal and hence upon the polarity of the output control signal from the motor controller circuit 34. The rotation of the dc motor 38 will cause pivotal movement of the motor 14 about axis X to an angular position corresponding to the angular position of the steering wheel 22 whereby steering of the boat 10 is effectuated.
Power for the electrical circuitry of the control system is provided via a battery B which is part of the standard, electrical system of the boat 10 and is typically a positive 12 volts with a negative ground. A power supply circuit 48 is connected to battery B and converts the voltage of battery B to the operating voltages required by the electrical components in the electrical circuit. Thus in the system as shown the battery B provides a B+ voltage of 12 volts dc while the power supply circuit 48 provides a regulated 8 volt dc via a voltage converter circuit 56, a 2B+ (24 volt dc) supply from a voltage doubler circuit 54 and a filtered voltage Vcc of around 12 volts.
A fault detector circuit 50 is provided to sense a number of predetermined fault conditions in the electrical control system and is operative on motor controller circuit 34 via a fault inhibit line to shut the system down by shorting out or grounding both sides of the rotor windings of the dc motor 38 through switch circuits 44 and 46 whereby rotation of the rotor of the dc motor 38 and hence movement thereby of the outboard motor 14 is inhibited via the permanent magnet field. As will be seen pivotal movement of the outboard motor 14 is further inhibited by the reverse mechanical advantage of the drive screw (210 in FIG. 3) connection between the dc motor 38 and outboard motor 14. The fault detector circuit 50 is designed to sense the following fault conditions:
(1) overload current to the rotor of dc motor 38,
(2) low limit sensor detection, i.e. short or partial short in either position sensor 28 or 32,
(3) high or open limit sensor detection, i.e. open in either position sensor 28 or 32, and
(4) initial power on inhibit, i.e. prevents inadvertent movement of motor 14 by dc motor 38 when system is first turned on.
The details of the circuits noted in FIG. 4 can be seen from the circuit diagram of FIG. 5.
In one form of the invention as shown in FIG. 5, the components in the circuit were of the following type and value:
______________________________________Resistors (ohms)1. R1-4, R9, R19, R22-24 10 k2. R6, R14, R17-18 100 k3. R8, R10, R11, R15-16 1 k4. R7 6805. R5 3006. R20-21 107. R25 1 megPotentiometers1. R12, R13 0-10 kCapacitors (Microfarads)1. C9, C11-13 .012. C13 .0013. C7 .474. C2 .225. C4,5 3.36. C8 107. C6 228. C1 100Diodes1. D1 In 40042. D2-11 In 41483. D18-20, D21-23 LED (red) D24 LED (green)Zener Diodes1. D12-17 IN 4747Integrated Circuits1. U1 LM29022. U2 MC330303. U3 LM39144. U4 MC78L085. U5 LM556CNTransistors1. Q1-2 2n65192. FETs Q3-4 IRFZ403. FETs Q5-6 MTP40N06M______________________________________
Diodes D1-D11 are of a type manufactured by Motorola; LED diodes D18-D24 (Rudder Display LED 28) are of a type manufactured by Panasonic; Integrated Circuits U1, U3 and U5 are of a type manufactured by National; Integrated Circuits U2 and U4 are of a type manufactured by Motorola; Transistors Q1-2 are of a type manufactured by Motorola; and FETs Q3-6 are of a type manufactured by Motorola.
The fault detector circuit 50 includes a solid state quad, operational amplifier integrated circuit 52 with operational amplifiers U1a, U1b, and U1c. The power supply circuit 48 includes the voltage doubler circuit 54 including a solid state device U5 (a timer chip) and the voltage converter circuit 56 including a solid state device U4. The voltage converter circuit 56 includes an input circuit having a diode D1 connected to ground via a filter capacitor C1 and, in the configuration shown, provides a regulated 8 volt direct current output across a capacitor C2 having one side connected to ground. In addition a filtered B+ voltage Vcc is provided at capacitor C1. A voltage of 2B+ is supplied from doubler circuit 54 via an oscillating voltage of B+ through diode D3 to B+ through capacitor C4, resulting in a low current supply of 2B+ voltage. Capacitor C3 and resistor R1 at the inputs (terminals 2 and 6) to timer chip U5 determine the B+ oscillating frequency while capacitors C4 and C5 (at U5 terminals 14 and 5, respectively) function as timing circuits with diode D2 to provide the 2B+ output.
The application of power to the dc motor 38 is accomplished by the motor drive circuit 36 which includes the four switch circuits 40, 42, 44 and 46 comprising four field effect transistors (FETs) Q3, Q4, Q5 and Q6, respectively, and the associated gating and output circuitry, connected in a power "H" configuration. The FETs Q5 and Q6 are "sense FETS" and are connected between the dc motor leads 60a, 60b and ground. FETS Q5 and Q6 are controlled by motor controller circuit 34. The motor control controller circuit 34 includes a motor control integrated circuit U2. Gate signals are provided directly from the motor controller integrated circuit U2 (terminals 10, 14) to gates G5 and G6 of FETS Q5 and Q6, respectively. The battery B is connected to the motor leads 60a, 60b through input terminals D3, D4 and output terminals S3, S4 of FETs Q3, Q4, respectively. In addition gate voltages to gates G5 and G6 of a magnitude of 2B+ are supplied from the voltage doubler circuit 54. The gate input to gates G4 and G6 of FETS Q4 and Q6 are provided via a gate circuit including a power transistor Q2 having its emitter connected to 2B+ of doubler circuit 54 and its collector connected to gate G4 and to ground via a dropping resistor R24; the base of transistor Q2 is connected to gate G6 of FET Q6 via zener diode D16 and dropping resistor R22. Similarly, the gate input to gates G3 and G5 of FETS Q3 and Q5 are provided via a gate circuit including a power transistor Q1 having its emitter connected to 2B+ of doubler circuit 54 and its collector connected to gate G3 and to ground via a dropping resistor R23; the base of transistor Q1 is connected to gate G5 of FET Q5 via zener diode D12 and dropping resistor R19. Each of the FETs Q3, Q4, Q5, and Q6 is protected from excessive gate voltage by zener diodes D13, D14, D15, and D17, respectively, connected from gates G3, G4, G5 and G6 to output terminals S3, S4, S5 and S6, respectively.
Thus each of the common pairs of FETs Q3 and Q5 and FETs Q4 and Q6 are each controlled by a single gate signal with an inverted signal to the FETs Q3-Q4 connected to B+. Thus gate signal Vg5 from U2 is connected to the gate G5 of FET Q5 and to the transistor Q1 to provide the inverted signal to the gate G3 of FET Q3 and gate signal Vg6 from U2 is connected to the gate G6 of FET Q6 and to the transistor Q2 to provide the inverted signal to the gate G4 of FET Q4. This ensures that the different pairs are not closed at the same time which would result in a low resistance path from B+to ground. If the gate voltage Vg6 is applied to FET Q6, the FET Q6 switch is closed. However, the high bias voltage at R22 through zener D16, turns transistor Q2 off. This allows R24 to maintain a low voltage at the gate G4 of FET Q4, thus assuring that the FET Q4 switch will be open. The other condition is a low bias voltage to the gate G6 of FET Q6, resulting in an open condition. The low voltage through R22 and D16 to the base of transistor Q2 turns Q2 on. This applies a voltage of 2B+ to the gate of FET Q4 and closes the FET Q4 switch. The 2B+ level is required to maintain a minimum of 10 volts from gate to source because the gate voltage is 2B+ minus the drop across the rotor of dc motor 38 and the series sense FET Q5 or Q6 to ground.
The motor controller circuit 34 receives a steering input signal to integrated circuit U2 (terminal 1) from the wiper W1 of steering potentiometer R12 via line 39. The same input terminal also receives a fixed input voltage from voltage Vcc via a pull up resistor R6. A motor-rudder input to U2 (terminal 8) is received from the wiper W2 of motor-rudder potentiometer R13 via line 41. The same input terminal also receives a fixed input voltage from voltage Vcc via dropping resistor R14. At the same time terminal 2 of U2 is connected to ground via a filter capacitor C13 while terminals 4 and 5 are connected to ground via line 43 and terminals 6 and 7 are connected together via jumper line 45. Note that the 8 volt supply is connected to one end of the sensor potentiometers R12 and R13 and the other end of the potentiometers is connected to ground. Thus the voltage at the wipers W1 and W2 will vary from 0-8 volts plus the percentage of Vcc voltage on the low voltage side of resistors R6 and R14, respectively. If either of the wipers W1 or W2 becomes open circuited, the voltage at terminal 1 or 8 will go to voltage Vcc. Integrated circuit U2 also receives an inhibit signal (terminal 16) from fault detector circuit 50 via fault line 58 and via a timing circuit defined by resistor R8 and capacitors C7 and C9 connected in parallel and to ground. Terminal 15 of U2 is connected to ground via dropping resistor R9 while U2 terminal 9 is connected to ground via filter capacitor C12. Operating voltage Vcc is connected to terminal 11 of U2 which is also connected to ground via a filter capacitor C11. U2 terminals 12 and 13 are connected to ground. Output signals are generated at U2 terminals 14 and 10 via lines 47 and 49 with a timing circuit comprising capacitor C10 and resistor R11 connected in parallel across lines 47 and 49. A pull up resistance for voltage Vcc is connected to output lines 47 and 49 via resistor R10 which is connected to line 47.
The function of the motor controller circuit 34 is to compare the signal voltage from the steering wheel position sensor 28 via steering potentiometer R12 to the voltage of the motor-rudder position sensor 32 via rudder potentiometer R13. If the two signals are equal, a gate voltage (Vg5, Vg6) is applied from each of the output terminals (10,14) of integrated circuit U2 to gates G5 and G6 of FETS Q5 and Q6 of switch circuits 44 and 46, respectively. This results in FETS Q5 and Q6 turning on and FETS Q3 and Q4 being turned off. This connects leads 60a, 60b to both sides of the rotor of dc motor 38 to ground and causes a dynamic braking action on the permanent magnet, dc motor 38. If the two output, gate signals (Vg5, Vg6) from integrated circuit U2 of motor control circuit 34 are different, a zero voltage is applied to one of the gates of FETs Q5 or Q6 such that one of the FETs Q3 or Q4 is gated whereby the rotor of the dc motor 38 is energized to cause rotor rotation and hence pivotal movement of the outboard motor 14 about its pivot axis X in the direction to decrease the difference in sensor voltages. This correction continues until the difference in sensor voltages or the error signal is zero and the output control signal from the integrated circuit U2 is zero resulting in dc motor 38 being deactuated and the outboard motor 14 being located in the angular steering position desired by the driver.
Another control condition is provided by the fault detection circuit 50 and occurs when one of the previously noted fault conditions is sensed; the fault detection circuit 50 provides an inhibit signal which is transmitted via inhibit line 58 to motor control circuit 34 via dropping resistor R8 to integrated circuit U2 (terminal 16). If this input reaches a preselected level, i.e. 7.5 volts in the circuit shown, the voltage to each of the output terminals (14 and 10) of integrated circuit U2 is removed. This would result in all of the FETs Q3, Q4, Q5 and Q6 being placed in an open condition and the dc motor 38 floating. To prevent unwanted rotation of the rotor of dc motor 38, a pull up resistor R10 has been provided to force a voltage to both output terminals 14 and 10 of integrated circuit U2 and to generate gate voltages Vg5 and Vg6, thus providing for a closed, short circuit condition of FETs Q5 and Q6 and an open circuit condition of Fets Q3 and Q4 resulting in dynamic braking being applied to the rotor of the dc motor 14 in the manner noted before.
As a convenience to the operator, the output from the potentiometer R13 of the motor-rudder sensor 32 is connected to an LED display driver U3 in the position indicator circuit 33. The position indicator circuit 33 is designed to turn on a green light emitting diode (LED) D24 if the motor 14 is in the center or neutral position relative to axis X, i.e. boat 10 being steered straight. As the motor 14 is pivoted about the axis X in a turning maneuver a series of red LEDs D18-D20 and D21-D23 in an assembly 35 are turned on to visually indicate the direction (port or starboard) and angular range of the motor 14 beyond its center or neutral position relative to axis X.
As noted the fault detector circuit 50 performs the following: (1) detects an excess current condition to the rotor of dc motor 38, (2) detects loss of sensor signals from position sensors 28 and/or 32, and (3) provides a "key on" signal inhibiting movement of the dc motor 38 when the actuating key K is turned on energizing the electrical control circuit. The fault detector circuit 50 includes the operational amplifiers U1a-U1c of quad amplifier 52 which are used as level detectors with respective output diodes D4, D5 and D6 coupled to the inhibit line 58. The signals being monitored are the sense voltages of the FETs Q5 and Q6 and the sensor outputs at steering and motor-rudder potentiometers R12 and R13. The sense voltages of sense FETS Q5 and Q6 provide an indication of the magnitude of current through the rotor of dc motor 38 and hence an indication of an overload condition. The sensed outputs at steering and motor rudder potentiometers R12 and R13 provide an indication of an open or shorted condition and hence a fault condition at one of the sensor potentiometers R12 and R13.
The voltages at the mirror gates M5, M6 of the sense FETs Q5 and Q6 are proportional to the magnitude of current through the inputs D5a, D6a and outputs S5 and S6. Resistors R20, R21 are connected from mirror gates M5, M6 to kelvin gates K5, K6 on each sense FET Q5, Q6. Input resistors R2, R3 connect the mirror gates M5, M6 (Q5 and Q6) to the positive input of operational amplifier U1a (terminal 12) via a time delay circuit including capacitor C6 which has one side connected to ground. The negative input of U1a (terminal 13) is connected to the 8 volt supply via dropping resistor R7 and resistor R4 which define a voltage divider circuit with resistor R5 whereby a reference voltage Vr1 is provided at the negative input (terminal 13) of amplifier U1a. The reference voltage Vr1 is selected to be equal to one-half of the voltage produced at the mirror gates M5, M6 when the dc motor current through the FETs Q5, Q6 is equal to the maximum level. This level is an adjusted value to reflect the design current capacity of the system. As an example, if the maximum design current in the system is 30 amps, the voltage at the mirror gate M5 (FET Q5) is 0.45 volts dc. With FET Q6 in the open condition, the voltage at the positive input is 0.225 volts dc. Operational amplifier U1a is connected to filtered voltage Vcc via terminal 4 with terminal 11 connected to ground. Thus the end result is an output voltage Vcc from the operational amplifier U1a through diode D4 if the current level is above the limit which is 30 amps for the circuit shown. This same result would occur if the sensed current was through FET Q6. In normal operation only one of the sense FETs Q5, Q6 would be conducting current. The capacitor C6 at the positive input of amplifier U1a delays the level detector function to allow the normal start-up current to the dc motor 38. In the event that both the FETs Q5, Q6 are conducting, the voltage to the positive input of the operational amplifier U1a is the average of the voltage at mirror gates M5, M6 of each of the FETs Q5, Q6.
The other two operational amplifiers U1b, U1c are used as level detectors to monitor the sensor feedback from the steering wheel potentiometer R12 and the motor-rudder potentiometer R13. Note that operational amplifiers U1a, U1b and U1c are in a common chip and hence amplifiers U1b and U1c share common connections to Vcc and ground via terminals 4 and 11. One operational amplifier U1b has at its positive input (terminal 10) a voltage reference level Vr2 (which is derived in the same manner and equal to Vr1) set to be equal to the low end of the range of the sensor voltages from R12, R13. The negative input of U1b (terminal 9) is coupled through two diodes D8, D9 via lines 39 and 41, respectively, to the position sensor potentiometers R12, R13. If either of the leads to sensor potentiometers R12, R13 is shorted to ground, the output of the operational amplifier U1b goes to voltage Vcc which is transmitted through diode D5 and resistor R8 via the inhibit input line 58 to motor control integrated circuit U2 (terminal 16). The other operational amplifier U1c uses a voltage reference level (Vr3) at its negative input (terminal 6) which is selected to be equal to the high end of the voltage range of the sensor voltage from potentiometers R12, R13. The positive input (terminal 5) is coupled through two diodes D10, D11 via lines 41 and 39, respectively, to the sensor potentiometers R12, R13. A dropping resistor R25 is connected from the juncture of diodes D9 and D10 to ground. Each of the leads from sensor potentiometers R12 and R13 has a pull-up resistor R6, R14. If either of the sensor leads to R12, R13 are opened or shorted to 8 volts dc, the output of the operational amplifier U1c goes to voltage Vcc which is transmitted through diode D6, resistor R8, and inhibit line 58 to U2 (terminal 16).
A capacitor C8 is connected to the negative input of U1c to delay the reference level when the key K is switched on. The result is an output voltage to the inhibit line 58 each time the unit is powered up. This prevents the rotor of dc motor 38 from turning at initial power up in an attempt to positionally balance the motor 14 relative to the existing position of the steering wheel 22.
In all of the noted inhibit conditions, the operator must move the steering wheel 22 to place the steering sensor potentiometer R12 into balance with the rudder sensor potentiometer R13 before the inhibit condition is removed and the system reset.
Thus as noted, the control circuitry allows the power H switch of motor drive circuit 36 to operate in three states:
1) stop/brake--FETs Q5 and Q6 gated "on" (closed circuit) and FETs Q3 and Q4 "off" (open circuit) as a result of gate signals Vg5 and Vg6 being at voltage Vcc. This results in the motor, rotor leads 60a and 60b being shorted to ground causing a braking action on the dc motor 38. This helps to hold the outboard motor 14 at the present position and to stop and to resist its rotation about axis X before the dc motor 38 changes rotational direction;
2) Clockwise rotation--FETs Q3 and Q6 gated "on" and, FETs Q4 and Q5 "off" as a result of gate signal Vg5 being low (zero volts) and gate signal Vg6 being high (11 volts). This results in current flow from the battery B through FET Q3 (input D3a to output S3) to the dc motor 38 through FET Q6 to ground; and
3) Counter Clockwise rotation--FETs Q4 and Q5 "on" and FETs Q3 and Q6 "off" as a result of gate signal Vg5 being high (11 volts) and gate signal Vg6 being low (zero volts). This results in current flow from the battery B through FET Q4 (input D4a to output S4) to the dc motor 38 through FET Q5 to ground.
The rudder position indicator 33 includes integrated circuit U3 and LED assembly 35. U3 receives an input voltage at terminal 5 through diode D7 and a voltage divider network including R18 and R17 to ground (through terminals 2 and 4 of U3). The input voltage is the motor-rudder sensed voltage at wiper W2 of potentiometer R13. U3 terminals 2 and 4 are connected directly to ground while terminal 8 is connected to ground via resistor R15 and terminals 6 and 7 are connected to ground via resistor R16 and resistor R15. The regulated 8 volt supply is connected to U3 terminal 3 and to the input of position LED assembly 35.
Thus the integrated circuit U3 will receive signals indicative of the magnitude and angular, positional location of the motor 14 via the combined voltage reference from voltage Vcc and varying voltage from wiper W2 of potentiometer R13. This results in a series of output signals from terminals 10 to 18 of U3 which are transmitted to internal LED diodes D18-D23 in rudder position LED 35 whereby the appropriate one of the diodes D18-D23 will be energized to provide a visual indication to the operator of the angular position of the motor 14 as previously noted, i.e. green LED, straight or neutral, red LED, port or starboard. Note that output terminals 10 and 11 and output terminals 17 and 18 of U3 are connected together to assure a visual signal from rudder position LED28 over the entire range of signals from Motor/Rudder circuit 32 and hence over the entire range of movement of steering wheel 22.
With this description of the electrical control and power circuit, let us next look to the construction of the steering unit 18 and power unit 23.
B. The Steering Unit 18
Looking now to FIG. 2 an exploded pictorial view of one form of the steering unit 18 is shown. FIG. 2A shows components of the steering unit 18 in an assembled condition.
A steering shaft housing 64 is shown and includes a tubular shaft section 66 and a generally rectangular cover section 68. A steering unit housing 70 has a flange 72 at its open end which is adapted to engage a generally mating surface on the cover section 68 and to be secured thereto via threaded fasteners 74 which extend through clearance holes 76 in the cover section 68 and engage threaded openings 78 in the flange 72.
A steering shaft 80 is supported for rotation within shaft housing 64 and is secured to the steering wheel 22, in a manner to be described. Thus the steering shaft 80 has a body portion 82 which is generally uniform in diameter and which terminates at its forward end in a tapered portion 84 and a reduced diameter threaded retention portion 86. The steering wheel 22 has a tapered opening 88 adapted to matingly engage the tapered portion 86 on steering shaft 80. The wheel 22 can be held onto the tapered portion by means of a nut and washer (not shown) with the nut engaging the threaded retention portion 86 to urge the wheel opening 88 onto the tapered portion 84 in frictional engagement. Slots 90 and 92 in the tapered portion 84 and wheel opening 92 are adapted to be moved into radial alignment and to receive a key (not shown) whereby the wheel 22 and steering shaft 80 are held together from relative rotation.
A bushing 94 is provided to function as a stop member to limit the number of clockwise and counterclockwise turns of the steering wheel 22. In this regard the stop bushing 94 is externally, axially fluted or slotted to define axially extending rib segments 96. The stop bushing 94 has a central, threaded bore 95 adapted to be threadably received on a threaded, reduced diameter portion 98 adjacent the body portion 82 on steering shaft 80. A stop collar 100 is also adapted to be threaded onto the reduced diameter portion 98 and, as will be seen, is located at a preselected position to define one stop position and, once located, is fixed in that position. The stop collar 100 has a flange 102 at one end which is selectively deformable for adjusting the one stop position of the stop bushing 94.
The stop collar 100 can be crimped or otherwise deformed onto the rear threaded portion 98 to inhibit the stop collar 100 from rotation and to thereby fix the stop location. A final adjustment of the stop position can be achieved by deforming the radially outer portion 103 of flange 102 axially in a direction forwardly or towards the stop bushing 94 to thereby more precisely determine the distance of axial travel of the stop bushing 94 in the rearward direction (see FIG. 2A).
A drive gear 104 is fixed to a reduced diameter shaft portion 106 at the rearward end of the steering shaft 80. An output gear 107 is adapted to engage and be driven by the drive gear 104 and is fixed to the drive rod 108 of the steering sensor potentiometer R12. The gear ratio between gears 104 and 107 is selected such that substantially the full, resistance range of the potentiometer R12 is utilized, but not exceeded, as the steering wheel 22 is turned from the clockwise stop to the counterclockwise stop.
To set the position of the components of the steering unit 18 just described, the steering sensor potentiometer R12 is adjusted via drive rod 108 to its center position. The steering shaft 80 is assembled with its slot 90 in the radially upright position. This then assures that the steering wheel 22 will be located in its center or neutral position when assembled with its mating slot 92 located in the radially upright, centered position.
Prior to assembly of the steering wheel 22 onto the shaft 80, the components of subassembly 109 are assembled as a unit (see FIGS. 2 and 2A).
Once the position adjustment via the outer portion 103 of flange 102 has been made, the steering shaft 80 can be axially fixed to the shaft housing 64 via a retaining washer 109 which bitingly engages the body portion 82 of steering shaft 80 and resiliently engages the forward end of shaft section 66.
A dash bracket 110 is secured to the dash 111 (see FIG. 1) in the driver's compartment 20 of boat 10. The bracket 110 has a mounting plate 112 secured to a support tube 113 having forwardly and rearwardly extending ends 114 and 116, respectively. The plate 112 has a plurality of mounting slots 118 adapted to receive fasteners whereby the dash bracket 110 can be removably secured to the dash 111 with rearward end 116 of the support tube 113 extending through a suitable opening (not shown) in the dash 111. The support tube 113 has a central bore 115 adapted to slidably receive a reduced diameter portion 120 of the tubular shaft section 66 of shaft housing 64. The reduced diameter portion 120 terminates in a shoulder 122 which is serrated on its radial face. The end surface 124 of rearward tube end 116 is similarly serrated to provide mating, matching surfaces such that relative rotation is prevented when the serrated shoulders are engaged.
The reduced diameter portion 120 is provided with a pair of diametrically opposed circumferentially extending slots 126. The slots 126 are located at an axial position along reduced diameter portion 120 such that, when the serrations of end surface 124 and shoulder 122 are engaged, the slots 126 will be in line with slots 127 in tube end 114 of support tube 113. The slots 126 and 127 are adapted to receive a flexible spring washer 130 which is adapted to engage the mounting plate 112 whereby the assembly is held in place. The end surface 128 of tube end 114 is also serrated.
Looking now to FIG. 2A, the steering shaft housing 64 has a plurality of stepped bores 130, 132, and 134 which are located in reduced diameter end portion 120, an intermediate diameter portion 136 and a large diameter opposite end portion 138, respectively, of the tubular shaft section 66. The small bore 130 and large bore 134 are smooth while the intermediate bore 132 is provided with a plurality of radially and axially extending ribs 140. The ribs 140 are constructed to define grooves which matingly receive the rib segments 96 of stop bushing 94. Thus as the steering shaft 80 is rotated by turning the steering wheel 22, the stop bushing 94 is held from rotation by the engagement of the ribs 140 and rib segments 96 but will move axially within the intermediate bore 132.
A forward stop shoulder 144 is defined on steering shaft 80 at the juncture of body portion 82 and the reduced diameter threaded portion 98. At the same time, the rearward stop is defined by the position of the radially outer portion 103 of flange 102 of stop collar 100. Thus the stop shoulder 144 and flange portion 103 define the limits of axial travel of the stop bushing 94 and hence determine the number of clockwise and counterclockwise turns of the steering wheel 22. Note that the location of the stops 144 and 103 can be set before the steering shaft 80 is assembled to the shaft housing 64 thus simplifying the stop setting. In this regard, after the stops have been set, the steering shaft 80 with stop bushing 94 and stop collar 100 is assembled into the shaft housing 64 until the rearward stop 103 on flange 102 engages the shoulder 148 defined by the juncture between intermediate bore 132 and large bore 134. In this position the forward stop shoulder 144 is located within the intermediate bore 140 in clearance with a forward shoulder 150 defined by the juncture of the reduced diameter bore 130 and intermediate bore 132. Next the retaining washer 109 is placed on the body portion 82 as shown in FIG. 2A whereby the steering shaft 80, stop bushing 94 and stop collar 100 are secured to the shaft housing 64. This subassembly is then mounted to the dash bracket 110 via the retaining washer 130.
Next a decorative cap or bezel 150 is located on the dash bracket plate 112. In this regard the opposite ends 152, 154 of plate 112 are arcuately contoured to match the inside diameter of the large end 156 of bezel 150 such that the bezel 150 can be resiliently mounted onto the plate 112 with a slight interference fit. Next the steering wheel 22 is fitted over the tapered end portion 84 and slots 90 and 92 aligned and a key (not shown) inserted; a nut and washer (not shown) are then engaged over the threaded end portion 86 to secure the steering wheel 22 to the steering shaft 80 in proper alignment.
As assembled, the housing 70 and cover 68 are sealed by a gasket and/or other means (not shown) as is the steering shaft 80 relative to the shaft housing 64 to provide a sealed condition for the potentiometer R12 and other components. Note that the preceding steering assembly is a modification of prior mechanical, cable type steering units adapted for the electrical steering system of the present invention.
With this description of the steering unit 18 let us now look to the details of the power unit 23.
C. The Power Unit 23
The power unit 23 is shown in exploded view in FIG. 3 and in assembled view in FIG. 3A. The dc motor 38 has its rotor leads 60a, 60b connected to power unit circuit 30. The physical components are mounted onto front and center boards 160 and 162, respectively, connected in a T-shaped configuration. Lines 164 and 166 are generally shown and provide electrical connections from the steering potentiometer R12, rudder position indicator 32 and battery B to the power unit circuit 30. The motor-rudder potentiometer R13 is shown connected to the power unit circuit 30 via representative lines 168. A pair of similarly shaped housing members 170, 172 are generally L-shaped. Housing member 172 has a leg portion 173 with a generally rectangular opening 174 at one end adapted to receive the boards 160, 162 with a generally snug fit. A smaller opening 176 above the lower opening 176 is adapted to receive the motor-rudder potentiometer R13 via a bracket 178 which can be mounted to a post 178 via screws 180. The potentiometer R13 is secured to a slotted end 182 of the bracket 178 via a nut and washer assembly 184 adapted to engage a threaded boss 186 on potentiometer R13. The potentiometer R13 has a drive shaft 188 which is adapted to receive a driven gear 190. An elongated body portion 192 extends from the housing leg portion 173 and is provided with a generally semi-circular contour to generally match the circular contour of the housing 194 of the dc motor 38. A pair of spaced shoulders 194, 196 restrain the dc motor 38 from axial movement. As can be seen in FIGS. 3 and 3A the outer surface of the housing members 170, 172 are ribbed to provide cooling for the internal electrical components.
The leg portion 173 has an elongated cavity 194 adapted to receive a pair of mounting and spacer brackets 196, 198. A gear train is shown and includes a drive gear 200, idler gear 202 and output gear 204. The gears 200, 202 and 204 are adapted to be rotatably supported between spacer brackets 196, 198 and supported thereon. Thus drive gear 200 is adapted to be located on the output, drive shaft 206 of dc motor 38, with the drive shaft 206 located via aligned openings 208, 209 in brackets 196, 198. Similarly, the idler gear 202 is supported in meshed engagement with drive gear 200 via a support pin or dowel 212 adapted to be supported in openings 214 and 216 in brackets 196 and 198, respectively. The output gear 204 is supported, in mesh with idler gear 202, upon the inner end of a drive screw 210 located in aligned openings 218 and 220 in brackets 196 and 198, respectively. The brackets 196 and 198 are held together in spaced relationship via fasteners 222 in mating openings 224 and 226, respectively. Thrust bearing and washer assemblies 228 and 230 are located on opposite axial sides of the output gear 204 to reduce axial, friction thrust loads between the output gear 204 and support brackets 196, 198.
The drive screw 210 has a plain inner end 217 which extends past mounting opening 218 in bracket 196 and receives a worm drive gear 232 which is adapted to be in driving engagement with drive gear 190 secured to drive shaft 188 on motor-rudder potentiometer R13.
A mounting flange 234 is adapted to be secured to the housing members 170 and 172 when the housing members 170 and 172 are secured together as by fasteners 236 through mating openings 238 and 240, respectively. The mounting flange 234 can be secured to the assembled housing members 170 and 172 via fasteners 239 via mating openings 241 and 243. Support bushings 242, 244, and 246 receive the inner end 217 of the drive screw 210 and are located in the support brackets 196 and 198 and mounting flange 234, respectively (see FIG. 3A). A drive tube assembly 248 includes the standard guide tube 250; guide tube 250 is externally threaded at its opposite ends with the mounting flange 234 having a boss 252 which is internally threaded to receive the one threaded end of the guide tube 250.
A steering tube 254 is slidably supported within the guide tube 250 and has a threaded drive nut member 256 secured at its inner end. A standard connector 258 is secured to the opposite outer end of the steering tube 254. Both the nut 256 and connector 258 can be secured to steering tube 254 by staking, crimping or the like. The connector 258 can be of a standard configuration similar to that used in cable assemblies where the cable is located in the standard guide tube (such as guide tube 250) and secured at its outer end to a connector (such as connector 258).
The drive screw 210 has an extended threaded section 260 which is adapted to be threaded into the nut 256. Thus as the drive screw 210 is rotated it is held in place axially but will cause the steering tube 254 to be moved axially, in translation. In a standard configuration, the connector 258 is pivotally connected to a pivot joint 272 on a pivot arm 262 which in turn is pivotally connected to a drive plate 264 on motor 14 (see FIG. 1). Thus as the steering tube 254 is moved in translation it will cause pivotal, steering movement of the motor-rudder 14 about axis X via pivot arm 262 and drive plate 264.
Thus in operation, when the operator turns the steering wheel 22, the steering wheel position potentiometer R12 will provide an unbalanced signal to the integrated circuit U2 of motor controller 34 resulting in a signal to the power circuit 36 rendering the appropriate pair of FETS Q3, Q4, Q5 and Q6 conductive whereby the dc motor 38 will be energized to rotate in the appropriate direction. This will result in the drive screw 210 being rotated in the proper direction via gears 200, 202 and 204 providing the appropriate translational movement of the steering tube 254 to appropriately pivot the motor 14 about its axis X. This action will be sensed by the motor-rudder potentiometer R13 via worm drive gear 232 and driven gear 190 and the appropriate signal fed to the integrated circuit U2 of motor controller 34. The action will continue until the sensed motor-rudder position sensed by potentiometer R13 provides the appropriate signal indicating the desired angular position of motor 14 relative to steering wheel 22 as sensed by steering wheel potentiometer R12. In this regard the gear ratio between gears 190 and 232 is selected such that substantially the full, resistance range of the potentiometer R13 is utilized, but not exceeded, as the motor 14 is pivoted from its maximum port to maximum starboard steering positions.
The power unit 23 will be secured to the guide tube 250 (see FIGS. 6B, 6C) and can be additionally fixed to the transom structure 16 via a suitable bracket or by other securing means.
In order that the system of the present invention provide versatility for use with a wide range of sizes and types of boats and motors, it was determined that the power unit 23 be capable of providing a maximum output thrust load at the steering tube 254 of around 200 pounds. At the same time the total linear travel of the steering tube 254 was determined to be between around 8.25 inches to around 9 inches. In order for the system to have a rapid response it was determined that in one form of the invention the steering tube 254 should be capable of its full travel, i.e. around 8.25 inches to around 9 inches for full port to full starboard turning, at a rate of around 2.5 inches per second or a total travel time of between around 3.3 seconds to around 3.6 seconds. Thus a travel rate of between a minimum of around 1.5 inches per second (5.5 seconds to 6 seconds total elapsed time) to a maximum of around 3.5 inches per second (2.35 seconds to 2.57 seconds total elapsed time) was desirable. A preferred elapsed time for total travel, i.e. full port to full starboard, was around 3 seconds. These objectives were accomplished by the appropriate dc motor 38 along with the proper gear ratio of the gear train defined by gears 200, 202 and 204 and the selection of the desired pitch of the drive screw 210 and drive nut member 256.
In a preferred form of the invention the gear ratio of gears 200, 202, 204 was selected to be around 2.4:1 with a range of around 6:1 to around 2:1; similarly a preferred thread pitch of drive screw 210 and drive nut member 256 was selected to be around 12 threads per inch with a range of around 6 threads per inch to around 12 threads per inch. In order to provide the desired response with the gear ratios and screw drive thread pitches noted the dc motor 38 was selected to be of the permanent magnet type and in a preferred form was of a one quarter horse power rating having an operating speed at full load, i.e. 200 pounds thrust load at steering tube 254, of around 3000 rpm with a range of from around 800 rpm to around 5500 rpm. In one form of the invention a dc motor manufactured by Specialty Motors was utilized.
Because of the high loads and power demands on the power unit 23, the housing members 170, 172 were, in one form of the invention, made of die cast aluminum and in a ribbed construction as shown. The use of aluminum, a good heat conductor, with the externally ribbed structure provides effective cooling to dissipate heat generated by the internal components.
To further improve the efficiency of the system for the high design loads, i.e. 200 pound thrust load, needle thrust bearings were selected for use in bearing assemblies 228 and 230. In addition self lubricating bearings were selected to rotatably support the gears 200, 202, and 204.
In order to reduce friction between the threads on drive screw 210 and the drive nut member 256 the threads on drive screw 210 were rolled to provide a smooth, engaged working surface. In addition the rolling also results in work hardening at the work surface of the threads which improves its strength and wear properties. In one form of the invention the drive screw 210 was made of high strength carbon steel.
Note that the use of a threaded drive via drive screw 210 and drive nut member 256 has the added benefit of providing a high resistance to reverse dynamic loads from the motor 14. Thus backlash from motor 14 and its attendant steering problems are substantially eliminated and shock loads from motor 14 to the internal components of the power unit 23, including the gears 200, 202, and 204 and gears 190 and 232, are also substantially eliminated.
As noted the power unit 23 is adapted to be used with a standard steering hookup including a standard guide tube 250. The parameters of the standard guide tube 250 as defined by the American Boating and Yacht Council is a tube of around eleven (11) inches minimum to around twelve (12) inches maximum in length, around 0.635±0.005 inches in internal diameter, and having an outside diameter of around 0.875 inches with its threaded end having a 7/8- 14 UNFS thread; the tube 250 can be made of aluminum or corrosion resistant steel.
Thus the system of the present invention provides a remote steering system having a high degree of versatility for boats and motors of various types and sizes and a desired rapid response rate and also provides a steering system which is adapted for use with standard steering components and is thus readily adaptable for use as a retrofit on existing boats with cable steering.
In this regard, the simplicity of such a retrofit is shown in FIGS. 6A, 6B and 6C. Looking now to FIG. 6A a prior art cable type steering system is shown. Here the motor 14 is secured to transom 16 via a mounting bracket and tilt assembly 270 with the pivot arm 262 connected to the pivot joint 272 on motor 14 for pivotal actuation of motor 14 about its axis X. The standard guide tube 250 is fixed to the mounting bracket assembly 270 via nut members 274 (only one shown) at opposite threaded ends of the guide tube 250. The connecting end section 276 of a prior art cable assembly for steering the motor 14 is shown pre-assembled relative to standard guide tube 250. Thus a drive cable 278 is supported from buckling in a support tube 280 which is slidably received within the bore of a hollow actuating rod 282 with the rod 282 swaged onto the inner end of the cable 278 and support tube 280 to mechanically hold these members together. Connector 284 is swage connected to the end of the rod 282 and (like connector 258 of FIGS. 3 and 3A) is adapted to provide a connection with the pivot arm 262. A nut 286 can be threadably connected to the associated threaded end of the standard guide tube 250 to thereby secure the end section 276 in place with connector 284 connected to pivot arm 262. Thus manipulation of the drive cable 278 by a remote steering wheel (not shown) causes reciprocation of the actuating rod 282 within the standard guide tube 250 whereby pivoting of the motor 14 about axis X is effected to steer the boat.
As shown in FIGS. 6B and 6C the retrofit from the prior art cable steering system to the present system is accomplished simply and quickly. Thus as shown in FIG. 6B, the power unit 23 is connected to the motor 14 via the mounting flange 234 which is adapted to be threadably received upon the associated threaded end of the standard guide tube 250 extending past the nut 274. Of course, the flange 234 is in turn connected to the drive housing defined by housing members 170, 172. In this regard, the flange 234 is first threaded onto the guide tube 250 and then is assembled to the housing (170, 172) via fasteners 236. Now the steering tube 254 will be slidably supported in the standard guide tube 250 with connector 258 connected to pivot arm 262 to provide the final assembly shown in FIG. 6C. Thus, as can be seen, the retrofit of an existing cable system can be quickly made by virtue of the compatibility of the present system with the standard guide tube 250.
While it will be apparent that the preferred embodiments of the invention disclosed are well calculated to fulfill the objects above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the invention; by way of example but not limitation, it should be understood that the word combination "motor-rudder" can refer to steering by pivoting a motor and/or steering by pivoting a separate rudder; along the same lines, reference to a steering unit can be a steering wheel, joy stick or other manually operated or actuated device to provide a selected directional steering signal. | A remote, electrical steering system for marine vehicles including an electrical motor operable by a control and power circuit to rotate a drive screw having a screw connection to a nut in a drive tube for moving the drive tube in translation to cause steering movement of a motor/rudder with the control circuit sensing various fault conditions for placing the electrical motor in a brake condition to inhibit inadvertent steering and with the screw and nut connection resisting backlash from the motor/rudder to inhibit inadvertent steering and isolate the electrical motor and associated gearing from backlash loads. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the national phase of International Application No. PCT/FR2014/052334, filed on Sep. 19, 2014, which claims the priority benefit of French Application No. 13/59117, filed on Sep. 23, 2013, which applications are hereby incorporated by reference to the maximum extent allowable by law.
BACKGROUND
The present invention generally relates to electronic circuits and, more particularly, to a circuit for generating a negative voltage from a positive power supply voltage.
DISCUSSION OF THE RELATED ART
Many charge pump circuits including circuits intended to generate a negative voltage from a positive power supply voltage are known. In particular, it has already been provided to use a field-effect transistor to supply, from a positive voltage, a switched-capacitance charge pump circuit. An example of such a circuit is described in article “Integrated Anti-Short-Circuit Safety Circuit in CMOS SOI for Normally-On JFET” of Khalil El Falahi et al. (CIPS 2012, Mar. 6-8, 2012, Nuremberg, Germany). A JFET transistor, used to recover the power from a positive power supply bus, has its gate permanently directly connected to ground. This circuit requires using a precharge circuit upstream of the capacitive charge pump circuit.
SUMMARY
An embodiment of the present disclosure aims at providing a circuit for generating a negative voltage from a positive voltage which overcomes all or part of usual solutions.
Another embodiment of the present disclosure aims at providing a circuit compatible with various applications capable of using a negative voltage.
Another embodiment of the present disclosure aims at a particularly simple solution.
Thus, an embodiment of the present disclosure aims at a circuit for generating a negative voltage from a positive voltage, comprising:
at least a first transistor between a first terminal of application of a voltage higher than a reference potential and a first node;
a first capacitive element between the first node and a second node, a control terminal of said first transistor being connected to the second node;
a first switch between the first node and a second terminal of application of the reference potential;
a second switch between the second node and a third terminal for providing said negative voltage;
a third switch between the second node and the second terminal; and
a second capacitive element between the third terminal and the second terminal.
According to an embodiment, the circuit comprises a first resistive element between the first terminal and the first transistor.
According to an embodiment, the circuit further comprises:
a fourth switch between the control terminal of the first transistor and the second node; and
a fifth switch between the control terminal of the first transistor and a fourth terminal of application of a potential higher than the reference potential.
According to an embodiment, the circuit further comprises:
at least a second transistor between said first terminal and the control terminal of the first transistor, the control terminal of the second transistor being connected to the second node; and
a second resistive element, interposed between the control terminal of the first transistor and the second node.
According to an embodiment, the circuit further comprises a third resistive element between the second transistor and the first terminal.
According to an embodiment, said transistor(s) are N-channel transistors.
According to an embodiment, all switches are N-channel MOS transistors.
The present invention also provides a method for controlling a circuit such as hereabove, wherein:
in a first phase, the first and second switches are off while the third switch is on; and
in a second phase, the first and second switches are on while the third switch is off.
According to an embodiment, the first and second phases are repeated.
According to an embodiment, intervals having durations shorter than those of the first and second phases, and where all switches are off, are interposed between the successive phases.
According to an embodiment:
during the first phase(s), the fourth switch is off and the fifth switch is on; and
during the second phase(s), the fourth switch is on and the fifth switch is off.
The invention also provides an electronic circuit comprising at least one circuit for generating a negative voltage from a positive voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings, among which:
FIG. 1 very schematically shows in the form of blocks a first example of application of a circuit providing a negative voltage;
FIG. 2 schematically shows in the form of blocks a second example of application of a circuit providing a negative voltage;
FIG. 3 shows an embodiment of a circuit for generating a negative voltage from a positive voltage;
FIG. 4 illustrates, in the form of timing diagrams, the operation of the circuit of FIG. 3 ;
FIG. 5 very schematically illustrates in the form of blocks an example of a circuit for controlling the circuit of FIG. 3 ;
FIG. 6 illustrates a variation of the circuit of FIG. 3 ; and
FIG. 7 shows another variation of the circuit of FIG. 3 .
DETAILED DESCRIPTION
The same elements have been designated with the same reference numerals in the different drawings. For clarity, only those elements which are useful to the understanding of the embodiments which will be described have been shown and will be detailed. In particular, the destination of the described charge pump circuit has not been detailed, the described embodiments being compatible with usual applications using a charge pump circuit for providing a negative voltage from a positive voltage. Further, when reference is made to the positive or negative character of the voltage, it is referred to a same intermediate potential between the positive voltage and the negative voltage. For simplification, it is considered that this reference potential is the ground (zero potential) of the electronic circuit, which will generally be true in practice, so that the positive and negative voltages correspond to the potentials of the corresponding terminals. However, all that will be described hereafter applies to positive and negative voltages defined by potentials, respectively upper and lower, to a reference potential which is not necessarily the ground (for example, potentials both negative with respect to ground, the ground then forming the upper potential of the positive voltage and the reference potential being the least negative potential).
FIG. 1 schematically shows, in the form of blocks, an example of application of a charge pump circuit 1 (NEG POW) for generating a negative voltage V− from a positive voltage V+. According to this embodiment, negative voltage V− is used to power a control circuit 2 (DRIVER) of a transistor 3 (typically, a MOS transistor) in series with a load 4 (Q) between terminals 12 of application of a positive potential V+ and 14 , for example, a ground potential, or a potential corresponding to the high point of the charge. In such an application, the voltages involved at the level of load 4 and the switching thresholds of transistor 3 result in the need for a negative potential V− in order to properly control transistor 3 .
FIG. 2 schematically shows in the form of blocks another example of application of a circuit for generating a negative voltage V−. Voltage V− is, here again, delivered to a circuit 2 for controlling a power transistor 3 , series-connected with a load 4 (Q) powered with a positive voltage. Transistor 3 is here connected on the ground side. Here again, according to the involved voltages and to the switching thresholds of transistor 3 , a negative potential may be needed in order to control it properly.
For example, the negative voltage may be used to lock a switch (transistor 3 ) having a normally-on state. Another example is the control of a power transistor having a threshold voltage close to zero and which requires a biasing of its control terminal with a negative voltage to draw away from its threshold voltage and avoid for parasitic voltages to modify the off or on state. Another example is the control of an IGBT transistor which sometimes uses a negative voltage to perform an efficient locking.
FIG. 3 shows an example of an electric diagram of an embodiment of a circuit 1 for generating a negative voltage, based on a capacitive charge pump.
A transistor M 1 , typically a normally-on MOS transistor, is connected, directly or via a resistive element R (illustrated in dotted lines), to a terminal 12 of application of a potential V+ positive with respect to ground (terminal 14 ). The other power terminal of transistor M 1 is connected to a node 16 via a first capacitive element C 1 and, to terminal 14 , by a first switch K 1 . The control terminal (the gate) of transistor M 1 is connected (directly connected) to node 16 . Node 16 is connected, by a second switch K 2 , to a terminal 18 for providing negative output voltage V− and, by a third switch K 3 , to terminal 14 of application of the reference potential. Terminal 18 is further connected to terminal 14 by a second capacitive element C 2 . Switches K 1 , K 2 are controlled in all or nothing by a signal CT 1 . Switch K 3 is controlled in all or nothing by a signal CT 3 . These switches are, preferably, N-channel MOS transistors.
FIG. 4 illustrates, in the form of timing diagrams, the operation of circuit 1 of FIG. 3 .
These timing diagrams respectively show examples of shapes of signal CT 2 , conditioning the off or on state of switch K 3 , of voltage V 15 of node 15 between transistor M 1 and capacitor C 1 , of signal CT 1 , conditioning the off or on state of switches K 1 and K 2 , of voltage V 16 of node 16 , and of output voltage V−.
Taking the preferred example of switches K 1 , K 2 , K 3 formed of N-channel MOS transistors and, to within the threshold voltages, these transistors are turned on when their gates are connected to a positive potential (high states of signals CT 1 and CT 2 ) and are turned off when their gates are grounded (low states of signals CT 1 and CT 2 ).
For simplification, the on-state voltage drops in switches K 1 to K 3 are neglected (the on-state drain-source resistances RdsON are considered as negligible).
An initially discharged state of capacitors C 1 and C 2 is assumed and all switches K 1 to K 3 are off. Voltage V− is then zero.
A charge pump cycle starts at a time t 0 at which switch K 3 is turned on (signal CT 2 in the high state), switches K 1 and K 2 being off (signal CT 1 in the low state). Node 15 starts by being grounded. Transistor M 1 being normally on, the potential of node 15 increases until a time t 1 when voltage V 15 reaches threshold voltage VT of transistor M 1 . This amounts to charging capacitor C 1 up to the locking voltage (threshold voltage VT) of transistor M 1 .
Then, the states of the switches are inverted to transfer the charges from capacitor C 1 to capacitor C 2 . In practice, to avoid a simultaneous conduction of the switches, it is started, at a time t 2 , subsequent to time t 1 , by turning off switch K 3 (signal CT 2 in the low state) and then, at a time t 3 , subsequent to time t 2 , switches K 1 and K 2 are turned on (signal CT 1 in the high state).
The fact of taking node 15 to ground, by the turning-on of switch K 1 , causes the discharge of capacitor C 2 and decreases the potential of node 16 , and thus of terminal 18 (switch K 2 being on), generating negative voltage V−.
At a time t 4 , subsequent to time t 3 , a reverse switching phase is started, that is, switches K 1 and K 2 are turned off (signal CT 1 in the low state), after which, at a subsequent time, corresponding to time t 0 of beginning of the next cycle, switch K 3 is turned on.
In the assembly of FIG. 3 , the minimum value (the most negative value) that voltage V− can take is −VT.
According to the power sampled from terminal 18 , value −VT is reached in one or a plurality of cycles. In the example of FIG. 4 , two cycles are assumed to be necessary.
The duration of phase(s) T 1 , between time t 0 and t 2 , is selected to be longer than the duration necessary for the charge of capacitor C 1 at level VT. This duration is a function, in particular, of the capacitance of capacitor C 1 and of the on-state drain-source resistance of transistor M 1 .
The duration of phase(s) T 2 , between times t 3 and t 4 , is selected to be longer than the time of recharge of capacitor C 1 through transistor M 1 .
Durations T 1 and T 2 are not necessarily identical. For example, a shorter duration T 2 , particularly, at the starting, enables to limit current inrushes.
Intervals Ta between times t 2 and t 3 , and Tb between times t 2 and t 3 , are selected to guarantee an absence of simultaneous conduction of switches K 1 to K 3 .
The biasing of transistor M 1 enables to make it normally on, which avoids a starting circuit.
Optional resistive element R is used to limit current inrushes.
An advantage of the circuit described in relation with FIGS. 3 and 4 is that it is compatible with an embodiment only using N-channel MOS transistors.
The fact of making transistor M 1 for supplying the switched-capacitance circuit switchable spares a start circuit. Further, advantage is taken of one of the switches used to switch the capacitive elements to switch the power supply transistor.
FIG. 5 shows, in simplified fashion and in the form of blocks, an example of a circuit for generating control signals CT 1 and CT 2 .
In this example, an oscillator 22 (OSC) controlled (activated) by a signal ACT delivered by a comparator 24 (COMP) between output voltage level V− and a threshold TH is used. For the circuit of FIG. 3 , threshold TH corresponds to a level higher than level −VT to stop the oscillator and thus decrease the power consumption. As a specific embodiment, a ring oscillator having a period conditioning durations T 1 and T 2 may be used, signals CT 1 and CT 2 being sampled at the output of two different inverters of the oscillator to define intervals Ta and Tb (then identical). Oscillator 22 and comparator 24 are powered, for example, with a positive voltage Vdd, which is not necessarily identical to voltage V+.
According to an alternative embodiment, a single-pulse generator, triggered when voltage V− has not reached a set point TH, is used.
According to another alternative embodiment, an analog regulation which monitors the voltage across capacitive element C 1 and its discharge into capacitor element C 2 is provided.
More generally, any circuit capable of generating control signals to respect the above-described switching phases may be used.
FIG. 6 shows another embodiment intended to provide an output voltage V−, lower than −VT (higher, in absolute value, than the absolute value of the threshold voltage of transistor M 1 ).
As compared with the circuit of FIG. 3 , the gate of transistor M 1 is further connected, via a switch K 4 controlled by signal CT 1 , to node 16 and, via a switch K 5 controlled by signal CT 2 , to a bias potential Vg higher than the reference potential (and lower than potential V+). Switches K 4 and K 5 preferably are NMOS transistors. During phase T 1 ( FIG. 4 ), switch K 4 is off and switch K 5 is on. Potential Vg, applied to the gate of transistor M 1 , results in the charging of capacitive element C 1 to a voltage VT+Vg. During the following phase T 2 , the inversion of the voltage generated by the capacitive switching results in that voltage V− can reach −Vg-VT. The generation of potential Vg from voltage V+ is not a problem (for example, a resistive bridge, preferably switchable to avoid a permanent power consumption, or a voltage regulator).
FIG. 7 shows another embodiment enabling to reach a voltage more negative than −VT.
As compared with the circuit of FIG. 3 , a second MOS transistor M 2 connects, optionally in series with a resistive element R 1 , terminal 12 to the gate of transistor M 1 , now connected to node 16 by a resistive element R 2 (or a capacitive element to decrease the dc power consumption (dc)). The gate of transistor M 2 is connected to node 16 .
Thus, during phase T 1 ( FIG. 4 ), element C 1 charges to a value corresponding to the sum of the two threshold voltages of transistors M 1 and M 2 and the generated negative voltage has this value in absolute value.
The embodiment of FIG. 7 may be extended to even lower negative voltages by adding other transistors on the basis of the same assembly (between the gate of transistor M 2 and node 16 ).
Various embodiments have been described. Various alterations and modifications will occur to those skilled in the art. In particular, time intervals Ta and Tb between periods T 1 and T 2 of the charge pump circuit may be adapted to the necessary switching times of the different transistors.
Further, although reference has been made to MOS transistors on the application circuit side, the generated negative voltage may be used to control any type of transistor (IGBT, JFET, etc.) and, more generally, to power any type of circuit requiring a negative voltage.
Further, the sizing of capacitive elements C 1 and C 2 , possibly made in the form of a plurality of capacitors in parallel, depends on the application and particularly on the expected power consumption of the element(s) connected to terminal 18 .
Finally, the practical implementation of the described embodiments is within the abilities of those skilled in the art based on the functional indications given hereabove and using, for the rest, usual electronic circuit sizing techniques. | A circuit for generating a negative voltage on the basis of a positive voltage, including: at least one first transistor between a first terminal for applying a potential greater than a reference potential and a first node; a first capacitive element between the first node and a second node, a control terminal of said first transistor being linked to the second node; a first switch between the first node and a second terminal for applying the reference potential; a second switch between the second node and a third terminal for providing said negative voltage; a third switch between the second node and the second terminal; and a second capacitive element between the third terminal and the second terminal. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to electric cookers incorporating radiant heaters and more particularly relates to glass ceramic top cookers, which have one or more radiant heaters arranged beneath the glass ceramic cooking surface.
DESCRIPTION OF PRIOR ART
A radiant heater for a glass ceramic top cooker generally comprises a metal dish containing a base layer and a peripheral wall made of an electrically and thermally insulating material. Arranged on the base layer is a heater element in the form of a bare helically-coiled wire which radiates heat upwardly towards and through the glass ceramic top when the heater is switched on. The heater is protected against overheating by means of a probe-type thermal cut-out device which extends across the heater element.
It is sometimes considered desirable to control the cooking process in a utensil placed on the glass ceramic cooking surface above a particular heater by means of a temperature sensor which senses the temperature of the bottom of the utensil and which controls the energy supplied to the heating element by means of an associated control device. Such a system is often called an "autocook" system. The temperature sensor may comprise a bulb filled with an expansible fluid, which bulb is inserted through a specially formed aperture through the base of the heater and is urged against the underside of the glass ceramic plate. Alternatively, the temperature sensor may be an electro-mechanical device which is inserted through the aperture in the heater and is urged against the underside of the glass ceramic plate. However, with a glass ceramic top cooker there is a problem because it is not possible accurately to sense the temperature of the utensil through the glass ceramic top and, additionally, the radiant heat from the heating element affects the operation of the temperature sensor.
OBJECT OF THE INVENTION
It is an object of the present invention to provide a radiant heater and a glass ceramic top cooker in which the temperature sensor accurately senses the temperature of the cooking utensil through the glass ceramic plate.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a radiant heater for an electric cooker, which heater comprises:
a continuous base layer of electrical and thermal insulating material;
a peripheral wall of electrical and thermal insulating material;
a heating element arranged on the base layer;
means disposed on the base layer for isolating a region within the peripheral wall from heat emitted by the heating element; and
a temperature sensor mounted within the isolated region so as to be sensitive in use substantially only to the temperature of a cooking pan which is heated by the heater.
According to a second aspect of the present invention there is provided a glass ceramic top cooker which includes at least one radiant heater, the heater comprising:
a continuous base layer of electrical and thermal insulating material;
a heating element arranged on the base layer;
means disposed on the base layer for isolating a region within the peripheral wall from heat emitted by the heating element; and
a temperature sensor mounted within the isolated region so as to be sensitive in use substantially only to the temperature of a cooking pan which is heated by the heater.
Thus, the temperature sensor is effective because there is created on the glass ceramic plate a cold patch through which the temperature of the cooking utensil can be determined.
The isolated region may be formed by a pad of insulating material. The pad may be arranged adjacent to the peripheral wall of the heater. The pad may be circular and may have a diameter of 40-50 mm. Alternatively, the pad may be part-circular at the radially inner region of the heater, but may conform to the curvature of the peripheral wall of the heater where the peripheral wall and the pad are close to one another. The pad may be made of ceramic fibre. Generally, the pad may have an area of approximately 4% to 8% of the area within the peripheral wall of the heater.
The temperature sensor may be a thermocouple and may be made, for example, of chromel/alumel or copper/constantan. The thermocouple wires may have a diameter of 1 mm to 2 mm. The temperature sensor may be mounted in the region of the centre of the isolated region. Alternatively, the temperature sensor may be mounted in the isolated region so as to be offset from the centre thereof towards the centre of the heater.
However, problems can still arise as a result of variations in the shapes and positions of cooking utensils. These problems may be overcome, though, by providing means for determining the location of the base of the utensil relative to the glass ceramic top and by controlling the supply of electric current to a heating element of the radiant heater in response to the apparent temperature of the utensil detected by the temperature sensor and in response to the location of the base of the utensil.
The location determining means may comprise a transducer positioned in the isolated region adjacent to the temperature sensor. The transducer may be a capacitative transducer.
For a better understanding of the present invention and to show more clearly how it may be carried into effect reference will now be made, by way of example, to the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows one embodiment of a radiant heater according to the present invention;
FIG. 2 shows a part of a second embodiment of a radiant heater according to the present invention;
FIG. 3 shows a part of a third embodiment of a radiant heater according to the present invention;
FIG. 4 is a diagrammatic cross-sectional view of a part of a glass ceramic top cooker according to the present invention with a utensil resting on the glass ceramic plate;
FIG. 5 shows a part of a radiant heater according to the present invention with a transducer positioned adjacent to a temperature sensor;
FIG. 6 is a schematic representation of an electrical circuit incorporating the transducer and the temperature sensor; and
FIG. 7 shows part of a radiant heater in which a transducer is positioned on both sides of the temperature sensor.
DESCRIPTION OF PREFERRED EMBODIMENTS
Throughout the figures, the same reference numerals are used to denote the same or similar parts.
There is shown in FIG. 1 a radiant heater 1 comprising a metal dish containing a base layer 4 of electrical and thermal insulating material and a peripheral wall 6 of electrical and thermal insulating material. The base layer 4 is formed with a pattern of grooves 8 and a heating element 10 of bare helically coiled wire is secured in the grooves, for example by means of staples (not shown). The ends of the heating element are connected to a terminal block 14 and in order to prevent excessive temperatures a temperature limiter 16 is arranged over the heating element and is connected in series with the heating element 10. The temperature limiter 16 may comprise a snapswitch operated by a differential expansion assembly in the form of an inconel rod arranged within a quartz tube.
As illustrated in FIG. 1, in place of the conventional autocook sensor, which extends through a hole formed in the bottom of the heater, the hole is absent and there is provided a circular pad 18 of electrical and thermal insulating material, such as ceramic fibre, on which there is arranged a temperature sensor in the form of a thermocouple 20. The wires of the thermocouple extend outwardly over the peripheral wall 6, avoiding any contact with the metal dish 2 which terminates below the level of the top of the peripheral rim, and enter a terminal block 22. The thermocouple is maintained in good thermal contact with the underside of the glass ceramic cooking surface by means of the pad 18.
The position and size of the pad 18 are selected to isolate the temperature sensitive portion of the thermocouple as effectively as possible from the heat emitted by the radiant heater and to link the thermocouple thermally to the temperature of a cooking utensil (not shown). In this respect, the bases of most cooking utensils are domed to a greater or lesser extent, as will be explained in greater detail hereinafter, so that, while the outer region of a utensil may be in contact with the glass ceramic cooking surface, the central region of the utensil is generally not in contact with the cooking surface and it is therefore not possible accurately to determine the temperature of the utensil in the central region thereof. For this reason it is convenient to position the pad 18 at the periphery of the heater 1.
Whilst it is desirable, in order effectively to decouple the thermocouple 22 from the heat emitted by the heating element, to have as large a pad 18 as possible, a pad having too large an area is undesirable because this will produce a large cold area on the cooking surface which is detrimental to cooking performance. The optimum size of pad is thus dependent on the power rating of the heater element and on the diameter of the heated area; for an 1800 watt heating element arranged within a heated area of 195 mm diameter a pad of 40 to 50 mm diameter is preferable for most situations, although this may be varied in individual cases. For heaters having smaller areas, the size of the pad may be reduced accordingly. The position on the pad of the temperature sensitive portion of the thermocouple can also be important, but in most cases it is preferable to arrange this portion generally in the region of the centre of the pad.
The dimensions of the thermocouple wires may also be varied. It has been found that thicker wires promote faster cooling of the thermocouple, which enable the thermocouple to follow the temperature of the utensil more clearly once the utensil has been heated to the desired temperature. However, thicker wires take longer to heat up and so give a relatively slow response to the initial heating of the utensil. Thus, although it is possible to determine the temperature of the utensil to within 2° C. during steady state conditions, there will be a larger temperature difference, perhaps as much as 20° C., during the initial transient conditions. The thermocouple may be made of many materials, but copper/constantan, and particularly chromel/alumel, have been found to be suitable. The thermocouple wires may have, for example, diameters of from 1 to 2 mm and in some cases it may be desirable particularly in the case of thicker wires to arrange the wires in a groove on the upper surface of the pad 18.
In the embodiment shown in FIG. 2, the thermocouple has been replaced by a platinum resistance 24. The platinum resistance provides greater sensitivity, but is much more expensive than the thermocouple shown in FIG. 1.
In the embodiment shown in FIG. 3, the circular pad has been replaced by a pad 26 which is semicircular at the radially inner region of the heater, but conforms to the curvature of the peripheral rim of the heater where the peripheral rim and the pad are close to one another. The infilling of the gaps left by a circular pad more effectively decouples the sensor from the heater, or alternatively enables a smaller pad to be used. Although a thermocouple is illustrated in FIG. 3, this is merely by way of example and any suitable temperature sensor may be provided.
A measure of the effectiveness of the construction according to the present invention is the time taken to bring a predetermined volume of water to the boil compared with other forms of heater. By comparison, the heater according to the present invention takes no more than 50% longer than the time it would take the same heater using continuous full power. However, a standard autocook heater takes several times longer than the heater according to the present invention.
The glass ceramic top cooker shown in FIG. 4 comprises a radiant heater 1 arranged beneath a glass ceramic plate 2. The base of the heater is enclosed by a base plate 28, for example of sheet metal. The radiant heater 1 may be the heater shown in any one of FIGS. 1 to 3.
A utensil 30 rests on the upper surface of the glass ceramic plate and, as can be seen from FIG. 4, the bottom of the utensil is domed and so creates an air pocket 32 between the top of the glass ceramic plate and the bottom of the utensil. The size and configuration of the air pocket varies from utensil to utensil and therefore makes it difficult to determine the actual temperature of the utensil, and thus of the contents of the utensil, with any accuracy or consistency.
It is current practice for manufacturers of cooking pans and other utensils, to form their utensils with a slight inwardly extending dome in the base in order to enhance the stability of the utensil on the cooker. However, the dome results in the formation of the air pocket 32 between the upper surface of the glass ceramic plate and the bottom of the utensil, in which pocket the temperature of the entrapped air tends to rise significantly above the temperature of the base of the utensil. This air pocket can itself lead to a temperature sensor detecting unexpectedly high temperatures. Moreover, the problem is magnified by the fact that no two utensils are alike and thus it is not possible to provide a generalised solution to the problem because the temperature detected will vary from one utensil to the next and, indeed, will vary depending on the position of the utensil on the cooking surface.
FIG. 5 shows how the radiant heater 1 may be adapted so as to overcome the problems caused by the air pocket 32. As can be seen from FIG. 5, in addition to the temperature sensor (i.e. thermocouple 20 or platinum resistance 24), there is arranged on the pad 18 a metallic plate 34. Both the temperature sensor and the metallic plate 34 are connected to a control device (not shown in FIG. 5) by way of a terminal block 22.
FIG. 6 shows schematically one embodiment of an electric circuit of a control device for the heater. A capacitative transducer is formed by a combination of utensil 30, thermocouple 20 (or platinum resistance 24) and the metallic plate 34. The utensil 30 forms with the thermocouple 20 a first capacitor and the plate 34 forms with the utensil a second capacitor in series with the first capacitor. Therefore, as the utensil is moved towards or away from the area of glass ceramic plate under which the transducer lies, the combined capacitance of the two capacitors formed between the thermocouple 20, the utensil 30 and the plate 34 will change. Thus, for a domed utensil, it is possible to determine the extent of the doming by electrical means and also to compensate for the effects of the doming by means of the control device.
The thermocouple 20 operates in a similar manner to a conventional autocook sensor. That is, the thermocouple 20 is intended to produce a signal, in this case an electrical signal, which is representative of the temperature of the utensil. The signal produced by the thermocouple 20 is processed by a controller C which controls an energy regulator R which itself controls an electric switch E such as a relay, transistor, thyristor or triac to supply electrical current to the heater H. TL represents the temperature limiter.
In addition, there is shown in FIG. 6 a constant frequency generator G which generates a signal of constant, relatively high frequency of, say, 1000 Hz. The signal is injected into the thermocouple 20 and is transmitted to the metallic plate 34 by way of the two capacitors formed by the utensil. The metallic plate 34 is also connected to the controller C by way of a capacitor C1 and a frequency-to-voltage converter F.
As is well known, the frequency detected by the frequency-to-voltage converter F will depend on the capacitance of the components through which the signal has passed--the higher the capacitance, the lower the frequency. However, since the only variable is the spacing of the bottom of the utensil from the thermocouple 20 and the metallic plate 34, the voltage produced by the frequency-to-voltage converter is representative of the spacing between the utensil and the plate 34.
The controller C uses the signal from the frequency-to-voltage converter F to modify the control of the regulator R which is based on the signal from the thermocouple 20 in order to compensate for the inaccuracies in the apparent temperature which is detected as a result of the doming of the utensil.
FIG. 7 shows an alternative configuration for the components on the pad 18. As can be seen from FIG. 7, the thermocouple 20 (or platinum resistance) and the metallic plate 34 are provided as in the embodiment of FIGS. 5 and 6. However, in addition a further metallic plate 36 is arranged on the pad 18. The capacitative transducer in this case is therefore formed between the plate 34, the utensil 30 and the further plate 36, with the constant frequency generator G being connected to the further plate 36.
Clearly, the capacitative transducer may have many forms. For example, one plate of the capacitor need not be the thermocouple 20 or the further plate 36, but may be any other metallic component of the heater such as the dish 12 (see FIG. 7) or part of the temperature limiter 16. Moreover, the metallic plates 34 and 36 need not be arranged on the pad 18, but may be fixed to the underside of the glass ceramic plate at any convenient position.
Further, the transducer need not be capacitative, but may operate on any principle which gives a response which is dependent on the position or shape of the utensil. For example, the transducer may be inductive or magnetoresistive.
While the invention has been described in detail above, it is to be understood that this detailed description is by way of example only, and the protection granted is to be limited only within the spirit of the invention and the scope of the following claims. | A glass ceramic top cooker has at least one radiant heater arranged beneath the glass ceramic surface, the or each radiant heater comprising a continuous base layer of electrical and thermal insulating material, a peripheral wall also of electrical and thermal insulating material, and a heating element arranged on the base layer. The radiant heater also includes means, such as a pad, disposed on the base layer for isolating a region within the peripheral wall from heat emitted by the heating element and a temperature sensor, such as a thermocouple or a platinum resistance, mounted within the isolated region so as to be sensitive in use substantially only to the temperature of a cooking pan which is heated by the heater. The temperature sensor is effective because there is created on the glass ceramic plate a cold patch through which the temperature of the pan can be determined. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] N/A
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the field of industrial trucks and, in particular, to a dynamic stability control system for a material handling vehicle having a lifting fork.
[0003] One method for improving material handling vehicle stability includes performing a static center-of-gravity (CG) analysis while the vehicle is at rest and limiting vehicle operating parameters (for example, maximum speed and steering angle) accordingly. However, this static calibration does not dynamically account for vehicle motion, changing lift heights, or environmental factors such as the grade of a driving surface.
[0004] Other methods for improving vehicle stability common in consumer automobiles include calculating vehicle CG during vehicle movement and employing an anti-lock braking system (ABS) to modify the cornering ability of the vehicle. These prior art methods only consider two-dimensional vehicle movement (forward-reverse and turning) and do not, for example, account for three-dimensional CG changes due to load weights being lifted and lowered while a vehicle is in motion.
[0005] It would therefore be desirable to have a method for dynamically maintaining the stability of a material handling vehicle that accounts for vehicle motion and complex CG changes imposed by a load weight.
SUMMARY OF THE INVENTION
[0006] The present invention overcomes the drawbacks of previous methods by providing a system and method for improving the dynamic stability of a material handling vehicle that is able to dynamically assess vehicle stability and adjust vehicle operation in response. The method includes analyzing dynamic vehicle properties such as velocity, travel direction, acceleration, floor grade, load weight, lift position and predicting wheel loads and three-dimensional center-of-gravity positions.
[0007] The present invention provides a method of maintaining the dynamic stability of a material handling vehicle having a vertical lift. The method includes continuously calculating dynamic center-of-gravity parameters for the vehicle over a time interval during which the vehicle is moving, wherein a vertical position of the dynamic center-of-gravity is strongly dependent on a position of the vertical lift. The method further includes continuously calculating wheel loads based on the calculated dynamic center-of-gravity parameters and adjusting vehicle operating parameters based on calculated and predicted wheel loads and center-of-gravity parameters to maintain vehicle dynamic stability.
[0008] The present invention also provides a material handling vehicle including a motorized vertical lift, traction motor, steerable wheel, steering control mechanism, and brake. The material handling vehicle further includes a stability control system having a plurality of sensors configured to measure dynamic vehicle properties, a sensor input processing circuit, a vehicle memory configured to store static vehicle properties. The control system further includes a stability computer, vehicle control computer, and a plurality of vehicle function controllers configured to maintain vehicle dynamic stability in accordance with the above-mentioned method.
[0009] Various other features of the present invention will be made apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a lift truck employing a stability control system in accordance with the present invention;
[0011] FIG. 2 is a schematic view of a control system for maintaining the dynamic stability of a material handling vehicle in accordance with the present invention;
[0012] FIG. 3 is a flowchart setting forth the steps for assessing and maintaining the dynamic stability of a material handling vehicle in accordance with the present invention;
[0013] FIGS. 4A-4C are alternate views of a free-body diagram for a three-wheeled material handling vehicle that may be employed to calculate vehicle center-of-gravity and wheel loads in accordance with the present invention; and
[0014] FIG. 5 is a schematic showing vehicle stability in relation to center-of-gravity position in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention provides a system and method for maintaining the dynamic stability of a material handling vehicle having a vertical lift. Generally, the vehicle's wheel loads and dynamic CG parameters are calculated over a time period during which the vehicle is moving and the vehicles operating parameters are adjusted based on the calculated wheel loads and CG parameters, as well as predicted wheel load and CG parameters.
[0016] Referring now to the Figures, and more particularly to FIG. 1 , one embodiment of a material handling vehicle or lift truck 10 which incorporates the present invention is shown. The material handling vehicle 10 includes an operator compartment 12 comprising a body 14 with an opening 16 for entry and exit of the operator. The compartment 12 includes a control handle 18 mounted to the body 14 at the front of the operator compartment 12 proximate the vertical lift 19 and forks 20 carrying a load 21 . The lift truck 10 further includes a floor switch 22 positioned on the floor 24 of the compartment 12 . A steering wheel 26 is also provided in the compartment 12 disposed above the turning wheel 28 it controls. The lift truck 10 includes two load wheels 30 proximate to the fork 20 and vertical lift 21 . Although the material handling vehicle 10 as shown by way of example as a standing, fore-aft stance operator configuration lift truck, it will be apparent to those of skill in the art that the present invention is not limited to vehicles of this type, and can also be provided in various other types of material handling and lift vehicle configurations. For brevity and simplicity, material handling vehicles are hereinafter referred to simply as “vehicles” and “loaded vehicles” when carrying a load weight.
[0017] Referring now to FIG. 2 , one embodiment of a control system 34 configured to maintain vehicle dynamic stability in accordance with the present invention is shown. The control system 34 includes an array of sensors 36 linked to a sensor input processing circuit 38 , which are together configured to acquire and process signals describing dynamic vehicle properties such as speed, direction, steering angle, floor grade, tilt, load weight, lift position, and sideshift. For example, the sensor array 36 may employ a motor controller, tachometer, or encoder to measure vehicle speed; a potentiometer or feedback from a steering control circuit to measure steering angle; a load cell, hydraulic pressure transducer, or strain gauge to measure load weight; an encoder to measure lift height; or three-axis accelerometers to measure tilt, sideshift, reach, and floor grade. The sensor input processing circuit 38 is linked to a vehicle computer system 40 that includes a stability CPU 42 , vehicle memory 44 , and vehicle control computer 46 , which together analyze static vehicle properties and dynamic vehicle properties to assess vehicle stability. Changes to vehicle operating parameters based on the assessed vehicle stability are communicated from the vehicle control computer 46 to function controllers 48 , which adjust the operation of vehicle actuators, motors, and display systems 50 to maintain vehicle stability. For example, adjusted vehicle operating parameters may be received by a lift function controller 52 that activates a motor 54 to change lift position; a travel function controller 56 to relay maximum speed limitations to a vehicle motor 58 ; a display controller 60 and display 62 to communicate present or pending changes in vehicle operating parameters to a driver; and a steering function controller 68 that directs a steering motor 70 to limit steering angle. The vehicle control computer may also include a braking function controller 64 and brake 66 to adjust vehicle speed.
[0018] Referring to FIG. 3 , the above lift truck 10 and control system 34 may be employed to maintain vehicle dynamic stability. A method for maintaining dynamic vehicle stability starts at process block 100 with the input of vehicle data to the vehicle computer system 40 . Vehicle data, which is retrieved from the vehicle memory 44 , may include static vehicle properties such as unloaded vehicle weight and CG, wheelbase length, and wheel width and configuration. At process blocks 102 and 104 respectively load weight and carriage height are input from the sensor array 36 and sensor input processing circuit 38 to the computer system 40 . A residual capacity is then calculated at process block 106 to determine if vehicle capacity, for example, vehicle position and load weight, is within acceptable bounds. If, at decision block 108 , it is decided that vehicle capacity is exceeded, then the driver is notified at process block 110 and vehicle operation may be limited at process block 111 . If vehicle capacity is within the acceptable bounds, then carriage position and vehicle incline angle are input at process blocks 112 and 114 respectively.
[0019] Referring now to FIGS. 3 and 4 , loaded vehicle CG is calculated at process block 116 by the stability CPU 42 based on static vehicle properties input at process block 100 and the dynamic vehicle properties such as those input at process blocks 102 , 104 , 112 , and 114 . For example, the free-body diagram (FBD) shown in FIG. 4 shows the position of the CG, indicated by X CG , Y CG , and Z CG , in relation to the turning wheel and load wheels of a three-wheel material handling vehicle and the loaded weight W at the CG. It should be noted that Y CG is strongly dependent on load weight and lift position and that heavy load weights at increasing lift heights elevate the CG and reduce vehicle stability. If, at decision block 118 , the vehicle is deemed stable, then vehicle speed is input at process block 120 and vehicle movement is assessed at decision block 122 . If the vehicle is moving, then the steering angle is input at process block 124 and operator commands are input at process block 126 .
[0020] At process block 128 , the effects of vehicle movement on wheel loading are calculated. For example, wheel loads for a three-wheeled vehicle can be calculated by again considering the FBD of FIG. 4 , which describes the distance A from the vehicle centerline C L to the turning wheel 28 , the distance B from the C L to the load wheels 30 , and the distance L between the turning wheel 28 and the axis-of-rotation of the load wheels 30 . From these distances and the steering angle θ input at process block 124 , a heading angle α and turning radius r are calculated using the following equations:
[0000]
α
=
A
tan
(
L
-
X
CG
L
tan
θ
-
B
+
A
)
;
and
Eqn
.
1
r
=
L
-
X
CG
sin
α
.
Eqn
.
2
[0021] Normal and tangential accelerations, a t and a n respectively, are then calculated using the following equations:
[0000]
a
i
=
v
-
v
o
t
;
and
Eqn
.
3
a
n
=
v
2
r
;
Eqn
.
4
[0022] where v is current vehicle velocity, v o is the last measured vehicle velocity, t is the time between velocity measurements. It is then possible, using these values and by analyzing the FBD of FIG. 3 , to produce the following equations describing wheel load:
[0000]
N
D
=
W
(
L
-
X
CG
)
cos
(
γ
F
)
-
WY
CG
sin
(
γ
F
)
+
WY
CG
386.4
(
a
i
cos
(
α
)
-
a
n
sin
(
α
)
)
L
;
Eqn
.
5
N
L
1
=
W
(
B
-
Z
CG
)
cos
(
γ
L
)
-
WY
CG
sin
(
γ
L
)
+
WY
CG
386.4
(
a
n
cos
(
α
)
-
a
i
sin
(
α
)
)
2
B
;
and
Eqn
.
6
N
L
2
=
W
cos
(
α
L
)
cos
(
α
F
)
-
N
D
-
N
L
1
;
Eqn
.
7
[0023] where γ L is the lateral ground angle and γ F is the fore/aft ground angle as determined at process block 114 . In this case, N D is the load at the turning wheel, N L1 is the load at the left load wheel, and N L2 is the load at the right load wheel.
[0024] Referring to FIG. 3 , at decision block 130 it is decided if the wheel loads are acceptable. If unacceptable, for example, a wheel load approaching zero or another predetermined threshold, then the system notifies the operator at process block 110 and adjusts vehicle operation at process block 111 to maintain vehicle stability. For example, the computer system 40 may adjust vehicle operation by limiting or reducing the vehicle speed and communicate these changes to the operator via the display controller 60 and display 62 . Advantageously, the present invention further improves vehicle dynamic stability by allowing future CG parameters and wheel loads to be predicted based on trends in the measured dynamic vehicle properties and for vehicle operating parameters to be adjusted accordingly.
[0025] Referring to FIGS. 3 and 5 , at process block 102 the CG position determined at process block 84 is compared to a range of stable CG positions. It is contemplated that this may be performed by locating the CG position 200 within a stability map 202 relating a range of potential CG positions to vehicle stability. It should be noted that the stability map 202 is for a four-wheeled material handling vehicles having two turning wheels 28 and two load wheels 30 . The stability map 202 may include a preferred region 204 , limited region 206 , and undesirable region 208 whose sizes are dependent on system operating parameters. For example, applications requiring a high top speed may employ more stringent vehicle stability requirements and thus reduce the size of the preferred region 204 . At process block 134 , trends in measured dynamic vehicle properties, CG parameters, and wheel loads are analyzed to predict future vehicle stability. This may be achieved, for example, by analyzing trends in CG position 200 to determine its likelihood of entering the limited region 206 or by analyzing wheel loading trends to ensure that they remain within stable bounds. To adequately model future vehicle stability it is contemplated that the CG parameters and wheel loads are calculated approximately ten times per second.
[0026] At process block 136 , vehicle operation rules are input to the computer system and, at process block 138 , parameters relating to future vehicle stability, for example, predicted wheel loads or CG position, are compared to the vehicle operation rules to determine if vehicle operating parameters should be adjusted in response. If, at decision block 140 , it is decided that vehicle operating parameters should be adjusted, then the driver is notified at process block 110 and the control system specifies an appropriate change in vehicle operating parameters to maintain vehicle stability at process block 111 . For example, if a wheel load falls below a minimum threshold specified by the vehicle operation rules, then vehicle speed may be limited to prevent further reduction in wheel load and the accompanying reduction in vehicle stability. It is contemplated that vehicle dynamic stability may also be improved in such an event by limiting steering angle, lift height, or vehicle speed.
[0027] In addition to the calculated CG parameters and wheel loads, potential force vectors projected by the vehicle may also be analyzed to maintain vehicle dynamic stability. An accelerating vehicle projects a force approximately equaling the mass of the vehicle (including a load) times vehicle acceleration. This force vector, which is centered at the CG and projected in the direction of travel, is typically counteracted by the weight of the vehicle. However, if the projected force vector exceeds the vehicle weight, then the vehicle parameters may require modification. Therefore, the present invention may analyze trends in the projected force vector and adjust vehicle operation if the force vector exceeds a threshold specified by the vehicle operation rules.
[0028] The present invention provides another method for maintaining vehicle dynamic stability. Possible low-stability scenarios such as a sudden change in vehicle speed or direction can be modeled and vehicle CG, wheel loads, and force vectors can be predicted in the event of such a scenario. If the modeled CG parameters, wheel loads, and force vectors fall outside a preferred range, then vehicle operation parameters may be adjusted to improve vehicle stability during the potential low-stability scenario.
[0029] The present invention has been described in accordance with the embodiments shown, and one of ordinary skill in the art will readily recognize that there could be variations to the embodiments, and any variations would be within the spirit and scope of the present invention. It is contemplated that addition sensors and vehicle properties could be employed to further improve vehicle stability. Conversely, vehicle properties and the associate hardware used to measure and process them may be excluded from the present invention to reduce system costs and complexity. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. | A system and method that maintains the dynamic stability of a material handling vehicle having a vertical lift. The method allows static vehicle properties, such as vehicle weight, wheelbase length, and wheel configuration, and dynamic operating parameters, such as vehicle velocity, floor grade, lift position, and load weight, to be accounted for when maintaining the dynamic stability of a moving material handling vehicle. The method may include calculating and predicting center-of-gravity parameters, wheel loads, and projected force vectors multiple times a second and adjusting vehicle operating parameters in response thereto to maintain vehicle stability. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to vehicle batteries, and in particular, to a battery for vehicles such as automobiles and the like which has constantly available reserve power.
2. Problems in the Art
Conventional automobile batteries, for example, include a fairly standard sized rectangular casing inside of which are positioned cells (six for 12 volt batteries--three for 6 volt batteries). The cells each contain positive and negative battery plates and appropriate electrolytic fluid to allow the battery to produce, store, and recharge electrical power. The operation of a conventional battery is well known within the art and will not be explained further at this point. Normal automobile batteries are rated between approximately 300 amps cranking power for the weakest batteries up to 800 or 900 amps for the most powerful.
Conventional battery technology has improved considerably in the last two decades. Conventionally sized automobile batteries have increased power, increased life, better response to discharge and recharge, and less maintenance than predecessors. This allows improved starting, as well prolonged operation of electrical equipment and auxiliary equipment with the automobile battery.
A significant problem still exists, however. If for any reason the conventional automobile battery loses power or is discharged, the needed source for electrical power is lost. There are no alternatives other than to jump-start the automobile or to restore or replace the battery.
The examples of situations where this scenario occurs are legion. If automobile lights are left on for extended periods of time without the car running, discharge of the battery is inevitable. If other auxiliary equipment such as radios, fans, or the like are left on without the engine running, similar problems can occur. Electrical shorts or bad connections to the battery, so that it does not recharge during use, are other types of problems where failure of the battery leaves the vehicle basically helpless.
Another common example is the diminishment of power output of a battery in extremely cold temperatures. In very cold conditions, even a fully charged battery in a car without any electrical problems may not be able to start the car.
Other problems that come with reliance on a single battery are well known. Despite these problems, conventional batteries are almost universally utilized. Some exotic attempts have been made to solve this problem but none have been accepted or apparently are satisfactory.
One example is the mounting of two conventional batteries in one automobile. When reserve power is needed, the second battery can be connected into the electrical system.
The problems with this system are very clear cut. The system doubles the cost for battery power, utilizes twice the space, which many times precludes such a system being used, and requires additional needed hardware, such as connecting wiring, switches, and additional mounting structure.
Other exotic attempts are exemplified in such issued patents as follows:
______________________________________U.S. PAT. NO. INVENTOR ISSUE DATE______________________________________2,044,917 Richardson Jun. 23, 19362,629,059 Baumheckel Feb. 17, 19532,729,750 Draper et al. Jan. 3, 19563,129,372 Warren Apr. 14, 19643,200,014 Roberts Aug. 10, 19653,758,345 Toth Sep. 11, 19734,336,485 Stroud Jun. 22, 19824,564,797 Binkley Jan. 14, 19864,684,580 Cramer Aug. 4, 19874,794,058 Thiess Dec. 27, 1988______________________________________
The Baumheckel, Warren, Draper and Stroud patents utilize two separate batteries which are interconnected or switchable. Thiess describes a portable reserve battery canister which can be plugged into the automobile's electrical system through the cigarette lighter plug.
Toth, Binkley, Richardson, and Roberts disclose battery having sub-parts. In Toth, each sub-part has its own terminals. In Roberts, the auxiliary battery includes compartments to separate the electrolytic solution from the plates until it is needed. Cramer has a large and small portion, the small portion is connected to the large when further power is needed. Binkley actually has three different sub-portions, two are which substantially smaller than the first, all of which are connected to a rather complex circuitry from which selection of electrical power can be made.
In all of these examples, either rather complex structure is required for the battery itself, or its circuitry; or the reserve units are all substantially smaller than the primary or main battery unit.
The obvious advantages of having reserve electrical power in an automobile battery can easily be appreciated. It eliminates the need to jump-start the vehicle, or try to reach some assistance when the primary battery will not suffice. It also eliminates the danger of trying to jump-start an automobile, where there is the potential for electrical sparking and explosion. Considerations of both safety and security exist when the car will not start and assistance to jump-start must be sought out. Time is also an important element. Re-charging a battery can take significant amounts of time, if it is even possible.
Additionally, reserve power allows the automobile to be operated even when the main battery is discharged or incapacitated. Thus, when the main portion is not usable, the reserve portion can be utilized until a replacement can be conveniently obtained for the entire battery.
Even with the existing attempts to provide readily available reserve power in an automobile battery, there is still room for improvement. As previously mentioned, many of the batteries are not conventionally shaped and therefore would not be readily adaptable to use universally in existing automobiles. Additionally, it is not seen in these prior attempts that the reserve power is necessarily sufficient to truly be reliable in all situations. These types of problems generally exist for most types of vehicle batteries, for instance, with respect to cars, trucks, tractors, etc.
For example, systems which have small auxiliary or reserve batteries may or may not be functional in extremely cold weather which affects all portions of the battery or batteries. Additionally, most automobiles do not require very much electrical power to start in normal conditions, and certainly do not require very much electrical power during operation, as that is generally supplied by the alternator or other electrical power producing device, or at least the battery is being constantly recharged.
It is therefore a primary object of the present invention to provide an improved vehicle battery which solves or improves over the problems and deficiencies in the art.
Another object of the present invention is to provide an improved vehicle battery which is generally universally installable in place of a conventional automobile battery.
Another object of the present invention is to provide an improved vehicle battery which contains sufficient reserve electrical power for most, if not all, situations, even in worst case type scenarios such as extremely cold weather.
A further object of the present invention is to provide an improved vehicle battery which provides always available, easy and virtually instantaneous access to reserve power.
A still further object of the invention is to provide an improved vehicle battery which is simple in construction, does not require substantial and costly structure, circuitry, or other components, and which is economical to manufacture and use.
Another object of the present invention is to provide an improved vehicle battery which is efficient, durable, and reliable.
These and other objects, features, and advantages of the present invention will become more apparent with reference to the accompanying specification and claims.
SUMMARY OF THE INVENTION
The present invention presents a battery which can be easily substituted for most conventional vehicle batteries. It contains, however, an always available reserve electrical power source which can be selectively used. The reserve power source also is isolated from use until specifically connected.
A housing of a conventional size contains first and second battery means. The first battery means is the primary electrical power source and includes terminals to connect it to the vehicle's electrical circuitry.
The second battery means is a similar voltage electrical storage battery but has at least 50% (fifty percent) of the total amount of electrical power stored in the primary or first battery means combined. Generally this requires the reserve battery means to physically be equal to or larger than the primary or first battery means, but both must be contained within the conventionally sized housing.
Connection means, either internal or external to the housing, provide switchable connection of the two battery means. Also, electrical components are utilized to ensure that electrical current cannot leave the reserve battery until it is hooked up with the primary battery, but allowing it to be kept at full charge when on reserve.
The invention therefore provides a direct substitute for conventional batteries with a primary battery having enough power to carry out required operations of the vehicle in most situations. When, however, the power is lost or additional power is needed, the reserve battery can be connected in parallel to the primary battery by operation of the switch. This can be either manual or automatic. One configuration for automatic switching is when a vehicle such as a car is started. The ignition switch could trigger the connection of the two batteries to always provide combined 100 percent starting power, and then disconnect the batteries and rely on just the primary battery for normal operation.
If the primary battery discharges or is run down and cannot accomplish its functions, an override switch, either on the battery housing or remotely mounted can tap into the reserve power.
The method of the invention utilizes the concept of incorporating two battery compartments within a standard sized housing, but configuring the reserve battery to be equal to or larger than the primary battery for the reasons expressed above.
A number of optional features or alternatives can be utilized with the invention to enhance its advantages. It can therefore can be seen that at least all the stated objectives have been met by the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the invention including certain circuitries shown schematically attached to it.
FIG. 2 is a cross section of the embodiment of FIG. 1 taken along lines 2--2 of FIG. 1.
FIG. 3 is an electrical schematic of an embodiment of circuitry for the invention.
FIG. 4 is an electrical schematic of a preferred embodiment of electrical circuitry for the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With particular reference to the drawings, a detailed description of the preferred embodiments of the present invention will now be described. This description is intended to aid in an understanding of the invention, but is not intended, nor does it specifically limit the invention.
Reference numerals are utilized in the drawings to designate indicated elements or locations in the drawings. Like reference numerals will be used for like parts or locations throughout the drawings unless otherwise indicated.
With particular reference to FIG. 1, an improved battery 10 according to the present invention is shown. Battery 10 in the preferred embodiment is a 12 volt D.C. automobile battery, but it is to be understood that the invention applies equally as well to analogous types of batteries for analogous types of uses or vehicles. A housing 12 of conventional rectangular dimensions surrounds the electrical power storage compartments contained therein. Positive and negative terminals 14 and 16 are operatively connected to housing 12. Access doors 18 to the interior of housing 12 are shown, but are not necessarily needed.
A switch means 20 is mounted on the top of housing 12 and contains a slide lever or any type of on/off switch 22 which can be used to switch into the reserve portion of battery 10. As depicted in FIG. 1, switch means 20 and on/off switch 22 could optionally be positioned remotely of battery 10, as shown by reference numerals 20A and 22a respectively.
FIG. 1 also depicts schematically various connections for certain elements. Negative terminal 16 would be connected to the "ground" side of the automobile circuitry.
Positive terminal 14 would be connected to the positive side of the electrical automobile circuitry, and in particular, to the starter motor 70, ignition switch 72, starter solenoid 74, and generator or alternator 76 depicted schematically in FIG. 4. As is well known, other automobile circuitry also would be electrically connectable to battery 10, either switched or unswitched.
Thus, the embodiment of FIG. 1 can be installed exactly the same as a conventional automobile battery. It would fit in present battery mounting hardware and electrical connections would b simply accomplished by connecting conventional automobile wiring harness positive and negative terminal connections 78 and 80 to terminals 14 and 16 respectively. The correct connection of elements such as 70, 72, 74 and 76 would automatically be accomplished by the wiring harness, such as is well known.
FIG. 2 shows in cross section the interior of battery 10. Pairs of positive and negative plates 26 and 28 are contained within a series of six cells 30 in one portion of housing 12. Terminals 14 and 16 are positioned directly above the opposite end cells 30 in that series and are operatively connected to the appropriate set of positive or negative plates 26 and 28, respectively.
Pairs of somewhat larger positive and negative plates 32 and 34 are contained within a series of six somewhat larger cells 36, which comprises a majority of the interior of housing 12.
Insulation 38, such as is well known in the art, is mounted between each positive and negative plate within each cell. As is conventional in automobile batteries, each of the positive or negative plates are electrically connected by connections 40 with each succeeding positive or negative plate through each series of cells.
Therefore, the combination of cells 30 presents a smaller 12 volt direct current (d.c.) power source whereas the combination of cells 36 presents a somewhat larger 12 volt d.c. power source, both in terms of physical size and in magnitude of electrical power (or alternatively in amperage rating). The electrical power of combined cells 30 will be referred to as the primary power source 42 whereas the electrical power of combined cells 36 will be referred to as the reserve power source 44. As is well known in the art, the amount of electrical power is a function of a number of parameters. In the present preferred embodiments, the materials of the plates and insulation, as well as the type of electrolytic solution contained in each cell, are all the same or similar and therefore the electrical power of each power source 42 or 44 is determined primarily on the basis of the combined area of the pairs of the adjacent positive and negative plates in each cell.
Control circuitry 46 for this embodiment of the invention is indicated by the box formed by dashed line 46 in FIG. 2. This circuitry controls electrical connection between primary power source 42, reserve power source 44, and switch means 20 (or 20A) of FIG. 1.
As can be seen in FIG. 2, each series of cells 30 and 36 are essentially isolated and fluid tight with respect to one another. Of primary importance is the isolation of cells 36 from cells 30. However, an electrical connection 48 exists between negative plate 28 and negative plate 34 in the adjacent end cells 30 and 36 as shown in FIG. 2. There is no other connection between plates in either power source 42 or 44 in the normal condition of battery 10, and therefore there is no exchange or combination of electrical power between sources 42 and 44 in its normal state.
FIGS. 3 and 4 depict two alternative schematics for control circuitry 46 and switch means 20. Either alternative can be built into the battery 10, or can be connected together in other ways according to desire.
FIG. 3 presents a basic non-complex circuit according to the present invention. The circuitry serves to allow a user, when it is desired, to add in the electrical power of reserve power source 44 with that of primary power source 42 by manually moving switch 20 (or 20A) to a closed position. Until that is done, all electrical power delivered to the automobile electrical circuitry will be from primary power source 42. Switch means 20 is shown connected on one side to a positive terminal 14, and at the other side to the actuating coil 56 of normally open relay 54, which is there after connected to ground (i.e. negative terminal 16). Closing of switch 20 would energize coil 56 and close armature 59 of relay means 54 to connect contacts 58 and 59. This would join primary and reserve power sources in parallel until switch 20 is opened. A component 50, connected in parallel to switch means 20 could optionally be used as an indicator means which will give some signal (audible, visual, etc.) to the user when the switch means 20 is closed. Component 50 is preferred to be an audible buzzer, such as are known in the art.
Additional circuitry includes a diode means 52 connected in parallel to armature 57 and contacts 58, 59. Diode means 52, as shown, blocks and prevents any electrical current from the reserve power source 44 to combine with primary power source 32 or pass out of positive terminal 14 when switch means 20 is open. It does allow, however, for electrical power to pass from the automobile recharging component (generator or alternator) into reserve power source 44 (as well as primary power source 42). Therefore, both power sources 42 and 44 will be constantly recharged when the automobile recharging means is operating, regardless of whether switch means 20 is open or closed. However, the reserve source will not have an electrical path to discharge its power when contacts 58 and 59 are not connected by relay armature 47.
In this straightforward form, primary power source 42 will be connected to the automobile circuitry and will provide only its proportionate share of available electrical power to the car's circuitry, until switch means 20 is closed. At that time, whether by utilizing a manual switch means 20, or remote switch means 20A, or some automatic or semiautomatic actuator controlling switch means 20, primary and reserve power sources 42 and 44 would be connected in parallel and provide combined or 100% of the available power contained within housing 12 to the automobile circuitry.
Therefore, sources 42 and 44 could be combined at any time desired to use the combined power of sources 42 and 44. If, however, primary power source 42 is discharged or otherwise weakened so that it does not adequately supply needed power to the automobile circuitry, switch means 20 would simply be closed and the proportional amperage of reserve power source 44 (at least 50% of the combined amperage) would then be available to the automobile circuitry.
It is to be understood that an important aspect of the present invention are the relative sizes of power sources 42 and 44. Normally, required electrical power to an automobile electrical circuit during operation under power of the engine is minimal compared with that many times needed when starting the car. Therefore, primary power source 42 does not normally have to be as big as a conventional battery to sustain the electrical power needs of a car. It is only when extraordinary events occur such as cold weather, weakening or discharge of the primary power source, or an extraordinary need for electrical power (as with starting the car), that primary power source 42 may be insufficient.
In cold weather, for example, any battery would be substantially weakened regardless of whether it has been used or not. Therefore, it was discovered that by apportioning the primary and reserve power sources 42 and 44 so that source 42 is equal to or smaller than 44, most normal operating conditions for an automobile could be handled by source 42 leaving a very substantial unaffected reserve source 44 always available.
The prior art attempted to overcome this problem by either looking to connection of two full sized batteries in parallel, and therefore not having to concern themselves with size considerations; or by having a small portion of a conventionally sized battery taken up by the reserve power source, as the amount of electrical power is limited according to the size of the housing. This of course decreases the power of the primary battery source proportionately. These attempted solutions still, however, maintain a primary source which is substantially bigger than the reserve source.
The present invention teaches away from either of these directions by utilizing a primary power source which is never bigger than the reserve source. This provides a substantially larger reserve power source to be formed in a conventionally sized housing, than has been previously taught.
While others have believed that one needed only to carry a very small auxiliary reserve source to be effective, such a reserve had deficiencies that did not allow it to be a totally reliable backup.
While those types of systems might work in optimum conditions (mild weather, excellent electrical contact to terminals, etc.), in extreme conditions, that is, worst-case scenarios such as very cold weather or bad terminal connections, a small amperage reserve source many times will not be sufficient.
The present invention solves this problem by realizing that the reserve portion must have sufficient power over a range of situations. Limitations of size of the battery housing, and therefore the plate sizes of the primary and reserve sources, required a novel solution that can be seen in the preferred embodiments.
FIG. 4 depicts a preferred control circuitry and switch means circuitry which can be used with the invention. It is similar to that shown in FIG. 3, except it presents an alternative way to control relay means 54, in addition to switch means 20, to connect primary and reserve power sources 44 and 42. The circuitry of FIG. 4 operates as follows. The coil 56 of relay means 54 is additionally connected to the starter solenoid 74 of the automobile. When solenoid 74 is energized, coils 84, 86 close armature 81 and normally open contacts 82, 83 which provide electrical power to starter motor 70. The closing of contacts 82, 83 would also provide electrical power to coil 56, closing contacts 58, 59 and therefore connecting primary and reserve power sources 42 and 44. In conventional automobile systems, solenoid 74 is only energized when ignition switch 72 is turned to ignition "start" position (as opposed to the other conventional ignition switch positions of "off", "acc" (accessory), and "off"), providing electrical power to coils 84 and 86 of solenoid 74. Therefore, the embodiment of figure provides an automatic way to always combine primary and reserve sources 42 and 44 of battery 10 every time the vehicle is started. This assumes, of course, that manual switch 20 is in the normally open position. It is to be understood that the connection between solenoid 74 and coil 56 of relay 54 is preferred because of easy connection to the terminal of solenoid 74, but this lead can also be connected to any circuit that is actuated when ignition switch 72 is in the "start" position.
This embodiment provides the valuable advantage of always, without throwing any switch, having 100% total combined power of battery 10 each time the vehicle is started, and then automatically returning to use of only the primary power source when running (ignition switch in "on" position); or not running (ignition switch in "off" or "acc" positions). As is known in the art, accessories can be used while draining only the primary source, even if the car is not running, if the ignition key is turned only to "accessory" position (or "on" position also). It is only when the solenoid actually engages the starter motor that the full battery power is used. Once the solenoid kicks out, however, such as is known in the art, relay means 54 would be deenergized and the system would automatically revert back to the primary power source 42.
It is to be understood that switch 20 can still be used.
When switch means 20 is open, no electrical power is conducted through coil 56 of relay means 54 thereby leaving contacts 58, 59 in their normally open position. When switch means 20 is closed, however, coil 56 is energized pulling armature 57 from normally open to a closed position bridging contacts 58, 59. In the closed position, primary and reserve power sources 42 and 44 are connected.
As can be seen, FIG. 4 can also include component 50 which signals when switch 20 is closed. Component 50 is valuable in notifying the user that the reserve power source 44 is being constantly utilized. Therefore, it assists in reminding the user to switch the system back to the primary source 42 (with automatic starting operation) unless reserve power source 44 continues to be needed.
In the preferred embodiment, primary power source 42 has approximately 35% of the electrical power of reserve power source 44, which would have 65% approximately of the power of battery 10. If battery 10 had an 800 amp rating of available electrical power for both sources 42 and 44 total, primary power source 42 would therefore have a 280 amp with reserve power source 44 having a 520 amp rating. This should be more than enough for most situations with respect to needs of the primary source 42, and backup reserve for even extreme or worst-case situations. It is to be understood, however, that while 35%-65% is the preferred ratio between primary and reserve sources 42 and 44, the invention achieves its advantages and objectives when source 44 is approximately as big or bigger than source 42. A range of ratios between 50--50 and 10-90 for primary and reserve sources 42 and 44 respectively would be acceptable. It is preferred that primary source 42 have at least 200-250 amps.
For a primary source 42 having 210 amps, and a reserve source 44 having 210 amps, diode means 52 could be a 30 amp diode available from any number of electrical component dealers. Switch means 20 could be any standard on/off switch that can handle the power requirements of the circuitry. Relay means 54 can be a 15 amp relay. The connections between switch means 20 and/or relay means 54, diode means 52 and component 50, as well as from battery 10 to the automobile circuitry can be wiring such as is conventional and well within the skill of those of ordinary skill in the art. The wiring through diode 52, contact 58, and between primary and reserve sources 42 and 44 should be heavy gauge wire because this path will carry significant current. Connections to coil 56 and switch 20 can be lighter gauge. These ratings can vary, of course, with different power ratings.
It will be appreciated that the present invention can take many forms and embodiments. The true essence and spirit of this invention are defined in the appended claims, and it is not intended that the embodiment of the invention presented herein should limit the scope thereof.
For example, the exact proportional relationship of the electrical power contained in primary power source 42 and reserve power source 44 can vary. At a minimum, the power of power source 42 should be equal to or less than that of reserve power source 44, and preferably between 10 and 50 percent of any combination of power of sources 42 and 44.
Still further, the invention could include options such as voltage or current monitors which would automatically energize or switch to incorporating the reserve power source 44 if the level of voltage or current enters a certain range.
Still further, electrical connections, such as are well known in the art, could be utilized to allow a plug-in remote switch to be placed inside the passenger compartment of the automobile, or to allow auxiliary electrical components to be plugged into the reserve power source 44. It has been found that utilizing battery 10, if audio equipment is directly connected to reserve power source 44, a substantial amount of interference caused by operation of the automobile engine can be filtered out.
Still further, it is to be understood that a diode means 60 (30 amp) could be placed in line from the starter solenoid 74 to the coil 56 of relay means 54 in the embodiment of FIG. 4 to prevent current from flowing to that circuitry and discharging any part of battery 10; while allowing current to come from the ignition circuitry for the purposes explained above. The system can be designed to operate properly without this diode 60, however, but would depend on the type of switch and relay used.
Also, switch 20 and diode 60 may not be needed if relay 54 had a manual override switch incorporated into it to close contacts 58, 59.
The present invention is relevant to 12 volt direct current automobile batteries and electrical systems. However, it is also applicable to the 6 volt systems, and other battery uses analogous to automobiles, such as any equipment powered by internal combustion engines or any system that requires a storage battery for some necessary function. | An improved vehicle battery providing a constant source of reserve electrical power. The primary source of electrical power is contained within a housing and is connectable to an electrical load. The reserve battery is also contained within the housing and is selectably connectable in parallel to the primary battery by a switch or relay. The reserve battery is of at least equal electrical power to that of the primary battery. Therefore, an adequate reserve is always maintained, even for adverse and extreme conditions that would be too much for smaller reserve batteries, but includes circuitry to disallow discharging of the reserve battery unless it is connected in parallel to the primary battery. | 7 |
This application is filed under 35 U.S.C. 371 and based on PCT/EP98/03543, filed Jun. 12, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for washing laundry, more particularly work clothing, in which the laundry is washed with a product combination of an alkali component and a surfactant component in a standard washing machine for institutional laundries and the wastewater is treated in a membrane filtration unit, and to a product combination containing an alkali component and a surfactant component for use in institutional laundries.
2. Discussion of Related Art
Work clothing and other linen from hotels and guesthouses, hospitals, the food industry, for example abattoirs, meat markets, etc. and textiles and work clothing from the automotive sector are mainly washed in institutional laundries. The soils occurring in work clothing and in the institutional sector often lead to particularly heavy pollution of the wastewater. Accordingly, efforts are made to treat the wastewater from institutional laundries before it is discharged into the public effluent system by removing the pollutants.
The pollutants and impurities can be removed, for example, by passing the wastewater through membrane filtration units after the washing process. The already known membrane filtration units have proved to be very effective systems in the treatment of wastewater. However, it has been found that the membranes clog up very quickly in the treatment of wastewater from institutional laundries. Studies have shown that this is due to the surfactants and polymers present in the detergents.
Although the clogged-up membranes can be cleaned with special auxiliaries, complete cleaning generally cannot be achieved by this cleaning process so that the membranes cannot be restored to their original capacity and their useful lives are thus shortened.
DESCRIPTION OF THE INVENTION
International patent application WO 92/05235, for example,
DESCRIPTION OF THE INVENTION describes a liquid nonionic surfactant combination with improved low-temperature stability containing
a) 20 to 50% by weight of an alcohol ethoxylate derived from primary linear C 12-15 alcohols containing on average 2 to 7 ethylene oxide groups (EO),
b) 20 to 50% by weight of an alkoxylate derived from primary C 12-15 alcohols containing on average 3 to 7 ethylene oxide groups (EO) and 2 to 8 propylene oxide groups (PO),
c) 5 to 50% by weight of an alcohol ethoxylate derived from mixtures of primary linear and 2-methyl-branched C 12-15 alcohols (oxo alcohols) containing on average 2 to 8 ethylene oxide groups.
However, the problem of membrane clogging could not be completely solved.
The problem addressed by the present invention was to provide a process for washing laundry, more particularly work clothing, in a standard washing machine for institutional laundries and subsequent treatment of the wastewater in membrane units, in which the laundry would be washed with a product combination of surfactant and alkali components which would have substantially the same cleaning performance as the detergents known from the prior art but which, in the treatment of the wastewater in membrane filtration units, would not have any adverse impact on the actual wastewater treatment process, i.e in particular would not lead to clogging of the membranes and hence to a reduction in the throughflow rate. In addition, the throughflow rate in the wastewater treatment process would actually be increased in relation to the throughflow of clean water.
The present invention relates to a process for washing laundry, more particularly work clothing, in which the laundry is washed in a standard washing machine for institutional laundries with a product combination of at least two components,
(A) a washing alkali component containing
(A1) anionic surfactant and water-soluble silicate and/or
(A2) alkali metal hydroxide and
(A3) complexing agent and
(B) a surfactant component containing preferably nonionic surfactant, and the wastewater is treated in a membrane filtration unit.
The present invention also relates to a product combination of at least two components,
(A) a washing alkali component containing
(A1) anionic surfactant and water-soluble silicate and/or
(A2) alkali metal hydroxide and
(A3) complexing agent and
(B) a surfactant component containing preferably nonionic surfactant, for use in institutional laundries.
It has surprisingly been found that not only is the throughflow rate through the membranes not impaired, it can actually be increased through the use of the product combination according to the invention, in other words the product combination appears to have a cleaning effect on the membranes.
In addition, this positive outcome is not dependent on the membrane material so that standard membranes based on polypropylene, ceramics and carbon may be used with considerable advantage.
The process according to the invention may be carried out in standard washing machines for institutional laundries. No special measures have to be taken in the washing process.
The washing alkali component (A) used in accordance with the invention may be present both in solid form and in liquid form. If component (A) is present in solid form, it preferably contains anionic surfactant and water-soluble silicate (A1) and a complexing agent (A3). If the washing alkali component is added in liquid form, it preferably contains alkali metal hydroxide (A2), more particularly in the form of an aqueous solution, and a complexing agent (A3).
The anionic surfactant used may be any of the anionic surfactants typically used in detergents such as, for example, C 8-18 alkyl sulfates, C 8-18 alkyl ether sulfates, C 8-18 alkane sulfonates, C 8-18 α-olefin sulfonates, sulfonated C 8-18 fatty acids, C 8-18 alkyl benzene sulfonates, sulfosuccinic acid mono- and di-C 1-12 -alkyl esters, C 8-18 alkyl polyglycol ether carboxylates, C 8-18 -N-acyl taurides, C 8-18 -N-sarcosinates, C 8-18 alkyl isethionates and mixtures thereof.
The anionic surfactants are present in a quantity of preferably 1 to 10% by weight and more preferably 2 to 6% by weight, based on the washing alkali component A.
The water-soluble silicates used may be any of the silicates used in detergents. The silicates not only act as a washing alkali, i.e. increase the pH value, they also have builder properties. Suitable water-soluble silicates are both crystalline and amorphous silicate. Crystalline layer-form sodium silicates corresponding to the general formula NaMSi x O 2x+1 .yH 2 O, where M is sodium or hydrogen, x is a number of 1.9 to 4 and y is a number of 0 to 20, preferred values for x being 2, 3 or 4, are particularly suitable. Crystalline layer silicates such as these are described, for example, in European patent application EP-A-0 164 514. Preferred crystalline layer silicates corresponding to the above formula are those in which M is sodium and x assumes the value 2 or 3. Both β- and δ-sodium disilicates Na 2 Si 2 O 5 .yH 2 O are particularly preferred.
Amorphous sodium silicates with a modulus (Na 2 O:SiO 2 ratio) of 1:2 to 1:3.3, preferably 1:2 to 1:2.8 and more preferably 1:2 to 1:2.6 are also suitable. Amorphous sodium silicates which dissolve with delay and exhibit multiple wash cycle properties are particularly preferred. The delay in dissolution in relation to conventional amorphous sodium silicates can have been obtained in various ways, for example by surface treatment, compounding, compacting or by overdrying. In the context of the invention, the term “amorphous” is also understood to encompass “X-ray amorphous”. In other words, the silicates do not produce any of the sharp X-ray reflexes typical of crystalline substances in X-ray diffraction experiments, but at best one or more maxima of the scattered X-radiation which have a width of several degrees of the diffraction angle. However, particularly good builder properties may even be achieved where the silicate particles produce crooked or even sharp diffraction maxima in electron diffraction experiments. This may be interpreted to mean that the products have microcrystalline regions between 10 and a few hundred nm in size, values of up to at most 50 nm and, more particularly, up to at most 20 nm being preferred. So-called X-ray amorphous silicates such as these, which also dissolve with delay in relation to conventional waterglasses, are described for example in German patent application DE-A-44 00 024. Compacted amorphous silicates, compounded amorphous silicates and overdried X-ray-amorphous silicates are particularly preferred.
The water-soluble silicates are present in a quantity of preferably 10 to 60% by weight and more preferably 20 to 50% by weight, based on component A.
Suitable alkali metal hydroxides are, in particular, KOH and NaOH, NaOH being particularly preferred. The alkali metal hydroxides may be present in component A in a quantity of 10 to 50% by weight and preferably in a quantity of 15 to 30% by weight, the alkali metal hydroxide generally being present in liquid preparations in the form of an aqueous solution with a concentration of 10 to 50% by weight.
Component A contains one or more complexing agents as a further constituent. The complexing agent(s) used may be any of the usual complexing agents suitable for detergents, salts of polyphosphonic acids, salts of organic polycarboxylic acids, such as citric acid, carboxyaspartic acid and nitrilotriacetic acid and mixtures thereof being particularly suitable. Preferred polyphosphonic acid salts are the neutrally reacting sodium salts of 1-hydroxyethane-1,1-diphosphonic acid, diethylenetriamine pentamethylene phosphonic acid or ethylenediamine tetramethylene phosphonic acid. The complexing agent is used in quantities of preferably 0.1 to 4.0% by weight and more preferably 0.3 to 2.0% by weight. N-(2-hydroxyethyl)-N,N-bis-methylene phosphonic acid (commercially available, for example, under the name of Cublen® R 60 from Zschimmer & Schwarz) and the sodium salt of carboxyaspartic acid (commercially available, for example, under the name of Nervanaid® GBS from Rhône-Poulenc) have proved to be particularly suitable compounds.
Other water-soluble builders, for example phosphates, and soda may also be present as further ingredients in component A.
Suitable phosphates are, in particular, the sodium salts of the orthophosphates, the pyrophosphates and, in particular, the tripoly-phosphates. Their content is generally no more than 60% by weight and is preferably between 10 and 60% by weight and more preferably between 15 and 40% by weight, based on the washing alkali component A.
Another possible ingredient is soda, Na 2 CO 3 , which contributes towards increasing the pH value of the wash liquor. Soda may be present in a quantity of up to 50% by weight, preferably 10 to 50% by weight and more preferably 15 to 30% by weight, based on component A.
Besides the ingredients mentioned, the washing alkali component (A) may contain known additives typically used in such washing alkali compositions, such as co-builders, optical brighteners, dyes and perfumes, optionally small quantities of nonionic surfactants and small quantities of neutral salts, such as sulfates and chlorides in the form of their sodium or potassium salts, providing they do not adversely affect the positive properties of the process.
Thus, it has been found in accordance with the invention that cellulose derivatives which are widely used as redeposition inhibitors in detergents often have a negative effect on the filterability of the wastewater by membranes. Accordingly, component A like component B of the process according to the invention is preferably free from cellulose derivatives such as, for example, carboxymethyl cellulose, hydroxyalkyl cellulose and alkyl cellulose.
In a preferred embodiment, preferably C 8-22 alcohol alkoxylates (B1) are used as nonionic surfactants of component B. The C 8-22 alcohol alkoxylates are preferably derived from primary saturated alcohols containing 12 to 18 carbon atoms in which the alcohol component may be linear or 2-methyl-branched or may contain linear and methyl-branched alcohols in the form of the mixtures typically present in oxo alcohol residues.
Preferred primary, saturated and linear alcohols are the mixtures present, for example, in alcohol mixtures of native origin which may be obtained, for example, by the Ziegler synthesis or from native fatty acids by reduction.
The oxo alcohols are normally a mixture of linear and 2-methyl-branched alkanols in which the linear alcohols generally predominate. The alcohol residues contain 12 to 15 and preferably 13 to 14 carbon atoms. Technical mixtures may additionally contain components with 11 to 15 carbon atoms.
The C 8-22 alcohol alkoxylates preferably contain at least 5 and more preferably at least 7 alkoxy groups. Component B1 contains ethylene oxide groups (EO) and/or propylene oxide groups (PO) as alkoxy groups. If component B1 only contains EO groups, the degree of ethoxylation in a particularly preferred embodiment is at least 7. If both EO groups and PO groups are present, the number of EO groups is preferably 4 to 8 and the number of PO groups is 2 to 8 and, more particularly, 3 to 4. The EO groups and PO groups may be statistically distributed although compounds in which the alcohol component is first completely ethoxylated and then propoxylated, as reproduced by the schematic formula R-(EO) x -(PO) y , are preferably used. In this formula, R stands for the alcohol component, x for the number of EO groups and y for the number of PO groups.
In another embodiment, a mixture (B2) of alcohol ethoxylates containing
a) 20 to 80% by weight of alcohol alkoxylates derived from primary linear or 2-methyl-branched C 12-22 alcohols containing on average 5 or more ethylene oxide groups (EO) and
b) 80 to 20% by weight of alcohol alkoxylates derived from primary linear or 2-methyl-branched C 12-22 alcohols (oxo alcohols) containing on average 4 to 8 ethylene oxide groups and 3 to 8 propylene oxide groups (PO) is used as the surfactant component.
In one preferred embodiment, surfactant component B contains the fatty alcohol alkoxylate in a quantity of preferably 50 to 90% by weight, based on component B, and between 10 and 50% by weight of other typical ingredients which increase washing performance and do not adversely affect the treatment of the wastewater in membrane filtration units.
Component B may advantageously contain one or more C 1-4 alkyl alcohols present in a quantity of preferably 2 to 10% by weight, based on component B, as a further component. Particularly preferred C 1-4 alkyl alcohols are methanol and ethanol.
Washing performance in the process according to the invention may be further increased by adding one or more fatty alcohols as detergency boosters to surfactant component B. Suitable fatty alcohols are in particular fatty alcohols containing 8 to 18 carbon atoms and the mixtures thereof obtainable from naturally occurring fats and oils.
The fatty alcohols may be present in a quantity of up to 20% by weight, preferably between 5 and 20% by weight and more preferably between 10 and 15% by weight, based on surfactant component B.
Surfactant component B may be water-free or may contain up to 20% by weight and preferably 5 to 15% by weight of water. So far as metering and storage stability are concerned, the water content is of secondary importance. However, since the nonionic surfactants B1 are technical products which may be obtained and supplied in various qualities and purities, it can happen that the concentrates turn cloudy or even form gel-like precipitates where certain technical product batches are used. Such clouding and precipitates are reliably avoided by the addition of water, additions of 5 to 10% by weight generally being sufficient for this purpose.
The mixtures may contain other additives providing it is guaranteed that they are soluble and do not affect the advantageous properties of the concentrates. Such additives include, in particular, dyes and perfumes with which the color and -odor, respectively, of the mixtures are masked. Although basically other solvents may be added, they are generally not necessary.
Surfactant component B normally behaves like a Newtonian liquid, i.e. its viscosity is independent of the shear forces applied. Corresponding mixtures are therefore easy to pump and meter, their viscosity undergoing relatively little change as a function of temperature. Even after several months' storage in a conditioning cabinet at temperatures repeatedly alternating between −10° C. and +40° C., they remain stable in storage, i.e. show no tendency to separate. The concentrates have a liquid consistency at least to 0C. They may be present in liquid or solid form between −10° C. and 0° C. Even the concentrates present in solid form at those temperatures give clear homogeneous liquids on thawing. These properties make them particularly suitable for fully automatic metering in institutional laundries.
Other suitable product additives are optical brighteners, enzymes, bleaching agents from the class of per compounds, which are normally used together with activators, active chlorine compounds and dyes and perfumes.
The process according to the invention is particularly suitable for washing heavily soiled work clothing and is distinguished by high cleaning performance against soils containing mineral oil.
In one preferred embodiment, at least one quaternary ammonium compound is added to the laundry in the final rinse. Suitable quaternary ammonium compounds are any ammonium compounds which do not clog the membrane during the wastewater treatment process, didecyl dimethyl ammonium chloride having proved to be particularly suitable. The quaternary ammonium compound is added to the final rinse in a quantity of preferably up to 10 g/l, more preferably between 0.05 and 2 g/l and most preferably between 0.1 and 1 g/l rinse water.
According to the invention, the wastewater accumulating from the washing process, including the rinses, if any, is treated by passage through a membrane filtration unit. In one preferred embodiment, the wastewater is passed through several membranes arranged in tandem. The wastewater and the prepurified wastewater may also be repeatedly passed through one membrane. The number of membranes arranged in tandem is normally determined as a function of the volume of water to be treated per unit of time and depends upon the size of the membrane.
The wastewater may be passed or circulated through the membranes until the water is sufficiently clean. In order to reduce the costs of the washing process as a whole and particularly the water demand, the water cleaned in this way by the membranes may be used as required for the pre-wash and, depending on the quality of the membrane, even for the final rinse and/or for the first or second rinse.
The residue obtained from the membrane filtration process may be disposed of as waste in known manner.
EXAMPLES
Example 1 (invention)
Work clothing was washed in a wash liquor containing 0.33 g/l of a washing alkali component A and 0.16 g/l of a surfactant component B. These products had the following composition (in % by weight):
A
sodium triphosphate
20.0
sodium alkyl benzenesulfonate
2.5
sodium silicate (SiO 2 :Na 2 O = 1:1)
47.0
acrylic acid/maleic acid copolymer as Na salt
2.0
Na hydroxyethane diphosphonate
0.4
sodium carbonate
25.0
C 12/14 fatty alcohol + 5 EO + 4 PO
1.5
rest water, perfume, optical brightener
B
C 12/14 fatty alcohol + 5 EO + 4 PO
75.0
isotridecanol + 5 EO
21.0
rest perfume and water
The wastewater accumulating after the washing process was adjusted to a pH value of 8 and, with a temperature of ca. 45° C., was filtered through a Microdyn polypropylene membrane (pore diameter 0.2 μm). The entry pressure was 0.8 bar and the exit pressure 0.4 bar.
For comparison, the throughflow of clean water at 20° C. was determined before the solution was passed through (t=o) and on completion of the test (t=∞).
Example 2 (comparison)
An aqueous solution containing 0.05% by weight of a conventional laundry detergent with the following composition was tested as in Example 1.
Comparison product:
88% by weight of a sodium citrate/sodium gluconate mixture
11% by weight of a carboxymethyl cellulose/methyl cellulose mixture
1% by weight of nonionic surfactant.
The results are set out in the following Table:
Example 1
Example 2
Time/mins.
L/hm 2
Time/mins.
L/hm 2
0
3500
0
3500
(water value)
(water value)
1
3590
5
2800
5
3510
5
2380
15
3500
15
1960
30
3490
30
1540
45
3300
45
1420
0
3290
60
1380
75
3260
75
1260
90
3260
90
240
105
3210
—
—
120
3210
—
—
∞
3400
∞
1400
(water value)
(water value)
It is clear from the tests that the performance of the membrane in Example 1 (invention) showed hardly change from its performance using clean water. On the other hand, the performance of the membrane in Example 2 (comparison) deteriorated continuously and could not be regenerated even by rinsing with water. | A process for washing laundry is provided in which a washing alkali component and a surfactant component are combined with water to form a wash liquor, the wash liquor is combined with laundry in a standard washing machine for institutional laundries, and the wastewater from the wash is treated by membrane filtration, where the throughflow rate is reduced by less than 10 percent over an operating time of 120 hours. The washing alkali component is composed of an anionic surfactant and a water-soluble silicate; an alkali metal hydroxide and a complexing agent; or an anionic surfactant and water-soluble silicate and an alkali metal hydroxide, a complexing agent, or a mixture of an alkali metal hydroxide and a complexing agent. The surfactant component is composed of a nonionic surfactant selected from the group consisting of C 8-18 fatty alcohol alkoxylates containing at least 5 alkoxy groups, C 8-18 fatty alcohol ethoxylates containing at least 7 ethoxy groups, C 8-18 fatty alcohol ethoxylate/propoxylates containing at least 4 ethoxy groups and at least 2 propoxy groups in the molecule, and mixtures thereof. | 2 |
BACKGROUND
Field of the Invention
[0001] The present invention generally relates to portable exercise equipment and specifically to exercise equipment whose physical weight is much less than the exercise forces that free weights can afford.
[0002] The area of physical exercise contains a large diversity of products. In addition, some systems provide feedback to a user of a weight stack machine having a stack of weight plates for lifting one or more of plates from a stack during lifts. Some of these systems use load cells for determining the weight of the weight plates prior to lift and for determining the weight of weight plates remaining on the stack after the user has lifted the plates. These systems may also provide means for evaluating the height of lifted weight plates or the distance that the weight stack is pulled.
[0003] One problem which arises from use of weight of a weight stack and the work done on the weight stack. The work done by the user in exerting a force on that weight provides only part of the resistance through which a user applies force and work. The work can also be done without a mass moving, strain work. Work can be done by accelerating the mass, not taken account by a straight weight-height calculation. The work done on a weight machine is not the desired quantity. What is needed is the force and work done by the muscle and on the muscle, which is not the same as the work done on an exercise object or weight stack. In addition, the weight stack machine variety is very heavy and not portable. What is needed are portable light-weight exercise apparatus for the traveler or just the weight lifter that wishes to store the equipment in a small closet.
[0004] There exists many body-part centric resistance training equipment such as Arm Curl Machine, Leg Curl Machine, Shoulder Press, Pull down Machine, Leg Extension Machine, Back Extension, Triceps Pushdown, and more. Some can accommodate more than one set of body muscles. But these are all relatively heavy and difficult to port. In addition to the portability is the physical weight cost. An exercise regime using weights for resistance machines are costly and stationary once assembled. Travel, storage space and quick assemble are barriers to regular exercise. What is needed is light, inexpensive and easily portable exercise equipment.
SUMMARY
[0005] The present invention discloses a portable tension-resistance exercise equipment with harness to replace much heavier physical weight load equipment. The harness couples an anchor component for wedging in an anchor apparatus conveniently in typical living environments using household furniture or dwelling door jams and alternate static household structures, flexibly attached to a harness having a housing assembly with a freely rotatable gear. An exercise harness with an anchor component for wedging between household furniture and dwelling household structures is flexibly attached to the exercise harness with attached main housing assembly having at least two subassembly friction resistance generation units. The first subassembly contains a magnetic friction unit housed in a cartridge and the second subassembly contains a viscous fluidic cylinder-piston friction unit housed in a separate cartridge with both subassembly units slidably mounted in the main housing assembly and gear mesh coupled to the main gear in the main housing assembly. Each subassembly unit gear is power engaged with the main housing main gear for transmitting resisting tension to power transmitting cable wrapping about the main gear center via a sprocket gear. The wrapping cable attached to the main gear shaft centered rewinding spring and sprocket coupled to the main gear center with both cable ends, entering the main housing structure and wrapping around the main gear center for transmitting power to and from the cable ends. The sprocket free wheel coupled concentrically with the main gear for unidirectional tension transmission and rewinding to its original position after each extension or traction of the power cable about the main gear center. The magnetic subassembly have a rotatable gear affixed to the magnetic subassembly housing, the gear having embedded magnets concentric with an equal number of fixed assembly embedded magnets having magnetic attraction to the concentric fixed non-rotating subassembly magnets in resistance to gear rotation in the magnetic subassembly housing. The magnetic subassembly unit gear with magnetic resistance is meshed with a main gear for power transmission from the cable. The main gear is rigidly affixed to a harness attached shaft common to a rewinding spring with one end affixed to the shaft storing tension with shaft winding. The main gear also has a flexible cable or rope with one end affixed to main gear for turning the gear with load. The cylinder-piston subassembly has a pair of tandem opposing cylinders-piston units alternately pressuring viscous fluid through a channel between the distal ends of the opposing cylinders-piston units. The complementing reciprocating cylinders each have racks coupled to each piston each with a pinion meshed with a half circle toothed pinion, each pinion half gear teeth complementary to the other to coincide with the push-pull piston-cylinder mechanism such that the unit gear upon which the two half gears are rigidly attached to a common shaft whose half gear teeth are 180 degrees out of phase to synchronize with the reciprocating cylinder-piston mechanisms. The cable are rotably attached to the main gear and upon user applied tension provides resistance to exerciser extension, whereby the harness provides resistance force to the turning of the main gear power rope or cable.
BRIEF DESCRIPTION OF DRAWINGS
[0006] Specific embodiments of the invention will be described in detail with reference to the following figures.
[0007] FIG. 1 illustrates the exercise harness anchor components and placement in an embodiment of the present invention.
[0008] FIG. 2 illustrates the exercise exemplars in application of embodiments of the present invention.
[0009] FIG. 3 illustrates a 5 magnet pair embedded in a gear and assembly according to an aspect of the present invention.
[0010] FIG. 4 illustrates a 5 magnet pair gear meshed with a main gear showing an aspect of the present invention.
[0011] FIG. 5 illustrates complementary half-toothed gears rigidly connected with power transfer gear according to aspects of the present invention.
[0012] FIG. 6 illustrates complementary pair of rack-in-piston cylinder friction mechanisms according to embodiments of the present invention.
[0013] FIG. 7 shows an integration of the complementing 180 degree teeth shifted half-gear components coupled to the synchronizing rack-in-piston-pinion components in an embodiment of the present invention.
[0014] FIG. 8 shows power transmission from the main gear meshed with the unit gear rigidly coupled to complementing opposite half-gears in an aspect of the present invention.
[0015] FIG. 9 shows a power transmission gear meshed with a complementary half-teeth gear component meshed with the magnetic friction assembly in an embodiment of the present invention.
[0016] FIG. 10 shows front and isometric views of a main housing base assembly with open slots for mechanism subassemblies in an embodiment of the present invention.
[0017] FIG. 11 shows front view of a main housing base assembly with slots occupied with friction mechanism subassemblies in an embodiment of the present invention.
DETAILED DESCRIPTION
[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.
OBJECTS AND ADVANTAGES
[0019] The present invention discloses a portable exercise apparatus. Accordingly, it is an object of the present invention to use light-weight components to create the load resistance equivalent to much heavier and more expensive weight load portable exercise equipment.
[0020] Embodiments of the invention are based on two separate types of force resistance integrated into a flexible harness which can be used inside a dwelling taking advantage of a dwelling structure door ways, furniture or exerciser feet as anchor component fix positions, to exercise the different muscle systems in various convenient living locations. The harness is to anchor exercise apparatus conveniently in typical living environments and light weight for portability, yet sturdy and strong enough to handle the typical tension load requirements for indoor and comparable exercise.
[0021] FIG. 1 illustrates the exercise harness, anchor components and placement in an embodiment of the present invention.
[0022] In this embodiment of the invention as Super Portable Weigh, SPW, an apparatus whose harness 112 , 113 , 101 is anchored to structures 109 , 115 at indoor convenient locations 107 , 110 , 117 for purposes of resistance type exercise indoor exercise. Locations on a door 109 frame or bed frame 115 are used to place anchors 101 , 107 , 110 , 117 . The anchor consists of lite-weight rigid 101 material blocks coupled by flexible fiber 103 , rope, ribbon, wire ribbon, plastic or composite tape or cable; a wire ribbon is shown. The flat fiber connection can be of any material that is flexible yet able to support a tension of at least 200 lbs. The anchor blocks 101 , 107 110 119 117 are positioned relative to the door frame 108 or a bed frame as 115 respectively as shown in FIG. 1 and have a coupling attachment 105 to the harness. The motion resistance device portion 112 113 121 is attached to the typical anchor 101 110 117 119 via the SPW harness with the anchor attaching coupler 105 . The harness anchor-wedge component 101 103 105 is designed to be wedged primarily in furniture or household structures for exercising trapazoids, perctoralis, supraspinatus, supraclavicular, deltoid, and other muscle groups.
[0023] The portable tension-resistance exercise apparatus, SPW, harness with an anchor component 101 110 117 119 for wedging between household furniture and alternate dwelling household structures to the anchor component is flexibly 105 attached via the exercise harness coupler 105 to a main housing assembly buckle FIG. 11 1101 with at least 2 subassembly friction resistance generation units.
[0024] FIG. 2 illustrates the exercise exemplars in application of embodiments of the present invention. The pulling or pushing motions 210 213 depicted by the thick arrows exercise the various muscle groups including the Trapezoids 207 , Supraspinatus/Supraclavicular/Pectoralis 209 , Deltoid 201 , Pectoralis 205 , and the Scapula 203 . The person figures illustrate some of the modes of exercise which can be done for the benefit of the above muscle groups.
[0025] FIG. 3 illustrates a 5 magnet pair embedded in a gear and assembly according to an aspect of the present invention. A magnetic resistance gear 301 is a component in the magnet pair embedded assembly view A-A. The A-A view of the holding plate and gear assembly shows a rigid stationary magnet holder plate 303 with concentric embedded magnets 307 each paired with a concentrically aligned rotating gear 307 rigidly coupled magnets 313 . Five such magnet pair placements are depicted 301 . The assembly housing is comprised of a flat lite weight but rigid plate casing 311 concentric to and coupled at the gear 307 center. The plate casing is coupled to the holder plate 305 with fasteners 309 on the periphery of the housing 311 . When the gear is rotated through the concentric magnet pair field lines are broken and opened causing the initiation and collapse of the coupling magnetic pair field lines producing a resisting mechanical force. The mechanical resistance force is proportional to the magnetic pairs, size, residual magnetism of the materials and components. Many materials and magnetic types can be used. The magnetic force of attraction increases the static and kinetic friction on the gear 313 plate surfaces causing opposing resistance to rotational motion. The magnet pairs are each split, with the gear 301 having one member of each pair 313 and the static plate or holder 303 housing having the other pair member 305 307 on the holder plate 303 . The embedded magnet pairs can be of variable size, thickness and shape, but are shown here as flat round and thin in one embodiment.
[0026] FIG. 4 illustrates a 5 magnet pair gear meshed with a main gear showing an aspect of the present invention.
[0027] The assembly of gear 403 , magnets 401 and back housing plate 405 are packaged with a thin flat rigid casing anchored to the plate 405 via fasteners 407 , allowing the magnet holding gear 403 to be rotated through magnetic friction about an axis meshed with another gear 409 , the main gear 409 , through a port cut on one side of this casing 403 . The rotational transmission of applied force received through wrapped cable coupled free wheel 411 and is transmitted from the main gear 409 to the meshed magnetic resistant gear 403 . The transmission cable and free wheel 411 are coupled to accommodate sudden repeated brief accelerations and intermittent surface seizing from dust. The intermittent friction bursts are smoothed out through alternative friction means. the magnetic subassembly having a rotatable gear 403 rotatably anchored to the magnetic subassembly housing 405 , the magnet embedded gear 403 having embedded magnet concentric with an equal number of fixed assembly embedded magnet 401 opposite partners having magnetic attraction to the concentric fixed subassembly magnets in resistance to gear 403 rotation in the magnetic subassembly housing 405 . The magnetic subassembly unit gear with magnetic resistance is meshed with a main gear for power transmission from an exerciser pulling cord, rope or cable.
[0028] FIG. 5 illustrates complementary half-toothed gears 503 505 rigidly connected by shaft with power transfer gear 501 according to aspects of the present invention. The half gears 503 505 are concentrically rigidly mounted to the power transfer gear 501 on a rigid coupling shaft, such that power is transmitted from the gear teeth engaging half gears 503 505 in complementary fashion, each half gear 503 505 with gear teeth on half the revolution and mounted 180 degrees opposite the other. This so that only one of the half gears is engaged for transmission for only half the revolution.
[0029] FIG. 6 illustrates complementary pair of rack-in-piston cylinder friction mechanisms according to embodiments of the present invention.
[0030] The reciprocating pair of rack-in-piston cylinder 611 603 provide a second type of force resistance to the a meshed gear force transmission. The cylinders 611 contain a viscous fluid that is pushed from one cylinder 611 to the reciprocating cylinder through a conduit 609 with a throttling section 607 for adjusting the viscous fluid resistance through a channel 609 cross section manipulation 607 via a valve or other flow control component. The piston 605 drives the rack-and-pinion 601 gear through the cylinder 603 .
[0031] FIG. 7 shows an integration of the complementing 180 degree teeth shifted half-gear 703 719 components coupled to the synchronizing rack-in-piston-pinion 705 721 components in an embodiment of the present invention.
[0032] The unit gear 701 is rigidly coupled to a shaft 701 , between two pinion half gears 703 719 concentrically mounted on a transmission shaft 701 . The two pinion half gears 703 719 are positioned with gear teeth covering only half of each gear and with the gear teeth on opposite gears having the gear teeth configured 180 degrees offset from each other, in such a way that when one half gear engages with its rack 705 721 , the other disengages with its own rack 705 721 . The resulting power transmission alternates from piston A 708 at top of stroke pushing the viscous substance into cylinder B 713 to out stroking the piston B 717 which is not gear teeth engaged to half gear 719 , and freely filling the cylinder 713 with viscous fluid without engaging power transmission to the unit gear 701 . As the unit gear 701 rotates the half gear 719 engages at the in stroke of the piston 717 driving the piston 717 into the cylinder 713 and pushing the viscous fluid through the connecting channel 711 to the reciprocating cylinder 709 . On this cylinder 709 piston 708 outstroke, the opposite half gear 701 drives the half gear on the opposite side. The cylinder-piston subassembly contains a pair of tandem opposing cylinders-piston 713 , 717 , 709 , 709 units alternately pressuring viscous fluid through a channel 711 between the distal ends 709 , 713 of the opposing cylinders-piston units; the complementing cylinders 709 713 each with racks 705 721 affixed to each piston 708 717 respectively each meshed with a half circle toothed pinion 703 719 , each pinion half gear teeth complementary to the other synchronous with the push-pull piston-cylinder mechanism such that the unit gear 701 upon which the two half gears 701 719 are rigidly attached to a common shaft whose half gear teeth are 180 degrees out of phase.
[0033] FIG. 8 shows power transmission from the main gear 807 meshed with the unit gear 801 rigidly coupled on a shaft 805 to complementing opposite half-gears 803 in an aspect of the present invention.
[0034] The main gear 807 in the assembly transmits power to the unit gear 801 which then transfers the power to its rigidly coupled concentric mounted half-gears 803 . The main gear 807 is concentrically coupled to a free wheel 817 coupled to one end of a cable or rope 811 from which the other end is used for human exercise extension and tension. A sprocket free wheel 817 is also coupled to an rewind spring cable 815 which serves to rewind the free wheel 817 and reposition the pulling cable 811 extension end after each extension.
[0035] FIG. 9 shows a power transmission main gear 907 meshed with a unit gear center shaft coupled to complementary half-teeth gear 905 component meshed with the magnetic friction assembly 911 in an embodiment of the present invention.
[0036] The main gear 907 engages the unit gear 903 coupled to the friction enhancing viscous piston-cylinder 901 rack-and-pinion 902 subassembly. The rack-and-pinion 902 assembly is coupled to the complementing half gears 905 such that the engaging half gear teeth are synchronized with the two opposite stroke reciprocating cylinder 901 pistons. The transmitted force originating in the power cable or exerciser pull cord 915 via the sprocket free wheel 909 and into the main gear 907 is attached to the free wheel 909 which is rotated by traction through a wrap around cord 915 . A rewinding spring and cord 913 is coupled to the free wheel 909 and functions to rewind the free wheel to its original position after each extension or traction were the rewind spring catch or stick. The sprocket free wheel 909 is coupled concentrically with the main gear 907 , for unidirectional tension transmission and to rewind the free wheel 909 to its original position after each extension or traction of the power cable 915 about the main gear center 907 .
[0037] FIG. 10 shows front 1001 and isometric view 1017 of a main housing base assembly with open slots for mechanism subassemblies in an embodiment of the present invention.
[0038] The Main housing base assembly 1001 is comprised of rigid materials such as metal, hard plastic or composites. A center hole 1007 for coupling the main gear anchors the main gear to the main housing base 1001 . Slots for the magnetic 1003 1011 and Cylinder-Piston subassembly cartridges are radial situated with respect to the main gear axial 1007 center. Fasteners 1009 secure the slot walls to the base 1001 which provide for slide placement of the magnetic and Cylinder-Piston half gear subassemblies. A suspension buckle 1015 is rigidly attached to the base to support the tensions and forces for the manual exercises to a ready indoor anchor point.
[0039] FIG. 11 shows front view of a main housing base assembly with slots occupied with friction mechanism subassemblies in an embodiment of the present invention
[0040] A port 1121 for a magnetic gear cartridge subassembly containing a magnetic friction unit housed in a cartridge and a port for a second subassembly containing the viscous fluidic cylinder-piston friction unit 1103 housed in a separate cartridge, both subassembly units slidably fixed to the main housing assembly 1102 and gear meshed to the main gear 1116 in the main housing assembly 1102 . Each subassembly unit gears 1121 1103 are power meshed with the main housing gear 1116 for transmitting resisting tension force to power transmitting cable 1113 wrapping about the main gear center 1115 .
[0041] The second assembly containing the viscous fluidic friction unit 1103 provides a smoothing function on the main housing unit and specifically on the first subassembly magnetic friction unit. Magnetic unit design can vary and some designs for the first assembly can produce intermittent surface seizing or friction bursts between the magnetic pair surface contact. The viscous fluid subassembly adds a dampening effect to the mechanism to smooth out any jerking motion from the magnetic subassembly.
[0042] A suspension buckle 1101 is hinge coupled to the main assembly housing base 1102 . The base slots are shown occupied with cylinder-piston 1103 cartridge and two magnetic cartridges 1107 1121 . These have locking mechanisms 1105 1109 1119 1123 to for slidably installing and removing the cartridges 1103 1107 1121 into their base slots. A slot opposite the suspension buckle 1101 is maintained for the extensor cord 1113 and sprocket rewind spring 1117 on the main gear. The main gear is coupled to the base through the base center hole 1115 .
[0043] The wrapping cable or exerciser pulling rope 1113 is power coupled to the main gear shaft 1115 centered free wheel rewinding spring 1117 and coupled to a main gear center 1115 shaft with both cable ends 1117 1113 entering the main housing structure 1102 and wrapping around the main gear center 1115 for transmitting power to and from using the cable 1117 . The main gear 1116 is coupled to the main housing 1102 shaft 1115 and user exercise tension is harnessed by coupling the tension to a free wheel sprocket rewinding spring with one end coupled to the shaft for transmitting tension to shaft winding. The main gear 1116 is coupled to the free wheel via a common shaft center, and the flexible puller component, cable or rope having one end coupled to main gear 1116 for turning the gear with load for transmission of load to the subassemblies 1121 1103 1107 . The rope or cable 1113 sprocket winding rotably coupled to the main gear 1116 upon which exerciser pulling will engage with the resistance gear subassemblies 1121 1103 1107 to provide resistance to puller tension. The exercise harness is coupled to the suspension buckle 1101 to anchor the exercise harness to provide resistance force to the turning of the main gear power rope or cable.
[0044] An embodiment of the invention is to provide a modularity to the SPW component of the exercise harness. The main housing provides slots for magnetic friction cartridges or viscous fluid cylinder-rack cartridges. These are all packed and packaged in strong durable rigid material with a small opening in the housing for the extension cable. The packaging can be of such materials as plastic, metal, composite, wood and combinations. A prototype composed of:
[0000]
1 magnetic resistor cartridge
8 OZ
provides 128 OZ resistance force
weighs
1 magnetic resistor cartridge
8 OZ
provides 128 OZ resistance force
weighs
1 magnetic resistor cartridge
8 OZ
provides 128 OZ resistance force
weighs
1 viscosity resistor cartridge
9 OZ
provides 114 OZ resistance force
weighs
The free wheel, the main gear,
16 OZ
the box weigh
The total weight
49 OZ
provides 488 OZ resistance force
[0045] This proves out an object of the invention to provide exerciser extension resistance force that is roughly 10 times the weight of the device.
[0046] Therefore, while the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this invention, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Other aspects of the invention will be apparent from the following description and the appended claims. | Pairs of magnetic disks and reciprocation piston-cylinders filled with viscous fluid are used to provide friction for a portable exercise harness. The viscous fluid in cylinder-piston push-pull configuration provide resistance to a extension cable for the physical exercise. The exercise apparatus fits in a harness for travel and easy attachment to ordinary household furniture and fixtures. | 0 |
BACKGROUND OF THE INVENTION
[0001] Cerebrospinal fluid, typically abbreviated as CSF, is a fluid that protects the brain and spine and helps distribute nutrients to these structures. CSF is a clear, colorless fluid that is primarily produced by the choroid plexus and surrounds the brain and spinal cord. Hydrocephalus is a condition in which a patient accumulates an excess volume of CSF. This often results from an obstruction of the cerebrospinal fluid pathways or from an inability to absorb the necessary volume of CSF. Increased CSF production relative to absorption causes the ventricles to become wider or dilate to make room for the extra fluid. Hydrocephalus is usually accompanied by an increase in CSF pressure which can be measured with a spinal tap, also known as a lumbar puncture. A spinal tap is a procedure in which a needle is inserted into a space inside the spinal canal for the purpose of removing some of the CSF.
[0002] The treatment of hydrocephalus has conventionally involved draining the excess fluid away from the ventricles and rerouting the cerebrospinal fluid to another area of the patient's body, such as the peritoneal cavity. A drainage system, commonly referred to as a shunt, is often used to carry out the transfer of fluid. In order to install the shunt, typically a scalp incision is made and a small hole is drilled in the skull. A proximal, or ventricular, catheter is installed in the ventricular cavity of the patient's brain, while a distal, or drainage, catheter is installed in that portion of the patient's body where the excess fluid is to be reintroduced. Generally, the shunt systems include a valve mechanism that operates to permit fluid flow only once the fluid pressure reaches a certain threshold level. That is, fluid flows through the valve only when the fluid pressure overcomes the valve mechanism's resistance to open. Some valve mechanisms permit the adjustment, or programming, of the opening pressure level, or resistance level, at which fluid flow commences. These valve mechanisms can comprise a variety of configurations. For example, the valve mechanism can be configured as a ball-in-cone as illustrated and described in U.S. Pat. Nos. 3,886,948, 4,332,255, 4,387,715, 4,551,128, 4,595,390, 4,615,691, 4,772,257, and 5,928,182, all of which are hereby incorporated by reference.
[0003] In some cases, however, hydrocephalus is characterized by an increase in the volume of CSF and a dilating of the ventricles with only slight or no increase in CSF pressure. This condition is known as normal pressure hydrocephalus. Even without an abnormal increase in CSF pressure, the widening of the ventricles to make room for excess CSF volume can have a deleterious impact on certain brain structures.
[0004] Normal pressure hydrocephalus can be difficult to diagnose. In part, the condition is difficult to diagnose because tests used to scan inside the brain, such as CT or MRI imaging, do not show a pattern that definitively indicates that a patient's condition is normal pressure hydrocephalus. A classic triad of symptoms (gait disorder, dementia, and incontinence) is also used in normal pressure hydrocephalus diagnosis. CSF pressure dynamics assessment can also be used, however, there is no convenient equipment for tracking and analyzing CSF pressure over time or measuring its response to stimulus. Once diagnosed, normal pressure hydrocephalus can be treated with shunting generally as described above.
SUMMARY OF THE INVENTION
[0005] The present invention provides a pressure sensor with integrated fluid dynamics assessment that can be coupled with a patient's fluid system, for example a patient's CSF system, to measure and analyze the patient's CSF pressure, as well as methods for doing the same. The invention can be used to diagnose a variety of conditions, especially, but not limited to, normal pressure hydrocephalus, and can further be used to aid in treatment, helping to determine for example the appropriate pressure characteristics of a shunt to be used in the treatment.
[0006] In a first aspect, the invention provides a pressure sensing apparatus having a pressure sensor component. The pressure sensor component includes a pressure sensing port, a pressure sensor for sensing a pressure of a fluid in the pressure sensing port, and a digital processor communicating with the pressure sensor for performing calculations involving fluid pressures sensed. The pressure sensing apparatus further includes a first chamber in fluid contact with the pressure sensing port, a second chamber fluidically connectable with a patient's cerebrospinal fluid system, and a membrane located between the first and second chambers so as to transmit fluid pressure from the second chamber to the first chamber.
[0007] In certain embodiments, the tube can be configured to be connected to a patient's cerebrospinal fluid system through a lumbar tap. The apparatus can also include a bolus apparatus, such as a three way stopcock located between a patient connecting end of the tube and the second chamber with the three way stopcock including a port through which a fluid may inserted or withdrawn, for example, using a syringe.
[0008] In still further embodiments, the pressure sensor component includes a display that can be configured to display a graph of fluid pressures sensed over time. The pressure sensor component can further be configured to calculate a resting pressure, an output resistance, and/or a pressure volume index based on fluid pressures measured. The pressure sensor component can also be an integrated, hand-held unit.
[0009] In another aspect, the invention provides a pressure sensor component including a pressure sensing port for containing a fluid for pressure sensing, a pressure sensor for measuring a pressure of a fluid in the pressure sensing port, and a processor in electrical communication with the pressure sensor. The processor is configured to calculate at least one selected from the group consisting of resting pressure, outflow resistance, and pressure volume index based on fluid pressure measured by the pressure sensor.
[0010] In a further aspect, the invention includes a method for measuring a pressure of a cerebrospinal fluid system in a patient using a pressure sensing system having sterile portion for connecting to a patient's cerebrospinal fluid system and a non-sterile portion including a pressure sensor component having a pressure sensor and a processor for analyzing cerebrospinal fluid pressures measured by the pressure sensor. The method further includes connecting the non-sterile portion to the patient's cerebrospinal fluid system and measuring and displaying the patient's cerebrospinal fluid pressure on the pressure sensor component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0012] FIG. 1 illustrates a system of the invention for measuring a pressure of a fluid system in a patient;
[0013] FIG. 2 is diagrammatic view illustrating additional features of the system of FIG. 1 ;
[0014] FIG. 3 illustrates a pressure sensor component of the invention; and
[0015] FIG. 4 illustrates a pressure graph used to illustrate calculations made by the pressure sensor of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] A system 10 representative of one embodiment of the invention is presented in FIG. 1 as including a pressure sensor component 12 with integrated fluid dynamics assessment that can be coupled with a patient's 14 CSF system to measure and analyze the patient's CSF pressure, as well as methods for doing the same. As shown, the system is coupled to the patient's CSF system at a puncture site 16 which may represent a conventional lumbar tap. Tubing 18 fluidically couples the puncture site to a coupling element 20 —in the illustrated embodiment, a three-way stopcock. The three-way stopcock 20 couples tubing 18 with syringe 22 (through tubing 24 ) and a first chamber 26 . First chamber 26 is separated from a second chamber 30 by a membrane 28 (internal to the system illustrated in FIG. 1 ) that is movable to allow pressure from a fluid in the first chamber to be transmitted to fluid in the second chamber. Second chamber 30 is in fluid communication with pressure sensor port 32 of pressure sensor component 12 where a pressure sensor of the pressure sensor component can measure the pressure of a fluid in the second chamber for analysis and display. Accordingly, system 10 can measure the pressure of fluid in the patient's CSF system by way of the fluid and pressure communication sequence from puncture site 16 to pressure sensor port 32 .
[0017] System 10 can be further described by reference to FIG. 2 which illustrates diagrammatically the system of FIG. 1 . The patient's CSF system is illustrated by functional block 40 which is fluidically coupled to CSF Access Equipment 42 . The CSF Access Equipment includes the elements necessary to tap into the patient's CSF system and provide access to that system outside of the patient's body. As noted above, this access is typically gained through a lumbar tap in which a large gage needle is used to access the CSF system in the space between the patient's vertebrae, often between the third and fourth lumbar vertebrae. As suggested in the Figure, however, this access could be gained using any variety of needle, catheter, stylet and/or connectors as might be appropriate for accessing the patient's CSF system. Further, if a system of the invention is deployed for use with a different fluid system of the patient, a person skilled in the art will recognize that access equipment suitable for coupling to that fluid system can be used within the spirit of the invention.
[0018] CSF Access Equipment 42 can be fluidically coupled to Bolus Equipment 44 if desired for manipulation of the fluid within the system. The Bolus Equipment typically includes a syringe for the injection and/or withdrawal of fluid from the system. A three-way stopcock can also be employed to control the flow of fluid. A person of skill in the art will recognize that other equipment may be used, a bi-directional or infusion pump for example, to inject or withdraw fluid from the system.
[0019] The elements so far described by reference to FIG. 2 fall within a sterile portion 46 of system 10 . As these elements are exposed within the patient by virtue of the flow of fluid within the system, these element should be sterile as is well known in the art. The fluid flowing within the sterile portion of system 10 will generally include fluid from the patient's system being measured, in the illustrated embodiment CSF, and can also include other biocompatible fluids such as saline. Such biocompatible fluids can be used within the syringe to provide a bolus. Further, where fluidic coupling is long, especially between CSF Access Equipment 42 and Bolus Equipment 44 so as to make the positioning of the Bolus Equipment and the pressure sensor component more convenient for use, at least portions of the system may be filled with saline prior to connection with the patient to minimize CSF volume loss.
[0020] The fluid in the sterile portion 46 of system 10 can be coupled through membrane 28 to the pressure sensor 48 . In general, pressure sensor 48 will reside in a non-sterile portion 50 of system 10 as it is likely to be re-used from patient to patient and the system can be constructed so as to separate the non-sterile portion from contact with the patient's fluids. Typical high accuracy pressure sensors require fluid coupling, such that there is a vetted surface on the sensor. This sensor is often located in a protected area within a lumen that is not easily accessed (e.g., within pressure sensor port 32 ). The pressure sensor lumen can be filled with water (or other liquids such as oil or alcohol depending on the particular sensor embodiment used) for this purpose. Membrane 28 can be located so as to contact fluid in the sterile region 46 on one side, and fluid in the non-sterile region 50 on the other. Where membrane 28 is movable or flexible, changes in fluid pressure in the sterile portion of the system (including the patient's CSF system) are transmitted by movement of the membrane to the fluid in the non-sterile portion 50 . These pressures can be read by pressure sensor 48 .
[0021] A pressure sensor component 12 for use with the invention can further be described by reference to FIG. 3 . Pressure sensor component 12 can be a known hand-held fully integrated pressure sensor having a digital processor that can be configured to analyze the pressure signals provided in accordance with the description of FIGS. 1 and 2 above. Such known pressure sensors could include, for example, the Dwyer Instruments Series 477 handheld digital manometer available from Dwyer Instruments, Inc. of Michigan City, Ind., or the Fluke Model 717 or 718 pressure calibrators available from Fluke Corporation of Everett, Wash. Pressure sensor component 12 includes pressure sensor port 32 , and also a second pressure sensor port 64 for pressure differential measurements. This second port can remain exposed to the atmosphere if it is not otherwise used. Pressure sensor component 12 also includes a display 60 for displaying pressure measurement results and analysis, and user input elements, buttons 62 , for operating the component.
[0022] Display 60 in FIG. 1 illustrates a graphical display of pressure measurements over time, while display 60 in FIG. 3 illustrates the current pressure 66 along with calculated values for the resting, baseline or starting pressure (Po) 70 , the pressure-volume index (PVI) 72 , and resistance to outflow (Ro) 74 . The results are indicated to be for a third iteration (n=3) 68 of measurements. These CSF pressure dynamics testing results can yield information that can be used to confirm the probable diagnosis of Normal Pressure Hydrocephalus and aid in the selection of a shunt opening pressure for a shunt to be implanted in the patient.
[0023] While the illustrated display shows outflow resistance and pressure-volume index values, and exemplary methods for calculating and using these values are described below, the invention described herein is not limited to this choice of parameters or particular methods of calculation. Pressure sensor component 12 can be programmed to calculate other pressure based parameters and also to calculate the aforementioned parameters in ways other than those disclosed herein. In fact, clinicians or researchers could develop new parameters to more accurately diagnose NPH or other fluid system abnormalities, the analysis of which using the systems and methods described herein is believed to fall within the present invention. In one embodiment of the present invention, pressure sensor component is programmable so as to allow a user to program the calculation of the user's own preferred parameters or to carry out the calculations using the user's preferred methods of calculation. Further information relating to the relationship between CSF abnormalities and pressure related parameters can be found in Shapiro K, Marmarou A, Shulman K, Characterisation of clinical CSF dynamics and neural axis compliance using the pressure - volume index , Annals of Neurology 7 (6) 508-514 (June 1980), which is incorporated herein by reference.
[0024] The resting pressure, P o , can provide general information that may be used as an indicator for shunt opening pressure selection; its value can also used in further calculations as described below. The PVI can be calculated from the pressure change resulting from a rapid injection or withdrawal of fluid from the CSF space and has found widespread use both clinically and experimentally as a measure of lumped craniospinal compliance. The outflow resistance, R o , has been shown to be a good indicator of patents who will benefit from CSF shunting. In general, normal values for R o are generally about 1.5 to 4 nm mmHg/ml/min, while patients suffering from NPH generally have R o values of about 4 to 12.
[0025] One exemplary approach to calculating these values using system 10 of FIG. 1 , including pressure sensor component 12 as further illustrated in FIG. 3 , can further be described by reference to FIG. 4 . FIG. 4 provides a graph of pressure versus time that represents the patient's CSF pressure over time including the pressure response of the patient's CSF system to a bolus injection. The resting pressure, P o , can be seen on the graph at a time before the bolus injection. At a given time, a bolus of volume V o is added to the system, for example using the syringe 22 of FIG. 1 . The bolus injection results in a sharp rise in pressure reaching a peak pressure of P p . The pressure drops over time from its peak and can be measured at a time t 2 , typically two minutes after bolus injection, to generate a pressure reading P 2 that is indicative of the return trajectory of the patient's CSF pressure.
[0026] With these variables known, the patient's pressure-volume index can be calculated as follows:
[0000] PVI= V o /Log( P p /P o )
[0000] and the CSF outflow resistance can be calculated as:
[0000] R o =t 2 ×P o /PVI×Log {( P 2 /P p )( P p −P o )/( P 2 −P o )}
[0027] As noted above, the bolus injection, measurements and calculations may be performed in multiple iterations, with either individual iterations or mean values. In one embodiment, a user can select iterations for averaging, leaving out any apparently abnormal data.
[0028] Pressure sensor component 12 can also provide user defined variables. For example, the following variables with the following exemplary default values can be set:
[0000] Infusion Volume 4 cc Recovery Time 180 sec PVI Limit 13 ml P o Limit 30 mmHg P p Limit 30 mmHg
These values/limits can be user adjustable to conform to particular circumstances.
[0029] Pressure sensor component 12 can also be configured to prompt a user through a measuring procedure. For example, with the pressure sensor component powered on, the user defined variables set as desired, and the system connected to a patient as illustrated in FIG. 1 , the component will begin by displaying the resting pressure P o . Once P o is recorded, the pressure sensor component can prompt the user to infuse the system with a measured volume of fluid. The user can then begin the infusion, typically by infusing 4 cc of saline at approximately 1 cc/sec. The user can watch the real-time pressure display to confirm the absence of anomalous peaks during infusion. Once the infusion is complete and P p is recorded, the pressure sensor component can prompt the user to wait, typically for three minutes or until the current pressure is less than P o plus 2 mmHg, while the component measures P 2 . The pressure sensor component can then calculate P o , PVI, and R o for that iteration and display them to the user. Once the pressure reading has recovered from the infusion, the pressure sensor component can prompt the user to perform another iteration or disconnect the system from the patient. The user can select iterations to include or exclude from mean calculations, and mean values can be calculated and displayed.
[0030] The pressure sensor component 12 illustrated in FIGS. 1 and 3 is shown as an integral handheld unit having a pressure sensor located within pressure sensor port 32 , and all of the digital electronic components required to perform the calculations described above. A person skilled in the art will understand, however, that other configurations are possible. For example, the pressure sensor port 32 , or only the sensor itself, could be fluidically coupled to second chamber 30 while maintaining electronic communication to a digital processing unit for performing desired display and calculation based on the pressure signal. Still further, the pressure sensor could be provided as part of the sterile portion 46 of system 10 , making second chamber 30 unnecessary.
[0031] Accordingly, the embodiments of the present invention are not limited by what has been particularly shown and described, except as indicated by the appended claims. All publications and references cited herein are expressly incorporated herein by reference in their entirety. | A pressure sensing apparatus has a pressure sensor component that includes a pressure sensing port, a pressure sensor for sensing a pressure of a fluid in the pressure sensing port, and a digital processor communicating with the pressure sensor for performing calculations involving fluid pressures sensed. The pressure sensing apparatus further includes a first chamber in fluid contact with the pressure sensing port, a second chamber fluidically connectable with a patient's cerebrospinal fluid system, and a membrane located between the first and second chambers so as to transmit fluid pressure from the second chamber to the first chamber. | 0 |
This application claims priority to U.S. Provisional Patent Application No. 60/589,779, filed Jul. 21, 2004.
TECHNICAL FIELD
This invention relates generally to heavy duty pistons for diesel engines, and more particularly to monobloc pistons manufactured with an integrated skirt and an oil cooling gallery in the head of the piston.
RELATED ART
Monobloc pistons for heavy duty piston applications are known to the industry and characteristically include an upper piston head portion formed with an outer ring belt region surrounding a recessed combustion bowl region and formed with an annular oil cooling gallery between the ring belt and combustion bowl in which cooling oil is fed to cool the upper portion of the piston during operation. Such pistons are further formed with a pair of laterally spaced pin bosses featuring aligned bores for receiving a wrist pin to couple the piston to a connecting rod. The pin bosses are provided in the lower portion of the piston beneath the head. Monobloc pistons further include a piston skirt region which is formed as one-piece with the pin bosses so as to be immovable relative to the pin bosses, as opposed to an articulated style piston in which the skirt is separately formed and coupled for articulated movement to the pin bosses through the wrist pin.
Monobloc pistons are traditionally made as either a one-piece casting of aluminum or cast iron, or as a two or more piece construction from various materials including iron and steel which are cast and/or forged and subsequently united to provide a one-piece joined structure through various means including bolting, brazing, or welding. The intricacy of the various passages and recesses, and in particular the cooling gallery regions, has restricted the choice of materials to aluminum or cast iron. The multipiece joined structure has the advantage of dividing the piston structure into discrete parts which can be individually manufactured and then joined to unite the parts. The typical multipart monobloc piston is divided across a parting line that passes through the oil cooling chamber. In this way, part of the cooling chamber is formed in the upper head or “upper crown” section, and the remaining part of the cooling chamber is formed in the lower pin boss or “lower crown” section. The upper crown is often cast of steel and is united across the parting line to the lower crown which is sometimes forged of iron. Steel has a higher modulus of elasticity than that of iron and thus has advantages for use in the upper crown section which is subjected to heat and cyclic loading of combustion. There has been little motivation to form the lower crown from other than forged cast iron since the lower crown is not exposed to the level of heat and loading as that of the upper crown.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein:
FIG. 1 is a perspective view, shown partly broken away, of a piston constructed according to a presently preferred embodiment of the invention;
FIG. 2 is a perspective view of the piston of FIG. 1 , shown from another angle and partly broken away;
FIG. 3 is a perspective view of the piston of FIG. 1 from a different angle;
FIG. 4 is a plan view of the piston;
FIG. 5 is a cross-sectional view taken along lines 5 - 5 of FIG. 4 ;
FIG. 6 is a cross-sectional view taken along lines 6 - 6 of FIG. 5 ; and
FIG. 7 is a cross-sectional view taken along lines 7 - 7 of FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A piston constructed according to an embodiment of the invention is shown generally at 10 in the drawings. The piston is of a monobloc construction and cast entirely of one piece of steel, and preferably of SAE 4140H steel. The piston has an upper head portion 12 formed with an upper wall 14 that is generally planar and includes a combustion bowl 16 recessed into the upper wall 14 and bounded by a contoured combustion bowl wall 18 that includes an undercut corner region 20 that extends radially outwardly of an upper lip 22 of the combustion bowl 16 to provide a reentrant structure to the combustion bowl 16 . Inward of the undercut region 20 , the combustion bowl wall 18 is dome-shaped, with the center of the dome-shaped wall 18 rising above the under cut region 20 toward the upper wall 14 , but terminating below the lip 22 .
The head portion 12 further includes an outer annular ring belt wall 24 that extends downwardly from the upper wall 14 and is formed with a plurality of ring grooves 26 that are either cast into the ring belt and then machined, or formed entirely by machining following casting. The ring grooves 26 accommodate a corresponding plurality of piston rings (not shown) as is conventional.
The head portion 12 is formed with an as-cast oil cooling gallery 28 inward of the ring belt 24 and below the combustion bowl 16 . The oil cooling gallery 28 has an outer annular wall defined by the ring belt 24 and, an upper wall defined by the undercut region 20 of the combustion bowl wall 18 . An inner annular wall 30 of the gallery 28 is spaced radially inwardly of the ring belt 24 and extends downwardly from the combustion bowl wall 18 at a location radially inwardly of the undercut region 20 . The ring belt 24 is relatively thicker than that of the inner annular wall 30 , and the inner annular wall is, in turn, relatively thicker than that of the combustionable bowl 18 .
The oil cooling gallery 28 includes a bottom wall or floor 32 which extends between the ring belt 24 and inner annular wall 30 to partially close the oil cooling gallery 28 to the bottom, as will be described in further detail below.
The piston further includes a pair of laterally spaced pin bosses 34 that are cast as one piece with the head portion 12 and which project downwardly from the bottom wall 32 of the head portion. The pin bosses 34 are cast with a set of pin bores 36 aligned along a pin axis 38 for receiving a wrist pin (not shown) for connection of the piston 10 to a connecting rod (not shown) in the usual manner.
The piston 10 is further formed with a piston skirt 40 which is cast as one piece with the head portion 12 and pin bosses 34 . This skirt 40 is connected to both the ring belt 24 and the pin bosses 34 and is otherwise unsupported. The skirt 40 is formed with a set of windows or openings 42 that are cast into the skirt 40 on laterally opposite sides of each of the pin bosses 34 , for a total of four such windows 42 . The windows 42 eliminate material mass and thus reduce the overall weight of the piston in areas where the skirt is not needed.
Turning back to the oil cooling gallery 28 , it will be seen that the relatively thin-sectioned inner annular wall 30 and undercut region 20 of the combustion bowl wall 18 are formed with reinforcement ribs 44 to provide locally thickened wall regions to enhance the structural rigidity of the wall portions to withstand the forces of combustion while minimizing the wall thickness in the adjacent unribbed regions to account for an overall reduction in weight of the piston. It will be seen that the ribs 44 extend behind the ring belt 24 and only partially into the oil gallery 28 and thus do not close off the gallery in the circumferential direction such that the gallery remains open and continuous in the circumferential direction. The size of the ribs 44 vary, with the thickest of the ribs lying over the pin bosses 34 in line with the pin axis 38 as shown best in FIG. 1 .
Ribs 46 are also provided on the underside of the combustion bowl wall 18 radially inward of the inner wall 30 to strengthen the otherwise thin wall structure of the combustion bowl wall 18 in the dome region.
The pin bosses 34 are formed with hollowed regions or pockets 48 forming a generally saddle-shaped chamber extending below the bottom wall 32 as an extension of the oil cooling gallery 28 in order to reduce material mass and allow cooling oil to drain from the oil cooling gallery 28 into the hollowed regions 28 of the pin bosses 34 . The hollowed regions 48 extend down into the pin bosses 34 on either side of the pin bores 36 and terminate short of the pin axis 38 . The bottom wall 32 is absent in the hollowed region areas 48 such that there is direct open communication with the oil cooling gallery 28 .
In the regions between the pin bosses 34 , the bottom wall 32 is preferably formed with at least one and preferably a plurality of openings 50 . The openings 50 allow the oil cooling gallery and the various associated hollowed regions and ribs inside the gallery to be formed during casting by means of a casting core which, following casting, can be removed completely through the openings 50 . In addition, the openings 50 contribute to a reduction in overall mass of the piston 10 . As shown best in FIG. 7 , there are preferably four such openings, each pair of openings being separated by an intervening ridge section of the bottom wall 32 , although the invention contemplates elimination of the bridge 52 from one or both of the sets of openings, if desired. The openings 50 further serve to provide access to the oil cooling gallery 28 for feeding cooling oil into the piston during operation and to allow, at least in part, for the escape of oil from the gallery. As seen best in FIGS. 1 and 7 , the openings 50 are spaced radially from the inner and outer walls 30 , 24 and are oblong in shape. The opening 50 is also shown as extending in the circumferential direction across the bottom wall between the pin bosses 34 to such an extend that the oil gallery 28 is rendered more open than closed in the circumferential direction across the bottom wall 32 between the pin bosses 34 . In other words, the oblong openings 50 are long enough relative to the overall length of the bottom wall 32 such that the oil gallery 28 is more than 50% open in the circumferential direction across the bottom wall 32 . The hollowed regions 48 may also include oil escape holes (not shown) for providing lubrication to the pin bores 36 and/or to the inner faces of the pin bosses 34 to enhance lubrication with the wrist pin and connecting rod interface.
The piston is preferably cast from 4140H steel. Although not limited to a particular process, the piston may be cast using slow-fill counter gravity casting techniques which enables steel, which is otherwise prone to solidification, shrinkage and porosity, to be cast in complex thin-walled sections with intricate features, as are presenting the piston 10 , without forming unacceptable levels of porosity and solidification defects in the resultant casting.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A piston for diesel engine applications has a piston body cast entirely of one piece of steel and includes a piston head with a combustion bowl, a ring belt and an oil cooling gallery. A pair of pin bosses and a piston skirt are cast as one piece with the piston head out of the same steel material. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims the benefit of U.S. Provisional Application No. 60/934,384 filed Jun. 13, 2007, which is incorporated herein by reference.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
N/A
FIELD OF THE INVENTION
The present invention relates generally to insulating blankets and more specifically to insulation blankets for high temperature systems. The blanket can be selectively manufactured to encompass turbines, pumps and valves, piping/conduit (straight, elbows, valves, T's and Y's), fans and blowers, nuclear components, exchangers, headers and tanks, dryers and hoppers, and component parts and specialty equipment used for transporting or storing different materials in difficult environments. The thermal insulation blanket of the present development has an inner blanket core of aerogel material and is encapsulated by an insulative fabric cover that includes one or more drain openings and one or more breather vents.
DESCRIPTION OF THE PRIOR ART
Blanket-type insulation is frequently used in power plants and other extreme conditions requiring protection, insulation and/or acoustical dampening due to heat, cold and/or sound. Such blankets are typically removable and reusable and have a fiberglass core incased or encapsulated by a fiberglass or glass fabric. The blanket is held around the component, such as a vessel or pipe, by connectors, buckles/straps, spring clasps, and hook and loop type fasteners.
In some environments, the blankets are covered by metal jackets to protect the blankets from moisture. In indoor and outdoor environments wherein blankets are employed without a metal or water repellant/water-impervious outer jacket, the blankets have an inherited problem, they can absorb and hold moisture. Specifically, the blanket's outer fabric's weave and the needle holes in the seam can let moisture pass through the fabric layer to the inner insulating core.
The resulting wet-blanket becomes heavy, causing the blanket to sag down. The ingress and holding of water not only affects the insulating properties of individual components of the blanket (cover and core) but the geometry of the blanket relative to the object being insulated.
Blankets used in the manholes and tunnels can become completely submerged in water or surrounded by steam for extended periods. Once the water is removed from the surrounding environment, these blankets can be difficult, if not impossible, to remove as they are holding large amounts of water within. A standard 10″ or 12″ valve cover can weigh up to 200 lbs.
The present invention is provided to solve the problems discussed above and other problems. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.
SUMMARY OF THE INVENTION
The present invention is directed to an insulation blanket system. The insulation blanket system comprises an insulating core produced from a flexible aerogel, an outer layer of a fabric, an inner layer of a fabric, a pair of opposing end layers of a fabric wherein the insulating layer is substantially encapsulated by a combination of the inner, outer, and pair of end layers; and a plurality of fasteners located adjacent the opposing end layers for drawing the pair of end layers together forming a substantially tubular arrangement.
The flexible aerogel of the insulation blanket system may be hydrophobic.
The flexible aerogel of the insulation blanket system may be doped with a hydrophobic agent.
The flexible aerogel of the insulation blanket system may be selected from the group consisting of: a silica aerogel, a nanoporous aerogel, and an aerogel with reinforcing fibers.
The insulating core of the insulation blanket system may have a thickness between 6 mm and 20 mm.
The insulating core of the insulation blanket system may comprise a first layer of the flexible aerogel and a second layer of the flexible aerogel.
The first and second layers of the insulation blanket system may have a thickness between 6 mm (0.24 ins.) and 10 mm (0.40 ins.)
The insulating blanket may further comprise a drain opening in the outer layer located adjacent the end layers exposing a portion of the insulating core.
The insulating blanket may further comprise a breather vent in the outer layer located opposite the opposing end layers exposing a portion of the insulating core.
The drain may be produced from a brass grommet.
The vent may be produced from a two-piece brass screen.
The insulating blanket of may further comprise a plurality of tuft supports in the outer layer enhancing structural integrity of the blanket.
The insulating blanket may further comprise a plurality of tuft supports in the inner layer enhancing structural integrity of the blanket.
The present invention is an improvement on existing systems and tries to alleviate the above problems. The improved blanket of the present development includes an inner blanket core of an aerogel material, preferably Pyrogel®E 6350 insulation or Pyrogel® 10350 insulation, and is encapsulated by an insulative fabric cover that includes one or more drain openings and one or more breather vents. The stitching is preferably Teflon® or like material and the hardware is pure brass.
Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a perspective view (cross-section) of thermal insulation blanket made in accordance with the teachings of the present invention;
FIG. 1A is a sectional view along line A-A of FIG. 1 ;
FIG. 1B is a sectional view along line B-B of FIG. 1 ;
FIG. 2 is a detail drawing of the grommet used for the drain opening;
FIG. 3 is a detail drawing of the breather vent;
FIG. 4 is a perspective view of a grommet used in association with the drain opening; and
FIG. 5 is a perspective view of a vent used in association with the breather vent.
DETAILED DESCRIPTION
While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.
A blanket made in accordance with the teaching of the present invention is shown in FIG. 1 by the general reference number 10 . Blankets of this type are typically used in sections of piping/conduit having a valve connected thereto. Specifically, a front portion 21 of the blanket 10 covers a portion of the conduit going to the valve (not shown), a rear portion 22 of the blanket 10 covers a portion of the conduit leaving the valve, and an upper portion 23 of the blanket covers the valve, leaving an opening 24 for the valve control, such as a turning knob. In the construction of FIG. 1 , the blanket 10 is constructed of two (2) halves, a right blanket portion 25 and a left blanket portion 26 . The two blanket portions 25 , 26 are mated or placed in confronting relationship with their butt surfaces 33 abutting one another.
The blanket 10 has an outer fabric or skin 31 , an inner fabric or skin 32 , and a butt-end fabric or skin 33 encapsulating the insulating core 41 . The fabric/skin is sewn together. A plurality of tuft supports 35 , 36 are sewn into the blanket 10 to enhance the structural integrity of the blanket and prevent shifting. A plurality of fasteners 37 , 38 are employed to secure the blanket in place around the component to be insulated. D-rings and straps are shown, however, it is recognized by those in the field that other fasteners can be used, such as hook and loop type fasteners, laces, etc.
As noted, once the blanket 10 halves 25 , 26 are put around the object to be insulated, the butt ends 33 of the blanket are pressed against one another in abutting relationship and the fasteners 37 , 38 are mated and locked to ensure the blanket stays in its desired location and position.
The blanket 10 includes one or more breather vents 50 in the upper portion of the blanket and one or more drain openings 60 in the lower portion of the blanket.
The drain opening 60 provides an opening through the outer fabric 31 to the core 41 . In the preferred embodiment, the opening 60 is supported or fixed by a two piece grommet 61 , 62 ( FIG. 4 ), specifically a pure brass # 1 grommet. It has been learned that pure brass is important as it does not corrode like stainless steel. The drain opening 60 permits liquids, such as water entering into the enclosed core to drain out of the system.
In the preferred embodiment, there are two (2) drain opening 60 per blanket on each side of the blanket (e.g., the right side and the left side of the blanket or the right blanket portion 25 and the left blanket portion 26 ). The preferred locations of the openings 60 are at the bottom of the valve (not shown), in the center and on each side of the valve.
The purpose of the breather vent 50 is to permit air to enter the outer fabrics or skins 31 of the blanket to the core 41 and to let moisture escape in the form of steam or vapor. It has been found that to the extent residual moisture stays inside the skins 31 , 32 , 33 or on the core 41 and/or inner skin surfaces 32 , mold can occur. The breather vent 50 is a pure brass vent #D3926. In the preferred embodiment, the opening vent 50 is supported or fixed by a two piece construction 51 , 52 ( FIG. 5 ). At least one of the two pieces 51 , 52 includes a mesh, e.g., surface with a plurality openings therein with a mesh or particle size. The breather vent 50 is installed just like a standard grommet.
It should be noted that preferably all hardware associated with the blankets of the present invention (such as tags, hooks, D-rings, etc.) are made of pure brass and the threading used to sew/stitch the blankets is pure Teflon® or similar material.
As to core insulation 41 , it is preferably made with Pyrogel® insulation, produced by Aspen Aerogels, Inc., Northborough, Mass. This material is a flexible aerogel, nanoporous insulation specifically designed for high temperature applications. Generally, aerogels are nanoporous solids created when silica is gelled in a solvent. When the solvent is removed, the remaining product is a puffed-up, sand-like substance with up to 99% porosity. The nanoporosity slows heat and mass transport, providing very low thermal conductivity. It has some of the following characteristics: very low thermal conductivity, high temperature resistance, good flexibility, and relatively easy of use. The material combines a silica aerogel with reinforcing fibers (non-woven, carbon- and glass-fiber batting). It can be cut using conventional textile cutting tools, including scissors, electric scissors and razor knives. The material can be stitched to high temperature cloth and encapsulated as with the present product.
The material is preferably used in two (2) thicknesses, that being 6 mm (0.24″) (Pyrogel® 6350 insulation) and 10 mm (0.40″) (Pyrogel® 10350 insulation). These sizes can be stacked to together to obtain thicknesses of 12 mm (0.48″), 20 mm (0.8″), 16 mm (0.64″), etc. Silica aerogels possess the lowest thermal conductivity of any known solid. For example, such aerogels can be used up to 725° F. (385° C.), are hydrophobic, and have a density of about 10.7 lb/ft 3 (0.17 g/cc). They are roughly 2 to 8 times better than other insulating products, and can be used with a smaller or reduced thickness or profile. They can be easily cut and conformed to complex shapes, tight curvatures, and spaces with restricted access. They are physically robust, soft and flexible but with excellent springback. For example the material recovers its thermal performance even after compression events as high as 50 psi. It has been found that the material has equal or better fire protection characteristics than mineral wool and/or calcium silicate. And, significantly, the material repels liquid but allows vapor to pass through. In addition, if the material is doped with a hydrophobic agent, it will help make the material resistant to moisture. Water ingression can be desorbed when the materials is exposed to a heated environment.
See Table 1 below.
TABLE 1
Product Specifications
Nominal
Max. Use
Product
Thickness
Thermal Conductivity
Density
Temp.
Pyrogel ®
6 mm
15.5 mW/m-K
0.17 g/cc
385° C.
6350
0.24 in
0.107 Btu-in/hr-ft 2 -° F.
10.7 lb/ft 3
725° F.
Pyrogel ®
10.0 mm
15.5 mW/m-K
0.17 g/cc
385° C.
10350
0.40 in
0.107 Btu-in/hr-ft 2 -° F.
10.7 lb/ft 3
725° F.
In experiments, it has been found that with the lower K factor (thermal conductivity), two inches (2″) of traditional Tem-Mat 9 lb./cu,ft density insulation can be replaced by 1 layer of the 6 mm and 1 layer of the 10 mm aerogel (approx. 16 mm or ¾″). It has been observed that for lower temperature environments, only one layer of the Pyrogel® insulation needs to be used, such as the 6 mm or the 10 mm sizes.
The terms “first,” “second,” “upper,” “lower,” “front,” “back,” etc. are used for illustrative purposes only and are not intended to limit the embodiments in any way. The term “plurality” as used herein is intended to indicate any number greater than one, either disjunctively or conjunctively as necessary, up to an infinite number. The terms “joined” and “connected” as used herein are intended to put or bring two elements together so as to form a unit, and any number of elements, devices, fasteners, etc. may be provided between the joined or connected elements unless otherwise specified by the use of the term “directly” and supported by the drawings.
Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood within the scope of the appended claims the invention may be protected otherwise than as specifically described. | The present invention discloses a thermal insulating blanket ( 10 ) including an insulating core ( 41 ) encased in a fibrous envelope with at least one breather vent ( 50 ) in the upper portion of the outer enveloping cover ( 31 ) and at least one drain opening ( 60 ) in the lower portion of the outer enveloping cover. | 8 |
This application is a continuation of application Ser. No. 07/417,289, filed Oct. 5, 1989 now abandoned which is a continuation of Ser. No. 797,777, filed on Nov. 12, 1985, now U.S. Pat. No. 4,884,563 issued on Dec. 5, 1989 which was a continuation-in-part of Ser. No. 707,233, filed on Mar. 1, 1985, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to wound dressings and methods for making same, and in particular to a wound dressing which can be applied to a patient without stretching thereof, and a method for the continuous production of a large number of such wound dressings.
2. Description of the Prior Art
Wound dressings consisting of thin flexible material, such as polyurethane, having adhesive on one side, which are applied to an open wound of a patient after medical treatment of the wound are known in the art. The flexible nature of the polyurethane permits the dressing to conform to virtually any contour of the patient at the location where the dressing is applied. The flexibility and thinness of the wound dressing, however, present the problem of applying the dressing to the patient without stretching the dressing. Stretching of the dressing prior to or during application thereof to a patient will momentarily expand the stretchable urethane, and even though the dressing may appear smooth when applied to the patient, the urethane will very quickly thereafter contract after the stretching forces are relieved, thereby causing discomfort to the patient and irritation to the area surrounding the wound. On weak or damaged skin, as in the elderly, the stretching forces can cause serious skin damage, such as an abcess. One proposed solution to the stretching problem was to use heavier polyurethane materials. These heavier materials are not desirable as a wound dressing due to decreased flexibility and less gas permeability.
Another proposed solution to this problem is to provide a flexible but non-stretching backing for the urethane wound dressing which remains in contact with the wound dressing by adhesive while the dressing is being applied to the patient, and is separated from the wound dressing only after the dressing has been placed on the patient, thereby eliminating stretching during application of the dressing. Such a wound dressing is described, for example, in European patent EP 0 066 899 A2. The wound dressing disclosed therein is a film sheet of polyurethane having adhesive on one side thereof which is applied to a patient. A non-stretchable film sheet carrier is pressed against the opposite side of the film sheet. The carrier may be bound to the film sheet either by the adhesion resulting from the polyurethane film sheet casting process, on a non-stretchable film sheet carrier or by a heat-dependent process to the non-stretchable carrier. A combination polyurethane film and MYLAR® polyester film (E. I. du Pont de Nemours, Wilmington, Del.) are commercially available. To this combination is added a free film of adhesive with the top adhesive backing left on the polyurethane film MYLAR® polyester film. Adhesive backing is peeled away prior to application to a patient. After the adhesive side of the film sheet is brought into contact with a patient, the Mylar® is peeled from the other side of the film sheet leaving polyurethane on the wound.
Another problem encountered when applying the polyurethane film to the wound is maintaining the sterility of the dressing during the application process. Previous products such as the polyurethane film wound dressings Ensure-It® (Deseret Medical, Inc.) and POLYSKIN® transparent dressing (Kendall Company, Boston, Mass.) required contact between fingers and the adhesive surface of the polyurethane film during application, thereby potentially contaminating the adhesive surface adjacent to the wound beneath the polyurethane.
Still another problem is the presence of a tab or tabs remaining on the polyurethane film after application to the wound surface. The presence of a tab often results in a gradual loosening of the polyurethane film to skin adhesive bond resulting in a curling-up of the polyurethane film edge adjacent to the tab.
One solution to this tab problem required a perforation adjacent to the tabs, thereby allowing removal of the tabs after application of the polyurethane film to the skin surface. However, the act of tearing of the tab perforations disturbs the adhesive bond, distorts or stretches the polyurethane film and microbially contaminates the adhesive, thereby resulting in a less secure, less sterile and less comfortable wound dressing.
There has been a long felt need for a polyurethane film product that provides ease of application, maintains sterility and does not require distortion of the film sheet by tearing operations. The tab systems of the present invention meet this need.
Alvarez et al., Infections in Surgery, p. 173, Mar. 1, 1984, presented evidence that a completely occlusive dressing such as hydrocolloid, best promoted the healing rate of wounds up to 96 hours. After longer periods of time, 96 hours or longer, a gas permeable polyurethane film resulted in superior healing rates as measured by collagen synthesis. These results suggest that for some applications the ideal wound dressing would function as a completely occlusive dressing for a first period of time, then function as a semi-occlusive dressing for a second period of time.
The layered construction of wound coverings containing gas permeable polymers has long experienced a problem in manufacturing. The casting of a polymer film sheet, such as polyurethane, on a casting sheet resulted in a weak electrostatic bond (corona coating) between the liner and polymer film sheet. This weak bond was weakly effective at holding the film sheet to the liner. If this liner was used as a cover sheet it was not-replaceable once removed. Wound coverings were limited to the types of liners that could be used as casting sheets for the polymer; such use requires resistance to casting heat. The most common liner being MYLAR® polyester film, a relatively stiff material not possessing the flexible properties desired in a material suitable for the application as a flexible wound cover contouring agent. A need existed for a production method allowing the insertion of adhesive and the substitution of a more flexible cover sheet.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a non-stretchable wound dressing which can be manufactured by overlying a series of continuous strips.
It is a further object of the present invention to provide such a wound dressing wherein the release characteristics between the wound dressing and the non-stretchable cover sheet can be controlled independently of the release characteristics between the wound dressing and the carrier sheet.
Another object of the invention is to provide a tab system that allows support of the non-stretchable wound dressing following removal of the carrier sheet. Still another object of the invention is to provide a tab system that allows manipulation of the wound dressing without contaminating contact between the sterile polyurethane film adhesive and the wound dressing applier's manipulating fingers. Yet another object of the invention is the presence of a tab system that prevents contact between the adhesive on the polyurethane film and the adhesive on the non-stretchable cover sheet, such contact being a source of defective applications. One object of the invention is the presence of a tab system that permits application of the wound dressing with one hand, such as self-application to the arm or hand. Another object of the invention is the optional presence of skin binding adhesive on the tabs of the non-stretchable cover sheet which permits the use of the cover sheet as a first 100% occluding wound cover, and following removal of this cover sheet, secondarily permits the semi-occluding polyurethane film to continue to cover the wound.
Yet another object of the invention is the coding of the tabs to indicate the sequential order of utilization of the tabs; Still another object of the invention is a wound dressing incorporating a hierarchy of adhesive strengths wherein the adhesive strength (1) of the bond between carrier sheet and polyurethane film is less than the adhesion strength (2) of the bond between the polyurethane film and the non-stretchable cover sheet, and this adhesion strength (2) is less than adhesive strength (3) of the bond formed between the polyurethane film adhesive and a biological surface or skin.
Yet another object of the invention is to provide a wound dressing wherein the film sheet contains an adhesive free area of less than 90% of the film sheet area, more preferably an adhesive free area of less than 50% of the film sheet area, and most preferably an adhesive free area of less than 30% of the film sheet area. Still another object of the invention is to provide a wound dressing wherein the film sheet contains an absorbent material covering less than 90% of the film sheet area, preferably less than 50% of the film sheet area and most preferably less than 30% of the film sheet area. The absorbent material may contain nothing; it may contain a medication such as an antibiotic, an anti-inflammatory compound, a pharmaceutical compound suitable for transdermal application, or a growth promoting hormone; and it may be opaque to block visualization of the wound and contain absorbent material as insulation to retain warmth in the wound region.
The above objects are inventively achieved in a non-stretchable wound dressing consisting of a thin film of material such as polyurethane having adhesive on one side thereof, and covered on the opposite side with a non-stretchable cover sheet, such as Mylar®, having two spaced tabs on opposite sides thereof. the adhesive side of the wound dressing is in contact with a release surface of a carrier, which may otherwise be comprised of heavy paper. Pulling the first gripping tab 1 lifts the combination wound dressing-cover sheet from the release surface of the carrier, and the second tab 2 provides another gripping area to place this combination over a wound without stretching the polyurethane sheet and without the necessity of the fingers of the person applying the dressing ever coming into contact with any part of the dressing which will be in contact with the patient, thereby avoiding transfer of dirt and infective microbes. After the combination wound dressing-cover sheet has been placed over the wound, the second tab 2 is pulled and, because the adhesive strength between the patient and the wound dressing is selected to have greater adhesive properties than the adhesive between the cover sheet and the wound dressing, the cover sheet is peeled away from the wound dressing, leaving it in place on the patient without stretching or wrinkling thereof. In one variation, a third tab 3 may be attached to a minor cover sheet located below the second tab 2, tab 2 being attached to the major cover sheet and tab 1.
Various different embodiments utilize a variety of agents and structures to promote easy release of the cover sheet from the wound dressing and/or of the wound dressing from the carrier sheet, among them gauze, and ink containing silicone or paraffin.
An object of the invention is a method of manufacturing wound coverings incorporating:
(a) a tab system for application, wherein roll stations continuously supply the materials for layered assembly of the tab system, and
(b) formation of a packaging envelope as a final layered assembly step wherein the packaging roll stations increase the feed rate of top and bottom packing material wider than the wound coverings such that sufficient excess packing material between wound coverings permit the formation of a package seal capable of maintaining a sterile barrier around the enclosed wound covering.
This method for manufacturing a large number of such wound dressings has a plurality of stands or stations each having a pair of rolls forming a nip, and the upper roll of each station receiving at least one component of the wound dressing package in continuous feed from a supply roll. The various components in this strip form are applied over each other in connected layers. A last station cuts the continuous web of layers so as to produce the individual wound dressings, and the now-cut wound dressings are transferred onto a moving paper web which will form one side of a packaging envelope. The opposite side of the envelope is provided from above, sandwiching the wound dressings therebetween. The speed of the rolls at the station following the web cutting station is slightly higher than the speed of the preceding rolls, thereby providing increased spacing between the cut wound dressings. The top and bottom of the envelope webs are heat sealed or pressure sealed, and the spaces between the separated wound dressings are cut to form individual packaged dressings.
Another object of the invention is a manufacturing process wherein beneath the first tab, a narrow bond is formed between the film sheet adhesive and the cover sheet adhesive thereby insuring the successful removal of the cover sheet--film sheet combination from the carrier sheet upon pulling the first tab. A roller apparatus is utilized to exert pressure on the cover sheet just above the film sheet edge beneath the first tab, thereby insuring that sufficient adhesive bleeds out along the edge of the film sheet and forms a strong bond to the cover sheet adhesive.
Still another objective of the invention is a manufacturing process wherein beneath the second tab, a sheet of material is placed along the edge of the film sheet to insure that no bond is formed by the leaking of film sheet adhesive to contact the cover sheet adhesive. This prevention of a bond forming beneath the second tab, between the two adhesive layers, is critical to insure the reliable removal of the cover sheet from an undistorted film sheet after application to the patient surface. One method of preventing the bond between the adhesive layers beneath the second tab is the presence of a minor cover sheet over the film sheet edge. Attached beneath the inner edge of the minor cover sheet is third tab suitable for removing the minor cover sheet by pulling the third tab in a direction opposite the pulling direction of the second tab. The third tab--minor cover sheet system insures the easy removal of the major cover sheet by physically blocking the formation of a bond between the film sheet adhesive and major cover sheet adhesive. The minor cover sheet is held in place by a narrow band of cover sheet adhesive that binds along the top edge of the film sheet, but that does not extend adhesively to the extended minor carrier sheet.
Yet another object of the invention is a manufacturing process wherein the polyurethane film sheet is applied to a carrier such that the edges of the carrier sheet extend beyond the edges of the film sheet a distance suitable for gripping the extended carrier sheet as a tab but not touching film sheet surface.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a packaged wound dressing constructed in accordance with the principles of the present invention;
FIG. 2 is an end view of the packaged wound dressing shown in FIG. 1;
FIG. 3 is a side view, partly in section taken along line III--III, of the wound dressing in FIG. 1 with the package removed;
FIG. 4 shows a first step in applying the wound dressing of FIG. 1 to a patient;
FIG. 5 shows a second step in applying the wound dressing of FIG. 1 to a patient;
FIG. 6 is a side view of a further embodiment of a wound dressing constructed in accordance with the principles of the present invention;
FIG. 7 is a side view of one end of a further embodiment of a wound dressing constructed in accordance with the principles of the present invention;
FIGS. 8, 9, 10, 11, 12 and 13 are perspective views of one end of a wound dressing constructed in accordance with the principles of the present invention showing different embodiments for promoting release of the cover sheet from the film sheet; and
FIG. 14 is a schematic side elevational view of an apparatus for manufacturing and packaging wound dressings in accordance with the method of the present invention in continuous feed.
FIG. 15 is a top view of the three tab system wound covering.
FIG. 16 is a sideview taken in section along the lines indicated in FIG. 15 marked 2.
FIG. 17 is a view of the three tab system showing the removal of the non-stretching carrier sheet and film sheet by pulling on the first tab.
FIG. 18 is a view of the film sheet adhesively bound to the skin with the second tab being removed to leave the film sheet on the skin surface, the third tab has been lifted in the right corner to demonstrate how removal of the third tab and minor cover sheet is accomplished.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention meets a long felt need for a wound dressing that can be easily and safely applied. This wound dressing can be applied to any type of wound or to an intraveneous site (I.V. site). The transparent construction of the cover sheet and film sheet allow visual observation of the wound site during application and while on the patient. The cover sheet provides temporary 100% occlusion of the wound and can be removed easily using the two or three tab application systems. The cover sheet and tabs provide support for the wound dressing until after application. The cover sheet can then be removed without distorting or stretching the film sheet affixed to the patient surface or skin. If necessary, this wound dressing can be applied with one hand. The tabs are optionally marked with indicia indicating the order of utilization, thereby permitting error free application on the first attempt even by the inexperienced. The wound dressing may contain an area free of skin binding adhesive to allow easier removal from the wound area. The wound dressing may contain an absorbent material adjacent to the wound surface to absorb moisture or to allow delivery of medication. The wound dressing may be a surgical wrap suitable for application to protect the patient surface during surgery.
A packaged wound dressing constructed in accordance with the principles of the present invention is shown in FIG. 1 generally referenced at 1. The wound dressing 7 is contained in a package or envelope 2 consisting of a bottom 3 and a top 4, as best shown in FIG. 2. The bottom 3 and the top 4 are joined together at their margins on at least three sides by an adhesive zone 5 which surrounds but does not touch the wound dressing 7. The zone 5 may be produced by pressure, heat, adhesive, or any other suitable web joining means known to those skilled in the art. The bottom 3 and top 4 of the envelope 2 may be comprised of relatively heavy paper, or one of the pieces, such as the top 4, may be at least partially transparent so as to permit viewing of the wound dressing 7 therethrough. In the embodiment shown in FIG. 1, one end of the envelope 2 is unsealed, leaving an opening 6 for access to the wound dressing 7. It is also possible, however, to seal that end as indicated by the zone 5a. The two pieces 3 and 4 can be pulled apart with relatively little effort because the adhesive zone 5 (and 5a) is intentionally not particularly strong, and it is also possible to offset the zone 5a from the extreme edge of the envelope so as to provide a non-adhering flap or tab to provide a location to start the separation.
The strength of the adhesion bonds between the respective layers of the wound dressing are as follows. The carrier sheet to film sheet adhesive bond that is broken by pulling on the first tab has adhesion strengths from 0.01 to 4 grams/inch, preferably from 0.5 to 2 grams/inch, and most preferably 0.75 to 1.5 grams/inch. The inch measurements refer to the width of the wound covering perpendicular to the direction of tab removal.
The cover sheet to film sheet adhesive bond that is broken by pulling on the second tab is from 2 to 7 ounces/inch, preferably from 3 to 5 ounces/inch and most preferred from 3.5 to 4.0 ounces/inch.
The film sheet to skin adhesive bond that holds the film sheet to the patient has an adhesion strength when measured by a stainless steel 180° peel test of from 2 to 4.5 lbs. per inch.
Procedure for 180° Peel Adhesion Test
Measurement of the adhesive strength is accomplished by use of the PSTC #1 Test. Briefly, the test measures the tension when pulling a 1 inch×6 inch sample from a clean stainless steel plate while pulling at a 180° angle at a rate of 12 inches per minute. The test is accomplished on a Keil release tester or constant extension rate testing machine. The standard test conditions are 23°±2° C. and a relative humidity of 50%±2%.
A need has existed for a wound covering production method that included a gas permeable film sheet, such as polyurethane, on a carrier surface that positioned the film sheet at the center strip on a carrier with the carrier extending on either side. The casting sheet material used in the standard production method of polyurethane, is a material similar to Mylar®, the trademark for a polyester film, particularly polyethylene terephthalate. The casting sheet extending from end to end beneath the film sheet. To produce a region on either side of the casting sheet that is not covered by the film sheet, requires cutting of the film sheet and removal of the cut sides from the casting sheet.
If an adhesive is placed between this casting sheet, or a replacement carrier sheet, and the film sheet; then a silicone coating is required on the casting or carrier sheet to facilitate release of the casting or carrier sheet from the film sheet. With the silicone and adhesive in place, the cutting of the film sheet will damage the silicone coating on the casting or carrier sheet. This damage to the silicone results in binding of the adhesive to the casting or carrier sheet resulting in a defective wound covering.
The film sheet material may be urethane, copolymer or any flexible breathable polymer.
The production method of the present invention process allows the insertion of an adhesive layer between a casting sheet or a carrier sheet and the film sheet without the requirement of a cutting step to produce tabs at either side of the film sheet.
The procedures described in examples 1 and 2 describe the production of a two and three tab system for applying a wound covering. The method described allows the highly efficient production of such wound dressings that contain adhesive between the carrier and film sheet. These methods allow use of film sheet and adhesive free areas of the carrier for grasping to facilitate release of the cover sheet.
The use of the production methods of this invention allows more than a 10-fold production increase over previous methods, such as those of heat sealing the cover sheet to the film sheet.
EXAMPLE 1
Two Tab System
A first embodiment of the wound dressing with the envelope package removed is shown in FIG. 3, partly in section. The wound dressing 7 consists of a carrier sheet 8 which may be of plastic or relatively heavy paper. If the carrier sheet 8 is comprised of paper, one side of the carrier sheet 8 may be provided with a slick, smooth release surface 9. A film sheet 10, which will be used to cover the wound, is placed over the release surface 9 of the carrier sheet 8, the film sheet 10 having adhesive 11 on one side thereof adjacent the release surface 9. The side of the film sheet 10 not having adhesive thereon is in contact with an adhesive layer 16 carried on one side of a non-stretching but flexible cover sheet 15, which may be comprised, for example, of MYLAR® polyester film. A first gripping tab or strip 12 is bonded at one end of the cover sheet 15 by any suitable adhesive. A second gripping tab or strip 13 is carried at an opposite end and on an opposite side of the cover sheet 15, connected thereto by any suitable bond schematically represented at 14.
Application of the wound dressing to a portion 17 of a patient is shown in FIGS. 4 and 5. The tab 12 is gripped and pulled. By the combination of the release surface 9 and the relative strengths of the adhesive layers 11 and 16, pulling on the gripping tab 12 causes release of the adhesive layer 11 from the release surface 9, with the cover sheet 15 still adhering to the opposite side thereof. This combination is then placed over the wound of a patient, with the person applying the dressing gripping the opposite end of the cover sheet 15 at the gripping tab 13. The fingers of the person applying the wound dressing therefore need never come into contact with the adhesive layer 11 which will be placed against the patient's skin. Once in place, the adhesion of the layer 11 to the patient's skin is greater than the adhesion via the layer 16 between the cover sheet 15 and the film sheet 10, thus as shown in FIG. 5, and tab 13 can be pulled thereby removing the cover sheet 15 and leaving the film sheet 10 adhering to the patient. This release can be accomplished solely by selecting the relative strengths of the adhesive layers 11 and 16, or can be assisted and promoted by various agents and structures shown in the embodiments discussed below.
Another embodiment of a wound dressing constructed in accordance with the principles of the present invention with the package removed is shown in side elevational view in FIG. 6. Components thereof which are identical to the embodiment shown in FIG. 3 are identified with the same reference numerals. In this embodiment, the gripping tab 12 is on the upper side of the cover sheet 15, being affixed thereto by any suitable bonding, schematically represented at 12a. The carrier sheet 8 may be scored along a line 8a to promote pulling of the tab 12, which extends slightly beyond the film sheet 10. Pulling the tab 12 again releases the combination of the cover sheet 15 with the film sheet 10 adhering thereto from the carrier sheet 8. This combination is again placed over the wound, and the tab 13, which may extend beyond the opposite end of the film sheet 10 is pulled to release the cover sheet 15 from the film sheet 10. Release may be promoted by a gauze or paper strip 19 affixed to the non-adhesive side of the film sheet 10 by a bonding of any suitable type schematically represented at 20. The strip 19 remains in place when the film sheet 10 is on the patient, however, the strip 19 is sufficiently flexible so as not to interfere with the ability of the film sheet 10 to conform to the contour of the patient. One source of material for strip 19 is the MICROPURE® surgical adhesive tape (3M Corporation, St. Paul, Minn.). The presence of strip 19 ensures the even application of the wound dressing to the patient surface by promoting evenly distributed tension between the cover sheet 15 and the film sheet 10 as it is released by pulling on tab 13. This even release ensures that the film sheet 10 will not be distorted by excessive distorting stress on any one region of the film sheet.
Yet another embodiment of one end of the wound dressing is shown in FIG. 7, wherein the tab 12 is beneath the film sheet 10, interposed between the adhesive layer 11 and the release surface 9 to promote the initial separation of the film sheet 10 from the carrier sheet 8.
Various embodiments showing different means for promoting release of the cover sheet 15 from the film sheet 10 once the film sheet 10 is in place over a portion 17 of a patient are shown in FIGS. 8 through 13. In FIG. 8, this means consists of a plurality of inked lines 21 printed over the adhesive layer 16. This provides sufficient interruption of the adhering properties of the adhesive layer 16 to facilitate easy removal. In the embodiment of FIG. 9, the release promoting means consists of a laterally inked zone 22 printed over the adhesive 16.
The inked zone is made by applying an ink containing an adhesive deadening agent. Among the adhesive deadening agents are silicone and paraffin. Ink is applied to the adhesive area to be deadened until 50% to 95% of the adhesive bond is lost, or more preferably 70% to 92% of the adhesive bond is lost; and most preferably 80% to 90% of the adhesive bond is lost.
In FIG. 10 the release promoting means consists of a plastic or fiber mesh 23.
In the embodiment of FIG. 11, the release promoting means consists of a smooth slick strip 24 which can either be left in place if made suitably narrow, or can be peeled away if desired.
In the embodiment of FIG. 12, the release promoting means is a paper strip 25 having a series of perforations 26 therein.
EXAMPLE 2
Three Table System
The general layered structure of Example 1 is repeated in the three tab system, except the release material 19 in FIG. 6 is functionally replaced by a third tab attached to a flexible sheet 27 in FIG. 13.
In the embodiment of FIG. 13, the release promoting means is not affixed to the adhesive 16, but is rather interposed between the adhesive layer 16 and the non-adhesive side of the film sheet 10. In this embodiment, a flexible sheet 27 has a release surface 28 which is interrupted in the zone indicated by the arrow 29. Normally the portion of the sheet 27 overlying the film sheet 10 is covered by the tab 13, however, when the tab 13 is pulled away, that portion of the sheet 27 is exposed and the non-adhering portion at the surface 28 provides a third tab to pull the remainder of the sheet 27 away, leaving the film sheet 10 in place on the patient. The third tab may be only the flexible sheet 27 as illustrated in FIG. 13 or it may have a tape tab affixed above or below the flexible sheet 27 in the region 28. In FIG. 15 a top view is shown illustrating the relative positions of the first tab (tab 1), the second tab (tab 2) and the third tab (tab 3). A cross section of FIG. 15 is shown in FIG. 16 which illustrates the positions of the third tab 30 beneath both the sheet 27 and the major cover sheet 15. The first tab 12 in FIG. 16 is lifted to remove the cover sheet 15 from the carrier sheet 8. This lifting of the first tab is illustrated in FIG. 17. After the wound dressing is applied to the wound, the second tab 13 (FIG. 16) is lifted to remove the major cover sheet 15. FIG. 18 illustrates the lifting of the second tab and major cover sheet to expose the third tab and minor cover sheet. In FIG. 16 the third tab 30 is exposed when the second tab 13 is lifted to remove the major cover sheet. The minor cover 27 is removed by pulling the third tab 30 in a direction opposite to the direction the second tab was pulled. This is illustrated by FIG. 18 where the right corner of tab 3 is being lifted to remove the minor cover sheet and leave a completely applied film sheet on the wound area without stressed areas or microbial contamination of the wound area.
All three tabs may bear an indicia indicating the order of use. The third tab may bear an indicia indicating it is the third tab in the three tab system. Similarly the first tab 12 may contain an indicia incidating it is the first tab in the three tab system and tab 13 may contain an indicia indicating it is the second tab in the three tab system. Indicia useful for marking on the three tab system include 1, 2, 3; I, II, III; A, B, C; Tab 1, Tab 2, Tab 3; First, Second, Third; Pull First, Pull Second, Pull Third; and other analogous instructions that allow the error free application of the wound dressing. This three tab system allows the application of the wound dressing using only one hand, particularly valuable for self-application to the hand or arm. Two hands are used to remove the carrier sheet 8, by holding the first tab 12 and the second tab 13 then the free hand applies the wound dressing and removes the flexible cover sheet 15 by pulling on the second tab. The third tab in region 28 of FIG. 13 is then pulled to leave the tab free wound dressing on the patient.
A suitable material for the film sheet 10 is urethane number 5020 available from Avery International, Fasson Industrial Division, of Plainesville, Ohio.
EXAMPLE 3
Wound Covering with Adhesive Free Area
The wound coverings of Examples 1 and 2 can be produced with an area free of the patient binding adhesive layer 11 (FIGS. 3, 6, 13). An adhesive free area is useful in wound coverings in that the wounded tissue may better heal if not in direct contact with adhesive. In addition, the removal of the film sheet 10 (FIGS. 3, 6, 13) from the wound surface can cause additional trauma to the healing wound surface. The adhesive free area may be less than 95% of the surface area of the film sheet 10, preferably less than 50% of the area of film sheet 10, and most preferably it is less than 30% of the area of film sheet 10. The adhesive free area may be prepared by any of several methods known in the adhesive industry. One method is the modification of the adhesive bearing web 39. (FIG. 14) before it is applied to the exposed side of the film sheet. A silicone coated cover sheet is mated with the adhesive bearing web 39 to reversibly enclose the adhesive layer between two silicon coated materials. A die of the desired shape (square, circle, diamond, ellipse, etc.) and of the desired area is used to punch out a hole in the adhesive plus enclosing material. The silicone coated cover sheet is then removed and the adhesive layer (web 39) is applied to the film sheeting as described in Example 5.
EXAMPLE 4
Absorbent Pad Containing Wound Covering
The wound coverings of Examples 1, 2 and 3 may be modified to contain an area of hydrophilic absorbent material. The area of absorbent material may cover less than 95% of the surface area of the film sheet 10 (FIGS. 3, 6, 13), more preferable the absorbent material may cover less than 50% of the surface area of film sheet 10, most preferably the absorbent material may cover less than 30% of the surface area of film sheet 10. The absorbent material may be of any desirable shape including a square, rectangle, circle, diamond or ellipse. The absorbent material may contain nothing in which case it is suitable for absorbing moisture from the wound area.
The absorbing material may contain medication. The medication may be an antibiotic, a healing promoting agent, an anti-inflammatory agent, a transdermal diffusable pharmaceutical, a coagulant or an anti-coagulant. Among the anticipated antibiotics are typical bacteriostatic and bactericidal agents, anti-fungal and anti-viral agents. Among the anti-bacterial agents and anti-fungal agents are the penicillins, streptomycins, sulfuramides, cephalosporins, kanamycins, gentamicin, tobramycin, neomycin, paromomycin, chloramphenicol, tetracyclines, lincomycin, novobiocin, nalidixic acid, rifamycins, polymyxin B, griseofulvin, pimaricin, conystatin, amphotericin B; and for viruses rifamycin, nucleic acid analogs, arabinosyl thymine, 5-iodo-5'amino-2'-5'dideoxycridine, arabinosyl adenine, arabinosyl cytosine, acycloguanosine, ribavirin, phosphono acetic acid, and idoxuridine. Among healing promoting agents are growth promoting hormones, among them epidermal growth factor and urogastrone. Among the anti-inflammatory agents are the corticosteroids. Among the transdermal diffusable pharmaceuticals are nitroglycerin, and other cardiac and blood pressure effecting agents. Among the coagulants are the blood clotting factors and activators of the intrinsic or extrinsic clotting pathways. Among the anti-coagulants are heparin, citric acid, protamine sulfate, and other inhibitors of blood clotting. Also useful as anti-blood clotting agents are thrombolytic enzymes such as streptokinase and urokinase.
The presence of an absorbent material or a hydrophilic absorbent material patch not only serves as an absorbent, it also serves as an insulating material that holds the body's warmth at the wound site. This increase warmth due to the patch facilitates a more rapid healing of the wound. If an absorbent material patch is present under a gas permeable wound dressing, and the moisture or medication on the patch is subject to excessive drying, a gas impermeable piece of material, such as polyethylene, can be placed over the absorbent patch area to decrease moisture loss.
An advantage of the use of adhesive to bind the cover sheet to film sheet is the ability to rebind the cover sheet to the film sheet. This allows inspection of the wound when vision is impeded by the cover sheet. The ability to remove the cover sheet for inspection is particularly useful in intraveneous punctures where the needle site must be regularly inspected. Visual inspection of the wound and replacement of the cover sheet is useful in applications with children, colostomy devices, burns and any situation when inspection is required, but a return of the gas impermeable cover sheet is desirable.
The absorbent material may be gauze, sponge or other inert absorbent material. The absorbent material may be clear or opaque to conceal the wound area. Among the hydrophilic absorbent materials are poly (D-Glucosamine) from Bentech Laboratories and ARASORB 720® superabsorbent polymer (Arakawa Chemical Inc., Chicago, Ill.).
EXAMPLE 5
Two Stage Wound Covering
In another embodiment of the invention, the wound covering of Examples 1, 2, 3 and 4 contains skin binding adhesive beneath the first tab (12, FIGS. 3, 6 and 13) and beneath the second tab (13, FIGS. 3, 6 and 13). This skin binding adhesive is of a strength similar to that on the film sheet (10) and permits the cover sheet to remain on the patient for a period up to 96 hours to allow gas impermeable, 100% occluded wound healing. The cover sheet can then be removed to allow the gas permeable film sheet (10) to remain on the wound for an additional period of time. This two stage wound covering allows flexibility in regulating the period of time the wound area will be covered by gas permeable and gas impermeable wound coverings without the need to change the wound covering in contact with the patient.
EXAMPLE 6
Tab System Surgical Drape
The wound coverings of Examples 1, 2 and 3 may be in the form of a surgical drape or wrap suitable for application to the surface of a patient before surgical procedures. The surgical wrap may contain a film sheet 10 (FIGS. 3, 6, and 13) that is either gas permeable or gas impermeable. It may be constructed of polyurethane or other gas permeable materials. It may be constructed of polyethylene or other gas impermeable materials. The tab systems permit the easy application to the patient surface with the tabs providing additional support to the flexible cover, allowing easy manipulation and placement at the appropriate location. The dimensions of the surgical wrap are variable and range from 1 inch×2 inches to 24 inches×36 inches.
EXAMPLE 7
Method for Wound Covering Production
An apparatus for undertaking the method disclosed herein for continuous production of wound dressings of this type solely from web material is shown in FIG. 14. The apparatus is generally referenced at 28 and has first motor 30 with a drive train schematically represented at 31 for rotating rollers comprising successive nips in stations or stands 32, 33, 34, 35, 36 and 37. Although in FIG. 14 both rollers in each nip are shown as driven by the motor 30, it is possible to operate the apparatus 28 with only one roller, such as the upper roller, in each nip being driven. A web of film sheet adhering to a liner is supplied from supply reel 40, the combination film sheet and liner web being indicated at 39. This web 39 passes between rollers 41 and 42 wherein an adhesive is applied to the exposed side of the film sheet. The web continues to the next station 33, passing through rollers 43 and 44 with the sheet transferring to roller 44 and the liner transferring to the roll 43. The now-separated liner 45 is received on a take up roll 46, which may be separably driven by a motor 47. The film sheet continues to station 34 wherein it is joined with the carrier sheet which has two tabs on each side thereof supplied from reels 48 and 49, passing around roll 50. The liner on which the tabs were originally carried is separated by a doctor assembly 51 and the liner 54 is disposed of. In the next station the inside paper tab supplied in web form 56 from a reel 55, passing through rollers 57 and 58 in station 35. The cover sheet is also supplied in web form to station 35 from a reel 59. The outside paper tab is then supplied from a reel 81 in station 36 between rolls 63 and 64. The liner 62 originally carrying the tabs is removed therefrom by a doctor assembly 61.
At this point, a continuous layered web has been constructed in the successive stations. The web in station 37 passes through a cutting nip formed by rolls 65 and 67, one of the rolls having a blade 66 thereon. Because the blade 66 simply cuts the continuous web, and results in very little space between the cut pieces, another drive train schematically represented at 80 is utilized to drive the rolls in station 38 and rolls 98 and 99 at a speed greater than the speed of the outer rolls in stations 32-37. Again, it may only be necessary to drive one roll in each nip, such as the upper rolls. A motor may be used to drive the rolls 98 and 99 and the rolls in station 38, at a faster speed than the motor 30 drives the other rolls; however usually the drive train 80 is connected by a gear box 79 to the motor 30. One portion of the package envelope is supplied from a supply reel 70 to the roll 98 and the cut wound dressings 68 pass an open draw following the nip formed in station 37 and are laid upon the faster moving envelope web 69, thereby increasing the spacing between the pieces 68. A top of the envelope package in web form 72 supplied from a reel 71 to the roll 99, and suitable bonding of the top and bottom portions with the wound dressings 68 therebetween is accomplished by rolls 73 and 74, and rolls 75 and 76 in station 38. A cutter 77, synchronized to the spacings between the wound dressings 68, severs the sealed envelopes, resulting in individual packages 78, of the type shown in FIG. 1.
The following examples of the types of wound coverage are illustrations of the tab systems and wound coverings of this invention. They do not limit the scope of wound dressings anticipated.
The size ranges of wound dressings can vary from 0.20×1.0 inch to 18×18 inches. Preferred sizes of wound dressing are 1"×3", 2"×3", 3"×4", 4"×5", 6"×8", 10"×12", 12"×18".
Although modifications and changes may be suggested by those skilled in the art it is the intention of the inventor to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of his contribution to the art. | A non-stretchable wound dressing has a flexible, non-stretching cover sheet having adhesive on one side thereof, and having two spaced strip-form gripping tabs at opposite ends thereof. The cover sheet covers a urethane wound dressing with the adhesive of the cover sheet being in contact with the urethane, and the urethane having an adhesive layer on an opposite side thereof. For storage and prior to application to a patient, the adhesive of the urethane wound dressing is in contact with a releasable surface of a carrier, such as cardboard. For application to a patient, one of the cover sheet gripping tabs is pulled so as to release the cover sheet and wound dressing from the carrier, the cover sheet preventing stretching of the wound dressing. The combination is then applied to a patient, with the adhesive of the wound dressing in contact therewith, again the cover sheet preventing stretching of the wound dressing. The other gripping tab of the cover sheet is then pulled to separate the cover sheet from the wound dressing, leaving the wound dressing on the patient with no stretching thereof. An optional third gripping tab and minor cover sheet may be located beneath the second gripping tab. | 8 |
TECHNICAL FIELD
This disclosure relates to a vehicle system and method associated with an electrified vehicle. The vehicle system is configured to modify a deceleration rate of an electrified vehicle based on a closing rate of the vehicle relative to an oncoming object.
BACKGROUND
The need to reduce fuel consumption and emissions in automobiles and other vehicles is well known. Therefore, vehicles are being developed that reduce or completely eliminate reliance on internal combustion engines. Electrified vehicles are one type of vehicle currently being developed for this purpose. In general, electrified vehicles differ from conventional motor vehicles in that they are selectively driven by one or more battery powered electric machines. Conventional motor vehicles, by contrast, rely exclusively on the internal combustion engine to drive the vehicle.
It is known to use an electric machine to decelerate an electrified vehicle. This is commonly referred to as regenerative braking. Regenerative braking can be achieved during braking or lift pedal conditions by configuring the electric machine as a generator. The act of generating power with the electric machine creates a negative braking torque, or regenerative torque, on the electric machine. The negative torque is transmitted to the drive wheels to slow the electrified vehicle.
An accelerator pedal can be calibrated to provide either more deceleration/regeneration or less deceleration/regeneration during lift pedal conditions. However, the ideal deceleration rate may change depending on specific driving events. For example, if a customer tips out (i.e., lifts foot off of accelerator pedal) when an oncoming object is relatively far away, the vehicle may slow too quickly requiring the driver to tip in (i.e., apply pressure to the accelerator pedal) to reach the oncoming object. Conversely, if the operator tips out when the object is relatively close, the vehicle may coast too much requiring the driver to apply the brakes to stop the vehicle.
SUMMARY
A method according to an exemplary aspect of the present disclosure includes, among other things, controlling an electrified vehicle by adjusting a deceleration rate based on a closing rate of the electrified vehicle to an oncoming object.
In a further non-limiting embodiment of the foregoing method, the closing rate is based on a distance and a closing velocity from the electrified vehicle to the oncoming object.
In a further non-limiting embodiment of either of the foregoing methods, the closing velocity is based on a first velocity of the electrified vehicle and a second velocity of the oncoming object.
In a further non-limiting embodiment of any of the foregoing methods, the controlling step includes detecting the oncoming object and determining the closing rate to the oncoming object.
In a further non-limiting embodiment of any of the foregoing methods, the method includes calculating a desired deceleration rate from the closing rate.
In a further non-limiting embodiment of any of the foregoing methods, the method includes determining a negative torque demand necessary to achieve the desired deceleration rate.
In a further non-limiting embodiment of any of the foregoing methods, the method includes modifying a torque demand associated with a predefined accelerator pedal position to be equal to the negative torque demand that is necessary to achieve the desired deceleration rate.
In a further non-limiting embodiment of any of the foregoing methods, the method includes applying the negative torque demand to an electric machine to decelerate the electrified vehicle at the desired deceleration rate.
In a further non-limiting embodiment of any of the foregoing methods, the controlling step includes correlating a desired deceleration rate to a negative torque demand and applying the negative torque demand to an electric machine of the electrified vehicle to decelerate the electrified vehicle using regenerative braking.
In a further non-limiting embodiment of any of the foregoing methods, the controlling step includes adjusting the deceleration rate without applying brakes of the electrified vehicle.
A method according to another exemplary aspect of the present disclosure includes, among other things, determining a desired deceleration rate of an electrified vehicle to an oncoming object and modifying a negative torque demand associated with a predefined accelerator pedal position to achieve the desired deceleration rate to the oncoming object.
In a further non-limiting embodiment of the foregoing method, the method includes applying the negative torque demand to an electric machine of the electrified vehicle to decelerate the vehicle using regenerative braking.
In a further non-limiting embodiment of either of the foregoing methods, the method includes detecting the oncoming object prior to the determining step.
In a further non-limiting embodiment of any of the foregoing methods, the modifying step includes changing the negative torque demand on an accelerator pedal map to less negative, or zero, for a predefined accelerator pedal position if the oncoming object is relatively far or changing the negative torque demand of the accelerator pedal map to more negative for the predefined accelerator pedal position if the oncoming object is relatively near.
In a further non-limiting embodiment of any of the foregoing methods, the predefined accelerator pedal position is between a 0% pedal position and a pedal position that corresponds to zero torque demand or zero acceleration.
A vehicle system according to another exemplary aspect of the present disclosure includes, among other things, an accelerator pedal and a control module in communication with the accelerator pedal and configured to modify a deceleration rate of a vehicle by adjusting a negative torque demand associated with a predefined position of the accelerator pedal.
In a further non-limiting embodiment of the foregoing vehicle system, an object detection subsystem detects an oncoming object ahead of the vehicle.
In a further non-limiting embodiment of either of the foregoing vehicle systems, the accelerator pedal includes a sensor that detects a position of the accelerator pedal.
In a further non-limiting embodiment of any of the foregoing vehicle systems, the system includes an electric machine. The control module commands application of the negative torque demand to the electric machine to decelerate the vehicle.
In a further non-limiting embodiment of any of the foregoing vehicle systems, the deceleration rate is based on a closing rate to an oncoming object.
The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.
The various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a powertrain of an electrified vehicle.
FIG. 2 illustrates a vehicle system that can be employed to adjust a deceleration rate of an electrified vehicle.
FIG. 3 schematically depicts an electric vehicle traveling toward an oncoming object.
FIG. 4 schematically illustrates a vehicle control strategy for adjusting a deceleration rate of an electrified vehicle based on its closing rate to an oncoming object.
FIG. 5 illustrates an accelerator pedal map.
DETAILED DESCRIPTION
This disclosure relates to a vehicle system and method for adjusting a deceleration rate of an electrified vehicle during specific driving events. A closing rate of the electrified vehicle to an oncoming object may be determined based on a distance and a closing velocity to the oncoming object. A negative torque demand, or regenerative torque, required to achieve a desired deceleration rate may be determined from the desired deceleration rate, which can be calculated using the closing rate. During various driving events, the negative torque demand associated with a predefined accelerator pedal position may be increased or decreased to achieve a smooth, linear deceleration to the oncoming object without the need to apply the brakes of the vehicle. These and other features are discussed in greater detail in the paragraphs that follow.
FIG. 1 schematically illustrates a powertrain 10 for an electrified vehicle 12 . Although depicted as a hybrid electric vehicle (HEV), it should be understood that the concepts described herein are not limited to HEV's and could extend to other electrified vehicles, including, but not limited to, plug-in hybrid electric vehicles (PHEV's), battery electric vehicles (BEV's), and modular hybrid transmission vehicles (MHT's).
In one embodiment, the powertrain 10 is a power-split powertrain system that employs a first drive system and a second drive system. The first drive system includes a combination of an engine 14 and a generator 18 (i.e., a first electric machine). The second drive system includes at least a motor 22 (i.e., a second electric machine), the generator 18 , and a battery assembly 24 . In this example, the second drive system is considered an electric drive system of the powertrain 10 . The first and second drive systems generate torque to drive one or more sets of vehicle drive wheels 28 of the electrified vehicle 12 . Although a power-split configuration is shown, this disclosure extends to any hybrid or electric vehicle including full hybrids, parallel hybrids, series hybrids, mild hybrids or micro hybrids.
The engine 14 , which could include an internal combustion engine, and the generator 18 may be connected through a power transfer unit 30 , such as a planetary gear set. Of course, other types of power transfer units, including other gear sets and transmissions, may be used to connect the engine 14 to the generator 18 . In one non-limiting embodiment, the power transfer unit 30 is a planetary gear set that includes a ring gear 32 , a sun gear 34 , and a carrier assembly 36 .
The generator 18 can be driven by the engine 14 through the power transfer unit 30 to convert kinetic energy to electrical energy. The generator 18 can alternatively function as a motor to convert electrical energy into kinetic energy, thereby outputting torque to a shaft 38 connected to the power transfer unit 30 . Because the generator 18 is operatively connected to the engine 14 , the speed of the engine 14 can be controlled by the generator 18 .
The ring gear 32 of the power transfer unit 30 may be connected to a shaft 40 , which is connected to vehicle drive wheels 28 through a second power transfer unit 44 . The second power transfer unit 44 may include a gear set having a plurality of gears 46 . Other power transfer units may also be suitable. The gears 46 transfer torque from the engine 14 to a differential 48 to ultimately provide traction to the vehicle drive wheels 28 . The differential 48 may include a plurality of gears that enable the transfer of torque to the vehicle drive wheels 28 . In one embodiment, the second power transfer unit 44 is mechanically coupled to an axle 50 through the differential 48 to distribute torque to the vehicle drive wheels 28 .
The motor 22 can also be employed to drive the vehicle drive wheels 28 by outputting torque to a shaft 52 that is also connected to the second power transfer unit 44 . In one embodiment, the motor 22 and the generator 18 cooperate as part of a regenerative braking system in which both the motor 22 and the generator 18 can be employed as motors to output torque. For example, the motor 22 and the generator 18 can each output electrical power to the battery assembly 24 .
The battery assembly 24 is an exemplary type of electrified vehicle battery assembly. The battery assembly 24 may include a high voltage battery pack that includes a plurality of battery arrays capable of outputting electrical power to operate the motor 22 and the generator 18 . Other types of energy storage devices and/or output devices can also be used to electrically power the electrified vehicle 12 .
In one non-limiting embodiment, the electrified vehicle 12 has two basic operating modes. The electrified vehicle 12 may operate in an Electric Vehicle (EV) mode where the motor 22 is used (generally without assistance from the engine 14 ) for vehicle propulsion, thereby depleting the battery assembly 24 state of charge up to its maximum allowable discharging rate under certain driving patterns/cycles. The EV mode is an example of a charge depleting mode of operation for the electrified vehicle 12 . During EV mode, the state of charge of the battery assembly 24 may increase in some circumstances, for example due to a period of regenerative braking. The engine 14 is generally OFF under a default EV mode but could be operated as necessary based on a vehicle system state or as permitted by the operator.
The electrified vehicle 12 may additionally operate in a Hybrid (HEV) mode in which the engine 14 and the motor 22 are both used for vehicle propulsion. The HEV mode is an example of a charge sustaining mode of operation for the electrified vehicle 12 . During the HEV mode, the electrified vehicle 12 may reduce the motor 22 propulsion usage in order to maintain the state of charge of the battery assembly 24 at a constant or approximately constant level by increasing the engine 14 propulsion usage. The electrified vehicle 12 may be operated in other operating modes in addition to the EV and HEV modes within the scope of this disclosure.
FIG. 2 illustrates a vehicle system 56 that may be incorporated into a vehicle, such as the electrified vehicle 12 of FIG. 1 . The vehicle system 56 is adapted to adjust a deceleration rate of an electrified vehicle during various driving conditions, such as lift pedal conditions, as is further discussed below. In one non-limiting embodiment, the exemplary vehicle system 56 includes an accelerator pedal 54 , an object detection subsystem 58 , an electric machine 59 , and a control module 60 .
The accelerator pedal 54 may be located within a passenger compartment 62 (shown schematically) onboard an electrified vehicle. The accelerator pedal 54 may be actuated by a driver to request a torque, power or drive command for propelling or decelerating the vehicle. The accelerator pedal 54 may be positioned at a plurality of accelerator pedal positions between fully tipped out (shown as position T 1 , also called lift pedal) and tip in (shown as position T 2 ). For example, at a 0% pedal position, the accelerator pedal 54 is completely tipped out (i.e., driver's foot has been removed from the accelerator pedal 54 ), and at a 100% pedal position the accelerator pedal 54 is completely tipped in (i.e., driver's foot has depressed the accelerator pedal 54 down to a floor board 64 of the passenger compartment 62 ).
The accelerator pedal 54 may an electronic device that includes a sensor 66 for indicating the accelerator pedal position during vehicle operation. In general, the sensor 66 may generate a pedal position signal S 1 that is communicated to the control module 60 as the accelerator pedal 54 is depressed and/or released.
The object detection subsystem 58 may be equipped to detect an oncoming object 76 (see FIG. 3 ). In one non-limiting embodiment, the object detection subsystem 58 utilizes GPS technology to detect the oncoming object 76 . The object detection subsystem 58 could alternatively or additionally utilize radar, ladar, cameras and/or vehicle-to-vehicle communication technologies to detect the oncoming object 76 . Stated another way, the object detection subsystem 58 may utilize any known technology, or combinations of technologies, to detect the existence of the oncoming object 76 .
Referring to FIGS. 2 and 3 , the object detection subsystem 58 may determine a closing rate to the oncoming object 76 once the oncoming object 76 has been detected. The oncoming object 76 may include another vehicle, a stop sign, a stop light or any other object ahead of the electrified vehicle 12 . In one embodiment, the closing rate is based on at least a distance D from the electrified vehicle 12 to the oncoming object 76 , and a closing velocity of the electrified vehicle 12 to the oncoming object 76 . The closing velocity may be based on a velocity V 1 of the electrified vehicle 12 and a velocity V 2 , if any, of the oncoming object 76 . A closing rate signal S 2 indicative of the closing rate may be communicated to the control module 60 from the object detection subsystem 58 .
The electric machine 59 may be configured as an electric motor, a generator or a combined electric motor/generator. Based at least upon input from the accelerator pedal 54 via the pedal position signal S 1 , the control module 60 may command torque (either positive torque or negative torque) from the electric machine 59 . For example, the electric machine 59 may receive torque command signals S 3 from the control module 60 for propelling the electrified vehicle 12 or for decelerating the electrified vehicle 12 during periods of regenerative braking.
While schematically illustrated as a single module in the illustrated embodiment, the control module 60 of the vehicle system 56 may be part of a larger control system and may be controlled by various other controllers throughout an electrified vehicle, such as a vehicle system controller (VSC) that includes a powertrain control unit, a transmission control unit, an engine control unit, a battery electronic control module (BECM), etc. It should therefore be understood that the control module 60 and one or more other controllers can be collectively referred to as “a control module” that controls, such as through a plurality of integrated algorithms, various actuators in response to signals from various sensors to control functions associated with the electrified vehicle 12 , and in this case, with the vehicle system 56 . The various controllers that make up the VSC can communicate with one another using a common bus protocol (e.g., CAN).
In one embodiment, the control module 60 includes executable instructions for interfacing with and operating various components of the vehicle system 56 . The control module 60 may include inputs 68 and outputs 70 for interfacing with the components of the vehicle system 56 . The control module 60 may additionally include a central processing unit 72 and non-transitory memory 74 for executing the various control strategies and modes of the vehicle system 56 .
In one embodiment, the control module 60 is configured to determine a deceleration rate for achieving a smooth, linear deceleration of the electrified vehicle 12 to the oncoming object 76 . A desired deceleration rate may be calculated during various driving conditions based at least on the pedal position signal S 1 and the closing rate signal S 2 . The control module 60 may communicate a torque command signal S 3 to the electric machine 59 to achieve a desired deceleration rate during specific driving events.
FIG. 4 , with continued reference to FIGS. 1-3 , schematically illustrates a vehicle control strategy 100 of an electrified vehicle 12 equipped with the vehicle system 56 described above. The exemplary vehicle control strategy 100 may be performed to adjust a deceleration rate of the electrified vehicle 12 during certain driving events. For example, the deceleration rate of the electrified vehicle 12 can be adjusted based on a closing rate of the electrified vehicle 12 to an oncoming object 76 . Of course, the vehicle system 56 is capable of implementing and executing other control strategies within the scope of this disclosure. In one embodiment, the control module 60 of the vehicle system 56 may be programmed with one or more algorithms adapted to execute the vehicle control strategy 100 , or any other control strategy. In other words, in one non-limiting embodiment, the vehicle control strategy 100 may be stored as executable instructions in the non-transitory memory 74 of the control module 60 .
As shown in FIG. 4 , the vehicle control strategy 100 begins at block 102 . At block 104 , an oncoming object 76 , such as another vehicle, a stop sign or a stop light ahead of the electrified vehicle 12 , is detected by the object detection subsystem 58 of the vehicle system 56 . Detection of the oncoming object 76 indicates that the electrified vehicle 12 must begin to decelerate. The closing rate signal S 2 may be communicated to the control module 60 if an oncoming object 76 is detected (see FIG. 2 ).
If an oncoming object 76 has been detected, the vehicle control strategy 100 determines a closing rate of the electrified vehicle 12 to the oncoming object 76 at block 106 . The control module 60 of the vehicle system 56 may determine the closing rate based on a distance D to the oncoming object 76 and a closing velocity to the oncoming object 76 (see FIG. 3 ). The closing velocity may be calculated based on both a velocity V 1 of the electrified vehicle 12 as well as a velocity V 2 of the oncoming object 76 , if any.
A desired deceleration rate of the electrified vehicle 12 can be calculated at block 108 . In one embodiment, the desired deceleration rate is based at least on the closing rate obtained at block 106 . For example, if the closing rate is calculated as 2 MPH/second, then the desired deceleration rate is approximately 2 MPH/second.
Once the desired deceleration rate is known, a negative torque demand necessary to achieve the desired deceleration rate can be determined at block 110 . The negative torque demand that is required to decelerate the electrified vehicle 12 may be correlated to the desired deceleration rate. For example, in one non-limiting embodiment, the negative torque demand can be obtained from a look-up table stored on the control module 60 that lists deceleration rates and negative torque demand rates required to achieve such deceleration rates.
Next, at block 112 , the deceleration rate of the electrified vehicle 12 may be adjusted to achieve a smooth, linear deceleration to the oncoming object 76 . In one embodiment, the deceleration rate of the electrified vehicle 12 is adjusted by modifying the negative torque demand that is associated with a predefined accelerator pedal position. In one embodiment, the predefined accelerator pedal position is set at a 5% pedal position. In another embodiment, the predefined accelerator pedal position is set at a 0% pedal position. In yet another embodiment, the predefined accelerator pedal position is set between a 0% pedal position and a 5% pedal position. In yet another embodiment, the predefined accelerator pedal position is between a 0% pedal position and a pedal position that corresponds to zero torque demand (i.e., the point where the accelerator pedal map 78 of FIG. 5 crosses from negative to positive) or that corresponds to zero acceleration. The negative torque assigned to the predefined pedal position may be modified to be equal to the negative torque demand obtained at block 110 in order to achieve the desired deceleration rate to the detected oncoming object 76 .
The deceleration rate adjustment that occurs at block 112 of FIG. 4 may be illustrated and described with reference to an accelerator pedal map 78 of FIG. 5 . The accelerator pedal map 78 plots torque demand (in N-m or lb-ft) versus accelerator pedal position (in %). In one embodiment, the deceleration rate is adjusted by increasing or decreasing a negative torque demand 80 of the accelerator pedal map 78 at a predefined accelerator pedal position 82 . The negative torque demand 80 may be raised to position 84 if lower deceleration is needed to stop the electrified vehicle 12 by the time it reaches the oncoming object 76 , or may be lowered to position 86 if higher deceleration is needed to stop the electrified vehicle 12 by the time it reaches the oncoming object 76 .
By way of a non-limiting example, if the oncoming object 76 is relatively “far,” and it is determined at block 108 that a 0.2 MPH/second deceleration rate is needed to achieve linear deceleration, then the negative torque demand 80 associated with the predefined accelerator pedal position 82 is adjusted so that the predefined accelerator pedal position 82 achieves the desired 0.2 MPH/second deceleration rate. Alternatively, if the oncoming object 76 is relatively “close,” and it is determined at block 108 that a 2 MPH/second deceleration rate is needed to achieve linear deceleration, then the negative torque demand 80 is adjusted so that the predefined accelerator pedal position 82 achieves the desired 2 MPH/second deceleration rate.
Finally, referring again to FIG. 4 , the control module 60 can command the necessary negative torque demand (via torque demand signal S 3 ) to the electric machine 59 to achieve the desired deceleration rate of the electrified vehicle 12 for any given driving event at block 114 . In other words, the negative torque demand may be applied to the electric machine 59 . The negative torque is transmitted to the vehicle drive wheels 28 to slow the electrified vehicle 12 using regenerative braking. The vehicle control strategy 100 may be performed to control vehicle deceleration based on a positioning of the accelerator pedal 54 and without the need to apply the brakes of the electrified vehicle 12 .
Although the different non-limiting embodiments are illustrated as having specific components or steps, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments.
It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure.
The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure. | A method according to an exemplary aspect of the present disclosure includes, among other things, controlling an electrified vehicle by adjusting a deceleration rate based on a closing rate of the electrified vehicle to an oncoming object. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a vibration sensing apparatus and, more particularly, to a device for indicating the location of the point of impact between an object and a member.
When an object impacts a member or vice versa, it is often desirable to determine the location of the point of impact on the member. For example, many sports require a player to strike a ball or other game object with a hand held athletic instrument, such as a bat, racket, or club. The player's success in the sport is often determined by his or her ability to swing the athletic instrument so that a preferred portion of the instrument collides with the game object. This preferred portion of the athletic instrument is generally referred to as the "sweet spot".
Athletic instruments which are hand held and designed to strike a game object contain two vibrational nodes. The first node is located under the player's hands, while the second node is located at the "sweet spot". When the game object impacts the instrument at the "sweet spot", a maximum amount of energy is transferred to the game object with a minimum amount of vibration generated within the instrument. However, if the point of impact occurs at a location other than at the vibrational node or "sweet spot", a damped vibration is generated within the instrument. This damped vibration absorbs much of the energy which was to be transferred to the game object. Thus, the game object is not propelled from the athletic instrument at an optimum velocity. It is therefore advantageous for the player to develop good eye-hand coordination so that the athletic instrument imparts the game object at the "sweet spot".
Sensing devices have been attached to athletic instruments for detecting whether the game object contacts a preselected location on the instrument. R. N. Conrey et al. in U.S. Pat. Nos. 4,101,132 and 4,257,594 disclose an athletic instrument, such as a tennis racket, with electronic sensors for detecting contact or proximity of the game element at a preselected location within the intended contact area. Specifically, optoelectrical sensors, resistance or capacitance change sensors, capacitive phase angle change sensors, piezoelectric or piezoresistive sensors, ambient light change sensors, reflected light sensors and electro-fiber optical sensors are employed to determine when the ball contacts the "sweet spot" of a tennis racket. Circuitry is provided which is responsive to the output from the sensor for providing an audible or audio-visual response when the ball contacts the "sweet spot".
The sensing equipment described by Conrey et al. requires the athletic instrument to be specially retrofitted with the electronic sensors. If optical sensors are employed, they are attached and properly aligned on the racket frame so that when the ball contacts the "sweet spot", the beam of light is broken. The optical sensor is either mounted within a hole formed in the racket frame or attached to the frame with tape which contains conductor paths. The conductor paths are used to electrically connect the sensor to the appropriate circuitry. When piezoelectric or piezoresistive elements are used, they are wound around the racket strings within the "sweet spot". If the ball strikes the strings in close proximity to these elements, the stress induced in the elements produces either a voltage or resistance change. The change in voltage or resistance is monitored with voltage or resistance measuring circuits. These circuits generate a logic "yes" when the characteristics change by a predetermined amount. The logic "yes" then activates a switch which controls a means for producing a response which indicates contact was made with the "sweet spot".
It would be desirable to have a sensing device which could be removably attached to a conventional racket, golf club, baseball bat or the like and avoid the need for a specially designed athletic instrument requiring the placement of sensors in or around the intended contact area. Furthermore, it would be desirable to have a sensing device which could be easily transferred to be used on a variety of different athletic instruments to determine whether the player is making contact with the "sweet spot".
SUMMARY OF THE INVENTION
The sensing apparatus of the present invention determines and indicates when the point of impact between an object and a member occurs at a preselected location on the member. The sensing apparatus includes a piezoelectric sensor for producing an oscillatory electrical signal which is proportional to the vibration in the member generated by the collision between the object and the member. A circuit is also provided which is responsive to the oscillatory electrical signal for producing a control signal when the amplitude and frequency of the electrical signal correspond to a point of impact at said preselected location. An indicating means, responsive to the control signal, is also included for indicating that the point of impact occurred at the preselected location.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates the first embodiment of the present invention where the sensing apparatus is attached to a baseball bat.
FIG. 2 is a partial side view of the baseball bat shown in FIG. 1 illustrating the attachment of the piezoelectric sensor to the bat.
FIG. 3 illustrates an alternative embodiment of the present invention wherein the piezoelectric sensor is attached to a glove.
FIG. 4a is a graph of voltage versus time for the oscillatory electrical signal which is produced when the object collides with a vibrational node of the member.
FIG. 4b is a graph of voltage versus time for the oscillatory electrical signal when the object collides with the member at a location other than at a vibrational node of the member.
FIG. 5 is an electrical schematic of the circuit means and indicating means used in the present invention for producing a response when the point of impact between the object and member occurs at a preselected location on the member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, the sensing apparatus of the present invention will be described in conjunction with its use on a baseball bat 100. When a baseball contacts the bat 100, vibrations are transmitted throughout the bat. The piezoelectric sensor 112 attached to the bat 100 produces an oscillatory electrical signal which has both an amplitude and frequency which are proportional to these vibrations. This oscillatory electrical signal is then transmitted via the cable 114 to the housing 116 which contains the circuitry and the indicatingn means which produce a response when the point of impact on the bat is at the preselected location. The housing 116 contains a lamp 118 and a speaker 120 for producing an audio-visual response. Alternatively, either the lamp 118 or the speaker 120 may be eliminated so that only a visual or audio response is produced. Although the housing 116 is shown as being remotely located from the bat 100, the components located with the housing may be mounted on or within the bat, such as in a bore formed in the handle of the bat.
The present invention provides two alternative modes of operation. In the first mode, a response is produced by the indicating means when the ball strikes a vibrational node or "sweet spot" of the bat. This mode of operation serves as a positive response stimuli indicating that the ball and bat are colliding at an optimum location. In the second mode of operation, a response is produced by the indicating means when the ball strikes a location other than a vibrational node or "sweet spot" of the bat. The second mode indicates that the ball and bat are not colliding at an optimum location. The housing 116 will contain a switching mechanism (not shown) which allows the player to select the desired mode of operation.
The location of the "sweet spot" or vibrational node of the bat depends on the physical characteristics of the bat, the hand location, and the grip strength of the player grasping the bat. However, since the sensing apparatus of the present invention only analyzes the vibrational pattern within the bat, the piezoelectric sensor 112 can be attached to any portion of the bat regardless of the grip strength or hand location of the player. However, it is particularly advantageous to attach the sensor 112 to a location which is remote from the intended impact area between the bat 100 and the ball. The placement of the sensor at the remote location ensures that sensor will not interfere with the bat's contact with the ball.
The piezoelectric sensor used in the present invention is a flexible, piezoelectric polymer film, such as polyvinylidene fluoride (PVDF), with electrodes formed thereon. The electrodes are typically electroconductive layers, such as a thin film metal or a conductive polymer, which are applied to opposing sides of the piezoelectric polymer film. Polyvinylidene fluoride is approximately 50% crystalline and 50% amorphous. The principal crystalline forms of PVDF are the highly polar β form and the nonpolar α form. High piezoelectric response is associated with the polar β form. In order to increase the piezoelectric properties of polyvinylidene fluoride, the film is mechanically oriented and subjected to an intense electrical field, otherwise known as poling, to cause the oriented β form crystallites to predominate. The piezoelectric polymer films used in the present invention are typically oriented d 31 . Piezoelectric polymer films which have been treated in this manner are available from the Pennwalt Corporation, Philadelphia, PA, under the trademark KYNAR. Other suitable piezoelectric polymers useful in the present invention include copolymers of vinylidene fluoride and tetrafluoroethylene (VF 2 -VF 4 ), and copolymers of vinylidene fluoride and trifluoroethylene (VF 2 -VF 3 ).
As is conventionally known, when piezoelectric polymer films are flexed, such that the film is put in compression and/or tension, a voltage is produced due to the change in the surface charge density of the polymeric material. When vibrations are transmitted to the film, such as when the ball contacts the bat, the repeated flexure of the piezoelectric film caused by the vibrations produces an oscillatory voltage output.
Referring now to FIG. 2, the attachment of the piezoelectric sensor 112 to the bat 100 is shown. In the present invention, it is advantageous to attach the piezoelectric sensor 112 in a manner such that it can be easily removed when the player does not want to utilize the sensing device. However, it should understood that the piezoelectric sensor 112 could be permanently affixed to the bat 100 or other athletic instrument. The piezoelectric sensor 112 is a piezoelectric polymer film 212 with opposed, metallized surfaces 214 and 216. The metallization material is typically silver ink or a sputtered metal film. This piezoelectric polymer film 212 is then folded in the manner shown such that the metallized surface 216 is put in a face-to-face relationship. The folded metallized surface is typically glued together with a suitable adhesive, such as cyano acrylate, epoxy or the like. The bottom portion of the other metallized surface 214 is then attached to the baseball bat 100 with double-sided tape 200 or other suitable adhesives, such as 3M 6065 spray adhesive. The cable 114 shown in FIG. 1 consists of two separate strands of conductors 218 and 220. The conductors 218 and 220 are attached to the metallized surfaces 214 and 216, respectively, with rivets, conductive tape or conductive epoxy. The piezoelectric sensor 112 may also be a metallized piezoelectric polymer film in an unfolded configuration.
Referring now to FIG. 3, an alternative embodiment of the present invention will be described. In this embodiment, the piezoelectric sensor 112 is attached to a glove 300, such as a baseball batter's glove or a golf glove. When the player wearing this glove grips a baseball bat or golf club, the piezoelectric sensor 112 is put in intimate contact with the bat or club. Thus, when vibrations are produced in the instrument by the ball contact, these vibrations are transferred to the piezoelectric sensor which generates the oscillatory electrical signal. As in the first embodiment of the present invention shown in FIG. 1, the oscillatory electrical signal is then transmitted to the appropriate electrical circuitry by a cable 114. The piezoelectric sensor 112 may be positioned within the palm of the glove, as shown in FIG. 1, or it may be positioned on the fingers of the glove so that the sensor contacts the bat when grasped by the player.
FIGS. 4a and 4b are graphs of the oscillatory electrical signals which are produced when a ball collides with the bat. FIG. 4a illustrates an oscillatory electrical signal 402 which is produced when the ball contacts the bat at a vibrational node. As shown in the figure, after the sharp initial peak, the signal dissipates because the subsequent vibrations within the bat have a very small amplitude. The dotted line 404 illustrates the voltage characteristics of a discharging capacitor. The electrical circuitry of the present invention compares the oscillatory electrical signal to this discharging capacitor. If the first mode of operation has been selected, after the initial peak caused by the ball contacting the bat, the circuit analyzes the oscillatory electrical signal from the piezoelectric film to determine if any subsequent vibrations have an amplitude which is greater than the voltage of the discharging capacitor at that point in time. If the voltage of the oscillatory electrical signal after the initial spike is less than the voltage of the discharging capacitor, the circuit recognizes that the ball contacted the "sweet spot" or vibrational node, and a response is generated by the indicating means.
Turning now to FIG. 4b, the oscillatory electrical signal 406 generated when the ball contacts a point other than the vibrational node is shown. This signal is damped because of the amplitude of the vibrations which are produced after the ball initially contacts the bat. Again, this signal 406 is compared to the voltage output of the discharging capacitor illustrated by the dotted line 404. However, the second peak of the oscillatory electrical signal has an amplitude which is greater than the voltage of the discharging capacitor. If the second mode of operation has been selected, the electrical circuitry of the present invention produces a control signal which is supplied to the indicating means for generating a response which signifies that a point other than the vibrational node of the bat has been contacted by the ball.
Referring now to FIG. 5, the schematic of the circuit means and indicating means used in the present invention is generally designated as 500. The piezoelectric polymer film 512 with its opposed metallized surfaces 514 and 516 is electrically connected to a full wave rectifier 518. The schematic illustrates that the full wave rectifier 518 is composed of diodes D1, D2, D3, and D4 along with resistor R1. The rectified signal is then supplied to an operational amplifier 520 which functions as the comparing means in the present invention.
A means 522 for charging and discharging the capacitor 524 is shown by the dotted line. The charging and discharging means 522 contains a voltage source, resistors R2, R3 and R4, and a PNP transistor T1. The output from the transistor T1 is supplied to the capacitor 524 which when discharging is used as a reference signal which is compared to the rectified oscillatory electrical signal produced by the piezoelectric polymer film 512. The capacitor 524 is also electrically connected to a voltage source through the resistor R5 and a potentiometer 526. The potentiometer 526 is used to adjust the voltage output of the discharging capacitor 524. This adjustment allows for the present invention to be calibrated when it is applied to different athletic instruments. Calibration is necessary because the amplitude of the oscillatory electrical signal will vary between instruments because of the differences in geometry and construction materials.
The output signal from the operational amplifier 520 is also supplied to a pair of Schmidt triggers 530 and 532 which are connected in series. The output of the Schmidt trigger 532 is connected to two one-shots 534, such as CD4528 available from RCA Corporation. Capacitors, C1 and C2, and resistors, R6 and R7, are connected to the two one-shots 534. The output from the two one-shots 534 is then supplied to the Schmidt trigger 536. A pair of switches 537 and 539 are positioned between the two one-shots 534 and the two one-shots 540. These switches 537 and 539 are used to select the desired mode of operation.
The two one-shots 540 are connected to capacitors, C3 and C4, and resistors R8 and R9. The output from the two one-shots 540 is the control signal which is supplied to the indicating means which produces a response to indicate that the ball has contacted the bat at the preselected location. A visual response is produced by the light emitting diode 542 which is connected through a resistor R10 to the two one-shots 540. An audio response is produced by the speaker 544 which is electrically connected with the resistors R11, R12 and R13, and an NPN transistor T2. Although FIG. 5 illustrates that an audio-visual response is produced, it may be desirable to eliminate either the light emitting diode 542 or the speaker 544 so only a visual or audio response is produced.
In the first mode of operation, where a response is produced only when the ball contacts a vibrational node or "sweet spot" of the bat, the switch 537 is set to contact the B terminal while the switch 539 is closed to contact the C terminal. When the first spike of the oscillatory electrical signal from the piezoelectric sensor 512 is supplied to the operational amplifier 520, the logic state of the output of the amplifier 520 changes from one to zero. The charging means 522 charges the capacitor 524 and then starts to discharge the capacitor 524 when the logic state of the output of the amplifier 520 changes. The changing logic state of the amplifier 520 also triggers the timers, Q 1 and Q 2 , of the two one-shots 534. The Q 2 timer changes from logic zero to logic one and then back to logic zero before the Q 1 timer changes from logic zero to logic one.
When the second peak of the oscillatory electrical signal is supplied to the operational amplifier 520, its voltage is compared to the voltage of the discharging capacitor 524 at that point in time. As shown in FIG. 4b, when the ball contacts a location other than the "sweet spot" or vibrational node of the bat, the voltage of the discharging capacitor is less than the voltage of the second spike of the oscillatory electrical signal. When this condition exists, the logic state of the output of the amplifier 520 again changes from zero to one causing the Q 2 trigger of the two one-shots 534 to change to logic one. If the logic state change in Q 2 occurs while Q 1 is at logic one, the reset pin RST on the two one-shots 540 is activated to prevent a control signal from being supplied to the light emitting diode 542 and speaker 544. Thus, a response is not produced by the indicating means.
As shown in FIG. 4a, if the voltage of the discharging capacitor is greater than the voltage of the second spike of the oscillatory electrical signal, a control signal will be supplied from the two one-shots 540 to the light emitting diode 542 and the speaker 544 to indicate that the "sweet spot" has been hit. The operational amplifier does not change its logic state because the capacitor voltage is greater than the voltage of the second spike. Thus, the Q 2 trigger is not activated on the two one-shots 534. Since the Q 1 trigger on the two one-shots 534 is still at its logic one state as a result of the first spike, the triggers TR1 and TR2 of the two one-shots 540 are activated to emit the control signal from Q 1 and Q 2 of the two one-shots 540.
In the second mode of operation, where a response is produced only when the ball contacts a location other than a vibrational node or "sweet spot" of the bat, the switch 537 contacts the A terminal while the switch 539 is open. When the first spike of the oscillatory electrical signal from the piezoelectric sensor 512 is supplied to the operational amplifier 520, the logic state of the output from the amplifier 520 changes from one to zero. This change in logic state causes the charging means 522 to charge and then discharge the capacitor 524. The changing logic state of the amplifier 520 also triggers the timers, Q1 and Q2, of the two one-shots 534 to a logic one state. However, the Q2 timer returns to its zero logic state while the Q1 timer remains at a logic one state.
When the second peak of the oscillatory electrical signal is supplied to the operational amplifier 520, its voltage is compared to the voltage of the discharging capacitor 524. If the voltage of the discharging capacitor is less than the voltage of the oscillatory electrical signal, the logic state of the operational amplifier 520 again is changed to zero causing the Q2 trigger in the two one-shots 534 to change from its zero logic state to a logic one. This condition corresponds to the graph shown in FIG. 4b. If the change in the logic state of the Q2 trigger occurs while the Q1 trigger is still at the one logic state from the first spike, the triggers TR1 and TR2 of the two one-shots 540 are activated and a control signal is supplied to the light emitting diode 542 and the speaker 544 which produce a response indicating that a location other than the "sweet spot" has been contacted.
If the voltage of the discharging capacitor is greater than the voltage of the second peak of the oscillatory electrical signal, as shown in FIG. 4a, the operational amplifier 520 does not change its logic state and an output signal is not supplied to the two one-shots 534 while the Q1 trigger is at a logic one state. Therefore, the triggers, TR1 and TR2, of the two one-shots 540 are not activated and a control signal is not supplied to the light emitting diode 542 and the speaker 544.
In both modes of operation discussed above, the two one-shots 534 and 540 in conjunction with the operational amplifier 520 analyze the oscillatory electrical signal to determine if it possesses an amplitude and frequency which correspond to the ball contacting the preselected location. Specifically, the decay of the oscillatory electrical signal produced when the ball hits the bat and vibrates the piezoelectric polymer film is compared to the decay of the discharging capacitor to determine if the hit occurred on the "sweet spot" or at a location off of the "sweet spot".
Although the present invention has been described using a baseball bat, other athletic instruments, such as golf clubs, tennis rackets and the like may be used without departing from the spirit and scope of the present invention. The sensing apparatus of the present invention can also be used to analyze vibrations in a beam used as a supporting structure or vibrations in a cantilever, such as an airplane wing. | A sensing device is disclosed which produces a response when the point of impact between an object and a member occurs at a preselected location on the member. When the member vibrates after being impacted by the object, an oscillatory electrical signal is produced by a piezoelectric sensor. Appropriate circuitry is provided for analyzing the oscillatory electrical signal and for producing a response if the object impacted the member at the preselected location. The sensing apparatus is particularly useful in athletics for determining whether a game object contacted the athletic instrument at its "sweet spot". | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to U.S. patent application Ser. No. 09/557,284, filed Apr. 24, 2000, entitled “Tilt Focus Method and Mechanism for an Optical Drive,” which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to disk drives and, more particularly, to laminated actuator assemblies made from composite materials and the method for making such actuator assemblies.
BACKGROUND OF THE INVENTION
Disk drives typically write data to or read data from some type of circular media, such as a magnetic or optical disk. The disk is usually arranged in concentric circles or tracks on the disk. As the disk rotates about a shaft, data is read from or written to the disk by operation of a read/write element or head assembly. An actuator assembly, including an actuator arm, positions the read/write element over the various tracks for purposes of reading data from or writing data to designated tracks on the disk.
It is a continuous goal of the disk drive industry to reduce the size and weight of disk drives while simultaneously increasing, or at least maintaining, storage capacity. With reduced size and increased capacity, disk drives can be used in an ever increasing variety of applications. For example, miniature disk drives not only allow for building smaller portable computers, but also provide enhanced functionality to personal electronic devices (PEDs) such as cameras, music players, voice recorders, cam corders, portable music recorders and other similar devices. In this regard, many disk drive components, like actuator assemblies, are being designed as plastic pieces to reduce weight and cost of production compared to metal actuator assemblies. However, plastic actuator assemblies are more susceptible to breakage from shock or extreme temperature variations that come with use in portable instruments. Moreover, plastic actuator assemblies also are less rigid and therefore susceptible to vibration and bending which can result in positioning errors which may lead to track encroachment. Lack of stiffness or rigidity can also create resonant frequency problems and, as a result, require limitations in the bandwidth of servo systems in which they operate to avoid such problems.
Plastic actuator assemblies are also susceptible to imprecision in molding processes. For example, while filled plastics may have improved properties, they also may have irregularities, such as anisotropic properties, which are difficult to control. Similarly, metal actuators are also susceptible to imprecision in manufacture, whether it be forging, etching or stamping. Such imprecision, even within acceptable tolerances ranges, may create problems in positioning the head assembly relative to the disk. Attaining desired degrees of precision in the manufacture of actuator assemblies is made even more difficult as actuator assemblies become smaller and smaller. Controlling manufacturing tolerances at increasingly smaller sizes in molding, forging, etching or stamping even if attainable, becomes prohibitively expensive.
SUMMARY OF THE INVENTION
One embodiment of the present invention is a laminated actuator assembly comprising three or more planar elements, with most of those planar elements comprising carbon fiber composite material made of several layers. These multi-layer carbon fiber composite planar elements are separated by a central planar element comprising a flexure and spacer. The number of individual layers or plies comprising the planar elements may vary. Fiber orientation among the various carbon fiber layers is selectively and strategically placed through the thickness of the carbon fiber planar element to align with principal axes of the beam elements of the actuator arm in order to optimize particular objectives, such as bending and twisting stiffness.
One of the planar elements also comprises a flexure member. The flexure member allows the forward portion of the actuator assembly to pivot relative to the rear portion of the actuator assembly, allowing an optical pick up unit disposed on the distal end of the actuator assembly to move relative to the surface of an optical disk for purposes of maintaining focus on the information layer of the disk. The flexure member is preferably made from a lightweight, flexible metal having a high yield strength and can be formed from either an etching, stamping or die cutting process. The flexure member may be positioned adjacent the outer surface of a carbon fiber planar element, or it may be positioned between two carbon fiber planar elements. In those instances when the flexure member is disposed between carbon fiber planar elements, a spacer also may be included to maintain appropriate spacing between carbon fiber planar elements directly separated by the flexure. The spacer provides for a more uniform adhesive layer in the completed laminated actuator assembly. The flexure member footprint does not necessarily have to match the footprint of the carbon fiber planar elements. Similarly the footprints of the carbon fiber planar elements may vary. Such variability facilitates attachment of other components, such as the optical pickup unit and flex circuit.
The fibers in the various layers of the planar elements need not be carbon but may be glass or light metals such as boron, magnesium or beryllium, or other materials such as kevlar or ceramic. Alternatively, the fibers in any particular layer may comprise a combination of two or more of these materials. The spacer may be made of the same material as the flexure member, or may be made of a laminate of fiber layers such as carbon or of other lightweight materials, such as magnesium, foam core, plastic or honeycomb. The combination provides a structure which is strong, light weight and resistant to bending, vibration and twisting, and one which is ideal for use in a miniaturized environment.
The fiber laminate planar elements provide the structural characteristics of the actuator assembly. These planar elements, or upper and lower composite planar elements when viewed relative to the surface of the disk, are manufactured in arrays of multiple component pieces. More specifically, a number of layers of fiber material are combined to form a composite planar element panel. A water jet or other appropriate cutting device, under computer control, cuts the composite planar element panel into an array of multiple copies of the upper and lower fiber planar elements, still attached to the exterior frame of the overall lamination panel. For efficiency and handling, the component pieces remain attached to the overall lamination panel in an array format. In addition, registration points are also formed in each panel for subsequent use in aligning the panel to the corresponding arrays of components in mating panels during subsequent processing. The panels of flexure elements include similar registration features for co-alignment with the panels of upper and lower carbon fiber planar elements.
As an alternative, unique or individual cuts may be initially made in the composite planar element panels before lamination and all cuts common to the planar elements made following the lamination of the planar elements. Using appropriate registration features, the individual composite planar element panels are laminated to create the laminated actuator assembly panels. Fabrication in this manner provides the option to have different footprint geometries of the individual planar elements or the overall laminate of the actuator assembly, since the component shape can be unique in each planar element.
The number of planar elements in the laminated actuator assembly could range from one, with the flexure on either the top or bottom surface, to as many as two dozen, with the flexure being located on either surface or between any two interior planar elements. The number of fiber layers in a single composite planar element is determined by the thickness limitations of the planar element, dividing the allowable planar element thickness by the fiber diameter at maximum material condition. Practical embodiments would likely range from one to seven planar elements in an actuator assembly. Each planar element can be optimized for directional stiffness properties via fiber orientation, based upon the final placement within the thickness of the planar element and the laminated actuator assembly.
Lamination is accomplished by aligning and bonding multiple fiber layers to form fiber planar elements, and by aligning and bonding one or more fiber planar elements to the flexure planar element. As previously stated, a spacer element may be positioned in a coplanar relationship with the flexure planar element. The bonding process may be accomplished by oven cure or room temperature cure. Pressure is applied to the stack of planar elements during the cure process, via a clamping fixture that can be set to establish a finished laminate stack thickness. Setting of the stack height effectively defines the bond line thickness dimensions so that bond strength and adhesive squeeze out can be optimized. Adhesive is applied to the fiber planar elements either prior to alignment and installation in the clamping fixture or as the arrays of planar elements are placed in the clamping fixture. Adhesive can be applied using silk screen techniques, with the silk screen also having registration members for accurate alignment with the fiber planar elements. Alternatively, the adhesive may be applied by roller or by spraying or other printing or as a film. The clamping fixture may also include a vacuum chuck to constrain movement and maintain alignment of the planar elements and silk screen pattern. The clamping fixture includes complementary registration features which interact with the registration features in the fiber and flexure planar element panels to accurately position the planar elements relative to each other.
In embodiments that utilize a flexure which does not match the footprint of the mating fiber planar elements, and in which a spacer layer is not utilized, a varying bond line thickness is created. In order to prevent adhesive overflow at the edges of the planar elements, the adhesive cannot be applied in a single, uniformly thick layer. To overcome this problem, the adhesive is applied in a single application of discreet stripes of adhesive, analogous to half tone printing procedures. In the areas where the flexure is present, fewer or less dense stripes of adhesives are applied. As a result, when the planar elements are all aligned and appropriate pressure is applied, the adhesive spreads out and uniformly fills the space between the planar elements that encapsulate the flexure member.
Once arrays of upper and lower fiber planar elements and flexure planar elements have been laminated into an array of actuator arms, the arms may be removed (singulated) from the laminated panel for further assembly operations, or left in the panel and further assembly operations performed in panelized, batch process operations.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this invention, one should now refer to the embodiment illustrated in greater detail in the accompanying drawings and described below by way of example of the invention. In the drawings:
FIG. 1 is a top plan view of an embodiment of the actuator assembly of the present invention.
FIG. 2 is a top plan view of an embodiment of the actuator assembly of the present invention, with the optical, magnetic and electrical components removed.
FIG. 3 is a side view of the assembly shown in FIG. 2 .
FIG. 4 is an exploded view of the actuator assembly shown in FIG. 2 .
FIG. 5 is a partial cut away perspective view of the layers of an upper and lower composite planar element and a composite planar element panel of the present invention, showing the orientation of the fibers in each layer.
FIG. 6 is a top plan view of an array of lower composite planar elements, further showing the various axes of orientation of the fibers within the layers comprising the upper and lower composite planar elements.
FIG. 7 is a separate top plan view of the forward and rearward portions of the upper composite planar element of the actuator assembly shown in FIG. 2 .
FIG. 8 is a separate top plan view of the forward and rearward portions of the lower composite planar element of the actuator assembly shown in FIG. 2 .
FIG. 9 is a top plan view of the flexure and spacer of the actuator assembly shown in FIG. 2 .
FIG. 10 is a top plan view of an array of upper composite planar elements of the actuator assembly shown in FIG. 2 .
FIG. 11 is a top plan view of an array of lower composite planar elements of the actuator assembly shown in FIG. 2 .
FIG. 12 is a top plan view of an array of flexure and spacer members of the actuator assembly shown in FIG. 2 .
FIG. 13 is an elevated perspective view of a vacuum chuck assembly used in assembling an actuator assembly of the present invention.
FIG. 14 is a partially exploded view of a vacuum chuck assembly, an array of upper composite planar elements and a silk screen adhesive pattern used in assembling an actuator assembly of the present invention.
FIG. 15 is a top plan view of the glue pattern for a complementary pair of upper and lower composite planar elements.
FIG. 16 is an exploded view of the lower bonding plate, composite planar elements, flexure panel, spacer panel and upper bonding plate, showing the depth stops.
FIG. 17 is a top view of the bonding fixture.
FIG. 18 is a cross-section view of the bonding fixture taken along line 18 — 18 of FIG. 17 .
While the following disclosure describes the invention in connection with one embodiment, one should understand the invention is not limited to this embodiment. Furthermore, one should understand that the drawings are not necessarily to scale and that graphic symbols, diagrammatic representatives and fragmentary use, in part, may illustrate the embodiment. In certain instances, the disclosure may not include details which are not necessary for an understanding of the present invention such as conventional details of fabrication and assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a first embodiment of the actuator arm 10 of the present invention. As generally shown, the actuator arm includes a rear portion 12 and a front portion 14 . The front portion 14 is also referred to as a focus arm. A voice coil 16 is positioned between two extensions or legs 18 , 20 formed in the rear portion and cooperate with permanent magnets, not shown, to form a voice coil motor (VCM) to position the actuator arm 10 relative to the surface of a disk. A bearing cartridge 22 is disposed within a circular bore formed between legs 24 , 26 of the front portion 14 and legs 28 , 30 of the rear portion 12 . An optical pickup unit 32 for reading information from or writing information to an optical disk is disposed at the distal end of the focus arm 14 . A second voice coil motor 34 acts to move the focus arm 14 of the actuator 10 in a direction generally perpendicular to the surface of the disk in order to maintain the optical pickup unit in focus with the information layer contained on the disk. The actuator arm 10 is discussed in greater detail in pending U.S. application Ser. No. 09/557,284, which is incorporated herein by reference. Although the actuator arm is described in the context of an optical disk drive, it should be understood that it applies equally to other applications, including but not limited to magnetic hard disk drives.
FIGS. 2-4 provide additional views of the actuator arm 10 , with the optical pickup unit, voice coil motor assemblies and bearing cartridge removed. The forward and rearward portions 12 , 14 of the actuator arm 10 of the preferred embodiment are each comprised of an upper planar element 36 and a lower planar element 38 with a flexure member 40 and spacer member 42 , comprising a third planar element 44 , disposed between the upper and lower planar elements. In the preferred embodiment, as partially illustrated in FIG. 5, both the upper and lower planar elements 36 , 38 comprise eight separate layers or plies of carbon fiber material L 1 -L 8 made from composite planar element panels 58 , although the number of layers or plies comprising the overall laminate structures which are the planar elements 36 , 38 may be more or less, provided symmetry about the neutral axis of the planar element is generally maintained. In particular, each carbon fiber layer L 1 -L 8 of the planar elements 36 , 38 has a distinct geometry and purpose such that the resulting carbon fiber planar element can take advantage of the separate benefits of the individual layers. In this regard, the fibers within each layer are oriented to optimize the purpose of the layer and each layer can form a uniaxial fiber matrix. For example, fibers are oriented parallel to the orientation of beam elements to provide desired stiffness and the fibers of different layers cross at high enough angles with respect to the other individual layers to provide an overall laminate structure which is stiff in some directions and flexible in others. Generally, the fibers are parallel to each other within each carbon fiber layer L 1 -L 8 , but the orientation of the fibers from layer to layer in an overall planar element of the actuator assembly may vary.
In the planar elements having eight carbon fiber layers, the fibers in each layer are approximately 0.002 inches in diameter. In addition, in four of the eight layers L 1 , L 2 , L 7 , L 8 , the fibers have a zero degree orientation, meaning the fibers are aligned parallel to the longitudinal axis A L of the actuator arm 10 as shown in FIG. 6 . Two of these zero degree oriented layers L 1 , L 2 , are the upper most layers and two of the zero degree oriented layers L 7 , L 8 , are the lower most layers of the planar elements 36 , 38 . The fibers in the center four layers L 3 -L 6 , are oriented alternately at plus or minus 29 degrees relative to the longitudinal axis A L . This orientation is shown in FIG. 6 at A +29 and A −29 . Twenty-nine degree fiber orientation is selected because it is the orientation of arm segments 24 and 26 relative to the long axis of the actuator arm. By orienting the fibers of these layers L 3 -L 6 to be parallel to the orientation of arm segments 24 , 26 , these arm segments or beam elements are stiffened with respect to bending. The layers L 1 -L 8 are arranged symmetrically by their fiber orientation to avoid curling of the composite planar element panels 58 and planar elements 36 , 38 . The varying fiber orientation of the layers also gives greater strength to the overall structure and helps reduce or eliminate damage to the planar elements 36 , 38 during handling and assembly. Also, it is desirable to carefully control the quantity of resin within each fiber layer L 1 -L 8 . By matching the thickness of the individual layers L 1 -L 8 as close as possible to the diameter of the fibers, the strength of the laminated layers, and thus the fiber planar element, increases.
Carbon is the preferred fiber because it has among the highest ratios of stiffness to density. For example, the specific gravity of a carbon fiber planar element is approximately 1.8, very near that of magnesium, but will have a Young's modulus of approximately 50 million pounds per square inch, whereas magnesium has a Young's modulus of approximately 7 million pounds per square inch. By way of comparison, steel has a Young's modulus of 30 million pounds per square inch, but a specific gravity of 7.8. Thus, a carbon fiber planar element is approximately four times less dense than steel, but is sixty-seven percent stiffer.
Each planar element 36 , 38 is comprised of a forward portion and a rear portion to allow the focus arm 14 of the actuator assembly 10 to pivot relative to the disk surface. Thus, with reference to FIGS. 4 and 7 - 9 , the upper planar element 36 includes a front portion 46 and a rear portion 48 and the lower planar element 38 includes a front portion 50 and a rear portion 52 .
FIG. 9 illustrates an individual flexure member 40 and spacer 42 and FIG. 12 illustrates an array of flexure members 40 and spacers 42 in panel forms 62 and 66 respectively. Preferably, the material used to make the flexures 40 is a flexible metal such as Sandvick 11R51, which is a 301 series stainless steel having a yield strength of approximately 283,000 psi. However, it should be appreciated that the flexures 40 can be made from any appropriate flexible material that can withstand repeated bending as the focus arm 14 is adjusted to maintain focus on the data layer within the disk. Alternatively, the spacer 42 may be made from fiber composite material like the upper and lower planar elements 36 , 38 . In addition, the footprint of the spacer 42 may closely match that of the forward portions 46 , 50 of the upper and lower planar elements 36 , 38 , respectively, or it may be smaller and have a profile different from the forward portions of the planar elements to reduce weight or provide different stiffness characteristics to the actuator assembly.
The flexure member 40 , as shown in FIG. 9, includes a front portion 54 and a rear portion 56 which generally match the contour of the adjacent areas of the front and rear portions of the upper and lower planar elements 36 , 38 . The rear portion 56 of the flexure member 40 includes an aperture 64 to receive a bearing cartridge 22 . Importantly, a pair of narrow bridges 57 or flexure portion of flexure member 40 connect the front portion 54 and the rear portion 56 and allow the front portion 54 to pivot relative to the rear portion 56 . In turn, because the front portion 14 and rear portion 12 of the upper and lower planar elements 36 , 38 do not overlap the flexure portion 57 as seen in FIGS. 2 and 3, the front portion 14 may also pivot relative to the rear portion 12 . The flexure portion or narrow bridge 57 avoids any glue seepage from the adjacently abutting upper and lower planar elements 36 , 38 from altering the frequency of the flexure. As a result, the desired response of the bending of the actuator arm is controlled. Absent this flexure portion/narrow bridge 57 being present, glue seepage into the area could alter the bending characteristics of flexure 40 . Altering the shape is more easily accomplished than controlling glue seepage. The array of flexure members in panel 62 , as shown in FIG. 12, is preferably made by a die cutting and coining process, but could be made by etching or any other process known to persons of skill in the art.
For purposes of manufacture, eight layers or plies of carbon fiber material L 1 -L 8 , with the fibers preferably substantially oriented at a predetermined angle (see FIGS. 5, 6 ), are joined together to form a single carbon fiber laminate or panel 58 , as shown in FIG. 5 . Arrays of upper and lower planar elements 36 , 38 are cut into the laminated panel 58 to form cut panels 78 and 80 (see FIGS. 10, 11 ). The number of individual component pieces to be cut in an array may vary. The embodiment shown in the drawings have six upper or lower planar elements 36 , 38 per array. Ideally, a computer or numerically controlled water jet is used to cut the component footprints in each panel 58 . Alternatively, similarly controlled milling machines can cut the array of component pieces from the panel 58 . A water jet, however, is not only faster, but is much more cost effective than milling machines. Where a milling machine utilizes a cutting tool that wears out and needs regular replacement, a water jet has no such problem. Moreover, a water jet can cut multiple panels 58 , creating multiple copies of cut panels 78 and 80 at one time, thereby further increasing output. FIGS. 10 and 11 illustrate arrays of six upper and lower planar elements 36 , 38 cut into two panels 58 of eight laminated carbon fiber layers, respectively. At the same time as the water jet, or other methods known and available to those skilled in the art cut the arrays of upper and lower planar elements 36 , 38 , registration members, such as holes 60 , are also cut in the panels 58 . The purpose for cutting the registration holes 60 at the same time as the component structural pieces are cut is to reduce subsequent errors in alignment when assembling and bonding the multiple planar elements into an actuator arm. In this manner, the only error is that which would result due to the CNC cutting process, but not to the alignment of the planar elements when combined. Alternatively, the individual layers L 1 -L 8 may be separately cut to form arrays of component pieces and then laminated to form panels 78 , 80 of planar elements 36 , 38 or uncommon cuts in each layer L 1 -L 8 can be made individually and all common cuts can be made following lamination of the multiple layers into a single planar element. The process of forming registration features in each layer would be the same in order to enhance accurate alignment of the individual layers L 1 -L 8 .
In general terms, a method of assembling the actuator of the present invention will now be described. As illustrated in FIGS. 5 and 6, depicting a first embodiment, eight carbon fiber layers L 1 -L 8 are combined to form the upper and lower panels 58 , which are then cut to create cut panels 78 , 80 , from which fiber planar elements 36 , 38 will result. Each layer L 1 -L 8 is impregnated with epoxy for bonding the individual layers together. The combined structure is placed in an autoclave under appropriate pressures and temperatures to activate the epoxy and secure the layers L 1 -L 8 into a laminate panel 58 . In connection with the preferred embodiment, the temperature is approximately 325° F. and the applied pressure is approximately 50 pounds per square inch.
Following the autoclave procedure, the laminated panels 58 , are cut, by means of water jet or other appropriate techniques, into an array of upper and lower carbon fiber planar elements 36 , 38 of the actuator arm 10 in panels 78 and 80 . Alternatively, the cutting of component pieces within the individual layers L 1 -L 8 may be done prior to bonding the layers together or some of the cut may be made in individual layers and the remaining cuts are made in the overall laminated panel. At this point, registration features 60 are also accurately located and cut into the panels 78 , 80 . Similarly, an array of flexures 40 are cut from metallic or other appropriately flexible material into a panel 62 which will mate with a pair of upper and lower fiber planar panels 78 , 80 . Also, an array of spacers 42 are cut from appropriate material into a panel 66 , which will also mate with the pair of upper and lower fiber planar panels 78 , 80 . The flexure and spacer panels 62 , 66 also have aligned registration features, such as apertures 60 , to match those in the carbon composite planar panels 78 , 80 . In the cutting process, a number of sprues 70 are left between the planar elements 36 , 38 and the surrounding panels 78 , 80 , as well as between the flexures 40 and spacers 42 and the remaining panels 62 and 66 respectively. The registration holes 60 maintain alignment among the panels 62 , 66 , 78 and 80 during further processing. It should be appreciated that other methods of providing registration among the various panels can be used instead. For example, alignment may be achieved by using panel edges or corners, or by optically detecting identified fiduciaries on the panel or by bearing bores.
At this point, the panels 62 , 66 , 78 and 80 are ready to be combined into an actuator arm assembly. The upper and lower carbon fiber panels 78 , 80 containing planar elements 36 , 38 , are placed on a clamping fixture, such as vacuum chuck 72 (FIG. 13 ). The registration pins 74 on the chuck 72 mate with the registration holes 60 in the panels 78 , 80 and properly co-align the panels. Vacuum pressure through slots 76 hold an upper and lower planar element panels 78 , 80 in position for application of adhesive. Silk screen techniques are then used to apply adhesive to both the upper and lower fiber planar element panels 78 , 80 . FIG. 14 illustrates a chuck 72 with a lower panel 80 of planar elements 38 positioned on registration pins 74 and an upper panel 78 of planar elements 36 , also intended to be positioned on chuck 72 but elevated from the surface of the chuck 74 for illustration. A silkscreen 82 , showing the openings for the pattern of adhesive to be applied, is also shown. The silkscreen also includes registration holes 84 for aligning the silkscreen 82 relative to the panels 78 , 80 . It should be appreciated however, that other techniques may be utilized to apply adhesive, including but not limited to application by roller, spray, other printing or as a film.
To simplify the glue application process, in the preferred embodiment, a single thickness of glue or adhesive is applied across the entire length of the upper and lower panels 78 , 80 in one application. Care must be taken to accurately place the adhesive away from edges of the upper and lower planar elements 36 , 38 to avoid adhesive being squeezed out along any edges. Yet, it is also necessary to have sufficient adhesive to fill all voids between the upper and lower fiber planar elements, taking into account the existence of the flexure and spacer. The glue pattern applied to upper and lower planar panels 78 , 80 is created by silkscreen 82 , as shown in FIGS. 14 and 15. The preferred adhesive is a 3M 2214 metal-filled, single-part epoxy. Because this epoxy cures at approximately 120° C. or higher, the glue can be applied to the upper and lower planar panels 78 , 80 using the silkscreen 82 pattern and stored in a cool location without concern that the glue will cure. This allows an inventory of arrays of combined planar elements 36 and 38 , with adhesive already applied, to be made in advance and be available for final assembly as demand requires. Alternatively, if the flexure 40 and spacer 42 do not match the shape of the planar elements 36 , 38 , a different thickness of glue may be applied at locations where the flexure and spacer are absent. In this regard, the glue may be applied in stripes, analogous to half-tone printing processes, rather than in a solid, continuous pattern.
As completed actuators 10 are needed, the planar panels 78 , 80 , with adhesive-applied as shown in FIGS. 14 and 15, flexure panels 62 and spacer panels 66 can be positioned within bonding plates 90 a and 90 b as shown in FIG. 16 using the registration holes 60 and registration pins 92 . The upper bonding plate 90 a is then placed over the combination and secured to the lower bonding plate 90 b under appropriate pressure and temperature conditions. As shown in FIGS. 17 and 18, the bonding plates include adjustable limit stops 94 , which establish the spacing between the upper and lower plates, thereby establishing the thickness of the actuator assembly. The bonding plates 90 containing the panels 78 , 80 , 66 and 62 are placed in an oven for bonding the component pieces into a final laminated structure. Presently, using the 3M epoxy, this process takes approximately two hours in an oven at 150° C. It should be understood that the process parameters can vary, particularly depending upon the epoxy used.
Once cured, the completed lamination can be removed from the bonding plates, while the individual component pieces remain attached to the surrounding structure due to the sprues 70 . This allows for ease of handling without damage to the miniature laminated structures. It further allows the other component pieces, such as the optical pickup unit, flex circuit, voice coil motors and bearing cartridge, to be assembled to the actuator structure with simplicity.
While various embodiments have been shown and described, it will be apparent that other modifications, alterations and variations may be made by or will occur to those skilled in the art to which this invention pertains, particularly upon consideration of the foregoing teachings. For example, the number of layers or plies within the fiber planar elements may vary as may the relative orientation of the fibers within each layer. In addition, while carbon fiber composite material performs well in this application, other materials such as glass, magnesium, boron, beryllium, Kevlar and ceramics, alone or in various combinations may also perform satisfactorily. It is also contemplated that the component shapes may be cut from individual layers of material, which layers are subsequently laminated to form a composite panel, or that the component shapes are cut from the composite panel. It is still further contemplated that the individual layers comprising a planar element may have varying shapes and sized relative to each other. The objective is to achieve a lightweight, but a strong and stiff actuator assembly. It is therefore contemplated that the present invention is not limited to the embodiments shown or described in such modifications and other embodiments as incorporate those features which constitute the essential functions of the invention are considered equivalent and within the true spirit and scope of the present invention. | The present invention relates to a laminated actuator assembly and the method for making the actuator assembly. The actuator assembly is intended for use in miniature personal electronic devices, but could be used in any type of disk drive. The actuator is primarily constructed from strong, stiff, lightweight composite materials. The upper and lower planar elements of the actuator assembly, each comprising multiple composite layers, include a forward portion and a rearward portion. A flexure member, typically positioned between the layers of composite material, allows the forward portion of each planar element to pivot in unison relative to the rear portion of each planar element. In this manner, the position of an optical pick up unit or other read/write device positioned at the distal end of the actuator assembly can be adjusted relative to the surface of a data disk. The composite and flexure planar elements are formed in arrays of multiple component pieces with aligned registration members. The registration members provide accurate alignment during assembly. Adhesive is applied in appropriate quantities to fully fill the space between the upper and lower layers, without seepage at the edges. By assembling the actuator components in arrays, the miniature actuator assemblies can be easily handled and the electronic, optic and magnetic subassemblies can be attached more easily. | 8 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to inserts for medical devices that are configured to elute an antimicrobial agent. In particular, an actuator for a side port of a ported catheter can be configured to elute an antimicrobial agent to disinfect the side port including any fluid contained within the side port.
[0002] Catheters are commonly used for a variety of infusion therapies. For example, catheters are used for infusing fluids, such as normal saline solution, various medicaments, and total parenteral nutrition into a patient, withdrawing blood from a patient, as well as monitoring various parameters of the patient's vascular system.
[0003] Catheter-related bloodstream infections are caused by the colonization of microorganisms in patients with intravascular catheters and I.V. access devices. These infections are an important cause of illness and excess medical costs. More importantly, these infections often result in patient deaths.
[0004] Many techniques have been employed to reduce the risk of infection from a catheter or other intravenous device. For example, catheters have been designed that employ an antimicrobial lubricant or an antimicrobial coating on an inner or outer surface of the catheter. Similarly, antimicrobial lubricants or coatings have been applied to the surfaces of other components of a catheter assembly, components attached to the catheter assembly, or other medical devices which may come in direct contact with the patient's vasculature or in contact with a fluid that may enter the patient's vasculature. Further, some devices or components are made of a material that is impregnated with an antimicrobial agent.
[0005] Although these techniques have been beneficial, there are various drawbacks that limit their usefulness. For example, it can be difficult and/or expensive to apply an antimicrobial coating or lubricant to the complex internal and external geometries of many devices or components. Also, some devices or components are preferably made of a material that is not suitable for the application of an antimicrobial coating or that cannot be impregnated with an antimicrobial agent. Because of such difficulties, the current techniques for providing antimicrobial protection are oftentimes not used or, if used, are not adequately applied to provide maximum antimicrobial protection.
[0006] Catheters with side ports (commonly referred to as ported catheters) are oftentimes used because additional bolus medications can be easily injected into the catheter adapter via the side port. An example of a typical ported catheter 100 is shown in FIGS. 1A-1C . As shown, ported catheter 100 comprises a catheter adapter 101 having a side port 103 and a catheter 102 that extends from the distal end of the catheter adapter. A valve for the side port 103 is commonly formed using a piece of tubing 104 positioned within the inner lumen 101 a of the catheter adapter 101 . The piece of tubing 104 is made of a resilient material and has an external diameter at least as large as the inner diameter of the inner lumen 101 a so that the tubing 104 seals the inner lumen 101 a from the side port 103 .
[0007] FIG. 1B illustrates how tubing 104 is displaced to open a flowpath through the side port 103 into the inner lumen 101 a. As shown, a separate device 105 (e.g. a luer connector) can be inserted into side port 103 . Fluid can then be expelled from device 105 . The pressure built up within side port 103 as the fluid is injected into side port 103 causes tubing 104 to collapse inwardly as shown in FIG. 1B . The inward collapse of tubing 104 creates the flowpath through which fluid may flow from device 105 and into lumen 101 a as indicated by the arrow.
[0008] Various problems exist with this type of ported catheter. For example, as the fluid is ejected from device 105 and prior to tubing 104 collapsing, a substantial amount of pressure can build within side port 103 . This pressure is necessary to cause tubing 104 to collapse. However, in some instances, if the pressure becomes too high, it can cause device 105 to separate from side port 103 allowing fluid to spray out from side port 103 .
[0009] Another problem that exists with common ported catheters is that, after fluids are injected via side port 103 , some residual fluid will remain within side port 103 on top of tubing 104 . FIG. 1C represents the state of the ported catheter 100 after device 105 has been removed from side port 103 . As shown, once fluid is no longer injected from device 105 , the lack of pressure will allow tubing 104 to snap back to its original position thereby sealing the opening into inner lumen 101 a. When this occurs, fluid 106 remains within side port 103 . This residual fluid 106 cannot effectively be removed from side port 103 . If side port 103 is not sealed after use, fluid 106 can quickly become contaminated. Then, when side port 103 is again used for infusion, the contaminated fluid 106 will be flushed into lumen 101 a and ultimately into the patient thereby increasing the risk of infection.
[0010] A further problem that exists with common ported catheters is that they only allow for fluid flow in a single direction. Because external pressure from fluid flowing into lumen 101 a is required to cause tubing 104 to collapse inwardly to open the flowpath, it is not possible to have fluid within inner lumen 101 a (e.g. a patient's blood) flow out through side port 103 .
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention extends to an actuator for a side port of a ported catheter and to ported catheters that contain actuators within their side ports. These actuators can be comprised of a material or contain a coating that elutes an antimicrobial agent when the actuator comes in contact with a fluid. Therefore, any residual fluid that remains within the side port after infusion can be disinfected by the antimicrobial agent eluted from the actuator.
[0012] The use of an actuator in the side port also facilitates bidirectional fluid flow through the side port. The actuator can be configured to open a flowpath when an external device is inserted into the side port. Accordingly, the flowpath can be opened without requiring the presence of built-up pressure within the side port.
[0013] In one embodiment, the present invention is implemented as a ported catheter. The ported catheter comprises a catheter adapter having an inner lumen; a catheter extending distally from the catheter adapter; a side port forming an opening through a sidewall of the catheter adapter into the inner lumen; tubing positioned within the inner lumen to cover the opening formed by the side port; and an actuator contained within the side port. The actuator is configured to compress the tubing inwardly when a device is inserted into the side port. The inward compression of the tubing opens a flowpath from the side port into the inner lumen.
[0014] In another embodiment, the present invention is implemented as a ported catheter comprising: a catheter adapter having a distal opening, a proximal opening, and a lumen that extends between the distal and proximal openings; a side port forming a sidewall opening into the lumen; tubing contained within the lumen and forming a seal over the sidewall opening; and an actuator contained within the side port. The actuator is configured to compress the tubing to open a fluid pathway through the sidewall opening.
[0015] In another embodiment, the present invention is implemented as a ported catheter comprising: a catheter adapter having a distal opening, a proximal opening, and a lumen that extends between the distal and proximal openings; a side port forming a sidewall opening into the lumen; tubing contained within the lumen and forming a seal over the sidewall opening; and an actuator for defeating the seal. The actuator is contained within the side port and comprises one or more antimicrobial agents that elute into a fluid when the fluid contacts the actuator.
[0016] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter.
[0017] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the invention. The features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0019] FIGS. 1A-1C illustrate a cross-sectional view of a prior art ported catheter. The prior art ported catheter includes tubing within the lumen of the catheter that is compressed inwardly when sufficient pressure is built up within the side port.
[0020] FIGS. 2A-2C illustrate a cross-sectional view of a ported catheter in accordance with one or more embodiments of the present invention. The ported catheter in accordance with embodiments of the present invention includes an actuator that compresses the tubing when a device is attached to the side port.
[0021] FIGS. 3A-3C illustrate detailed views of the actuator shown in FIGS. 2A-2C respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention extends to an actuator for a side port of a ported catheter and to ported catheters that contain actuators within their side ports. These actuators can be comprised of a material or contain a coating that elutes an antimicrobial agent when the actuator comes in contact with a fluid. Therefore, any residual fluid that remains within the side port after infusion can be disinfected by the antimicrobial agent eluted from the actuator.
[0023] The use of an actuator in the side port also facilitates bidirectional fluid flow through the side port. The actuator can be configured to open a flowpath when an external device is inserted into the side port. Accordingly, the flowpath can be opened without requiring the presence of built-up pressure within the side port.
[0024] In one embodiment, the present invention is implemented as a ported catheter. The ported catheter comprises a catheter adapter having an inner lumen; a catheter extending distally from the catheter adapter; a side port forming an opening through a sidewall of the catheter adapter into the inner lumen; tubing positioned within the inner lumen to cover the opening formed by the side port; and an actuator contained within the side port. The actuator is configured to compress the tubing inwardly when a device is inserted into the side port. The inward compression of the tubing opens a flowpath from the side port into the inner lumen.
[0025] In another embodiment, the present invention is implemented as a ported catheter comprising: a catheter adapter having a distal opening, a proximal opening, and a lumen that extends between the distal and proximal openings; a side port forming a sidewall opening into the lumen; tubing contained within the lumen and forming a seal over the sidewall opening; and an actuator contained within the side port. The actuator is configured to compress the tubing to open a fluid pathway through the sidewall opening.
[0026] In another embodiment, the present invention is implemented as a ported catheter comprising: a catheter adapter having a distal opening, a proximal opening, and a lumen that extends between the distal and proximal openings; a side port forming a sidewall opening into the lumen; tubing contained within the lumen and forming a seal over the sidewall opening; and an actuator for defeating the seal. The actuator is contained within the side port and comprises one or more antimicrobial agents that elute into a fluid when the fluid contacts the actuator.
[0027] FIGS. 2A-2C illustrate an example of a ported catheter 200 that employs an actuator 210 to open and disinfect the side port 203 of the ported catheter. FIGS. 3A-3C illustrate detailed views of the actuator 210 within side port 203 and correspond to FIGS. 2A-2C respectively. As shown, ported catheter 200 comprises a catheter adapter 201 having an inner lumen 201 a. A side port 203 extends from the catheter adapter 201 and forms an opening into the inner lumen 201 a. This opening is sealed by a piece of tubing 204 positioned within the inner lumen 201 a as was described with reference to FIGS. 1A-1C .
[0028] Unlike ported catheter 100 , ported catheter 200 includes an actuator 210 positioned within side port 203 . As better shown in FIG. 3A , actuator 210 comprises a bottom portion 210 a having a diameter that is smaller than the diameter of the opening within side port 203 (shown as 305 in FIG. 3 ) and a top portion 210 b having a diameter that is larger than the diameter of the opening within side port 203 . Actuator 210 also includes a lumen 210 c through which fluid may flow. As best shown in FIGS. 3A and 3B , side port 203 can include ridges 310 (forming opening 305 ) which prevent actuator 210 from passing completely through opening 305 .
[0029] Referring now to FIGS. 2B and 3B , when a device 205 is inserted into side port 203 , the tip of device 205 can force actuator 210 against tubing 204 causing tubing 204 to collapse inwardly. As best seen in FIG. 3B , the collapsing of tubing 204 creates a flowpath through actuator 210 and into lumen 201 a. In some embodiments, the bottom portion 210 a can include one or more channels or openings (in addition to the opening formed by lumen 210 c ) through which fluid may pass out from actuator 210 and into lumen 201 a. For example, the bottom portion 210 a can include one or more channels that extend upwardly from the bottom tip or one or more holes through the bottom portion 210 a.
[0030] It is noted that the collapsing of tubing 204 can be accomplished entirely from the force applied by actuator 210 to tubing 204 and therefore no fluid pressure needs to be built up to cause tubing 204 to collapse. For this reason, the use of actuator 210 minimizes the likelihood that any fluid will be sprayed out from side port 203 .
[0031] Additionally, because the flowpath around tubing 204 is formed by actuator 210 and not by pressure built-up within side port 203 , the use of actuator 210 allows fluid to flow bidirectionally within side port 203 . In other words, because actuator 210 will maintain the flowpath from side port 203 into lumen 201 a even when no fluid is flowing out from device 205 , device 205 can be used to collect fluid from within lumen 201 a. For example, if device 205 is a syringe, the syringe can be used to collect blood from within lumen 201 a.
[0032] In some implementations, side port 203 and/or device 205 can be modified (not shown) to allow device 205 to be interlocked within side port 203 . This may be desired in situations where fluid will be injected from device 205 at high pressure to prevent the forces generated by the high pressure injection (i.e. forces caused when the fluid exists device 205 ) from causing device 205 to back out from side port 203 . However, in many implementations, no locking between device 205 and side port 203 is required because the flowpath created when actuator 210 compresses tubing 204 enables fluid flow without the buildup of pressure.
[0033] Referring now to FIGS. 2C and 3C , once the injection of fluid has been completed and device 205 has been removed from side port 203 , the resiliency of tubing 204 will cause tubing 204 to return to its original position thereby forcing actuator 210 back out of lumen 201 a. At this point, tubing 204 again forms a seal between lumen 201 a and side port 203 . Once this seal is formed, residual fluid 206 will remain within side port 203 . Actuator 210 can be configured so that it remains positioned within side port 203 and particularly within opening 305 . In this position, actuator 210 will be in contact with residual fluid 206 as shown in FIGS. 2C and 3C . Various techniques can be employed to maintain actuator 210 within side port 203 such as by forming ridges, channels, or other structure within side port 203 and/or actuator 210 that limit the upward movement of actuator 210 .
[0034] In some embodiments of the invention, actuator 210 can be comprised of a material or contain a coating that elutes antimicrobial agents when actuator 210 is in contact with a fluid. In such cases, as fluid 206 contacts actuator 210 , the antimicrobial agent contained within or on actuator 210 will elute into fluid 206 thereby maintaining the sterility of fluid 206 as well as the sterility of surfaces within side port 203 . By maintaining the sterility of side port 203 , the likelihood that microbes will be introduced through side port 203 during a subsequent infusion is reduced.
[0035] Antimicrobial actuators in accordance with one or more embodiments of the invention can be comprised of a base material matrix and one or more antimicrobial agents. In some embodiments, the base material matrix can be a UV curable, hydrophilic material that contains an antimicrobial agent with controlled release (elution) characteristics. Alternatively, a base material can be coated with an antimicrobial coating from which an antimicrobial agent will elute when subject to a fluid. Examples of materials that could be used to form the antimicrobial actuator of the present invention include those disclosed in U.S. Pat. No. 8,512,294 titled Vascular Access Device Antimicrobial Materials And Solutions; U.S. patent application Ser. No. 12/397,760 titled Antimicrobial Compositions; U.S. patent application Ser. No. 12/476,997 titled Antimicrobial Coating Compositions; U.S. patent application Ser. No. 12/490,235 titled Systems And Methods For Applying An Antimicrobial Coating To A Medical Device; and U.S. patent application Ser. No. 12/831,880 titled Antimicrobial Coating For Dermally Invasive Devices. Each of these patent documents is incorporated herein by reference.
[0036] In one particular embodiment, the antimicrobial agent used to form an actuator can be chlorhexidine including chlorhexidine diacetate (CHA) and chlorhexidine gluconate (CHG). However, any other antimicrobial agent that will elute from a base material or from a coating on a base material could be used. Any material having elution characteristics can be employed as the base material of an actuator. Examples of suitable materials include UV cured acrylate-urethanes and heat-cured polymers which soften in water, such as hygroscopic polyurethanes. Also, if an antimicrobial lubricant is employed to provide antimicrobial agents, the actuator can be formed of any suitable material on which the lubricant can be applied whether or not it provides elution characteristics.
[0037] The amount of antimicrobial agent employed within a base material matrix or a lubricant coating can be varied to provide a desired mechanical property or elution characteristic. For example, in some instances a matrix is provided which comprises solid antimicrobial agent particles in an amount representing approximately 0.1-40% w/w of the matrix. These particles may range in size from 100 nm (fine powder) to 0.15 mm (salt-sized crystals). Additional additives may also be used to attain a particular characteristic. These additional additives include: multiple antimicrobial agents to widen the spectrum of microbes that will be affected; viscosity modifiers such as silica; color modifiers such as dyes or titanium dioxide; strength or stiffness modifiers such as glass fibers, ceramic particles such as zirconia, or metallic fibers; radiopacity modifiers such as barium sulfate; and magnetic susceptibility enhancers such as gadolinium chelates.
[0038] In some embodiments, a matrix can be used to form a coating on another material of the actuator. In such cases, the matrix can comprise 9% chlorhexidine diacetate (or chlorhexidine gluconate) mixed in a UV-curable acrylate adhesive (e.g. mCAST 7104 manufactured by Electronic Materials, Inc. or Breckenridge, Colo.).
[0039] In embodiments where a lubricant coating containing the antimicrobial agent is used, the lubricant coating can comprise 9% chlorhexidine diacetate or chlorhexidine gluconate mixed with MED-460 silicone lube. The viscosity of the lube can be modified by adding fumed silica in concentrations up to 3%. The use of 9% chlorhexidine represents specific examples; however, other percentages could equally be used to provide a desired elution duration.
[0040] To summarize, an antimicrobial actuator in accordance with one or more embodiments of the invention can be molded out of any material and then coated with an antimicrobial eluting coating or lubricant, or can be cast or formed out of a base material matrix that incorporates the antimicrobial agent. Regardless of how the actuator is formed or the materials used to form it, an actuator in accordance with the present invention can elute antimicrobial agents into fluid to sterilize or maintain the sterility of the fluid and contacting surfaces.
[0041] Because actuator 210 can include antimicrobial agents to sterilize fluid contained within side port 203 , the present invention minimizes the likelihood of infection when ported catheter 200 is used. In some embodiments, when side port 203 is not in use, a cap or other cover can be placed over side port 203 to prevent contaminants from entering side port 203 . However, because actuator 210 can provide antimicrobial benefits, a cap or other cover may not be required or may not need to provide any level of antimicrobial protection to side port 203 . Accordingly, actuator 210 can facilitate the aseptic use of a ported catheter.
[0042] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | The present invention related to a catheter device having a side port in which is contained an actuator, the actuator being configured to compress a tubing of the catheter device inwardly when a separated device is inserted into the side port, thereby opening a flowpath from the side port to the inner lumen of the catheter device. In some instances, the side port actuator further comprises an antimicrobial agent or is formed from an antimicrobial material whereby the actuator prevents antimicrobial growth or colonization within fluid that remains in the side port following use thereof. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an X-arm type window regulator for an automotive vehicle, and more specifically to a structure of a single subarm rotatably supported on either side of a main arm to constitute an X-arm-type window regulator for an automotive vehicle.
2. Description of the Prior Art
The background of the present invention will be explained with respect to its application to the window regulator for an automotive vehicle.
As is well known, a window regulator is used for an automotive vehicle in order to raise and lower a window pane provided for a vehicle door. The prior-art window regulator for an automotive vehicle usually uses a link mechanism and therefore includes a main arm and a pair of subarms. The two subarms are rotatably supported on either side of the main arm separately by using a special axle having a pair of square projections on either side thereof. The projections fit into square hole formed in each subarm.
In the above-mentioned structure of the prior-art window regulator, however, since the two subarms and a special axle must be used in the construction of the X-shaped arm for the window regulator, the number of required parts is relatively high and also it is relatively complicated to assemble the axle having two square projections formed on either side thereof to the respective square holes formed in the two separate subarms.
The arrangement of the prior-art window regulator for an automotive vehicle will be described in more detail hereinafter with reference to the attached drawings under DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
SUMMARY OF THE INVENTION
With these problems in mind, therefore, it is the primary object of the present invention to provide a novel X-arm type window regulator for an automotive vehicle which is easy to assemble and requires few moving parts.
To achieve the above-mentioned object, the window regulator for an automotive vehicle according to the present invention comprises a main arm having a middle pivot hole formed therein, a single crank-like subarm having a stepped portion connecting a first and a second subarm at the middle thereof, and a pair of arc-shaped, roughly semicircular pivots to rotatably support the crank-like subarm on either side of the main arm with the stepped portion of the subarm sandwiched between the semicircular pivots in the middle pivot hole of the main arm.
Further in this case, after the crank-like subarm has been passed through the middle pivot hole formed in the main arm, the subarm is rotatably supported on either side of the main arm by sandwiching the stepped portion of the subarm by the pair of arc-shaped, roughly semicircular pivots.
The window regulator according to the present invention can improve productivity of its manufacture and thus reduce manufacturing cost.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the window regulator according to the present invention will be more clearly appreciated from the following description taken in conjunction with the accompanying drawings in which like reference numerals designate corresponding elements in which:
FIG. 1 is a front view showing a sample prior-art window regulator for an automotive vehicle;
FIG. 2 is a perspective view showing a sample prior-art structure to rotatably support a pair of subarms onto a main arm;
FIG. 3 is a fragmentary sectional view showing a state where the main arm and the subarm according to the present invention engage via a pair of arc-shaped semicircular pivots;
FIG. 4 is a perspective view showing the crank-like subarm according to the present invention;
FIG. 5 is a front view showing the crank-like subarm according to the present invention;
FIG. 6 is a front view showing the arc-shaped roughly semicircular pivot according to the present invention;
FIG. 7 is a perspective view showing the semicircular pivot according to the present invention; and
FIG. 8 is a fragmentary front view showing the main arm according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
To facilitate understanding of the present invention, a brief reference will be made to a prior-art window regulator for an automotive vehicle, with reference to the attached drawings.
In FIG. 1, the reference numeral 1 denotes a main arm one end of which moves along a movable channel-shaped guide rail 8 with a roller 10 rotatably mounted on the extreme end thereof and the other end of which is rotatably supported by a pin 3 fixed to a base member 2 fixed to a vehicle door (not shown). The reference numeral 61 denotes a first subarm, one end of which moves along the movable channel-shaped guide rail 8 with another roller 11 rotatably mounted on the extreme end thereof and the other end of which is rotatably supported by an arm pin 7 fixed at the central position of the main arm 1. The reference numeral 62 denotes a second subarm, one end of which moves along a fixed channel-shaped guide rail 9 with the other roller 15 rotatably mounted on the extreme end thereof and the other end of which is rotatably supported by the arm pin 7 at the central position of the main arm 1 coaxially with the end of the first subarm 61. The reference numeral 4 denotes a fan-shaped rack fixed to the free end of the main arm 1. The rack 4 is rotated clockwise or counterclockwise by a pinion 5 rotatably supported by a pinion shaft 14 fixed to the base 2 so as to gear with the rack 4.
In the prior-art window regulator thus constructed, when the pinion 5 is rotated clockwise or counterclockwise, the main arm 1 pivots about the pin 3 due to the engagement of the rack 4 and the pinion 5. Therefore, the positions of the main arm 1 and the first and second subarms 61 and 62 are changed, thereby, changing the angle θ subtended by the main arm 1 and the subarm 62. Since the roller 15 rotatably supported at the end of the second subarm 62 moves along the fixed guide rail 9 without changing its vertical position, the movable guide rail 8 within which the rollers 10 and 11 are rotatably engaged is moved up and down, so that the window pane 13 is also moved up and down in conjunction with the up-and-down movement of the movable guide rail 8.
In the above-mentioned X-arm-type window regulator, when the window pane is lowered, since the rollers 10 and 11 are also lowered below the roller 15, that is, beyond the fixed rail 9, the subarms 61 and 62 must be on opposite sides of the main arm 1 in order not to interfere with the main arm 1. In order to avoid the interference of the fixed rail 9 with the window pane 13, the subarm 61 on the window glass side and the subarm 62 on the fixed rail side must be constructed so as to rotate independently with respect to the main arm 1. Therefore, conventionally, as depicted in FIG. 2, the subarm is divided into two separate parts 61 and 62, and are pivotably supported on the main arm 1 by of an axle 7 having a square pillar projection 71 or 72 on either side fitted into the respective square holes 61' and 62' formed in the base portion of the respective subarms 61 and 62, the axle being installed within an axle hole 1' formed in the main arm 1.
In the above-mentioned structure, however, since the subarm 6 must be divided into the two members 61 and 62, the number of necessary parts increases and also it is troublesome to manufacture the axle having square pillar projections on either side to the subarms 61 and 62.
In view of the above description, reference is now made to a preferred embodiment of the window regulator for an automotive vehicle according to the present invention, in which a novel single subarm is rotatably supported on either side of the main arm by a pair of arc-shaped, roughly semicircular pivots.
As shown in FIGS. 3, 4, and 5, the subarm 6 is integrally formed in such a way that the two subarms 61 and 62 are connected to each other by a stepped portion 6a.
In the subarm 6, as depicted in FIG. 4, the stepped portion 6a thereof has a widest dimension d and the other portions 61 or 62 thereof have width equal to or a little smaller than d. Further in this case, the width d of the stepped portion 6a is a little smaller than the diameter D of an pivot-fitting hole 1' formed in the main arm 1 shown in FIG. 8.
The subarm 6 formed as explained above is inserted into the pivot hole 1' in the main arm 1, beginning from the one end of the subarm 6, until the stepped portion 6a of the subarm reaches the pivot hole 1' in the main arm 1. That is to say, the subarm 61 and the subarm 62 are placed on either side of the main arm 1, respectively, as depicted in FIG. 3.
Next, two arc-shaped, roughly semicircular pivots 12, each having a pivot pin 12a on one side surface and a flange portion 12b on the other side as shown in FIGS. 6 and 7 and a slidable portion 12d therebetween, are fitted to the pivot hole 1' in the main arm 1 with the stepped portion 6a of the subarm 6 sandwiched by the two cut end surfaces 12c of the two roughly semicircular pivots 12 and with the pivot pins 12a of the semicircular pivots 12 fitted to the fitting holes 6b formed near the center of the subarm 6 as shown in FIG. 3. Thereafter, the top ends 12a of the pivot pins 12 are deformed to form flanges by using an ultrasonic pressing apparatus or a spinning device to fix the pivots 12 to the respective subarms 61 and 62.
Therefore, the two pivots 12 sandwiching the stepped portion 6a of the subarm 6 are so combined so as to function as an axle fitted to the pivot hole 1' of the main arm 1. In this case, there must be provided a clearance c between the surface of the main arm 1 and the surface near the base portion of the subarms 61 and 62 with the main arm sandwiched between the flange portion 12b and the subarm 61 or 62, so that the main arm 1 and the subarm 6 can be rotatably connected by the two roughly cemicircular pivots 12.
Further, in this embodiment, since the surface 12c of the roughly semicircular pivot 12 is truncated from a completely semicircular surface by one half of the plate thickness t of the subarm 6 as shown in FIG. 6, in other words, since the diameter D of the middle pivot hole 1' formed at the middle portion of the main arm 1 is roughly the same as the sum total of the plate thickness of the subarm 6 and twice the radial height h of the slidable portion 12d of the roughly semicircular pivot, when the stepped portion 6a of the subarm 6 is sandwiched by the two pivots 12, the outer peripheral surface of the two pivots 12 becomes a complete, circular surface for sliding in the pivot hole 1' of the main arm 1.
Further, in this embodiment, it is desirable that the semicircular pivot 12 is made of a synthetic resin such as nylon or polyacetal which is hard and slides easily.
Further, the height H of the stepped portion 6a of the subarm 6 is determined by to the height of the slidable portion 12d of the pivot 12, which is a little larger than the thickness of the main arm 1.
As described above, in the X-arm-type window regulator, since the subarm is provided with the stepped portion formed integraly therewith and inserted into the pivot hole of the main arm with the stepped portion of the subarm placed in the central pivot hole of the main arm, and since two semicircular pivots are fitted to the pivot hole of the main arm, so as to sandwich the stepped portion of the subarm, and fixed to the subarms, it is possible to combine the subarm conventionally divided into two elements into a single element, thus resulting in reduction of the number of parts, simplification of assembly, improvement of strength in the arm assembly, and reduction of manufacturing cost.
It will be understood by those skilled in the art that the foregoing description is terms of preferred embodiments of the present invention wherein various changes and modifications may be made without departing from the spirit and scope of the invention, as is set forth in the appended claims. | An X-arm type window regulator for an automotive vehicle for raising and lowering a window pane comprises a novel crank-like subarm with a stepped portion at the middle portion thereof, a main arm with a middle pivot hole, and a pair of arc-shaped, roughly semicircular pivots, in addition to the conventional elements such as a movable guide rail, a fixed guide rail, a rack and a pinion, a plurality of rollers, etc. The stepped portion of the crank-like subarm is positioned in the middle pivot hole of the main arm perpendicular to the main arm and is sandwiched by the two semicircular pivots, so that the subarm is rotatably supported on either side of the main arm to form an X-arm link mechanism. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a Divisional of U.S. patent application Ser. No. 12/053,476, filed on Mar. 21, 2008, which claims the benefit of U.S. Provisional Application No. 61/027,356, filed on Feb. 8, 2008, the contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] This disclosure relates generally to image sensors, and in particular but not exclusively, relates to backside illumination CMOS image sensors.
BACKGROUND INFORMATION
[0003] FIG. 1 illustrates a conventional frontside illuminated complementary metal-oxide-semiconductor (“CMOS”) imaging pixel 100 . The frontside of imaging pixel 100 is the side of substrate 105 upon which the pixel circuitry is disposed and over which metal stack 110 for redistributing signals is formed. The metal layers (e.g., metal layer M 1 and M 2 ) are patterned in such a manner as to create an optical passage through which light incident on the frontside of imaging pixel 100 can reach the photosensitive or photodiode (“PD”) region 115 . The frontside may further include a color filter layer to implement a color sensor and a microlens to focus the light onto PD region 115 .
[0004] Imaging pixel 100 includes pixel circuitry disposed within pixel circuitry region 125 adjacent to PD region 115 . This pixel circuitry provides a variety of functionality for regular operation of imaging pixel 100 . For example, pixel circuitry region 125 may include circuitry to commence acquisition of an image charge within PD region 115 , to reset the image charge accumulated within PD region 115 to ready imaging pixel 100 for the next image, or to transfer out the image data acquired by imaging pixel 100 . As illustrated, in a frontside illuminated configuration, pixel circuitry region 125 is positioned immediately adjacent to PD region 115 . Consequently, pixel circuitry region 125 consumes valuable real estate within imaging pixel 100 at the expense of PD region 115 . Reducing the size of PD region 115 to accommodate the pixel circuitry reduces the fill factor of imaging pixel 100 thereby reducing the amount of pixel area that is sensitive to light, and reducing low light performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Non-limiting and non-exhaustive embodiments of the invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
[0006] FIG. 1 is a cross sectional view of a conventional frontside illuminated imaging pixel.
[0007] FIG. 2 is a block diagram illustrating a backside illuminated imaging system, in accordance with an embodiment of the invention.
[0008] FIG. 3A is a circuit diagram illustrating pixel circuitry of two 4T pixels within a backside illuminated imaging system, in accordance with an embodiment of the invention.
[0009] FIG. 3B is a circuit diagram illustrating pixel circuitry of an active pixel sensor including analog-to-digital conversion circuitry within a backside illuminated imaging system, in accordance with an embodiment of the invention.
[0010] FIG. 4 is a hybrid cross sectional/circuit illustration of a backside illuminated imaging pixel with overlapping pixel circuitry, in accordance with an embodiment of the invention.
[0011] FIG. 5 is a flow chart illustrating a process for operating a backside illuminated imaging pixel with overlapping pixel circuitry, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0012] Embodiments of a system and method for operation of a backside illuminated image sensor with overlapping pixel circuitry are described herein. In the following description numerous specific details are set forth to provide a thorough understanding of the embodiments. One skilled in the relevant art will recognize, however, that the techniques described herein can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring certain aspects.
[0013] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0014] Throughout this specification, several terms of art are used. These terms are to take on their ordinary meaning in the art from which they come, unless specifically defined herein or the context of their use would clearly suggest otherwise. The term “overlapping” is defined herein with reference to the surface normal of a semiconductor die. Two elements disposed on a die are said to be “overlapping” if a line drawn through a cross section of the semiconductor die running parallel with the surface normal intersects the two elements.
[0015] FIG. 2 is a block diagram illustrating a backside illuminated imaging system 200 , in accordance with an embodiment of the invention. The illustrated embodiment of imaging system 200 includes a pixel array 205 , readout circuitry 210 , function logic 215 , and control circuitry 220 .
[0016] Pixel array 205 is a two-dimensional (“2D”) array of backside illuminated imaging sensors or pixels (e.g., pixels P 1 , P 2 . . . , Pn). In one embodiment, each pixel is a complementary metal-oxide-semiconductor (“CMOS”) imaging pixel. As illustrated, each pixel is arranged into a row (e.g., rows R 1 to Ry) and a column (e.g., column C 1 to Cx) to acquire image data of a person, place, or object, which can then be used to render a 2D image of the person, place, or object.
[0017] After each pixel has acquired its image data or image charge, the image data is readout by readout circuitry 210 and transferred to function logic 215 . Readout circuitry 210 may include amplification circuitry, analog-to-digital (“ADC”) conversion circuitry, or otherwise. Function logic 215 may simply store the image data or even manipulate the image data by applying post image effects (e.g., crop, rotate, remove red eye, adjust brightness, adjust contrast, or otherwise). In one embodiment, readout circuitry 210 may readout a row of image data at a time along readout column lines (illustrated) or may readout the image data using a variety of other techniques (not illustrated), such as a serial readout or a full parallel readout of all pixels simultaneously.
[0018] Control circuitry 220 is coupled to pixel array 205 to control operational characteristic of pixel array 205 . For example, control circuitry 220 may generate a shutter signal for controlling image acquisition. In one embodiment, the shutter signal is a global shutter signal for simultaneously enabling all pixels within pixel array 205 to simultaneously capture their respective image data during a single acquisition window. In an alternative embodiment, the shutter signal is a rolling shutter signal whereby each row, column, or group of pixels is sequentially enabled during consecutive acquisition windows.
[0019] FIG. 3A is a circuit diagram illustrating pixel circuitry 300 of two four-transistor (“4T”) pixels within a backside illuminated imaging array, in accordance with an embodiment of the invention. Pixel circuitry 300 is one possible pixel circuitry architecture for implementing each pixel within pixel array 200 of FIG. 2 . However, it should be appreciated that embodiments of the present invention are not limited to 4T pixel architectures; rather, one of ordinary skill in the art having the benefit of the instant disclosure will understand that the present teachings are also applicable to 3T designs, 5T designs, and various other pixel architectures.
[0020] In FIG. 3A , pixels Pa and Pb are arranged in two rows and one column. The illustrated embodiment of each pixel circuitry 300 includes a photodiode PD, a transfer transistor T 1 , a reset transistor T 2 , a source-follower (“SF”) transistor T 3 , a select transistor T 4 , and a storage capacitor C 1 . During operation, transfer transistor T 1 receives a transfer signal TX, which transfers the charge accumulated in photodiode PD to a floating diffusion node FD. In one embodiment, floating diffusion node FD may be coupled to a storage capacitor for temporarily storing image charges.
[0021] Reset transistor T 2 is coupled between a power rail VDD and the floating diffusion node FD to reset the pixel (e.g., discharge or charge the FD and the PD to a preset voltage) under control of a reset signal RST. The floating diffusion node FD is coupled to control the gate of SF transistor T 3 . SF transistor T 3 is coupled between the power rail VDD and select transistor T 4 . SF transistor T 3 operates as a source-follower providing a high impedance connection to the floating diffusion FD. Finally, select transistor T 4 selectively couples the output of pixel circuitry 300 to the readout column line under control of a select signal SEL.
[0022] In one embodiment, the TX signal, the RST signal, and the SEL signal are generated by control circuitry 220 . In an embodiment where pixel array 205 operates with a global shutter, the global shutter signal is coupled to the gate of each transfer transistor T 1 in the entire pixel array 205 to simultaneously commence charge transfer from each pixel's photodiode PD. Alternatively, rolling shutter signals may be applied to groups of transfer transistors T 1 .
[0023] FIG. 3B is a circuit diagram illustrating pixel circuitry 301 using an active pixel sensor (“APS”) architecture including an integrated analog-to-digital converter (“ADC”) 305 , in accordance with an embodiment of the invention. Pixel circuitry 301 is another possible pixel circuitry architecture for implementing each pixel within pixel array 200 of FIG. 2 . The APS architecture illustrated includes only two transistors (reset transistor T 2 and select transistor T 4 ); however, if the ADC 305 were not integrated into pixel circuitry 301 , then SF transistor T 3 would be included and pixel circuitry 301 would be referred to as a 3T pixel design. It should be appreciated that FIG. 3B is just one possible implementation of integrating an ADC into a pixel and that other implementations may be used with embodiments of the invention. For example, an ADC may be incorporated into the 4T design illustrated in FIG. 3A .
[0024] The illustrated embodiment of pixel circuitry 301 includes a PD, a reset transistor T 2 , a select transistor T 4 , and ADC 305 . The illustrated embodiment of ADC 305 includes a comparator (“COMP”) 310 , a counter 315 , and memory 320 . During operation, ADC 305 may operate to convert the analog image charge accumulated by the PD into image data having a digital value representation prior to output on the column bus by select transistor T 4 . Memory 320 is a multi-bit register (e.g., 8 bit, 16 bit, 20 bit, etc.) for temporarily storing the digital image data. In one embodiment, the pixel circuitry of each pixel P 1 to Pn within pixel array 205 includes its own ADC 305 . In one embodiment, two or more adjacent pixels may share one or more components of ADC 305 . In a sharing embodiment, the circuitry of a shared ADC 305 may overlap two or more adjacent pixels.
[0025] FIG. 4 is a hybrid cross sectional/circuit illustration of a backside illuminated imaging pixel 400 with overlapping pixel circuitry, in accordance with an embodiment of the invention. Imaging pixel 400 is one possible implementation of pixels P 1 to Pn within pixel array 205 . The illustrated embodiment of imaging pixel 400 includes a substrate 405 , a color filter 410 , a microlens 415 , a PD region 420 , an interlinking diffusion region 425 , a pixel circuitry region 430 , pixel circuitry layers 435 , and a metal stack 440 . The illustrated embodiment of pixel circuitry region 430 includes a 4T pixel (other pixel designs may be substituted), as well as other circuitry 431 (e.g., gain circuitry, ADC circuitry, gamma control circuitry, exposure control circuitry, etc.), disposed over a diffusion well 445 . A floating diffusion 450 is disposed within diffusion well 445 and coupled between transfer transistor T 1 and the gate of SF transistor T 3 . The illustrated embodiment of metal stack 440 includes two metal layers M 1 and M 2 separated by intermetal dielectric layers 441 and 443 . Although FIG. 4 illustrates only a two layer metal stack, metal stack 440 may include more or less layers for routing signals over the frontside of pixel array 205 . In one embodiment, a passivation or pinning layer 470 is disposed over interlinking diffusion region 425 . Finally, shallow trench isolations (“STI”) isolate imaging pixel 400 from adjacent pixels (not illustrated).
[0026] As illustrated, imaging pixel 400 is photosensitive to light 480 incident on the backside of its semiconductor die. By using a backside illuminated sensor, pixel circuitry region 430 can be positioned in an overlapping configuration with photodiode region 420 . In other words, pixel circuitry 300 can be placed adjacent to interlinking diffusion region 425 and between photodiode region 420 and the die frontside without obstructing light 480 from reaching photodiode region 420 . By placing the pixel circuitry in an overlapping configuration with photodiode region 420 , as opposed to side-by-side configuration as illustrated in FIG. 1 , photodiode region 420 no longer competes for valuable die real estate with the pixel circuitry. Rather, pixel circuitry region 430 can be enlarged to accommodate additional or larger components without detracting from the fill factor of the image sensor. Embodiments of the present invention enable other circuits 431 , such as gain control or ADC circuitry (e.g., ADC 305 ), to be placed in close proximity to their respective photodiode region 420 without decreasing the sensitivity of the pixel. By inserting gain control and ADC circuitry in close proximity to each PD region 420 , circuit noise can be reduced and noise immunity improved due to shorter electrical interconnections between PD region 420 and the additional in-pixel circuitry. Furthermore, the backside illumination configuration provides greater flexibility to route signals over the frontside of pixel array 205 within metal stack 440 without interfering with light 480 . In one embodiment, the shutter signal is routed within metal stack 440 to the pixels within pixel array 205 .
[0027] In one embodiment, pixel circuit regions 430 over PD regions 420 of adjacent pixels within pixel array 205 can be grouped to create communal die real estate. This communal die real estate can support shared circuitry (or inter-pixel circuitry) in addition to the basic 3T, 4T, 5T, etc. pixel circuitry. Alternatively, some pixels can donate their unused die real estate above their PD regions 420 to an adjacent pixel requiring additional pixel circuitry space for larger or more advanced in-pixel circuitry. Accordingly, in some embodiments, other circuitry 431 may overlap two or more PD regions 420 and may even be shared by one or more pixels.
[0028] In one embodiment, substrate 405 is doped with P type dopants. In this case, substrate 405 and the epitaxial layers grown thereon may be referred to as a P substrate. In a P type substrate embodiment, diffusion well 445 is a P+ well implant while photodiode region 420 , interlinking diffusion region 425 , and floating diffusion 450 are N type doped. Floating diffusion 450 is doped with an opposite conductivity type dopant as diffusion well 445 to generate a p-n junction within diffusion well 445 , thereby electrically isolating floating diffusion 450 . In an embodiment where substrate 405 and the epitaxial layers thereon are N type, diffusion well 445 is also N type doped, while photodiode region 420 , interlinking diffusion region 425 , and floating diffusion 450 have an opposite P type conductivity.
[0029] FIG. 5 is a flow chart illustrating a process 500 for operating BSI imaging pixel 400 , in accordance with an embodiment of the invention. Process 500 illustrates the operation of a single pixel within pixel array 205 ; however, it should be appreciated that process 500 may be sequentially or concurrently executed by each pixel in pixel array 205 depending upon whether a rolling shutter or global shutter is used. The order in which some or all of the process blocks appear in process 500 should not be deemed limiting. Rather, one of ordinary skill in the art having the benefit of the present disclosure will understand that some of the process blocks may be executed in a variety of orders not illustrated.
[0030] In a process block 505 , photodiode PD (e.g., photodiode region 420 ) is reset. Resetting includes discharging or charging photodiode PD to a predetermined voltage potential, such as VDD. The reset is achieved by asserting both the RST signal to enable reset transistor T 2 and asserting the TX signal to enable transfer transistor T 1 . Enabling T 1 and T 2 couples photodiode region 420 , interlinking diffusion region 425 , and floating diffusion 450 to power rail VDD.
[0031] Once reset, the RST signal and the TX signal are de-asserted to commence image acquisition by photodiode region 420 (process block 510 ). Light 480 incident on the backside of imaging pixel 400 is focused by microlens 415 through color filter 410 onto the backside of photodiode region 420 . Color filter 410 operates to filter the incident light 480 into component colors (e.g., using a Bayer filter mosaic or color filter array). The incident photons cause charge to accumulate within the diffusion region of the photodiode.
[0032] Once the image acquisition window has expired, the accumulated charge within photodiode region 420 is transferred via the transfer transistor T 1 to the floating diffusion 450 by asserting the TX signal (process block 515 ). In the case of a global shutter, the global shutter signal is asserted simultaneously, as the TX signal, to all pixels within pixel array 205 during process block 515 . This results in a global transfer of the image data accumulated by each pixel into the pixel's corresponding floating diffusion 450 .
[0033] Once the image data is transferred, the TX signal is de-asserted to isolate floating diffusion 450 from PD region 420 for readout. In a process block 520 , the SEL signal is asserted to transfer the stored image data onto the readout column for output to the function logic 215 via readout circuitry 210 . It should be appreciated that readout may occur on a per row basis via column lines (illustrated), on a per column basis via row lines (not illustrated), on a per pixel basis (not illustrated), or by other logical groupings. Once the image data of all pixels has been readout, process 500 returns to process block 505 to prepare for the next image.
[0034] In one embodiment, other circuitry 431 may include a storage capacitor coupled to FD 450 to temporarily store the image charge so that post image acquisition processing may be executed within each pixel prior to readout in process block 520 . Such circuitry may include gain circuitry, ADC circuitry, or otherwise. Other circuitry 431 may even include exposure control circuitry and gamma control circuitry. The overlapping BSI configuration provides room within each pixel to enable such intra-pixel processing without sacrificing the fill factor of pixel 400 .
[0035] The processes explained above are described in terms of computer software and hardware. The techniques described may constitute machine-executable instructions embodied within a machine (e.g., computer) readable storage medium, that when executed by a machine will cause the machine to perform the operations described. Additionally, the processes may be embodied within hardware, such as an application specific integrated circuit (“ASIC”) or the like.
[0036] A machine-readable storage medium includes any mechanism that provides (i.e., stores) information in a form accessible by a machine (e.g., a computer, network device, personal digital assistant, manufacturing tool, any device with a set of one or more processors, etc.). For example, a machine-readable storage medium includes recordable/non-recordable media (e.g., read only memory (ROM), random access memory (RAM), magnetic disk storage media, optical storage media, flash memory devices, etc.).
[0037] The above description of illustrated embodiments of the invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize.
[0038] These modifications can be made to the invention in light of the above detailed description. The terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification. Rather, the scope of the invention is to be determined entirely by the following claims, which are to be construed in accordance with established doctrines of claim interpretation. | A method of operation of a backside illuminated (BSI) pixel array includes acquiring an image signal with a first photosensitive region of a first pixel within the BSI pixel array. The image signal is generated in response to light incident upon a backside of the first pixel. The image signal acquired by the first photosensitive region is transferred to pixel circuitry of the first pixel disposed on a frontside of the first pixel opposite the backside. The pixel circuitry at least partially overlaps the first photosensitive region of the first pixel and extends over die real estate above a second photosensitive region of a second pixel adjacent to the first pixel such that the second pixel donates die real estate unused by the second pixel to the first pixel to accommodate larger pixel circuitry than would fit within the first pixel. | 7 |
FIELD OF THE INVENTION
The invention relates to a roller drafting device for spinning machines in which the covering for the pressure rollers consists of an outer and an inner layer and the outer layer has a thinner wall than the inner layer, as well as to a belt or casing for use as a covering for pressure rollers in such drafting devices for spinning machines in which the thinner-walled outer layer loosely surrounds the thicker inner layer so that the outer layer can move relatively to the inner layer.
BACKGROUND
During the drafting of fiber bands in drafting devices, the clamping action of the roller pairs plays a decisive part for the transfer of the drafting forces onto the fiber band. The roller pairs of the drafting device therefore consist of a fluted steel cylinder, the so-called lower cylinder, and of a pressure roller, the so-called upper roller, that is pressed by load onto the steel cylinder. As a rule, this pressure roller comprises an elastic covering so that no clamping line is produced but rather a clamping surface formed by the deformation of the elastic covering, which surface brings about a significantly better fiber retention. A good clamping action is exerted on the fiber structure without damaging the fibers. Experience has shown that soft roller coverings therefore yield better drafting results since the softer the covering is, the greater is the clamping surface. However, soft roller coverings have the disadvantage that they wear down very rapidly and that grooves are produced in particular in the area of the fiber passage. This so-called “shrinking” is eliminated by buffing over the entire covering surface. This alters the geometry of the drafting device rollers and therewith also the covering properties, which for its part has a disadvantageous effect on the drafting conditions and thus on the yarn values. In addition, the regrinding of the roller coverings is a quite expensive measure.
The attempt has therefore already been made to counteract this disadvantage by means of a multi-layer roller covering. DE 1 815 739 U teaches a pressure roller whose elastic jacket is subdivided into at least two layers of which the outer layer is designed as an elastic casing consisting of a thin hose that can be drawn over the elastic jacket of the pressure cylinder. The designing of the outer layer as a hose makes it easy to draw a cover over the elastic jacket and also to easily remove it from the latter when this outer circumferential surface has become worn. The fixing of the elastic hose is ensured by the natural friction between rubber and rubber. This known design does make it possible to readily replace the elastic outer layer; however, it was not able to solve the problem of the rapid wear and of the shrinking.
DE 1 685 634 A1 teaches a covering for drafting device rollers of spinning machines which covering is composed of two superposed cylindrical layers of which the outer layer is harder and has a thinner wall than the inner layer. The two layers are adhered to one another. As a result thereof, very different materials can be combined with each other in order to avoid the formation of windings and electrostatic charging. However, it turned out that the problem of a good drafting ability and of wear were not satisfactorily solved. In addition, as a consequence of the adhesion the changing of the outer layer is expensive.
SUMMARY
The invention has the problem of eliminating these disadvantages and of finding a roller covering that has high wear resistance and long-lasting elasticity in the running layer and thus ensures optimal drafting conditions for a long time. 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.
It surprisingly turned out that it is important in a multi-layer covering with a thin outer layer and a thicker inner layer that a relative movement can take place between the two layers. The milling motion of the soft covering and the tension forces produced thereby are then transferred only onto the inside of the outer, thin-walled layer but not on the fibers and the fluted cylinder. Practically no wear occurs any more, in particular no groove formation (shrinking), so that the outer layer has a service life that is more than three times longer than certain prior devices discussed above.
The outer layer is advantageously adapted on its outside as a fiber contact surface to the requirements of a good fiber clamping and on its inside as a running surface to the smoothest possible, low-friction running of the pressure roller. This is achieved, e.g., in a simple manner by the selection of appropriate material compositions for the fiber contact layer and the running layer of the outer layer. This outer layer can be designed as the casing around the inner pressure roller layer as well as an endless belt. It must only be so flexible that it adapts to the deformation of the soft inner layer. It proved to be especially advantageous to design the outer layer in the direction of travel of the fiber structure, that is, transversely to the roller axis, as inelastically as possible, that is, with the lowest possible extensibility. The tension forces in the clamping surface producing wear and acting negatively on the drafting are eliminated in this manner, whereas the outer layer can adapt in the axial direction to the rugosities of the fiber structure. An excellent clamping is achieved in this manner. The desired reduction of the expansion of the outer layer transversely to the axis of the pressure roller is achieved quite well by a yarn insert without limiting the expandability in the direction of the roller axis. The relative motion between the outer layer and the inner layer is favored by the smoothest possible surface of the running layer of the outer layer, and as a consequence thereof the breakdown of the tension forces is furthered in an even better manner.
It is advantageous for a high delivery speed to use an outer layer designed as a belt and to run this belt through a deflection rail. In addition, this deflection rail can also comprise side rims for a more reliable guidance. It also proved to be especially advantageous at high delivery speeds for a trouble-free travel if the belt rolls off the pressure roller at an angle α>30° to the plane of the fiber structure. The belt advantageously consists of several layers and the inside is designed as a smooth travel layer and the outside as a fiber contact layer. A yarn insert is provided between the layers which prevents the belt from expanding in the direction of travel without adversely influencing a desired transverse expansion.
Further details of the invention are explained using the figures.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows the design of the two-layer roller covering in longitudinal section in accordance with the invention.
FIG. 2 shows a cross section through the device according to FIG. 1 .
FIG. 3 shows the design of the outer layer as belt.
FIGS. 4 , 5 schematically show the design of the outer layer with an insert for stiffening in the direction transverse to the cylinder axis.
FIG. 6 shows in section the guidance of the belt by means of a deflection rail.
FIG. 7 shows a plan view accompanying FIG. 6
DESCRIPTION
Reference is now made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each embodiment is provided 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.
In FIGS. 1 , 2 pressure roller 3 is arranged above drafting device cylinder 5 and comprises covering 2 permanently connected in a customary manner to pressure roller 3 . Drafting device cylinder 5 and pressure roller 3 form the exit roller pair of a drafting device running at a high speed in accordance with the delivery. Another coating 1 is provided as an outer layer over this inner layer coating 2 of pressure roller 3 . This outer layer consists in the embodiment shown here of thin-walled casing 1 consisting of flexible material that behaves practically without expansion relative to the material of inner layer 2 in the direction of travel of casing 1 . This casing 1 is slipped loosely over inner layer 2 of pressure roller 3 so that intermediate space 6 can form in the non-loaded area between inner and outer layers. It is essential that casing 1 can move relative to inner layer 2 of pressure roller 3 . On the other hand, inner layer 2 is drawn firmly onto pressure roller 3 , as is customary. Under the loading of pressure roller 3 soft inner layer 2 is pressed onto drafting device cylinder 5 and deformed, so that no linear contact with drafting device cylinder 5 takes place but rather an area or planar support takes place. Since outer layer 1 is thin and flexible, it adapts to the deformation of inner layer 2 without being substantially compressed itself. Therefore, in contrast to the inner layer, no appreciable pressing work is performed in the case of outer layer 1 . The clamping surface generated by the deformation of inner layer 2 is transmitted by outer layer 1 so that fiber structure F ( FIG. 6 ) provided for the drafting is clamped by this clamping surface when passing through roller pair 3 , 5 .
In the customary pressure roller coverings, a clamping surface is formed by the soft elastic covering which surface produces a good clamping action. However, tension forces are produced in the area of the clamping surface by the pressing work of the covering that have a negative effect on the fiber structure during drafting and also cause the known high wear of the covering. However, the arrangement of an outer layer 1 that flexibly adapts to the deformation of soft and elastic covering 2 of pressure roller 3 , but that causes no or only a very low pressing work on account of its lower thickness and deformability, surprisingly led to the result that this outer layer 1 exhibits a significantly greater stability and also the soft inner layer 2 displays none of the customary phenomena of wear and shrinking. It turned out in extensive tests that outer layer 1 still ran without any problems even after three times the run time and did not have to be replaced. The drafting values were even able to be improved compared to new traditional coverings. It is to be assumed that this surprising result can be traced to the fact that the tension forces conditioned by the pressing work of soft and elastic inner layer 2 of pressure roller 3 can not affect the clamped fiber structure. These tension forces are degraded by the relative motion that is possible between soft inner layer 2 and smooth run layer 102 ( FIG. 4 ) of outer layer 1 . No relative movement takes place between the fibers and drafting device cylinder 5 as well as outer layer 1 so that the clamping takes place in the area of static friction. Thus, no wear caused by sliding can occur.
In the exemplary embodiment according to FIGS. 1 , 2 the outer layer is designed as cylindrical casing 1 . However it can also be designed as a rather long endless belt. This cylindrical casing 1 as well as a belt 10 or 100 can be readily replaced in case of wear or the formation of grooves in the area of fiber structure F. FIG. 3 shows endless belt 10 that surrounds pressure roller 3 with its soft elastic inner layer 2 and is guided by deflection rail 4 . The construction as a rather long endless belt 10 or 100 and its guidance by deflection rail 4 proved to be particularly advantageous when the device is run at high delivery speeds.
It should be taken into consideration that, depending on the particular draft, drafting devices 3 , 5 forming the delivery roller pair run approximately 20 to 30 times more rapidly than the roller pairs arranged in front of the main drafting field, that are customarily surrounded by fiber guide belts. These known fiber guide belts proved to be unsuitable for being used as outer layer 1 on exit roller pair 3 , 5 . These belts are insufficient in their properties. Thus, it turned out, e.g., that it is important that outer layer 1 or belt 10 or 100 is as inelastic as possible in the direction of travel of fiber structure F, that is, transversely to roller axis 31 , so that it can not expand.
Of course, not every expansion can be eliminated in the physical sense but it should be as small as possible. This achieved in a simple manner by yarn insert 103 . Furthermore, the known belts favor the sliding of the fibers during drafting, which is undesired for the exit roller pair.
FIG. 4 shows the design of outer layer 1 , 10 or 100 in section, that is directed specifically toward these desired properties. The outer layer designed as casing 1 or lengthened endless belt 10 or 100 is advantageously composed of several layers: Of fiber contact layer 101 and of run layer 102 . Yarn insert 103 is arranged between both layers 101 , 102 for eliminating the expansion in the longitudinal direction, which insert is firmly connected to fiber contact layer 101 and also to run layer 102 . Fiber contact layer 101 is designed in its surface and in its material in contact with fiber structure F for receiving the retention forces necessary during drafting. This is achieved, e.g., by using a material like the one used for pressure roller coverings. On the other hand, run layer 102 is provided with a smooth surface favoring sliding, in order to make possible a relative motion relative to outer layer 100 , 10 or 1 around inner layer 2 . A material favoring sliding is preferably used for run layer 102 like the material used, e.g., for the known belts for fiber guidance in the main drafting field.
Yarn insert 103 takes the elasticity from belt 100 in the direction of travel so that an expansion is practically not possible. However, the expandability remains transversely to the direction of travel, that is, in the direction of pressure roller axis 31 . The belt can adapt to the rugosities of drafted fiber structure F so that a good clamping is always ensured. In spite of these multi-layers of the outer layer, the latter must naturally not be too thick in order to impart good flexibility to it for adaptation to the deformation of inner layer 2 and to fiber structure F. A total thickness of 0.8 to 1.0 mm has proven to be especially advantageous in this connection as regards the stability and also the drafting results. No groove formation (shrinkage) could be determined even after several years of run time.
The desired properties of run layer 102 and a fiber contact layer 101 can also be achieved by an appropriate physical shaping of the surfaces. However, run layer 102 and fiber contact layer 101 preferably consist of different materials that have the desired sliding properties and the necessary grip. Measurements according to DIN 53375 have shown that e.g., the above-described material for fiber contact layer 101 has a frictional force value that is at least twice as high as the frictional force value of run layer 102 when the latter consists of a material like that used for belts for fiber guidance in the main drafting field. Run layer 102 thus has good sliding properties while fiber contact layer 101 achieves an excellent clamping of the fibers.
The manufacture of such an endless belt in accordance with FIGS. 4 , 5 takes place, e.g., in such a manner that at first run layer 102 is applied onto a tubular body with a circumference corresponding to the length of the belt, onto which run layer a yarn is wound that forms yarn insert 103 . Then, this yarn insert 103 is covered with fiber contact layer 101 .
In the embodiment according to FIGS. 6 , 7 a belt 100 is run through deflection rail 4 . In order to ensure a light run of belt 100 , deflection rail 4 is not only rounded but additionally provided with a low-friction coating. Cage 42 with guide rims 41 follows this deflection rail 4 . The space between deflection rail 4 and drafting device roller 3 is encapsulated by this cage 42 and its guide rims 41 , so that collections of fluff in this space are avoided. Belt 100 runs from drafting device roller 3 at an angle α relative to the plane of fiber structure F. This avoids turbulence and fly formation in the exit area of fiber structure F. Cage 42 is supported on holding rail 44 via pressure springs 43 so that deflection rail 4 exerts a tension on belt 100 . Side rims 41 serve to laterally guide belt 100 . An easy and rapid replacement of belt 100 is also possible in this embodiment. Belt 100 is relieved by pressing deflection rail 4 back and can also be readily lifted over side rims 41 . These side rims 41 also serve in addition to encapsulating the space between pressure roller 3 and deflection rail 4 for the lateral guiding of belt 100 . If outer layer 1 of pressure roller 3 is arranged asymmetrically to fiber structure F, outer layer 1 can be turned so that the left side is located on the right side and thus fiber structure F runs over an unused surface of the outer layer.
It should be appreciated by those skilled in the art that various modifications and variations can be made to the embodiments of the invention described herein without departing from the scope and spirit of the claims or their equivalents. | A spinning machine drafting device includes a pressure roller loaded against a lower roller such that a fiber structure is conveyed between the roller pair. The pressure roller has an outer circumferential layer disposed around an inner circumferential layer of different low friction material as compared to the outer layer. The outer layer is thinner than the inner layer and disposed around the inner layer so as to slide relative to the inner layer upon rotation of the pressure roller in operation of the drafting device. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of networking. More specifically, the present invention relates to the field of providing security to a network.
BACKGROUND OF THE INVENTION
[0002] Transmission Control Protocol (TCP) allows applications on networked computers to generate connections to each other. Over these connections, the applications are then able to exchange data packets. Many applications such as the world wide web and email utilize TCP. TCP is reliable and guarantees in-order delivery of data.
[0003] Applications send streams of 8-bit bytes to TCP to be delivered through the network. TCP divides the byte stream into appropriately sized segments and then passes the resulting packets to the Internet Protocol (IP) for delivery through the network to a TCP module of a target computer on the network. TCP ensures that no packets are lost by assigning a sequence number to each packet. This sequence number also ensures the packets are delivered in the correct order. The TCP module of the target computer sends back an acknowledgment for packets which have been successfully received. If an acknowledgment is not received within a reasonable amount of time, a timeout is triggered on the transmitting computer. Then, the data packet is re-sent.
[0004] As briefly described above, a 3-way handshake is implemented to establish a TCP connection. The transmitting computer first sends a synchronization packet to initiate the connection. Then the target computer sends an acknowledgment packet back. Finally, the transmitting computer sends an acknowledgment back to the target. By utilizing a 3-way handshake, computers are able to verify their connection.
[0005] The concern with TCP is that hackers are able to utilize this 3-way handshake to locate future victims to be hacked. Using scanning software, a set of packets are sent out across the network. Any clients on the network will respond to these packets. Then, hackers are able to determine which computers are accessible on the network and which ports are open on those computers. Using that information, a hacker is able to abuse the computer by crashing it or performing other malicious activity with it such as stealing data.
[0006] User Datagram Protocol (UDP) is a connectionless protocol that allows applications on networked computers to send short messages known as datagrams to each other. Unlike TCP, UDP does not provide guaranteed reliability. Datagrams are able to arrive disordered or get lost without notice. The reason for this is that UDP does not utilize the 3-way handshake of TCP where a target computer acknowledges that it is present when an unknown transmitting computer sends an initiating connection. However, as mentioned above, UDP has a number of drawbacks including being unreliable, not ordered, and other issues that make UDP insufficient for a specified purpose.
SUMMARY OF THE INVENTION
[0007] A system for and method of securing a network are described herein. A receiving device listens for packets with proper credentials. If a transmitting device sends the correct credentials, the receiving device will respond with an acknowledgment and further data is able to be transmitted. However, if the transmitting device does not send a packet with the proper credentials, then the receiving device will drop the packet and not respond. Thus, the transmitting device will be unaware of the presence of the receiving device, in particular when hackers are using scanning software to locate target devices.
[0008] In one aspect, a method of increasing network security comprises transmitting a packet from a first device to a second device, receiving a packet at the second device from the first device, verifying the packet for proper credentials and sending an acknowledgment from the second device to the first device only if the proper credentials are verified. The first device is a client and the second device is a server. Alternatively, the first device is a server and the second device is a client. The method further comprises dropping the packet if the proper credentials are not verified. A protocol for receiving the packet is similar to or the same as User Datagram Protocol. A protocol for sending an acknowledgment is similar to or the same as Transmission Control Protocol. The first device and the second device are coupled by a network. In one embodiment, the network is the Internet. In another embodiment, the network is an intranet.
[0009] In another aspect, a method of increasing network security comprises transmitting a packet from a first device to a second device, receiving a packet at the second device from the first device, verifying the packet for proper credentials, sending an acknowledgment from the second device to the first device only if the proper credentials are verified and dropping the packet if the proper credentials are not verified. The first device is a client and the second device is a server. Alternatively, the first device is a server and the second device is a client. A protocol for receiving the packet is similar to or the same as User Datagram Protocol. A protocol for sending an acknowledgment is similar to or the same as Transmission Control Protocol. The first device and the second device are coupled by a network. In one embodiment, the network is the Internet. In another embodiment, the network is an intranet.
[0010] In yet another aspect, a system for increasing network security comprises one or more first devices for transmitting a packet, one or more second devices for receiving the packet, wherein the one or more second devices are coupled to the one or more first devices through a network and a set of credentials within the packet for verification, wherein the one or more second devices send an acknowledgment back to the one or more first devices only if the set of credentials are verified. The first device is a client and the second device is a server. Alternatively, the first device is a server and the second device is a client. The one or more second devices drop the packet if the set of credentials are not verified. A protocol for receiving the packet is similar to or the same as User Datagram Protocol. A protocol for sending an acknowledgment is similar to or the same as Transmission Control Protocol. In one embodiment, the network is the Internet. In another embodiment, the network is an intranet.
[0011] In another aspect, a network of devices for increasing network security comprises one or more client devices for transmitting a packet, one or more server devices for receiving the packet, wherein the one or more server devices are coupled to the one or more client devices through a network and a set of credentials within the packet for verification, wherein the one or more server devices send an acknowledgment back to the one or more client devices only if the set of credentials are verified. The one or more server devices drop the packet if the set of credentials are not verified. A protocol for receiving the packet is similar to or the same as User Datagram Protocol. A protocol for sending an acknowledgment is similar to or the same as Transmission Control Protocol. In one embodiment, the network is the Internet. In another embodiment, the network is an intranet.
[0012] In yet another aspect, a packet for increasing network security comprises data and a set of credentials, wherein the set of credentials are analyzed by a receiving device such that the receiving device sends an acknowledgment back only if the set of credentials are valid. The set of credentials are selected from the group consisting of a key, a code and a signature. The set of credentials are stored within a header. Alternatively, the set of credentials are stored within a wrapper. The set of credentials are encrypted. The packet is substantially similar to a User Datagram Protocol packet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a block diagram of the preferred embodiment of the present invention.
[0014] FIG. 2 illustrates a flow chart of the preferred embodiment of the present invention.
[0015] FIG. 3 illustrates a network of devices implementing the preferred embodiment of the present invention.
[0016] FIG. 4A illustrates a User Datagram Protocol packet.
[0017] FIG. 4B illustrates a User Datagram Protocol packet within a wrapper.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] The present invention overcomes the issues described above by using a combination of elements of User Datagram Protocol (UDP) and Transmission Control Protocol (TCP) in addition to modifications of each. Using these modifications, a connection is established by only those properly authenticated devices. Furthermore, a target device remains hidden and anonymous to those devices that are not properly authenticated.
[0019] FIG. 1 illustrates a block diagram of the preferred embodiment of the present invention. A system 100 for securely networking devices includes one or more first devices 102 and one or more second devices 104 . A device of the one or more first devices 102 sends a packet 106 with credentials to a device of the one or more second devices 104 over a network 108 . The packet is sent using a protocol 110 such as UDP or a similar protocol. The device of the one or more second devices 104 is listening to the specified protocol. If a packet 106 ′ does not have the correct credentials then the packet 106 ′ is dropped and no response is sent from the device of the one or more second devices 104 . If the credentials are validly verified, then an acknowledgment 114 is sent from the device of the one or more second devices 104 over the network 108 to the device of the one or more first devices 102 . The acknowledgment 114 is sent over a protocol 112 such as TCP, UDP or a similar protocol. After the initial connection is established, data is communicated between the devices.
[0020] FIG. 2 illustrates a flow chart of the preferred embodiment of the present invention. In the step 200 , a device of the one or more first devices 102 transmits a packet 106 to a device of the one or more second devices 104 . In the step 202 , the device of the one or more second devices 104 receives the packet 106 . In the step 204 , the device 106 of the one or more second devices 104 determines if the packet 106 has the proper credentials. Proper credentials are able to be included as a specific key, code, signature or other appropriate verification device. Furthermore, the credentials are stored in a header, wrapper or other location to accompany the packet. In some embodiments, the set of credentials are encrypted. If the packet 106 does not have the proper credentials, the packet 106 is dropped and no acknowledgment is sent back to the device of the one or more first devices 102 , in the step 206 . If the packet 106 does have the proper credentials, then an acknowledgment 114 is sent back to the device of the one or more first devices 102 , in the step 208 . By utilizing an implementation such as this, hackers' net scans will produce no results, as the devices will not respond, thus giving no indication that the device is even there.
[0021] FIG. 3 illustrates a network of devices implementing the present invention. One or more client devices 300 are coupled to a server 310 through a network 308 . The one or more client devices 300 initiate communication with the server 310 by sending a packet 304 with credentials. The server validates the credentials and then responds by sending an acknowledgment 306 back to the appropriate client device 300 . If a hacker 302 attempts to communicate with the server 310 by sending a packet 304 ′ with either the incorrect credentials or no credentials, the server receives the packet 304 ′ but then drops the packet 304 ′. The server does not respond to the hacker 302 . Thus, only properly authenticated clients 300 with correct credentials are able to communicate with the server 310 and hackers 302 are not. In an alternate embodiment, a server sends the packet with credentials to a client device.
[0022] FIG. 4A illustrates a UDP packet 400 . Within a header 402 of the UDP packet 400 are four 16 bit fields including a source port, destination port, length and checksum. A data portion 404 of the packet contains the data to be transmitted.
[0023] FIG. 4B illustrates the UDP packet within a wrapper 410 . The wrapper 410 is formatted appropriately to contain the necessary components including any additional credentials such as a signature, a key or a code. Furthermore, the wrapper 410 is able to have a wrapper header 412 where the credentials are able to be stored. The credentials necessary to verify a valid incoming packet are located within the wrapper header 412 in some embodiments or within the wrapper 410 elsewhere in other embodiments.
[0024] To utilize the present invention a network of devices is configured so that only properly authenticated devices are able to communicate with devices on the network. A transmitting device sends a packet with credentials to a receiving device. If the credentials are valid, the receiving device responds with an acknowledgment similar to that in TCP so that other communications are possible. If the credentials are not valid or if a packet does not have credentials, then the packet is dropped. This aspect is similar to UDP and unlike TCP which always responds with an acknowledgment. By only responding to authorized users, the system is able to remain undetected by unauthorized users such as hackers. After a connection is established, the devices communicate as typical network devices do, allowing the transfer of data from device to device over and through networks.
[0025] In operation the present invention performs very similarly to standard networks that implement TCP with the exception that unauthorized packets are dropped. For authorized users, standard operations are available with the network such that users of an intranet are able to print to network printers, share data across computers and access applications from servers. In some embodiments, the network is the Internet. Many other typical network operations are possible with the present invention aside from those that require access to a device without valid credentials.
[0026] The devices that are able to implement the present invention include, but are not limited to laptops, personal computers, Apple computers, handhelds, servers, thin clients and cell phones.
[0027] The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto. It will be readily apparent to one skilled in the art that other various modifications may be made in the embodiment chosen for illustration without departing from the spirit and scope of the invention as defined by the claims. | A system for and method of securing a network are described herein. A receiving device listens for packets with proper credentials. If a transmitting device sends the correct credentials, the receiving device will respond with an acknowledgment and further data is able to be transmitted. However, if the transmitting device does not send a packet with the proper credentials, then the receiving device will drop the packet and not respond. Thus, the transmitting device will be unaware of the presence of the receiving device, in particular when hackers are using scanning software to locate target devices. | 7 |
CROSS-REFERENCE TO PROVISIONAL APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional Application No. 60/171,712, filed Dec. 22, 1999.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The invention generally relates to material handling apparatus and more particularly to a rack for producing transport bundles of stacked lumber as well the use of such rack in the production of such bundles. Additional aspects and objects of the invention will be apparent in connection with the discussion further below of preferred embodiments and examples.
[0003] It is an object of the invention to provide a rack for a lumber yard to facilitate producing transport bundles of stacked lumber gotten from a collection of diverse sources.
[0004] It is an alternate object of the invention that the above rack facilitate the successive handling and deposit of the lumber in the stack from any of the successive diverse sources by the heft of a forklift.
[0005] It is another object of the invention that the above rack be provided with structures to facilitate the addition of dunnage and accomplishment of banding during the process of producing and completing a transport bundle of stacked lumber.
[0006] These and other aspects and objects are provided according to the invention by a rack for producing transport bundles of stacked lumber. The rack comprises a frame deck propped up on feet, posts, and gutters as more particularly described below. The frame deck extends between at least spaced lateral members and spaced forward and rearward cross-members. Also, the rack has a pair of upright spaced posts that are mounted to the deck. The posts align in a generally vertical plane that defines a rear margin of the deck.
[0007] Moreover, the rack has plural elongated dunnage-and-banding gutters mounted to extend across the deck generally along a front to back axis. The dunnage-and-banding gutters are arranged to define a major channel that has a bottom wall extending between spaced sidewalls and is sized to receive dunnage stock. The dunnage-and-banding gutters also define a minor channel recessed in the major channel's bottom wall. The minor channel is sized to receive banding material that relative to the dunnage stock is relatively compact.
[0008] For example, the dunnage-and-banding gutters might be sized such that the major channels accept the axial sliding in of two by four (4.5 cm×9 cm) dunnage stock as the minor channels accept the axial sliding in of flat band material not probably wider than an inch (2.5 cm).
[0009] Given the foregoing, transport bundles of stacked lumber can be built from succesive loads of lumber deposited at successive times on the deck or the top of the stack on the deck by a forklift which preferably approaches from the rear of the rack. To do this, the loads are hefted over the posts and by the occasion of touchdown the forklift's forks are reaching through the posts. The posts thereafter afford the forklift counteraction against the lumber from shifting rearward as the forklift drags the forks out in reverse. Then, any completed bundle may be banded with or without dunnage and preferably lifted off from the front of the rack.
[0010] Optionally, the dunnage-and-banding gutters may be formed by a pair of opposed angles having spaced base flanges mounted opposite a gap from one another on a planar mounting surface such that the further-apart spaced upright flanges define the major channel's sidewalls as the co-planar base flanges generally define the major channel's bottom wall. That way, the gap between the spaced base flanges defines the minor channel.
[0011] The dunnage-and-banding gutters are preferably spaced up off the plane of the deck by a spacing structure which defines the planar mounting surface therefor. Such a spacing structure might be an inverted channel. The dunnage-and-banding gutters might be mounted to cross-members of the deck either for re-positioning or not to vary the number of gutters, the spacing between, as well as how long or short the gutters may be.
[0012] The posts are preferably removably mounted to lateral members of the deck. The posts might include rearward diagonal braces to strengthen how sturdily the posts can oppose a rearward force applied at a given elevation higher than the deck.
[0013] The feet to the deck are given lengths such that the deck occupies a plane either about parallel with the given ground elevation or else is tilted to decline relatively in the rear. The feet may have either a fixed length or are adjustable.
[0014] Additional aspects and objects of the invention will be apparent in connection with the discussion further below of preferred embodiments and examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] There are shown in the drawings certain exemplary embodiments of the invention as presently preferred. It should be understood that the invention is not limited to the embodiments disclosed as examples, and is capable of variation within the scope of the appended claims. In the drawings,
[0016] [0016]FIG. 1 is a rear perspective view of a rack in accordance with the invention, for producing transport bundles of stacked lumber;
[0017] [0017]FIG. 2 is a side elevation view of FIG. 1;
[0018] [0018]FIG. 3 is a top plan view of FIG. 2;
[0019] [0019]FIG. 4 is a front elevational view thereof; and,
[0020] [0020]FIG. 5 is an enlarged scale view of DETAIL V in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] [0021]FIG. 1 is a perspective view of a rack 20 in accordance with the invention, for producing transport bundles of stacked lumber (not shown). In a preferred use environment, the rack 20 is utilized by way of non-limiting example in say wholesale or retail lumber yards. The rack 20 assists in multiple ways the process of the breaking apart of larger bundles of lumber stock, and the production therefrom of a particularized bundle which may be of diverse stock. Such a particularized bundle is likely a particular customer's order. The trouble of bundling it is undertaken for shipment as by trucking and the like.
[0022] The rack 20 provides more general utility on diverse job sites as a general-purpose lumber stacking apparatus. Diverse example usages and aspects of such use of the rack 20 will be more particularly described further below.
[0023] The rack 20 is preferably constructed very sturdy as the weight of lumber is tremendous in certain cases. For example, if the rack is constructed as a metal frame, it might weigh about 1,000 pounds (455 kg). A heavy frame like this can be moved around the lumber yard or job site or whatever by a forklift (eg., tow motor) or the like, but this is not shown.
[0024] With general reference to FIGS. 1 through 4, the inventive rack 20 comprises a set of removably-connected sub-assemblies 22 and 24 . Each sub-assembly 22 or 24 may be constructed by the fastening, welding or joining together of metal component pieces. These assemblies 22 and 24 comprise a main deck assembly 22 and a pair of post super-assemblies 24 set up on the back edge of the main deck 22 . Each post super-assembly 24 comprises a footing 28 , a post or mast 30 standing upright on the footing 28 , and a brace 32 set an angle between the footing 28 and post 30 to strengthen the mounting of the upstanding post 30 .
[0025] The braces 32 are preferred because they prop the posts 30 in the direction counter to the main applied force that the posts 30 must sustain. That is, a forklift ordinarily will deposit lumber on the deck 22 by approaching the deck 22 from the rear edge. To do this, the forklift must elevate the load all the way above the posts 30 to clear their tops and then deposit the load on the deck 22 by having the forks reaching through the posts 30 . Once this is done, the forklift retracts its forks by reversing such that the posts 30 oppose the lumber from shifting backwards as the forks scrape out from underneath their load. Hence, the braces 32 prop the posts 32 in opposition to the lumber shifting rearwards with the forks while the forks are dragged out from behind in this process.
[0026] Each post 30 and brace 32 is preferably produced from square-tube stock as the footing 28 is preferably produced from flat-plate stock. All are preferably fixed together sufficiently sturdily as by welding or the like. The posts 30 might alternatively be produced with telescoping inner sleeves (not shown). Such telescoping inner sleeves would allows the posts to be given an adjustable greater height in cases when users would desire the extra height. The inner sleeves could be releasably fixed in place by thumb-tab headed set screws or the like twisted into threaded holes for them in the main or outer sleeve 30 (no set screws are shown, nor are inner sleeves).
[0027] The post super-assemblies 24 are preferably removably connected to the main deck assembly (or sub-assembly) 22 by bolts 34 or other like fastening means. For one, easy connection and disconnection allows shipment of the rack 20 in a collapsed position (not shown) such that the rack 20 can be erected and bolted together in the erected position, as shown by the drawings, when the collapsed rack 20 reaches the job site. FIG. 2 shows the preferred mode of connecting the post super-assembly(ies) 24 to the main deck sub-assembly 22 to comprise bolts 34 through the footing 28 of the post super-assembly 24 . For another reason, disconnection and re-connection affords the opportunity to move the post assemblies 24 about on the deck 22 . It is advantageous that the post assemblies 24 can be erected in varying widths apart. This allows workers to change the gap between the posts 30 , perhaps very narrow in some cases or wider in others. To do this, the support rack 20 would likely include a base board (not shown) lapped across and fastened down on the rearward extensions of siderails 40 as above struts 52 . Such a base board (again, not shown) would preferably be pre-formed with bolts holes at given locations allowing incremental adjustment of the width between the post assemblies 24 .
[0028] To turn to the main deck sub-assembly 22 , it comprises four legs 38 . The legs 38 prop up a pair of left and right side rails 40 . Preferably the front legs are a bit longer than the rear legs. That way the deck 22 has a rearward tilt to it. Such a rearward tilt helps keep stacked lumber product leaning into the posts 30 at rest. Also, when a fork lift is reversing itself, dragging its forks from out between layers of stacked lumber, the rearward tilt helps keep the rack 20 standing in its place. That is, the rack 20 's rear legs 38 ought to dig in the ground. A preferred option is either or both sets of front and back legs 38 are provided with an extensible lower leg (no such lower leg is shown). A way to achieve an extensible lower leg is to produce it out of a threaded rod which terminates in a foot. The bottom of the main leg 38 might be provided with a threaded hole in which the threaded-rod extensible foot twists in. That way, the tilt of the main deck 22 can be adjusted by twisting the threaded lower leg (again, not shown).
[0029] The span between the side rails 40 is fixed by a set of three spaced main deck members 42 . Suspended from each of the front and back deck members 42 are full-width rungs 44 , of which the front rung 44 is more clearly shown by the front elevational view of FIG. 4. The rungs 44 are suspended from each one's respective deck member 42 by a series of short hangers 46 . The left and right openings 48 defined below the deck members 42 by the rungs 44 and hangers 46 operate as flat passages 48 for the removable insertion and retraction of the forks of a fork-lift and so on (not shown).
[0030] With reference to FIGS. 1 and 2, the rigidity between the legs 38 and side rails 40 is afforded extra support from struts 52 as well as stiffening plate 54 . Each leg 38 , side rail 40 , deck member 42 , rung 44 , hanger 46 and strut 52 is preferably produced from square-tube stock, and all which are preferably fixed together sturdily as by fastening or welding and so on. The stiffening plate 54 is preferably produced from flat-plate stock and is likewise preferably attached sturdily by welding or fastening and the like.
[0031] The main deck members 42 carry on top of themselves a set of spaced dunnage gutters 60 . Three such dunnage gutters 60 are shown. Each extends on axes parallel with the front to back direction. FIG. 5 shows a preferred format of construction of the dunnage gutters 60 . The dunnage gutters 60 are propped up off the main deck members 42 by an inverted channel member 62 . The web of the inverted channel 62 member carries a pair of angles 64 arranged such that the pair of angles 64 provide a pair of spaced base flanges 66 as well as a pair of further-spaced apart upright flanges 68 . The upright flanges 68 cooperatively define the gutter walls for the dunnage gutter 60 . The spacing between the base flanges 66 defines an open way 70 or passage-way for banding material.
[0032] Hence, the upright flanges 68 define a main channel for the nesting or axial sliding in of dunnage such as 2″×4″ runners or the like. In contrast, the much smaller sub-channel 70 defined between the in-turned base flanges 66 defines a banding sub-channel 70 which allows the nesting or axial sliding in of band strapping material. The dunnage gutters 60 are preferably produced from metal stock that allows welding at the weld-zones 72 indicated in FIG. 5.
[0033] Whereas FIG. 5 shows the dunnage gutters 60 welded to the deck member 42 , alternatively the gutters 60 could be attached by fastening such as bolts or the like. The inverted channel piece 62 might be featured with little tabs or ears that lay flat on the deck piece 42 (such ears or tabs are not shown). The ears or tabs would likely be formed with holes for accepting a bolt that inserts through a complementary hole in the deck member 42 . That way, the dunnage gutters 60 can be varied by number in use, the spacing between those put to use, as well as substituting for elongated gutters which might greatly extend beyond the front deck piece 42 in order to give the deck 22 a greater span in the front to back direction for certain applications, say for exceptionally wide panel products or the like (only one length of dunnage gutters 60 are shown).
[0034] Diverse example usages, as well as aspects of such use of the rack 20 include the following. The rack 20 ships in a collapsed condition such that the receiving party assembles the rack 20 in the erect position as for example shown by the drawings when received. This generally entails bolting together the disassembled base and super-assemblies 22 and 24 .
[0035] The upright posts 30 allow a forklift to approach the rack 20 from the rear, elevate the lumber high up over the posts 30 and then deposit and stack the lumber either • on the dunnage gutters 60 , if that is the first deposit on the rack, or • on lower layers of lumber if the current load is just being piled on earlier deposits on the rack 20 . The posts 30 act to obstruct and stabilize the deposited lumber as the forklift drags its forks out from under lumber layers by reversing backwards away from the rack 20 .
[0036] The dunnage gutters 60 are sized to accept two-by-four dunnage therein, as laid on a broad flat side (eg., two-by-fours being roughly equivalent to 5 cm×10 cm). However, the dunnage gutters can be sized as appropriate for whatever sizes most likely to be used by users. Indeed, it is preferred if the gutters 60 are slightly oversized to allow the axial sliding in of dunnage to be accomplished after when the bundle is already stacked up in place on the rack 20 .
[0037] Banding material can be fed through the ways or sub-channels 70 for the banding material. The two-by-four dunnage and the lumber bundle piled up on top can all be strapped together by encircling bands—three for example—spaced on the spacing set by the dunnage gutters 60 . This allows a forklift to approach the rack 20 preferably from the front and remove the bundle as for deposit on a flat bed and delivery thereafter. That is, while the forklift preferably builds a bundle predominantly by approaching the rack 20 from the rear, the forklift preferably removes a completed bundle from the front of the rack 20 .
[0038] The elevation of the dunnage gutters 60 above ground level preferably measures about eighteen inches (45 cm) for the comfort of workers who manually pile and unpile lumber on and off the rack 20 . This height is preferable for limiting the flexion of the back to a relatively powerful and safe position to handle lumber. If a whole lot lower, the workers might have to stoop over to relatively disadvantageous positions.
[0039] The rack 20 is sufficiently sturdy and strong for a forklift to deposit an entire, complete unit of lumber on it. Some units of lumber are so heavy that it might crush a less sturdy design. Nevertheless, the rack 20 is sufficiently sturdy to withstand the weight of heavy bundles. That way, after the heavy bundle has been deposited on the stand, the forklift operator might separate the bundle once there, and remove away upper layers that don't belong to that particular customer's order. The forklift operator can countdown from the top of the bundle how many layers he or she needs to go down in order to remove away the proper amount. Additionally, the posts might be labeled with measure indicia to give the forklift operator an external reference.
[0040] Also, the fork passages 48 (see FIG. 4) are spaced to promote stable transport of the rack 20 on a forklift.
[0041] The invention having been disclosed in connection with the foregoing variations and examples, additional variations will now be apparent to persons skilled in the art. The invention is not intended to be limited to the variations specifically mentioned, and accordingly reference should be made to the appended claims rather than the foregoing discussion of preferred examples, to assess the scope of the invention in which exclusive rights are claimed. | A rack for producing transport bundles of stacked lumber comprises a deck over which is laid plural rows of dunnage-and-banding gutters. The which dunnage-and-banding gutters are arranged to define a major channel that has a bottom wall extending between spaced sidewalls and is sized to receive dunnage stock. Two by four lumber (4.5 cm by 9 cm) is common for dunnage stock. The dunnage-and-banding gutters also define a minor channel recessed in the major channel's bottom wall. The minor channel is sized to receive banding material such as strap. Preferably both the dunnage stock as well as the banding can be fed in axially from either open end of the gutters after the lumber has already been stacked up on top. | 1 |
RELATED APPLICATIONS
This application is a §371 application from PCT/EP2008/063283 filed Oct. 3, 2008, which claims priority from French Patent Application No, 07 58133 filed Oct. 8, 2007, each of which is herein incorporated by reference in its entirety.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a device and a method for driving the pump of a rocket engine using an inertia wheel. The technical field to which the present invention relates is that of high-thrust rocket propulsion, like that required for a space launcher.
BACKGROUND OF THE INVENTION
For this type of application, there are three families of technologies, depending on the physical state of the propellants used: solid propulsion, wherein the propellant is stored in a combustion chamber, liquid propulsion, which can use one, two or even more propellants, wherein propellants must be transferred from storage tanks to a combustion chamber, and hybrid propulsion, which uses a liquid propellant and a solid propellant, and wherein a liquid propellant must be transferred to a combustion chamber in which a solid propellant is stored.
The present invention relates more precisely to devices for transferring liquid propellants to the combustion chamber and more specifically to the drive system for this transfer.
In order to be capable of providing high thrust, rocket engines must run at a high pressure of several tens of bar, for example from 30 to 50 bar for Ariane engines, with a high flow of matter.
In the case of liquid propulsion, it is the propellant feed system that must provide this flow and this pressure. Two methods are commonly used to produce this pressurized feed: direct pressurization of the propellant tanks and pumping with pumps from a low-pressure tank.
The first solution has the virtue of simplicity, but requires tanks capable of withstanding high pressures, which creates problems in terms of mass and safety. This solution is limited in practice to low-power engines, such as attitude control engines or the upper stages of launchers for example, where installing an external means of pressurization is less advantageous.
The second solution requires the use of specific pumps capable of producing the substantial flow required by the engines. This flow, combined with the huge increase in pressure required, results in pumps of considerable power, from several hundred kilowatts to several megawatts.
In current and past space launchers, these pumps are systematically driven by turbine engines, generally using the same propellants as the main engine.
These turbines are driven by hot gases. These hot gases are generally produced by taking a portion of the propellants for the rocket engine and burning these portions in a specific small combustion chamber. They can also be produced by a gas generator, often a small powder rocket.
The turbine/pump assembly is called a turbopump. A turbopump is a complex, fragile object because it must transmit very high levels of power—several megawatts—using very high rotation speeds, for example from 10,000 to 30,000 rpm, which exerts very high mechanical stresses on the materials.
In addition, being driven by hot gases resulting from combustion produces very high temperatures in the turbine and very large temperature gradients in the transmission shafts between the turbine and the pump.
This thermal gradient effect is further accentuated when the propellants are cryogenic, the pump temperature being several tens of degrees Kelvin while only a few centimeters away, the temperature of the driving centrifugal turbine is more than 1,000 degrees Celsius.
Lastly, because of these extreme operating conditions, starting a turbopump is difficult, with one part being cooled, the other being heated, and the assembly being brought to rotation gradually enough not to cause an even higher transient gradient capable of rupturing the turbopump.
Ultimately, a turbopump is a very expensive object with a short life, used in conventional launchers which have a short operating life that is measured in minutes.
In reusable launchers like the space shuttle, the turbopumps must be replaced for nearly every flight, which is quite onerous in terms of maintenance costs.
One proposed solution for replacing a turbopump is described in the document U.S. Pat. No. 6,457,306.
This document describes replacing the drive turbine of the pump with an electric motor powered by batteries or other devices such as inertia wheels.
OBJECT AND SUMMARY OF THE INVENTION
Thus, there is no longer a need for a small rocket engine driving a turbine, less propellant is consumed, there are no longer such high temperature gradients, and the assembly is more reliable and better adapted to a reusable launcher.
It is also possible to adjust the rotation of the electric motor and thus easier to vary the propellant flows, and hence the thrust; it is also easier to control the start of the pump so as to prevent excessively high transient gradients.
On the other hand, the energy source that powers the engine must be capable of supplying a power that is measured in megawatts during the thrust phase, which entails significant mass and size constraints for this energy source and for the means for powering the electric motor.
The energy storage and motor system is ultimately very heavy.
The object of the present invention is to provide a system for driving a propellant pump that is simple and reliable, weights less, can be started in flight, and can in particular be used in reusable propulsion systems.
To this end, the invention proposes replacing the turbine engine of the pump or the electric motor with a simple device, separate from the propellants, that can be started and controlled independently of the operation of the propulsion system of the vehicle, and accordingly provides for using a device with an inertia wheel set in rotation in advance to drive the pump.
More particularly, the invention relates to a device for driving a pump for fueling a rocket engine of a space vehicle, characterized in that it comprises an inertia wheel and a means for transmitting the rotation of the inertia wheel to the pump.
One of the main advantages of the inertia wheel is that it is simple to implement and that it directly stores mechanical energy.
Preferably, the transmission means is a common shaft between the inertia wheel and the pump.
Advantageously, the transmission means includes a device for modifying the drive ratio between wheel and pump.
According to a particular embodiment, the device includes a clutching device adapted for coupling and decoupling the inertia wheel and the pump.
According to an advantageous embodiment, the device includes an electric motor for starting the wheel.
The electric motor is powered either by an electrical source outside the vehicle, or by an electrical source inside the vehicle whereby the electric motor makes it possible to conserve energy in the inertia wheel after the takeoff of the vehicle.
According to a particular embodiment of the invention, the pump and the wheel are disposed inside the vehicle in a position that provides gyroscopic stabilization as a result of their rotation on at least one axis of the vehicle.
According to an alternative embodiment, the device includes at least one pair of identical wheels turning in opposite directions so as to neutralize the gyroscopic effects of the rotation of the wheels.
Advantageously, the device includes means for measuring the rotation speed of the wheel and means for decoupling the wheel and the pump for a speed lower than a given speed lower than the nominal rotation speed of the wheel.
According to an advantageous embodiment, the device includes means for controlling the flow rate of the pump comprising a device for bleeding off a variable quantity of the flow leaving the pump and returning this flow to the tank.
Alternatively or additionally, the device includes means for controlling the flow rate of the pump comprising a valve placed downstream from the pump.
In the latter case, the valve is preferably an adjustable valve placed at the outlet of the pump and adapted for maintaining a constant flow rate by opening gradually.
Advantageously, the wheel is disposed in a housing forming a shield between the wheel and the tank.
The invention also relates to a device for fueling a rocket engine characterized in that it includes at least two pumps, each driven by a device according to the invention, and a space plane comprising a rocket engine wherein the fuel supply system comprises at least one pump driven by a device according to the invention, and means for starting the device while the plane is in flight.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will be more clearly understood by reading the following description of a nonlimiting exemplary embodiment of the invention accompanied by the drawings, which represent:
In FIG. 1A through 1F : a schematic representation of the principle of the device of the invention according to various embodiments;
In FIGS. 2A and 2B : exemplary installations of one and two inertia wheels, respectively, in an aircraft;
In FIG. 3A through 3C : exemplary embodiments of inertia wheels of the invention;
In FIG. 4 : a graph of the characteristics of a centrifugal pump driven by the device of the invention;
In FIG. 5 : a graph representing the operating parameters of the device of the invention as a function of time.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The invention relates to space vehicles and is particularly applicable to space planes.
Space planes are launchers capable of taking off from the ground like an airplane, then leaving the earth's atmosphere to reach outer space.
In space, these space planes use a non-air-breathing, rocket-type mode of propulsion. For their atmospheric flight, they use air-breathing propulsion systems such as jet engines.
An inertia wheel is, as its name indicates, an object that is made to turn around an axis and is used to store energy in a kinetic form. The stored energy increases with the square of the rotation speed of the wheel and in proportion to its mass.
To store the energy, the wheel is made to rotate as fast as possible, since the extraction of the energy slowing the rotation of the wheel.
In the simplified example according to the diagram shown in FIG. 1A , the wheel 1 is mounted on the same shaft 20 as the pump 2 it must drive. It is started prior to the takeoff of the vehicle by a starting motor 3 , which is either powered by an external electrical source A 1 as represented in FIG. 1C , or powered by an internal electrical source A 2 as represented in FIG. 1D when the vehicle has an electrical generation system, as is the case for suborbital vehicles or space planes having conventional aeronautical engines, satellites with solar panels, or even launchers equipped with batteries.
When this electrical energy is available on board, the electric motor makes it possible after takeoff to conserve the wheel's nominal energy.
The pump 2 receives the propellant from the tank 6 via an inlet pipe 4 and sends the pressurized propellant through an outlet pipe 5 to a traditional rocket engine, not shown.
The friction on the bearings and in the air (the rotor of the pump is in rotation) are low enough to require only a modest amount of power, typically several tens of Watts.
In the case of a space plane, the designer of the vehicle can omit the internal electrical source if the time between takeoff and the start of the engine is short, for example typically less than an hour.
Once it arrives at the altitude at which the rocket engine is fired, the pump or pumps 2 are cooled, then the valves of the tanks are opened. The pressure from the tanks primes the pumps and the rocket engine is fueled by the latter, their rotation being maintained by the wheel.
After the propellants have been exhausted, the pump and the wheel continue to turn. It can be advantageous to leave them in motion during the exo-atmospheric flight, in order to benefit from the gyroscopic stabilization caused by their rotation. If for example as shown in FIG. 2A the wheel 1 is mounted on the pitch axis 101 of the vehicle 100 , it will provide effective stabilization along the roll and yaw axes.
Thus, when the device is installed in a space plane, the mounting of the inertia wheel on the pitch axis will provide stability along the roll and yaw axes.
Pull-up maneuvers, on the other hand, will not be affected.
Conversely, it is possible to prevent gyroscopic effects by mechanically coupling two identical wheels turning in opposite directions, as represented in FIG. 2B where wheels 1 a and 1 b are positioned on the pitch axis 101 of the vehicle 100 and are counter-rotating.
The invention avoids the use of a turbine engine and the associated problems of starting it with or without the use of pyrotechnical means, the problems of fueling the turbine, and the problems of stabilizing the operation of the turbine coupled with the pump.
The inertia wheel, which by nature offers a stable rotation speed, also provides stabilized operation without requiring any adjustment other than that due to the compensation of the continuous deceleration of the wheel.
In addition, the device of the invention avoids the problems of coupling very hot and very cold areas on the same shaft.
One constraint of the inertia wheel system is the fact that the speed of the wheel decreases as the energy is extracted from it.
FIG. 4 illustrates the operating parameters of a centrifugal pump with radial blades like those used to fuel rocket engines.
The flow rate of such a centrifugal pump is proportional to its rotation speed and the outlet pressure of the pump is proportional to the square of the rotation speed of the wheel.
The direct consequence when an inertia wheel is mechanically coupled with the pumps is that, since their flow rate is proportional to the rotation speed of the wheel, the flow rate therefore decreases in proportion to the reduction in the speed of the wheel, and the pressure decreases in proportion to the square of the decrease in the speed of the wheel as it slows.
In general, the fact that the flow rate decreases over time, and that hence the thrust decreases, is not directly disadvantageous because the mass of the vehicle also decreases due to the consumption of the propellants.
The decrease in the flow rate in such a case prevents a continuous increase in the acceleration of the vehicle.
This is only a disadvantage for rocket engines designed for an optimal operation based on a near constant flow rate.
Likewise, the decrease in the outlet pressure of the pump decreases the pressure in the combustion chamber. This phenomenon disturbs the operation of the engine less than the variations in the flow rate, but it does proportionally reduce the thrust.
To handle these problems, the invention provides several solutions, depending on the particular engine in question.
A first solution consists of reducing the speed range of the wheel from which power is extracted to run the pump.
Vmax is defined as the maximum speed reached by the wheel, 0.5 Vmax is half that speed, reached after a given rotation time of the wheel, and nVmax, n<1, is the speed relative to Vmax at a given moment.
Instead of extracting the energy between Vmax and 0.5 Vmax, it is possible to use the wheel only between Vmax and n.Vmax, n being greater than 0.5. In order for the required quantity of energy to be extracted from it, the wheel must store more energy, and therefore must be heavier.
To put this method into practice, a clutch 21 is placed between the wheel and the pump as illustrated by FIG. 1B .
In this variant of the invention, the means for transferring the rotation of the wheel 1 to the pump 2 include half-shafts 2 a , 20 b which can be coupled and decoupled via the clutch 21 .
This also makes it possible, in particular, to start the wheel 1 with the motor 3 while the pump is disengaged, using an external supply of electricity A 1 before the flight, then during the flight, to couple the wheel and the pump in order to run the latter.
The clutch may be replaced or supplemented by a device for modifying the drive ratio between wheel and pump, such as a variable speed transmission for limiting the variation in the flow rate over a wider range of rotation speeds of the wheel.
A second method for limiting the variation of the flow rate consists of using so-called “bypass” flow control, as represented by the embodiment of FIG. 1E .
This method of flow control consists of bleeding off a variable amount of flow by means of a valve 7 on the flow leaving the pump 2 and returning it to the tank 6 via a return line 41 .
In the case of a speed variation from 100% to 50%, half of the flow is bled off at the beginning, and the bleed-off is decreased during operation down to a bleed-off of zero when the wheel reaches its maximum speed. In this case, some of the energy transmitted to the fluids is lost, but the overall result is still advantageous.
Experience has shown that instead of having 75% of the energy of the wheel, no more than 54% is available, which also leads to using a wheel of greater mass.
Given the increase in the mass of the wheel, these approaches only make sense if the rocket engine accepts no more than a 40 to 40% variation in flow rate.
A third method of flow control consists of controlling the flow rate using adjustable valves on the inlet and/or outlet pipes of the pump.
It is used in the exemplary embodiment illustrated in FIG. 1F , which includes a valve 8 on the outlet pipe 8 of the pump 2 .
This method has an impact on the pressure delivered by the pump due to the variable head losses it induces.
It is nevertheless an effective solution when desiring to maintain a constant flow rate with a chamber pressure that decreases over time. In fact, an adjustable valve placed at the outlet of the pump makes it possible to adjust the flow while also creating a head loss. Assuming, for example, a wheel whose speed varies by a ratio 2 during the propelled flight, the pressure generated by the pump at the start of the flight is quadruple that generated at the end.
When the pump 2 is coupled with a valve 8 that maintains a constant flow rate by gradually opening until it is completely open at the end, the valve 8 absorbs half of the pressure through head loss, and reduces the flow rate by half.
The engine chamber is then fed at a nearly constant flow rate, with a pressure that decreases over time, which contributes to a reduction in the accelerations experienced by the vehicle during the flight.
Thus, based on the characteristics of the rocket engine to be fueled, the most suitable arrangement among the different variants defined in FIG. 1A through 1F will be used, while retaining the possibility of combining the features of these variants depending on the circumstances.
For purposes of an exemplary embodiment, the following hypotheses corresponding to a concrete embodiment in the case of a space plane will be considered:
The rocket engine uses liquid methane (LCH4) and liquid oxygen (LOx); it runs properly at a pressure of 15 to 30 bar; it runs for a period of about 80 seconds and requires 6 tons of propellants.
Furthermore, the pump speed is on the order of 15,000 rpm. This is the usual speed for LOx pumps.
In this example, a tank on the order of 2.5 m in diameter with a pressure of 5 bar is chosen, making it possible not to cause excessive structural stresses on such a tank.
In fact, assuming a skin of the tank on the order of 3 mm thick, a pressure of 5 bar results in a stress in the cylindrical main part of less than 200 MPa according to the equation σ=PR/e.
Assuming a tank built of 2219T87-type aluminum (σ yield=407 MPa), this results in a safety factor greater than 2.
As seen above, the engine operates at a pressure of 30 bar at the start of the flight, and 15 bar at the end.
The chosen approach is to operate with a flow rate of the propellant flow that is adjusted to a constant value by means of the valve 8 placed downstream from the pump.
The graph of FIG. 5 summarizes the behavior of the wheel and the pump in such a configuration.
The speed 9 of the wheel has been plotted relative to the initial speed; it decreases from 100% to 50%.
The pressures □ tank pressure 9 , pump outlet pressure 12 , feed pressure of the chamber 14 □ are plotted relative to the initial pump outlet pressure. It is noted that the head loss or pressure drop 13 imposed by the controlled valve is 40% at the start and decreases rapidly until it disappears at the end.
The feed pressure of the chamber 14 also decreases by half during propulsion, thus providing a decreasing amount of thrust which is compensated by the reduction in the mass of the vehicle generated by the propellant consumption. The propellant flow rate 15 is constant.
The efficiency of the pump is on the order of 70%, which is a conservative value.
Exemplary embodiments of inertia wheels are shown in FIGS. 3A through 3C .
The wheel includes a band 16 which is made of high-strength carbon fiber with a breaking point of 2,300 Mpa, a density of approximately 1,750 g/dm3, having a maximum acceptable stress of 1,500 Mpa while maintaining a safety factor of 1.5, and includes a composite strip with a thickness and a width of approximately 10 cm.
It includes a rim 17 and a hub 18 for joining it to a rotating shaft, both made from a lightweight alloy.
The dimensions of the wheel are defined based on the necessary operating parameters of the rocket engine, and in particular the energy required to compress the propellants.
The mass of propellants to be compressed is on the order of 6,000 kg, which corresponds to a volume of approximately 7.5 m3.
Since the energy required to compress the propellants is first and foremost purely a function of the volume (E=V·ΔP), no distinction is made between the two propellants, and the mass of the wheel that will be capable of driving the LOx and LCH4 pumps is determined.
In such a fuel/oxidizer application, the wheel may be split in two so as to have one wheel per pump.
For a rotation speed of 15,000 rpm, the maximum acceptable diameter of the wheel is:
R= 1/ω√ρ=0.585 m.
The energy required to compress the propellants is nominally expressed by the integral over the flow time multiplied by the pressure differential provided by the pump and by its efficiency. The calculation provides a value of approximately 24 MJ.
It should be noted that generating this energy requires a power of 580 KW at the start of the propelled phase.
Assuming that the energy of the wheel is harnessed between its full speed and the point at which it reaches a half-speed, 75% of its energy is available; it is therefore necessary for the wheel to store approximately 32 MJ, which under the conditions of the example results in a mass on the order of 80.5 kg.
It is appropriate to add to the mass of the inertia wheel the other masses in rotation (rim, shaft, pump rotor, electric drive motor rotor), which are estimated at some twenty kg overall, and the fixed masses (housing, electric motor stator, pump nozzle, pipes, etc.), also estimated at some twenty kg.
Although the masses in rotation also contribute to the low kinetic energy value, for the sake of simplicity they are not factored in.
In addition, regulations require that the wheel turn inside a housing that is capable of retaining any projectiles resulting from a rupture of the wheel. An estimate based on the “Punch equation” method of NASA standard SSP 52005B indicates that 2-kg composite fragments propelled at 900 m/s will be stopped by an 8-cm aluminum wall. This results in a housing comprising a 20- to 25-kg shield between the wheel and the tank.
In total, according to the example described, the device has an overall mass of approximately 150 kg for the assembly of pumps, wheel(s) and accessories.
In addition to the advantages of simplicity and reliability, the inertia wheel drive system makes it possible to avoid the constraints inherent in a technology that does not use a turbopump but uses pressurized propellant tanks.
The present invention makes it possible to eliminate the production complexity of such a solution with pressurized tanks, the development time required to produce them, their fragility, and problems due to the pressurization of these tanks.
The inertia wheel drive system of the present invention makes it possible to use low-pressure tanks which can be structural.
It should be noted that using pressurized tanks involves storing a gas for pressurizing the propellant tanks, and that structural tanks are tanks capable of providing the vehicle with longitudinal stability whereas other tanks must be fixed to a support frame.
The table below shows a comparison of three solutions that fulfill the function of storing 6 tons of propellants, with an average engine inlet pressurization of 25 bar, and a rocket stage approximately 5 m long.
Structural
Composite
Structural
aluminum tanks,
tanks
aluminum tanks,
25 bar (kg)
25 bar
5 bar
Tanks (kg)
2,050
1,000
700
Supports (kg)
0
50
0
Stage (5 m) (kg)
50
500
50
Pumps (kg)
0
0
150
Tank
500
500
100
pressurization (kg)
Total (kg)
2,600
2,050
1,000
The savings provided by the solution using low-pressure structural tanks with pumps driven by an inertia wheel is approximately 1 ton compared to the solution using high-pressure structural tanks.
The invention has applications in the field of astronautics, and more generally in all sectors using rocket engine propulsion with liquid propellants and in those in which a very high fluid flow rate is required for a relatively short time.
It is particularly advantageous when the propellants are cryogenic (liquid oxygen with liquid hydrogen, methane or kerosene), and particularly suitable for reusable suborbital vehicles for which the total mass of the pump assembly is not critical, and for which reliability and ease of maintenance are essential.
On the other hand, the present invention has many advantages such as the simplicity of its design, lower development and production costs, very high reliability, a stabilized pumping speed, and the very important possibility of reusing the pump assembly, whereas the current turbopumps are capable of being started no more than a few times.
The present invention has been described herein as an example in the context of the use of an inertia wheel to drive the rocket of a space plane. In such a vehicle, rocket propulsion is only used after an airplane-type flight.
However, the invention can be used for any application of a rocket engine, be it a launcher stage, an interplanetary vehicle or a satellite, insofar, of course, as the replacement of a turbopump fueling the rocket engine is advantageous.
The drawings provided are merely exemplary embodiments, and in particular, certain features described in FIG. 1A through 1F can be combined while remaining within the scope of the invention defined by the claims.
For example, it is possible to consider the use of a clutching device 21 according to FIG. 1B with an internal electric power supply for the motor 3 as in FIG. 1D or an external electric power supply as in FIG. 1C .
Likewise, a device comprising a flow control system using valves as represented in FIGS. 1E and 1F can be supplemented by a clutch 21 and an electric motor 3 with an internal or external power supply, the powering of the motor by an internal power supply making it possible to start the wheel in any flight phase with the pump disengaged, to fuel the rocket engine with the pump engaged, and then, when the rotation speed of the wheel is no longer sufficient, to disengage the pump and allow the wheel to operate as a freewheel in order to maintain gyroscopic stabilization. | An apparatus for driving a pump for fueling a rocket engine of a space vehicle. The apparatus comprises an inertia wheel and a transmitting device to transmit a rotation of the inertia wheel to the pump. The apparatus further comprises a measuring device to measure the rotation speed of the inertia wheel a clutching device to decouple the wheel and the pump for a speed lower than a pre-determined speed lower, which is lower than the nominal rotation speed of the wheel. The invention is particularly applicable to a space vehicle comprising a rocket engine wherein the fuel supply system comprises at least one pump driven by the apparatus of the invention and a starting device to start the apparatus while the space vehicle is in flight. | 5 |
FIELD OF THE INVENTION
This invention relates to drilling and more particularly to lateral underground drilling, e.g., to provide a conduit for communication lines.
BACKGROUND OF THE INVENTION
Communication lines are commonly placed underground. As permitted, a narrow trench is dug along the intended path of the line and the line is laid in the trench and then covered. This procedure is not complex and relatively inexpensive. However, often it happens that an obstruction lays in the path and digging a trench is not permitted or is too difficult.
In such instances, the alternative is to drill a hole through the ground and under the obstruction. For example, if the lines are to be buried to a four foot depth, a partial trench is first dug to the four foot depth prior to the obstruction and a drill bit mounted on an extendable pipe is fed laterally along the desired path. The pipe is moderately flexible and, in at least one version, the pipe is turned by a powerful motor to turn the bit and thereby auger through the ground with the pipe being fed behind it. A flushing slurry is fed through the pipe and into and through to the leading end of the drill bit. Material that is loosened by the drill bit is flushed by the slurry back through the hole. The line is then pulled through the hole formed by the drill bit and pipe.
All of the above is common to the art of directional drilling. Not referred to, however, and also common to the process explained above, is the need to control the direction of drilling. The drill bit is designed so that it can be maneuvered to change direction. The drill bit itself has a digging head that is non-symmetrical, i.e., teeth are projected angularly from the axis of the drill bit on one side only. During normal drilling, the drill bit is rotated so that the digging action is symmetrically applied and the drill bit travels in a straight line. To change direction, the rotation is stopped and the drill bit is pushed through the ground. At whatever direction the teeth are projected, that is the direction that the drill bit will turn toward (up, down or to either side). When the desired new direction is achieved, the rotation of the bit is commenced to head the digging action in the new direction.
The location of the drill bit and the position of the teeth on the drill bit is monitored through the use of a known detection device. Thus, an operator may determine that the hole is headed too deep, too shallow or otherwise off line in one direction or the other. He stops the rotation of the drill bit with the teeth facing the desired direction. He then pushes the bit forward until the bit is properly directed (which may include a sequence of side to side oscillation of the drill bit) and the normal drilling action is continued.
Whereas existing drill bits work quite well in dirt, they do not work so well in rock or shale. A cone-type drill bit cutting head has been developed to improve performance in rock or shale. Rows of circularly arranged teeth are provided on a conical cutter head that is rotatably mounted about its conical axis to the end of a forwardly protruded and outwardly directed shank of the drill bit. The base portion of the cone side of the conical head carries one of the rows of teeth and with the mounting arrangement described is adjacent to the shank and extends laterally outwardly of the shank. The axis of the rotatable cone is directed inwardly and forwardly. The apex of the cone side and the teeth adjacent the apex cuts the material from the center of the hole while the teeth adjacent the base provide the laterally outermost cutting which forms the hole side.
Whereas the conical cutter is considered an improvement when directional drilling through rock and shale, it is not completely satisfactory (and sometimes unsatisfactory), and an objective of the present invention is to improve on the above-described cone-type drill bit.
BRIEF DESCRIPTION OF THE INVENTION
The present invention modifies the above-described cone-type drill bit. A shank provided on the drill bit is projected forwardly and inwardly. The base of a cone-type (conical) cutter head is rotatably secured to the shank in a manner whereby teeth near the base of the cone side of the cutter (the base portion of the cone side) cuts the material from the center of the hole and the apex of the cone side is projected laterally from the shank to cut the side wall of the hole. This difference can be viewed in the comparison of FIG. 1 (which illustrates the prior art) and FIG. 2 (which illustrates the present invention).
This modification is significant in terms of performance. Whereas the prior art drill bit head does not readily produce the desired directional change, such is readily produced by the device of the invention. The reason for the improved performance has not been verified and the following explanations are theories as to why such improvement is achieved.
FIGS. 1A and 2A, respectively, show the configuration of a hole being dug-by the prior art device and that of the present invention. When attempting to turn the drill bit, only one side of the hole is extended forwardly as indicated by dash lines 12 and 14 in FIGS. 1A and 2A, respectively. The desired change of direction is upwardly as viewed in the drawings and as indicated by the arrows. With reference to FIG. 1 and comparing it to FIG. 1A, it will be appreciated that the leading end of shank 16 will engage the upper side wall of the extended hole and resist turning of the tool in the upward direction. Applicant's shank 18 is on the opposite or bottom side of the hole and as it engages the extended portion of the hole, it urges the tool upwardly and in the direction of desired turning.
A second theory is suggested by the configuration of the hole being cut. Referring to the configuration of FIG. 2A, the center of the hole (point X) is the point of furthest extension. When full rotation of the tool is commenced, the bit will follow the path of least resistance and because the upper side is relieved, the bit will be urged upwardly.
In FIG. 1A, the center of the hole (point y) is inset from the side extensions. As the bit rotates to the bottom side of the hole, the inset center of the hole and the cam-like configuration that it produces will urge the bit back toward the bottom and directional change is resisted.
The above differences, advantages and benefits will, however, be more fully appreciated by reference to the following detailed description having reference to the accompanying drawings, referred to therein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a tool of the prior art;
FIG. 1A is a side view of a hole produced by the tool of FIG. 1;
FIG. 2 is a side view of a drill bit of the present invention;
FIG. 2A is a side view of a hole produced by the tool bit of FIG. 2;
FIG. 3 is a side view of the tool of FIG. 2 illustrating also the profile of the hole produced in normal operation;
FIG. 4 is an end view as taken on view lines 4 — 4 of FIG. 3 illustrating a condition of partial rotation or oscillation of the drill bit;
FIG. 5 is a view similar to FIG. 3 illustrating the profile of the hole produced in a directional changing operation; and
FIG. 6 is a view illustrating a typical bore produced by the drill bit of FIGS. 2 - 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 3 illustrates a drill bit 20 for directional drilling a hole 70 (or bore) in the ground. The bit 20 has an elongate housing 22 that has a threaded end 24 . The end 24 is provided to connect the housing 22 to a pipe-line 26 (see FIG. 6 ). A shank portion 18 is fixedly mounted to the housing at the end opposite the threaded end 24 . As illustrated, the shank portion 18 , which is somewhat triangular in shape extends from the housing 22 and has edges (surfaces) 42 , 44 inclined at an angle to the longitudinal axis 50 of the housing 22 . The peak 46 , whereat the surfaces 42 , 44 meet, is at a greater distance from the longitudinal center line 50 (axis) of the housing 22 than an apex portion 38 of a conical cutting head 30 . The peak 46 will, however, very in height depending on the soil conditions. For example, when drilling rock, the peak 46 may have the same height as apex 38 (or it will quickly wear down to that height).
The conical cutting head 30 is rotatably mounted to the shank portion 18 about an axis a. The conical head 30 has a base side 32 and a cone shaped cutting side 34 including a base portion 37 and an apex 38 . Multiple cutting teeth 40 are provided on the cutting side 34 with the teeth 40 being spaced at intervals on the head 30 extending from the base side to the apex 38 .
The housing 22 and the pipe-line 26 as seen in FIG. 6 have a common axis of rotation 50 . The housing 22 (and the pipe-line 26 ) are rotatably driven in either rotative direction by a known power unit (not shown). The power unit also provides forward movement and retraction of the housing 22 and the pipe-line 26 . FIG. 6 illustrates the drill bit 20 boring a lateral hole 70 through the ground.
The housing 22 includes a conduit in communication with the hollow pipe for pumping a carrier such as water through the pipe-line 26 and through the housing conduit to an aperture 48 . Aperture 48 is provided in the end of housing 22 in close proximity to the conical head 30 . The water will carry the material cut away by the conical head 30 back through the hole 70 outside the pipe-line 26 .
A known sensor mechanism 52 (FIG. 6) is provided in the pipe-line 26 . The sensor mechanism 52 will provide data on the depth and location of the drill bit below the surface and will also provide the rotational orientation of the drill bit 20 , particularly the rotational orientation of the conical head 30 . The operator thus will have data on the depth as well as the rotational direction of the conical head 30 .
With reference now to FIG. 3, a hole or bore is produced by directing the drill bit 20 through the ground in a desired direction. For example, a trench is dug and the drill bit is directed in a lateral path (parallel to the surface) at a depth of, e.g., 4-6 feet. The power unit rotates the pipe-line 26 and the drill bit 20 attached thereto. As the drill bit is rotated the power unit will apply a force to the pipe-line 26 to force the drill bit through the ground. Water is pumped through the pipe-line 26 with the water discharging from the aperture 48 .
The conical head 30 , as it is rotated, will remove material and generate a leading hole 60 . The hole 60 is sized by the rotational path of the cone head 30 . As the cone head 30 progresses, the inclined edge 42 adjacent the peak 46 will enlarge the hole as illustrated by reference 70 .
When it is desired to change the directional path of the drill bit 20 , the drill bit 20 is stopped as well as the forward advancement of the pipe-line 26 . The sensor mechanism 52 conveys information to an above ground detector (known to the art) which provides the operator with the orientation of the cone head 30 of the drill bit 20 as well as the depth the drill bit is below the surface. The drill bit 20 is rotated, if required, until the cone head 30 is in the desired rotative position. The cone head 30 will be positioned with the apex 38 of the cone head 30 facing toward the new direction, which is upwardly as illustrated in the drawings.
The drill bit 20 is then rotated back and forth, clockwise and counter clockwise, e.g., 30° to 90° (hereafter sometimes referred to as oscillation) as the drill bit 20 is forced further through the ground. This oscillation is schematically illustrated in FIG. 4 with the degree of oscillation being indicated by arrow 43 . This action will produce a partially formed leading hole 60 ′ (see also FIG. 5 ). Only the upper portion of the material (as compared to hole 60 ) is removed to form the hole 60 ′ as best seen in the view of FIG. 5 . As the drill bit 20 is forced inwardly to form the partial hole 60 ′, the edge 42 of shank 18 (near peak 46 ) will be engaging the edge 66 of the hole 60 to urge the drill bit upwardly as indicated by arrow 64 . It is also believed that the leading end of edge 42 will also engage the partial hole 60 ′ and add to the upper urging of the drill bit. After a small advancement of the oscillating drill bit, the drill bit is retracted out of the hole 60 ′, full rotation is commenced and the drill bit is again advanced forward. The rotating drill bit is believed to center on the partial hole 60 ′ which functions as a pilot hole to direct the drill bit in the direction 68 as depicted in FIG. 5 .
It will be appreciated that the operation of changing direction of the drill bit 20 may have to be repeated more than once to accomplish the full directional change desired.
Whereas the above explanation of what produces the directional change is qualified as theoretical, the device has been built and placed in operation and the results demonstrate a significant improvement in directional drilling.
Those skilled in the art will recognize that modifications and variations may be made without departing from the true spirit and scope of the invention. The invention is therefore not to be limited to the embodiments described and illustrated but is to be determined from the appended claims. | A drill bit that is arranged to change the direction of drilling. A cone head is rotatably mounted on a shank portion extending from an elongate housing. When the housing is rotated, the cone head generates a concave hole. When a change in direction is required, the housing is rotated a few degrees in one direction and then counter-rotated in the opposite direction. This generates a partial but redirected pilot hole that is also substantially concave in configuration. Continued full rotation causes the drill bit to follow the partial pilot hole in the new direction. | 4 |
This application is a continuation of application Ser. No. 07/794,917 filed Nov. 20, 1991, now abandoned.
BACKGROUND OF THE INVENTION
In a known device and method for cutting or punching out blanks or circular discs for further processing into drawing parts, a band of strip (generically referred to as a web) is advanced stsepwise. If a series of blanks are to be cut out from a band, the advance takes place stepwise in the longitudinal direction of the band. However, if at least two series of blanks are to be cut out at locations displaced in the longitudunal and transversal direction, in order to improve the utilization of the band, the latter must be advanced in a zigzag or a sawtooth manner.
Generally, the advance takes place by means of a grip which in the simplest case advances stepwise the band in its longitudinal direction. This grip must execute a backward motion between consecutive cutting operations, must seize the band and advance the latter. It must thus execute a double displacement and still further change the direction of the motion. In the case of zigzag advancing of the band, a combined longitudinal and transversal advance is necessary which leads to complicated, expensive constructive solutions which do not even permit any higher working speed.
From EP-A-0 321 602, it is known to drive two grips to and fro movable in the advancing direction from a common driving pinion through toothed racks and to advance the band stepwise by alternate couplings with one of the grips during its motion in the advancing direction. Except for that this device is only appropriate for an advance in the direction of the band, the drive is executed by means of an expensive mechanism which does not permit a very high number of strokes.
SUMMARY OF THE INVENTION
It is an object of the present invention to permit by means of alternate acting first and second grips, a feed with a very high number of steps, together with a simple construction and a simple control. The solution is that one transforms a motion directed transverse to the general feeding motion of a common drive to a working motion of inclined motions of the grips. A device for carrying out this invention comprises a common to and fro movable driving element which is coupled via a coupling member with the grips which are guided along respective guide, in directions which with respect to the direction of the driving motion form an angle up to 90°. The deviation of the motion from the drive to the grips can take place for any angle up to 90° by means of sliding coupling elements or twistable rods. The transport can take place straight lined in the longitudinal direction of the band when only one series of blanks is cut, or the transport can take place zigzagwise in that both grips are moved in one direction which is inclined to the longitudinal direction of the band or perpendicular to the latter. This results in a simple construction and a simple synchron motion and control with relatively few movable masses and one can achieve cutting cadences up to e.g. 300/min. As will be seen later on, practically no limits are set to the course of the motions.
The invention will be explained further by means of the drawings of two examples of execution.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plain view of a first embodiment of the present invention,
FIG. 2 is a section along the line II--II of FIG. 1,
FIG. 3 is a section along the line III--III of FIG. 1,
FIG. 4 is a schematic plain view a second embodiment of the present invention and
FIGS. 5 to 8 show possibilities for cutting of blanks in more than two series.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the web or band 1 to be transported from which blanks, e.g. circular discs are to be cut out by means of a cutting tool. A zigzag line 2 in FIG. 1 indicates the manner in which the band is to be transported in order for the blanks to be punched out in two rows in longitudinal and transverse displaced locations, to achieve an optimal utilization of the material. This zigzag path of the transport of the band is achieved by means of first and second grips 3 and 4 of the same kind. These grips are in the form of oblong slides which are guided by means of U-guides 5 along first and second guiding rails 6 which, as shown in FIGS. 2 and 3, are fastened to the machine frame. The two grips 3 and 4 can also be moved along the guiding rails 6 in a direction which is inclined with respect to the longitudinal or forward feed direction of the band 1, approximately 60°, such that both guiding rails 6 are inclined in opposite directions and each of the grips 3 and 4 also enclose an angle of 60°. The two grips each comprise an air cushion 7 to which pressurized, pulsed air is supplied through flexible leads 8 in order to clamp a clamping rail 9 against the band 1, which is shown between the clamping rail 9 and the bottom 10 of the grips, to ensure the transport. The clamping rails 9 are movable vertically and are guided by guiding screws 11.
Each of the grips comprises a slotted coupling box 12 which is supported on a coupling rod or member 13 along which it can slide. The coupling rod 13 is connected to a driving frame 14 which, by means of a driving motor 15 through a spindel 16, is movable to and fro in the direction of the axis of the spindel 16 in order to move to and fro the grip 4 over the coupling boxes 12, along their guides 6. The grips 3 and 4 each comprise two band guides 23.
The working of the illustrated transporting device follows largely from the above description. By means of the driving motor 15, both grips 3 and 4 are moved to and fro in opposing directions relative to one another in synchronism. By each course of this motion, one of the grips 3 or 4 receives compressed air in order to couple or engage it with the band 1 by pressure of the clamping rail 9 and to carry along the same in the direction of motion of the grip concerned. This situation is indicated in FIG. 3, that is the clamping rail of the grip 4 is pressed pneumatically against the band 1, so that the latter must follow the motion of the grip 4. In this way, the band is alternately advanced in the direction of the motion of the grip 3 when the grip 3 is in engagement with the band and moving in the forward feed direction, and in the direction of the motion of the grip 4 when the grip 4 is in engagement with the band and moving in the forward feed direction. The guides 23 provided to the grips 3 and 4 provide for a straight guiding of the band in the region of the transporting device so that the band is also always brought in the right position to the cutting tool, not represented. The drive of the grips 3 and 4 by means of a controlled electromotor 15 permits a very simple programming of the efflux of the motion, that is of the course of the motion and of the tact of the motion as well as of the precise time interval during which the band is advanced. Another drive, e.g. a pneumatic drive is also possible.
FIG. 4 schematically illustrates a second embodiment of the present invention. Two grips 17 and 18 are used which are displaceable along guiding rails 19 and 20 in the longitudinal direction or forward feed direction of the band 1. They can be moved in push-pull by means of a motor 15, the spindel 16, a pinion of spindel 21 and coupling rods 22. During displacement in the desired advance direction of the band 1 the grip 17 or the grip 18 are coupled with the band in a manner already described in order to advance the latter one step. In addition each grip 17 or 18 excutes only one step in a direction for advancing the band one step and during the next advance of the band it is moved back to its initial position. Further, with this embodiment a particularly high working cadence can be achieved, in the first place because the inertia forces of the grips 17 and 18 compensate mutually.
Other forms of execution are possible. In the example of FIGS. 1 to 3, it is admitted that the grips 3 and 4 are rigidly coupled with their coupling boxes 12 such that the angle which is enclosed by the directions of motions of both grips is not variable. It would be possible, however, to render at least one of the grips and its associated guide rail 6 adjustable with respect to its coupling box 12, as shown in FIG. 9. In this case, one of the grips 3 or 4 could be placed perpendicularly to the longitudinal or forward feed direction of the band while the other one of the grips is inclined to the forward feed direction in order to impart to the band a sawtooth advancing motion.
While a zigzagwise advancing of the band is practically significant only in relation with a cutting tool for cutting of blanks, a straight advance according to FIG. 4 can be used in correspondance with another tool, e.g. a follow-on tool.
It is mentioned above that the drive of the grips by means of a controlled motor 15 renders possible a versatile control of the motion by means of appropriate software. In such a case the course of the grip can more particularly be freely selected. FIGS. 5 to 8 show the possibilities for cutting blanks in more than two rows of blanks by means of appropriate control of the course and the efficacy of the grips 3 and 4. In these figures, the single courses, the cyclic order of the steps in the different cutting positions, are designated by a to f. FIGS. 5 to 8 show that alternately double and single steps are executed in order to reach only one time each cutting position. By cutting blanks in two rows according to FIG. 1, numbers of courses up to 300/min are possible. By cutting in more then two rows according to FIGS. 5 to 8, a number of courses up to 200/min. is achieved because double steps have to be excuted.
Further forms of execution are possible. Preferably, a driving unit appropriate for all needs can be present which would be detachable with interchangeable carriage units coupled with the grips. In this case it is specially advantageous that different advancing module units be mounted in accordance with the needs while the same driving unit can always be foreseen. This is more particularly possible when the driving unit can operate in the described manner with any courses and number of courses due to the electronic control.
The running of the motions are not limited, so that e.g. a straight lined advance can be executed by two inclined zigzag steps. | Method and device for feeding a band or web into a downstream machine, including two grips that serve for the stepwise advancing of the band, the grips moving in synchronism to and fro in opposing directions. The grips are alternately coupled with the band or web each during its course in a determined direction in order to impart to the latter a zigzag advancing motion. The driving frequency of the advancing device is in this case half as high as the cadence of the following tool and very high cadences can be achieved. | 8 |
DESCRIPTION OF RELATED ART
It seems there is a divergence of opinion as to the validity of these concepts. This applicant has attached a copy of some of his prior Disclosure Documents as adheres to accepted laws of science. But the mathematics and logic involved and some documentation data all point to its potential. The example of a simple weight midway of a stretched coil spring secured at both ends to a loose horizontal board displaced either direction and released returns to equilibrium without moving nor keep from moving the board; i.e., force=0. This experiment has worked every time and recognized as the "null phase" which obviously changes the center of gravity. This fact assured the validity of inertial propulsion in that it was all it needed to work. It is as though a single weight or M 2 is the secondary mass is both speeding up and slowing down simultaneously in its effect on M 1 . The craft less the weight(s)=primary mass.
This "null phase" with the springs is effective on earth even on an incline including vertically. But the power phase requires some pure external force assist because upgrade M 1 , the craft is more difficult to advance and the M 2 (s) weight(s) less able to do the task. This fact leads to the reality of hybrid systems.
Long ago, the belief was expressed that if someone could ever change the order of the sequence, accel, decel, etc., that self-contained propulsion might be possible. This "power phase" then "null phase" and so on alternately does just that. A one-weight model actually has two weights; i.e., the primary mass, M 1 the craft and one secondary mass, M 2 the weight(s). Of course, this application shows models with 2 & 3 M 2 's. The most likely mode for launch purposes beyond Lockheed Martin's X-33 would appear to be using gyroscopic propulsion since it will need only minimal pure external assist. But that will require powerful linear actuators and engines to manage the tumbling gyroscopes.
This applicant has cited his own gyroscopic propulsion U.S. Pat. No. 3,653,269 with some prior art at least with the same objectives. But no equivalent of the null phase to cancel out return reactions has been evident, nor has the application of pure external force derived from the pathway been found. Furthermore, the harnessing of the displacement for non-travel related tasks appears to be new art.
There have been other grooved cylinder prior art found but not for managing weights for propulsion. Some prior art found:
______________________________________1. Atherton No. 11851 18542. Wueller No. 5,040,426 19913. Garaud No. 3,465,602 19694. Van Doren No. 2,872,825 19595. Franklin No. 1,867,504 1932______________________________________
BACKGROUND OF THE INVENTION
1. Technical Field
The field of endeavor of this invention appears to be for Art Group 3502 and represents efforts beginning in 1958 by this applicant to solve this problem. It deals with momentum drives using a craft M 1 and secondary mass (M 2 's) or weights that are separated and then returned for reuse to the craft called the primary mass or M 1 . It was known that when one weight is pushed away from another, the craft, that if their mass ratios were, e.g. 10 to 1, the weight will move ten units distance and the craft one unit. It was discovered over time that there are a number of ways to return the weight M 2 for reuse without disturbing M 1 .
This so called "null phase" obviously changes the center of gravity from within this multi-component system. These methods can advance the center of gravity for propulsion or retract it for braking. Laterally deployed ones can be used for steering and positioning. For propulsion, it requires the "power phase" which has the function of advancing the craft M 1 at the expense of a weight M 2 which goes rearward, and this does not change the center of gravity. This is common knowledge, but the "null phase" which is alternated with this "power phase" each cycle is new and different. There are eight general ways to do this and probably more.
This means that Newton meant a unitary or one component system when he said, "A body at rest or in motion tends to remain that way unless acted on by an external force." With a two or more component system, the forces between them are obviously external with respect to one another. So, this invention is only an extension of the common interpretation of Newton's laws. The "power phase" extends the masses apart, while the "null phase," whereby these return phase reactions cancel out, obviously does change the center of gravity of the system. This old type is alternated with a new type, and this opens up a new field of opportunities that are long overdue.
In gravity, a small jet or rocket can be used to initiate external assist which can be increased by an on-board multistage pilot unit for that purpose. On earth, these "Inertial Propulsion, Plus" units generally require a combination of existing forces exerted between the weights of the system and pure external force derived from the pathway. Examples are shown in FIGS. 10A, B, C and D. This external assist can make up any deficiencies in the force exerted between a weight M 2 and the craft. This yields a very useful hybrid system.
The above is true because up-grade M 1 is harder to lift and correspondingly, M 2 is less able to lift it. For vertical lift, it differs by one gravitational unit; i.e., 1 G. The difference required in this mix or blend is either enough pure external force to support the weight(s), not the entire craft, or else an amount proportional to the sine of the angle of incline.
Many people have sought to solve this elusive problem made more difficult by controversy which discouraged experimentation. But this breakthrough will set the record straight end open up the field for the development of other related technologies.
For non-travel-related applications, the net displacement inherent in Inertial Propulsion Plus can be harnessed to add to the power obtained from engines. It should be noted that for jets and rockets, although they are both power sources and propulsion means, over half of the input energy is wasted. So, in any event, these new hybrids should extend life of known energy reserves world wide and greatly reduce pollution.
SUMMARY OF THE INVENTION
As described in the background, this invention involves now workable systems of weights that are manipulated in a proven manner to achieve propulsion, braking and steering. It has the power phase to extend the craft from the weights, alternated with a null phase to advance the center of gravity, along with the application of external force from the pathway of the craft to make a workable combination or hybrid. A small excess of pure external force will result in higher velocity of the craft. For non-travel related processes, the inherent net displacement can be utilized to yield engines both reciprocating and rotary. The "null phase" together with the "power phase" allows the weight to be returned for reuse without any adverse effect on the craft and its related system. Many uses are visualized for these and other various systems in many applications.
BRIEF DESCRIPTION OF DRAWINGS
In all Drawings, the weight(s) represent the secondary mass M 2 50 while the remainder of the craft is the primary mass M 1 51.
FIG. 1A and 1D show plan view and elevation view of one embodiment of the propulsion system. FIG. 1B shows a pneumatic version and FIG. 1C is an electromagnetic version.
FIG. 2A is a schematic for the two-weight system shown in FIG. 2B where propulsion is achieved by ramming.
FIG. 3A depicts a 3-weight grooved-cylinder version the plot of the curve for which is shown in FIG. 3B.
FIG. 4 shows a version whereby the weight is a spinning gyroscope.
FIG. 5A represents a 3-weight rotary model and FIG. 5B represents a 2-weight rotary model.
FIG. 6 shows a reciprocating model yielding lift and propulsion.
FIG. 7 is a schematic that represents the use of two opposite power phases to cancel unwanted reactions along with another power phase for propulsion.
FIG. 8A is a schematic of using the impact of one returning weight to accelerate another weight return phase to cancel reactions; FIG. 8B represents a lever system to do this.
FIG. 9 shows how to harness the displacement for engines in non-travel-related tasks.
FIGS. 10A, 10B, 10C and 10D show various kinds of external force assists.
DESCRIPTION OF THE DRAWINGS
The following drawings show the variety of apparatus utilizing a power phase whereby a weight is forced away from the advancing craft and a null phase to return the weight for reuse without any adverse effect on the craft. This null phase changes the center of gravity from within. All of the units shown do require an engine 10 or motor 10 as shown in the drawings. In a gravitational field, all require some external assist 30, 31, 32 generally exerted between the craft M 1 51 and the weights M 2 's 50 and derived from the pathway. Thus M 1 is the device not including the weight(s) 50.
FIGS. 1A and 1D have a flipper 60 displacing weight 50, two inches to rear and on two polished steel rods 170 supported by posts 17 using linear bearings. Weight 50 is released and returned by pretuned springs 80 fastened to weight by threaded screw 19 to equilibrium with no effect on the model for the null phase. External assist 30 is given by small wheel in contact with floor. Powered by cordless screwdriver 10 via geared shaft 171 supported by posts 18, it travels to left as is the case with 1B and 1C and 1D also. FIG. 1B is pneumatic, being powered by compressed air. The upper cylinder 20 has a sealed pot reservoir 61 at each end and cancels return phase reactions. FIG. 1C is similar but uses electro-magnetic coils acting as pretuned springs to both extend and retract the weight 50.
FIG. 2A is a schematic for the two weights 50,50 with collapsible pins 82,82 which impart momentum in the right direction on separation and collection. This allows the weights to complete strokes. In FIG. 2B, flippers 60 supported by posts 18 actuate weights 50. The external assist is made using air jets 31. This speeds up the weight 50 going in the direction of the large travel arrow enabling the weight 50 to reach the end of the stroke and impart its momentum to the craft before the other weight 50 completes its stroke. Return springs 81 conserve kinetic energy. This results in pulsating travel displacement.
Like FIGS. 1A and 1D, the three-weight model shown in FIGS. 3A and 3C is operational and is being further tested. The grooved cylinder 90 model has three six-pound steel weights 50 actually proportionally larger than shown in FIG. 3A and is powered with an electric motor. Weights 50 take turns in the power stroke which advances model as the weight goes rearward. The "null phase" wherein the force from the weight 50 speeding up at uniform acceleration while a counterpart, already in motion, is decelerating likewise during the duration of the second half of the return trip. Motor 10 rotates cylinders 90 and external force 30 proportional to the sine of angle of incline is derived from the pathway. It is applied to the cylinder 90 to augment forces between the actuator 60 and the weights 50. Each weight has centrally located linear bearings riding on two polished steel rods 170 for each weight 50 which have cam followers or styluses fitting into the continuous groove. FIG. 3B shows the type of modified bell curve for motion equation S=vt+1/2 a t 2 . There is prior art cited for grooved cylinders but not for this purpose nor for propulsion and not for managing weights. This type grooved cylinder can, instead of having each weight, during the power phase, accelerate half a stroke then decelerate second half of stroke, it can accelerate almost the entire power stroke. This would be followed by a short transition groove. FIG. 4 shows a gyroscopic version with a gyrostat 150 which spins and is tumbled out of its desired plane of rotation as it is forced rearward by crank and connecting shaft 111. The gimbal for the gyrostat 150 has teeth 64 as does the base track 63 below. One-way clutches 65 have been used on an existing model to insure that the return stroke allows the spinning gyrostat 150 to return on this null stroke without tumbling. Only minimal assist 30 derived from the pathway may be required. Sample calculations shown in the detailed description indicate that since gyroscopes can exhibit many times the force that non-spinning masses can, the relative mass ratios are different on the power stroke and the null stroke.
FIG. 5A and 5B show rotary adaptations of the three-weight system and the two-weight system. In FIG. 5A, the weights 50 are advanced and then retracted using grooved cylinders 90 mounted on disk 91. External assist 30 is provided by the pathway. In FIG. 5B, the weights 50 are advanced by the actuators 60 and returned by the spring system 80 much like with the one-weight system. Both are powered by engine or motor 10. The weights are centrally pivoted and slidable with respect to the rotor wheel. In FIG. 5A, the three-grooved cylinders have one weight 50 advancing in time. "t" while another weight 50 is retracting in the first half and its counterpart likewise in the second half of the return trip.
FIG. 6 illustrates one of other reciprocating models. Unlike helicopters, this one is self-contained, an engine 10 drives a blower 20 and the then upward air stream 32 is sufficient to support the weights 50 which are forced down on power stroke by motor-driven actuators 66 driven by motor 10 via gears 67. The weights 50 could be returned for reuse with any of the spring versions as in FIGS. 1A and 1D. But the exit air is directed downward and can be baffled to help propel the craft. The linear actuator 66 also driven by engine 10 can take any of many forms.
FIG. 7 is a schematic illustrating that two opposite power phases cancel out to a null phase as in the weights 50 in a bracket. The third line or track represents a power phase in which the weight 50 moves oppositely. About the only way this scheme could be useful is if there were spare weights to return; e.g., two at a time as needed for the logistics of the system.
FIG. 8A and 8B show ways to use non-uniform travel rates wherein weights 50 reaching the end of their stroke cancel out the force needed to return another weight 50 for reuse. Generally, anytime a weight is decelerated as in FIG. 8B, which is only the return null phase, it is advantageous to use levers 113 such as in FIG. 8 to recycle the kinetic energy. FIG. 8B shows that if the weights 50 are timed, that a weight arriving at D can strike a lever 113 tied to one at C to accelerate it. There are a variety of options to accomplish this.
FIG. 9 shows that for non-travel related engines that the inherent displacement can be harnessed to add to the available power from an engine. For travel-related tasks, a set of auxiliary weights 50 can be employed to help move the vehicle. The engine 10 drives any inertial-plus apparatus with external assist 30 as similar to FIGS. 1A and 1D as shown in FIG. 9. In lieu of travel, the displacement is harnessed on a treadmill 190. This power is added to the power from the engine and the total output is @ shaft 0. Optimally the inertial machine may travel about an oval back to localize it to its vicinity.
FIGS. 10A, 10B, 10C and 10D show graphically some types of external assist 30 or 31 required for inertial-plus propulsion. FIG. 10A shows a land craft upgrade having the weight track tilted back, although it can be level. Thus, one can have gravity assist. FIG. 10B shows a boat with a small screw propeller to provide external force assist to between weight and craft. Likewise, FIG. 10C represents an airplane flying with a small propeller, in this case for external assist to the weight 50. A craft in microgravity so powered in space needs a small rocket for external assist to augment the force exerted between weight 50 and the craft 112.
DETAILED DESCRIPTION OF THE INVENTION
Since there are eight or more different ways to zero the effects of resulting reactions known to this applicant, there are likewise that many drawings. All of these have a power phase which is common knowledge alternated with a null phase to cancel out unwanted reactions. Efforts are made to recycle the kinetic energy of decelerating weights which can be done in a reciprocating process. Where other external force is applied, generally between the weights and the craft, it generally must be done for both phases, although gravity assist is possible especially in the null phase having a reversely tilted track. Synchronization of the reactions with the actions must be maintained. It can naturally occur but sometimes facilitated by a power synchronizer. Otherwise, scrambling will occur which will adversely affect the travel progression. The drawings FIGS. 1A and 1D and 1B and 1C through FIGS. 10A, 10B, 10C and 10D depict sketches of each type of Inertial Propulsion Plus. Laterally deployed smaller units can be used for steering. Braking can be done by reversing the process and having the null phase retract the center of gravity rather than advancing it.
FIGS. 1A and 1D show pretuned stretched extension springs attached to a slidable weight 50 which returns the weight for reuse without any adverse effect on the model(s). For some models, the springs can be independently stretched and be coupled and uncoupled from the weight. This way is completely neutral as to its effect on M 1 .
For any of the type machines require some external force to be added to the force exerted between the weight(s) and the craft. This may be obtained in sufficient quantity by an on-board multi-stage pilot unit. This could be increased by; e.g., a three-stage unit of inertial propulsion units beginning with an air scoop and becoming greater with each stage's output until it is great enough to satisfy the main driver unit.
Most any appropriate power source 10 including nuclear can be used. Besides using coil or leaf springs, the null stroke can be pneumatic as FIG. 1B or electromagnetic as FIG. 1C. The springs ahead of the weight 50 and behind it need not even have the same stretch indices; i.e., inches per pound. They do need to be roughly compatible so that when released the decreasing tension on the forward spring is accompanied by a corresponding increasing tension of the rearward spring. Thus the reaction upon release of the weight is completely countered by the rearward spring which completely absorbs this reaction as it returns to equilibrium. Then the variations as of FIGS. 1A and 1D and FIGS. 1B and 1C, when properly executed, can totally handle any reaction the driving force can produce. A system dealing with hundreds or thousands of pounds must be strong enough for the task. For example, using the model in FIGS. 1A and 1D and without the flippers touching the weight 50, one can release the manually-displaced-to-the-rear weight 50. This has no adverse effect on M 1 the craft, the mode as weight is returning to equilibrium. With a one-pound tension on the springs at rest, the tension on the front of the model becomes one and one-half pounds and on the rear of the model one-half pound. The maximum driving force is 11/2-1/2=lb. which becomes 1 lb.-1 lb.=0 at rest or equilibrium. But on the return null phase, the Δf=11/2-1#=1/2 lb. loss to the front while the net gain in the rearward spring is 1-1/2#=1/2 lb. gain. This relationship is true for however great or small the tension even thousands of pounds. Also, dynamically, when the model is in operation, there is an imbalance of forces as they affect M 1 the craft. Therefore, the thrust of the power phase must be >1 lb. for the model to travel. This model has extension springs and must be operated in a range to where the opened loops do not close. A variety of stock springs, both extension up to 145 lbs/inch and compression springs, are available from the Gardner Spring Inc. of Tulsa. Either type can be used with these limitations. The above condition must also be observed with pneumatic cylinders or electromagnetic springs.
Inertial Propulsion tends to require a power phase alternated with a null phase to cancel out unwanted reactions. Even gyroscopic propulsion, as in FIG. 4, must have a M 1 /M 2 effective weight ratio more nearly equal on the power phase as regards the null phase or non-tumbling.
Traditionally, the non-ejected weight 50 M 2 may have an excess of momentum MV on the power stroke which would tend to drive the craft M 1 51 back to its prior position. So, with Inertial Plus, some of this force can be countered with pure external force and shunted to ground. Likewise, the other function of the assist is to either support the weight itself for vertical travel or partially support it for upgrade. With reciprocation, it is relatively easy to get internal forces equivalent to more than 10 G's. But the upward opposite travel of M 1 can absorb all but 1 G with vertical travel. For horizontal travel, with no friction nor obstacles to advancement, all the force can be absorbed. The craft M 1 and the weight M 2 will continue to travel in opposite directions relative to each other until the end of the stroke. Since both M 1 and M 2 move apart inversely proportional to their relative mass, then the weight must return a greater distance for reuse. This means the total; e.g., 1+10 or 11 units of distance on the null phase. But once the system gets going, this stop and go becomes speeded up and slowed down each stroke or pulsating travel. But any ripple, if it does occur, can be smoothed out by blending in residual pure external force. Experimental results have been encouraging. Net displacement in itself sets up a progression rate in its own right and residual and added momentum at the end of each cycle makes possible high travel velocities.
These basic and fundamental systems should not be confused with methods which rely on friction to retain position and having a fast stroke in one direction alternated with a slower stroke in the other direction. Even these have some useful applications but differ greatly from the types described by this applicant. Nor is the old reliable pendulum test a good criterion except if it were performed in space as external force may be required on earth. Weights can be in the form of fluids circulated or even clusters of particles blasted back and forth. The M 1 /M 2 mass ratios may vary greatly over a wide range from 1 to 1 if employing only one weight but typically 10 to 1 or even greater. Stroke length may range from a few inches to many feet for large crafts. As for the stroke times, the null stroke can be even faster than the power stroke if desired as this is not a factor. Instead of working due to friction, these new concepts need as little as possible friction. But to have a large thrust, the mass of the craft may be large; i.e., loaded.
FIG. 2A,B is for a two-weight momentum drive system. The two weights 50,50 can be like cannon balls on tracks and interceptor pins 82 to intercept the weight going in the desired direction, allowing it to impart most of its momentum MV to the craft it strikes before the rearward weight 50 reaches the end of its stroke and slows the craft. Pulsating travel occurs, although on earth the ripple can be smoothed out with external assist. Conversely, on the return strokes, the weights are forced back by a flipper or otherwise back toward their initial positions. On this phase, the rearward one, now going in the desired direction of travel, is intercepted by another collapsible interceptor pin 82. In both cases, the weights are allowed to complete their strokes. The necessary external force assist can be provided to desired weight by these flippers or boosters or by any other appropriate means. This additional speed of that weight 50 means that it will reach interceptor pin more quickly than the one which decelerates the craft. For any type, the flippers have been made to uniformly accelerate half way or fully while the weight is being accelerated. Brush type boosters midway will boost the speed of the weight and can be used in lieu of the air jet accelerator.
FIG. 3A shows a 3-weight system. An existing 66 lb. model has three six-pound weights 50 much larger in proportion than shown in the drawing. Each weight 50 has two parallel linear bearings and rides on two polished steel rods. The weights have cam followers which fit into the 1/2 inch continuous groove in a 65/8 inch O.D. aluminum cylinder which is 14 inches long for a 12 inch stroke. The curve for this cylinder was plotted from the motion equation S=vt+1/2 a t 2 and was plotted and enlarged more precisely than FIG. 3B indicates. There was prior art later found for grooved cylinders but not for handling three weights where the return phase reactions cancel out. One of the weights is always outbound as the cylinder is rotated by an electric motor. The other two weights at any given time have one speeding up at constant acceleration in the first part of its return trip while a counterpart already in motion slows down likewise at the same value of constant deceleration. The weights take turns and the outbound power phase makes a stroke in time `t`. But the returning weights take a time `t` for a half stroke. The entire return or inbound stroke takes time `2t`. The power phase can have a weight speed up to on-half stroke or almost the full stroke before decelerating to the end of the stroke as in the case of a spare grooved cylinder. So, while the power stroke of accel/decel is sequential, the return stroke is simultaneous. Also, the power stroke and the null strokes are simultaneous although a design option using actuators can have sequential as in the case with other types. In horizontal operation on earth, these equal but opposite forces cancel out to zero. An external assist 30 like a roller on the pathway taking any of the many possible forms is required. This assist adds to the forces exerted by the cylinder to the weights.
On earth, this small assist can be a small wheel in contact with the road or it can be to the support wheels. On water, this assist can be done using a small dummy screw propeller or through the existing one. Likewise with an aircraft, inertially propelled, the assist can be through the prop or jet or to a dummy one. There can even be combinations of hybrids like an inertially-assisted conventionally-propelled craft. In a helicopter-like craft, a nozzle-type air stream can be used to support the oscillating weights.
FIG. 4 Gyroscopic Model. Since a gyroscope can produce many times the inertial force resistance as can a non-spinning weight when forced out of their plane of rotation, one or more gyros can be effective to produce propulsion. The idea in this type system is to force the gyro unit away from the craft as this gyro is forcibly tumbled out of its plane of rotation. The gyro unit is then returned for reuse without tumbling. The one shown has only one weight (gyro 150) although e.g., three gyro units can be utilized similar to FIG. 3A. Likewise in FIG. 4, the gyro unit is labeled (150).
The gyro unit(s) can be managed in a rotary system. They can also be managed in a reciprocating fashion. All it takes is a double rack and pinion track and a motor-driven reciprocator that moves the gyro unit outbound while tumbling and retract them for reuse without tumbling; i.e. while maintaining its desired plane of rotation. This is done by use of one-way clutches on the gimbal-pivoted-rings for the gyro unit.
Since this process actually constrains the craft as well as the gyro unit on the power phase, the mass ratio of the gyro to the craft is much greater on the power phase. As long as one gets in between the force couple of the twist, effective resistance will occur.
FIG. 6 shows other reciprocating systems. This figure shows a sketch of a craft that could replace the common helicopter for many applications such as rescue tasks. Since there are no exposed rotor blades or props, they will be much safer near mountains and also for fires in high rise buildings and rescue tasks.
This is only a sketch representing necessary components for such a craft and not the actual design which can take many forms.
In this example, the weights 50,50 are supported in a vertical air stream 32 in a stack. A blower or small prop provides the small external assist by the air stream in the stack enough to support the weights not the entire craft. This air stream can also be used to help guide and steer the craft. Meanwhile, mechanical actuators cause the weights to go up and down in this stack. Even then, nulling springs or else a double acting pneumatic cylinder with pot reservoirs at each end may be required to cancel out the return reactions. Electromagnetic coils and fields can be used to mimic the actions of extension spring systems.
FIG. 7 represents a "null phase" component using any two opposite "power phases" and variable weight M 2 units to maintain the needed mass transfer for the logistics of the process. Thus some strokes have a one-weight unit while others have two weights on the same stroke to maintain the continuity of the process. Then adjunct and opposite power phases can be used alternated with a single power phase in the selected direction for travel.
FIG. 8 depicts miscellaneous e.g. pairing up of end points to "null out" effect.
In lieu of uniform accelerating and decelerating the weights as done in previous cases, the weights 50 may travel at constant velocity e.g. like bowling balls and be tossed by a flipper or other actuator. The M 2 's can be the form of clusters, particulates, powders, or else fluids blasted across the enclosed course and received on the other end and returned back and forth. The M 2 's in any form can be forced backward and the craft go forward each pulse. The M 2 leaving the rearmost part of the course may be timed just as the previous M 2 is impinging in front. This cancels out these effects in horizontal operation.
A design goal is to try to recycle the kinetic energy of decelerating weights to help power the system. Rods and levers can be used to transfer the kinetic energy from one end of the track to the other end of the same track or as accelerating or decelerating M 2 is in the return path or track.
The M 2 can even strike a lever near the end of the stroke and apply the kinetic energy electromagnetically through wires to accelerate the M 2 being forced away from the craft.
Another design choice is to "connect" each M 2 on the power stroke. The weights can be fitted with tow strips so that near the end of each power stroke the tow strip engages the next weight and puts it into motion and so on. This can be done without any direct effect on M 1 the craft.
Rotary models, FIGS. 5A and 5B. This system works similarly to the one-weight unit in FIGS. 1A, 1D, 1B and 1C or even the three-weight unit in FIGS. 3A and 3C. Sector-designed weights are more applicable for rotary systems but in effect they are very much alike and merely mounted on arms or disks and provide thrust by rotating around these thrust forces. They can be used laterally to provide steering as well as reversed for braking. FIGS. 5A and 5B depict two different ways of producing a null phase on the return stroke.
FIG. 5A illustrates a three-weight model wherein the forces on two of the weights at any given time are canceling out on the null phase. FIG. 5B shows a two-weight rotary design which employs the nulling spring arrangement. This also can be done with a pretuned pneumatic cylinder or else by electromagnetic coils which serve as springs. One returns the weight and the other cancels out the reaction completely.
FIG. 9 depicts harnessing displacement to provide power from an engine.
The net displacement potential for non-travel-related engines can be converted to rotary motion with the engine power source in place. On earth, a very small external source assist may be used resulting in obtaining power for stationary use.
FIGS. 10A, B, C and D. Inertial Propulsion Plus is used in a gravitational field which requires some pure external force derived from the pathway to be blended in to give a highly useful hybrid. With inertial plus device assisted properly to the weights using a pencil jet or rocket will result in greater thrust. On land, there may be a small fifth wheel or existing wheel(s) in contact with the roadway and a shaft leading to and helping the actuator that manipulates the weights. In water, likewise the assistance can be by a small prop or existing prop. In air, there can be a small prop or existing prop or jet. For helicopter-like vertical travel machine, there can be a small enclosed prop or turbine in a stack or a blower sufficient to externally support the weights.
In general, even with the alternating of a power phase to null phase which changes and advances the center of gravity, this process can only work in a horizontal plane and even then with no friction or obstacles to advancement. Upgrade also needs some pure external assist derived from the pathway and proportional to the sine of the angle of incline. By meeting these basic requirements, a highly useful combination or hybrid can be obtained. This assisting force is usually applied to the force being exerted between the craft and the weight.
FIGS. 10A, B, C and D is a sketch of this process for various media.
For upgrade travel on earth, Inertial Plus with minimal assist may just cause the craft to move less each stroke than will horizontal travel. A slidable ratchet-type escapement fastened to the three-weight model and sliding on an all-thread rod has been used to get the reactions in synchronization with the actions.
A concentric dwell ring groove can be utilized at the ends of stroke using a grooved cylinder to facilitate phase timing. Also, if sequential power phase then null phase rather than simultaneous, it can be done by means of a constant velocity mid section of the return null phase. This is a design option.
With external assist between the weights and the craft, a power phase followed by a null phase and repeating is all that it takes to get unidirectional motion or called self-contained propulsion.
The spring model cannot kick back as long as the sets of springs are roughly compatible. Anyone should try this to verify that it changes center of gravity.
In FIGS. 5A and 5B, the rotary models can have a harmonic balancer or else design the weight strokes on a slant to maintain balance as it moves.
With, for example, a 10 to 1 ratio of M 1 /M 2 , M 1 moves only 1/10th of that for M 2 , so since they are on the same base, relative acceleration versus actual is not significant on the power stroke. M 2 falls behind M 1 and then catches up on the null phase.
Weights including gyro's take hold where they are so if already in motion, the force through a distance is like a dotted or dashed line in that you can have skips on the power phase since much force can be generated for a short impulse of duration of the stroke. The distance M 1 the craft moves may be increased using levers each stroke. "Inertial Propulsion Plus" gives something to push against and the push. Other applications of Inertial Propulsion Plus may include recoil systems and suspension systems.
How It Operates
All of these examples of reaction propulsion devices in art group unit 3502 were made workable by extending a craft and weight(s) apart by reacting against each other and returning the weight for reuse while cancelling out the return reactions. But since for upgrade travel, the craft is harder to move and the weight less able to move it, some outside or external force derived from the travel medium must be selectively applied to the weight(s) itself rather than to the craft. The latter would have added the same force to the craft and the weight and thus not change this otherwise balanced system. But by applying this outside force to oppose the weight, but in the direction of travel, causes the actuator to exert a greater over-riding force to propel the craft. This also is enough to prevent the weight from ramming the craft back to its prior position. The craft's reaction each stroke is great enough to absorb most of the reaction.
The return phase reactions can be cancelled by spring means or by having two or more weights react simultaneously i.e. go apart as with the two-weight apparatus and the three-weight apparatus. The three-weight apparatus has one weight at constant acceleration during the first half of the return stroke, while a prior weight, already in motion, likewise decelerates at the same constant value during the second half of the return stroke. Thus, these return reactions cancel out to zero. In any case, a small external assist must be applied to the weight(s) in the travel direction to prevent the weight from causing the craft to return to its prior position. A small excess of external force assist will add residual momentum each stroke and yield increasing velocity to the craft.
Reversing the process can be used to provide braking and laterally deployed smaller auxiliary units can provide steering.
Placing and securing any of these units on a disk or turntable can add to the power derived from an engine for stationary or non-travel-related applications. The propulsion device must travel around in an oval or circle. To have the device remain stationary and the weights react against belts on treadmills tends to require two belts or disks to make the equal and opposite direction action and reaction separate or can be done in opposite directions on one treadmill belt also serving as the weight.
FIG. 1A and FIG. 1D elevation and plan views have motor 10-driven actuator 60 turning about 180 RPM which cyclically drives a 4" long by 1" rod 50 connected forward and rearward to model by prestretched spring 80. Weight goes 2" rearward as the model goes forward in direction of travel arrow. Weight 50 releases and is returned for reuse by spring system which also absorbs the reaction. External assist enough to keep weight from ramming the model back to its prior position is provided by a friction wheel to a slipping wheel to brake the actuator causing a greater overriding force from the actuator. Continuation of this process gives travel.
FIG. 1B has an air-driven means to force the weight 50 rearward as the model goes forward. A separate pneumatic cylinder 20 has been recharged and returns the weight to equilibrium without affecting the travel process. External assist is provided by a friction wheel 30 to oppose the rearward travel of the weight enough to prevent back-sliding.
FIG. 1C works much the same as the others but uses controlled electromagnetic fields 20 which are wound so as to provide the driving means as well as cancelling the return reactions as weight 50 returns to equilibrium. External assist 30 is provided by a friction wheel opposing the rearward travel of the weights and enough to keep the weight 50 from ramming the model back to its prior position.
FIG. 2A for a two weight system is a sketch showing how forcing one weight 50 forward simultaneous with forcing a second weight rearward to the same extent cancels out reactions. FIG. 2B shows the apparatus using two on-board air jets 31 to add to the velocity of the weight 50 going in the desired direction to reach the end of its stroke before the other weight strikes and slows the craft. This provides enough external assist to prevent back-sliding. Timed actuators 60 driven by motors 10 keep the ramming process going. The springs 81 shown conserve and recycle the kinetic energy.
FIGS. 3a and 3c show plan and elevation views of a 3-weight model whereby one six-lb. weight 50 is always going rearward as the model goes forward while two others 50 are returning forward in response to the grooved cylinder 90 which is rotated by motor 10. There is always one weight 50 speeding up in the first half of the return stroke while another already in motion is slowing down in the 2nd half of its return trip. This cancels out the return stroke reactions. The right amount of external force assist is provided in this case by a friction wheel 30 to add to the forces exerted by the cylinder 90 working with the parallel steel rods 170 to the weights 50 to make it travel by preventing back-sliding to prior position.
FIG. 4 shows a propulsion system wherein the weight(s) is a spinning gyrostat 150 which is forced tumbling out of its preferred plane of rotation on the outbound stroke by means of a second motor 10. This much more effective force causes the model to travel in the opposite direction. Then the gyrostat 150 is returned for reuse without engaging the twist by means of one-way clutches 65. An optional spring means 80 could be used if desired to completely cancel the return reactions. An external force assist is applied to the weight(s) 50 i.e. gyrostat 150 to prevent it from driving the model back to its prior position.
FIG. 5A has a disk 91 upon which are mounted three sets of grooved cylinder 90 actuators driving weights 50 to, in turn, each advance its weight. This exerts an opposite force on the disk 90 about which the disk rotates around and travel occurs. External assist to the weights is provided by a friction wheel 30. The weights 50 are returned for reuse, in order, and these forces cancel out without returning model to prior position each stroke.
FIG. 5B likewise advances weights 50 much as the one in FIG. 5A and the external force assist 30 is similar. The weights 50 are returned for reuse by springs. Enough external force assist 30 is used to prevent the model from being driven back to its prior position each stroke.
Since the craft and the weights 50 shown in FIG. 6 react upon one another, a useful application would be an air vehicle much like a helicopter. The two weights 50 are forced up and down in a stack or chamber and an upward air blast 32 supports and returns the weights and provides the external force assist 32 sufficient to prevent the craft from returning to its prior position. The two engine-driven weights churn up and down in the stack for lift and the return phase can be augmented by springs 80 (not shown). Two engines 10 are shown in FIG. 6 although one engine could be used.
In FIG. 8A, there is one weight 50 forced by an actuator 60 outbound to the right which causes the model to travel left. There is a weight 50 flipped forward at the instant a prior returning weight impinges at the front end of stroke cancelling out the return reactions. Enough external assist 30 is applied from the friction wheels to prevent back-sliding.
FIG. 9 shows a craft such as FIG. 1A and 1D on a treadmill whereby the displacement is harnessed for stationary power applications.
FIGS. 10A, 10B, 10C, and 10D show how external assist 30, 31, or 32 can be applied to the weights 50 for various travel media. The inertial-propulsion-plus devices such as for FIG. 1A of course, are on board and the external assist 30 is designed to oppose the motion of the weight 50 on the power stroke causing a greater overriding force to be exerted on the weight on the power stroke. Enough external assist 30 prevents the weight 50 from ramming the craft back to its prior position. | Devices herein described utilize vehicles that are propelled, braked, and steered by means of a process called Inertial Propulsion Plus. This consists of a "power phase" to extend the weight(s) from the vehicle, alternated with a "null phase" to cancel out the return phase or stroke reactions. This process is made workable by selectively applying a pure external force derived from the pathway and opposing the movement of the weight(s) on the power phase. For non-travel-related applications, the inherent displacement can be harnessed by a treadmill or other ways for a power source to increase available power and reduce pollution. | 5 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/371,812, filed Feb. 16, 2009, which is a continuation-in-part of U.S. patent application Ser. No. 11/395,848, filed Mar. 31, 2006, now U.S. Pat. No. 7,799,097, which is a continuation-in-part of U.S. patent application Ser. No. 10/601,820, filed Jun. 23, 2003, now U.S. Pat. No. 7,033,403, the contents of all of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention is related to fabric coloring. More particularly, the present invention is related to a system and method for spray dyeing and/or bleaching fabrics.
BACKGROUND OF THE INVENTION
[0003] Today, fabrics are made from a wide variety of natural fibers, such as cotton, synthetic fibers, and combinations thereof. The basic fabric is a greige fabric that must be dyed and/or bleached in order to provide the desired color to the resultant fabric and/or garment. Many dye compositions and methods have been proposed for dyeing fabrics; however, dyeing greige fabric remains costly in terms of materials, labor, and/or processing time.
[0004] One conventional dyeing method, known as yarn dyeing, involves dyeing individual fibers or yarns prior to the fibers or yarns being sewn, knitted, or woven into a fabric. A significant problem associated with this method is the substantial inventory requirement to maintain a supply of the various colored yarns needed to produce various products, and the prohibitively high inventory costs resulting therefrom.
[0005] Another conventional dyeing method is known as bulk dyeing. In bulk dyeing, un-dyed fibers or yarns are knitted or woven into a raw or undyed fabric. The raw fabric is subsequently scoured or bleached, and then dyed.
[0006] Common bulk dyeing methods include vat dyeing, beam dyeing, jet dyeing, and bath dyeing. Vat dyeing typically consists of immersing a piece of fabric in a vat of liquid dye. Beam dyeing involves winding a length of fabric about a perforated beam. The beam is then placed in a vessel where dye is pumped into the center of the beam, out of the perforations, and through the fabric. Jet dyeing involves placing the fabric in a high-pressure, high-temperature kettle of liquid dye. Bath dyeing involves immersing the fabric in a bath of dye in a rotating drum.
[0007] There are a number of problems, however, associated with bulk dyeing methods. First, the bulk dyeing process necessitates large volumes of water, which increases the costs of the bulk dyed fabrics, and has an adverse impact on the environment and conservation of natural resources. Also, some of the dyed fabric must be cut away from templates during the manufacture of a garment from the fabric. Since the bulk fabric has already been dyed, this results in increased costs due to the wasted dye and fabric.
[0008] A more significant problem with bulk dyed fabrics in the manufacture of garments is the unpredictability of consumer color preferences. In the garment industry, changes in consumers' preferences for one color over another color can lead to an overstock of the undesired colored garments and a back-order of the desired colored garments.
[0009] Other methods of dyeing fabrics involve printing dyes onto a surface of a fabric. These methods are commonly used to apply a decorative pattern on the surface of the fabric. Such printing methods include screen-printing and inkjet printing. While these methods have proven useful in quickly changing from one decorative pattern to another, they have not proven useful for large scale production of fabrics or garments.
[0010] Accordingly, there is a continuing need for flexible, low cost, low waste processes for dyeing fabrics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic view of an exemplary embodiment of the system for dyeing and/or bleaching fabric according to the present invention.
[0012] FIG. 2 is a perspective view of the ring guides and the scroll roll of the exemplary embodiment of the system of FIG. 1 .
[0013] FIG. 3 is a schematic view of the spray dyeing station of the present invention.
[0014] FIG. 4 is a schematic view of the rinsing stations of the present invention.
[0015] FIG. 5 is a schematic view of the collection unit of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring to the figures in general, and to FIG. 1 , in particular, one aspect of the present invention is directed to a system, shown generally as reference numeral 100 , for continuously dyeing a fabric. Another aspect of the present invention, as described herein, is the method for continuously dyeing a fabric with reference to the system.
[0017] In one exemplary embodiment, the system 100 comprises a fabric positioning station 110 , a spray station 120 , a fixation station 150 , and at least one rinse station 160 . As described in greater detail below, the system 100 may further comprise a drying unit 180 or a fabric handling station 190 (shown in FIG. 4 ). Shown generally as reference numeral 14 , the fabric 14 may be a tubular knit fabric in its un-dyed or raw (greige) state, although the invention is not limited to dyeing tubular knit fabric. Indeed, any fabric substrate can be dyed using the system and method of the present invention.
[0018] In one exemplary embodiment, fabric 14 is drawn from a supply of fabric, such as a knitting machine or fabric roll 12 by a downstream roller 117 , as described in greater detail below. As shown in FIG. 1 , at the fabric positioning station 110 , folds are removed from the fabric 14 . For example, the fabric 14 may be drawn through opposed ring guides 112 , on either side of the flat fabric 14 , over a spreader bar 114 , or former, that opens the tubular fabric 14 . As shown in FIG. 2 , the ring guides each comprise a pair of balls, which rotate about a vertical axis to engage and hold the fabric 14 taut. The spreader 114 ensures that the fabric is flat and, thus, any folds or creases in the fabric are substantially removed.
[0019] After passing over the spreader 114 and through the ring guides 112 , the fabric is allowed to relax as it passes beneath roller 115 , which serves to maintain the appropriate tension on the fabric and guide the fabric to a driven scroll roll 117 . As best shown in FIG. 2 , the scroll roll 117 is a roller having a rubber outer coating with angled, raised ribs 117 a , which diverge outwardly from the center of the roller toward the opposed ends 117 b of the scroll roll 117 . As the scroll roll 117 rotates, drawing the fabric 14 across the top of the roller 117 , the ribs pull the fabric outwardly to keep it taught and smooth.
[0020] The fabric 14 is next drawn through the spray station 120 by downstream rollers 154 , where at least one surface, i.e., the technical face or technical back, of the fabric is sprayed with dye. As illustrated schematically in FIG. 1 , in one embodiment the spray station 120 comprises upper and lower portions 120 a and 120 b, for spraying both technical faces of the flat tubular fabric 14 . Referring to FIG. 3 , the spray station 120 is shown in greater detail. A vessel 121 holds the desired volume of a dye composition, such as a reactive dye mixture. The terms “reactive” or “reacts,” as used herein, refer to the reaction of the dye with the fabric that results in the formation of an attachment to one or more components of the fabric, such as by a covalent bond. Suitable reactive dye compositions are described in U.S. Pat. No. 4,786,721 and in pending U.S. patent application Ser. Nos. 11/338,346, 11/656,769, and 12/329,684, which are incorporated herein by reference. The present invention reduces the amount of water required for dyeing the fabric. Specifically, whereas conventional dyeing processes require about a 6:1 ratio of water to dye, the system and method of the present invention require only about a 1:6 ratio of water to dye.
[0021] The dye composition is drawn from the vessel 121 by fluid pumps 122 . As shown in FIG. 3 , where the spray station comprises upper and lower portions 120 a and 120 b, the system 100 comprises two parallel paths and two fluid pumps 122 a, 122 b in parallel. To regulate the volume of dye composition sprayed onto the faces of the fabric 14 , the dye composition is pumped through flow meters 123 a, 123 b, which are selectively set for the particular fabric type and construction, as well as the type and composition of the dye composition. The dye composition next moves through pressure regulators 124 a, 124 b where the pressure of the spray also is selectively set, depending upon the width of the fabric and the percentage of wet pickup needed for penetration of the dye. In one exemplary operation, the pressure of the spray is about 40 pounds per square inch. Lastly, the dye composition is delivered to manifolds 126 a, 126 b, each manifold 126 being in fluid communication with a plurality of spray nozzle heads 127 a, 127 b. In the embodiment shown in FIG. 3 , each manifold 126 has three spray nozzle heads 127 ; however, the actual number of spray nozzle heads is dependent upon factors that include width of the fabric being sprayed.
[0022] The spray nozzle heads 127 apply the dye composition to the top and bottom surfaces, i.e., technical faces, of the open fabric 14 with dye. In one exemplary embodiment, the spray nozzles are arranged to deliver the dye composition to cover an angle of 110 degrees or less, as measured from the center of the manifolds 126 a, 126 b. As will be appreciated, this coverage is dependent upon the width of the fabric and the distance between the spray nozzles 127 and the face of the fabric 14 . More particularly, the spray nozzles are arranged so that the dye is applied up to, but not beyond, the edges of the fabric, such that there is no overspraying of the fabric and no wastage of dye. This permits the dye to migrate around the edges of the fabric and through the fabric. Additionally, the spray nozzles are configured so that the dye composition is sprayed evenly across the width of the fabric. Further, the spray nozzles are sized, and the settings of the flow meters 123 and pressure regulators 124 selected to achieve between about 65 percent and 85 percent saturation of the total fabric, i.e., the percentage of the maximum amount that the fabric can hold.
[0023] The fabric positioning station 110 and the spray station 120 described herein are equally effective in applying a bleach composition to the fabric 14 . For bleaching applications, the system may be configured so that the bleach composition and optical brighteners are mixed at the spray nozzles 127 via a separate fluid line (not shown). A suitable bleach composition is described in pending U.S. patent application Ser. No. 12/329,680, also incorporated herein by reference. The particular fabric construction and the constituents of the bleach composition will determine the extent to which the remaining portions of the system 100 described herein may be employed to treat the bleached fabric; however, it is contemplated that the system may be used to further treat the bleached fabric, such as applying softeners, stain releases, wicking agents, etc.
[0024] In some embodiments of the present invention, the system further comprises one or more heating devices 130 positioned between the spray station 120 and the downstream fixation station 150 . The heating devices are set to initiate the chemical reaction of the dye.
[0025] The dyed fabric 14 is next drawn over a guide roller 129 and through the fixation station 150 by rollers 154 a, where the dyed fabric 14 is exposed to atmospheric steam, i.e., steam at atmospheric pressure, before the dye dries on the fabric. As discussed above, the color fixation station 150 exposes the fabric 14 to steam and heat in a manner and amount sufficient to spread the dye throughout the fabric, i.e., from the technical face to the technical back, and affix the dye to the fabric as the fabric is continuously moved through the station 150 . As shown in FIG. 1 , the color fixation station 150 comprises a steam box 152 , and a plurality of rollers 154 a, 154 b for transporting the fabric through the steam box 152 in a lengthy path, exposing both technical faces of the fabric to similar conditions. In one embodiment, only the uppermost rollers 154 a are driven. More particularly, steam entering the steam box maintains the exposure temperature in the steam box 152 at between about 196 degrees Fahrenheit and 210 degrees Fahrenheit, and at a relative humidity of between about 60 percent and 90 percent. In one embodiment, the arrangement and rotational speed of the rollers 164 creates a path through the steam box of about nine yards (27 feet) and a dwell time within the steam box 152 of between about three minutes and four minutes. While FIG. 1 schematically shows five rollers 154 a, 154 b, the number of rollers may be increased or decreased depending upon the desired amount of exposure of the fabric 14 to the steam.
[0026] Of course, it is contemplated by the present disclosure for rollers 154 to be horizontally arranged, angled with respect to the horizontal or vertical, or combinations thereof. It is also contemplated to adjust the speed of rollers 154 with respect to one another so that the fabric 14 relaxes as it moves through the fixation station 150 . Advantageously, the rollers 154 are configured to minimize surface contact with the fabric 14 during the fixation process.
[0027] Following fixation of the dye in the fixation station 150 , the dyed fabric is advanced through ring guides 153 into at least one rinse station. Again, the ring guides 153 hold the fabric taut as it advances into the first rinse station. As shown in FIG. 1 , in one embodiment there are two stations provided, shown as 160 and 170 , respectively. The fabric also may be overfed into the first rinse station 160 to reduce residual stresses in the fabric.
[0028] Turning to FIG. 4 , the rinse stations 160 and 170 are shown in greater detail. Upon passing into the first rinse station 160 , the fabric 14 is sprayed with pressurized hot water having a temperature of between about 100 degrees Fahrenheit and 180 degrees Fahrenheit, with about 160 degrees Fahrenheit being preferred. The use of pressurized hot water ensures the minimal use of water in the rinse process. Upon entering the first rinse station 160 , the fabric is drawn through ring guides 163 by downstream nip rollers 167 before spray nozzles 161 and 163 direct a pressurized spray vertically upward and vertically downward against the fabric. The spray action of these nozzles serves two functions. First, the vertical action of the pressurized spray cleans the dyed fabric, removing any unaffixed hydrolyzed dye, residual chemicals, and insolubles from the fabric 14 . Second, the pressurized action of the vertically directed nozzles serves to compact the tubular knitted fabric 14 . As the fabric approaches a first set of nip rollers 167 , two additional spray nozzles 165 are directed angularly upward and angularly downward toward the entrance to the nip rollers 167 to further clean and to further compact the tubular knitted fabric by the mechanical action of pushing the knitted loops (courses) of the fabric 14 against the nip rollers 167 . This effectively reduces the subsequent residual shrinkage in the fabric and apparel formed therefrom.
[0029] Each of the nozzles 161 and 165 deliver about 2.6 gallons of fluid per minute at a pressure of about 1,800 pounds per square inch, for a spray volume of about six gallons per linear yard of fabric 14 . The cleaning fluid mixture comprises water at a temperature of about 160 degrees Fahrenheit, and a neutralizing agent. One suitable neutralizing agent is acetic acid. If the fabric is being bleached instead of being dyed, a peroxide scavenger is also added to the mixture. Upon passing through the first set of nip rollers 167 , about 60 percent of the excess rinse water and chemical mixture is extracted from the fabric 14 . In addition to substantially reducing the volume of water required for the cleaning and treatment at the first rinse station 160 , the resulting extracted hydrolyzed dye and liquid are not environmentally harmful.
[0030] After passing through the nip rollers 167 , the fabric is drawn through ring guides 173 by downstream nip rollers 177 where two spray nozzles 175 , angled in the same fashion as the angled spray nozzles 165 , further compact the fabric 14 as it enters the second set of nip rollers 177 . The nozzles also may apply a finish such as a softener and water composition. Spray nozzles 175 also deliver about 2.6 gallons per minute at a pressure of about 1,200 pounds per square inch, for a total volume of about six gallons per linear yard. Upon passing through the nip rollers 177 , approximately 60 percent of the excess rinse water and softener finish is extracted.
[0031] In some embodiments, one or more of the rinse stations may provide a pH adjustment. Alternatively, the system 100 may comprise a third rinse station 180 , shown in FIG. 4 , wherein the rinse water has a predetermined pH level so that the rinse water adjusts the pH of the dyed fabric to a pH that is neutral or slightly acidic. Any of the rinse stations may further deliver a fragrance, a stain repellant component, a water repellant component, etc. Additionally, the first set of nip rollers 167 and second set of nip rollers 177 may have differential rotational speeds; i.e., the speed of the first set 167 may be greater than the speed of the second set 177 , thus overfeeding to the second set 179 to further facilitate compaction. The pressure applied by the nip rollers 167 , 177 sets the moisture level remaining in the fabric 14 to between about 20 percent and 60 percent saturation.
[0032] In one embodiment, the system 100 of the present invention is configured to recirculate rinse water from the rinse stations to further reduce the amount of water consumed during the dyeing and finishing of the fabric 14 . As will be appreciated by those in the art, the rinse water collected in the rinse station basis of the most downstream rinse station will be the cleanest, as it will contain the least hydrolyzed dye, chemicals, and/or insolubles. Thus, as shown by the arrows, W, collected rinse water from rinse station 180 is recirculated to the spray nozzles 175 in the second rinse station 170 . Similarly, the collected rinse water from the second rinse station 170 is recirculated to the spray nozzles 165 in the first rinse station 160 . Finally, the rinse water from the first rinse station 160 is drained or pumped for wastewater disposal.
[0033] Upon exiting the second rinse station 170 , or third rinse station 180 , if included in the system configuration, the system and process may comprise a collection unit 190 for the finished, wet fabric 14 . An exemplary embodiment of a collection unit 190 according to the present disclosure is shown in FIG. 5 . The collection unit 190 includes an opening unit 191 , an inclined relaxing conveyor 195 a platter 196 and a fabric receptacle 198 .
[0034] As shown in FIG. 5 , as the fabric 14 exits the second rinse station 180 , it is opened by the opening unit 191 . The fabric is engaged by a final set of edge drives 193 , which set the width of the fabric for the subsequent collection and drying. The fabric 14 is then deposited onto the inclined relaxing conveyor 195 in a tensionless state. The fabric 14 exits the conveyor 195 via the platter 195 and is collected in the fabric receptacle 198 .
[0035] While the present invention has been described with reference to one or more 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 present invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present invention not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this invention, but that this invention will include all embodiments falling within the scope of the present disclosure. | A rinsing station for removing residual materials from a fabric being dyed or bleached. The rinsing station includes a first pair of rinse spray nozzles. One of the first pair directed to spray a rinse fluid downwardly onto incoming dyed fabric. The other of the first pair directed to spray the rinse fluid upwardly onto the incoming dyed fabric. The rinsing station also includes a pair of nip rollers downstream for the first pair of rinse spray nozzles for extracting the rinse fluid. | 3 |
RELATED APPLICATION
This application claims priority from Provisional Application 60/084,750 filed on May 8, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and apparatus for sealing between a tubular member and a wellhead structure from which the tubular member is suspended, and more particularly to an apparatus and method for sealing between the upper end of a well casing stub having a generally rough unfinished outer surface and a tubing head or a Christmas Tree adapter, for example.
2. Background of the Invention
Casing strings are normally suspended from a wellhead assembly. The wellhead assembly includes a casing head, which with a casing hanger, supports a casing string which extends into the well. A casing string may extend upwardly from the casing head higher than a preferred height for installation of a tubing head about the casing and with connection to the casing head. The upper extension of the casing is called a "casing stub". Normal installation includes providing a metal-to-metal seal between the exterior casing stub wall and an interior surface of the tubing head. Normal installation is accomplished with a finished exterior of the casing stub so that sealing with a metal-to-metal seal is effective. A seal is necessary between the OD of the casing stub and the ID of the tubing head to prevent possible hydrocarbon spillover from the producing strings inside the casing to the annulus outside of the casing. The tubing head which fits about the casing stub supports the production tubing which extends into the casing to a hydrocarbon pay zone in the well.
During completion operations it may be desirable or necessary under various conditions, such as when a casing string is stuck downhole, to cut off or remove an upper longitudinal section of the casing string which projects from the upper end of the casing head. When an upper section of the casing is cut off, a projecting portion of the casing remains which projects above the casing head. It is not finished. Its outer surface may be rough in texture with a Root Mean Square (RMS) roughness of about 64 RMS, but the roughness may be as high as 250 RMS. Relatively hard metal seals are used for sealing between the finished or relatively smooth OD of the projecting upper end section of a casing and the adjacent ID sealing surface of a tubing head. A hard metal seal may not be acceptable in sealing about unfinished or relatively rough textured casing due to serrations on the casing caused by the sharp seal teeth.
Regular length casing which has not been cut has a sealing surface which has been finished or machined with a RMS roughness less than about 32. Therefore in the past when a top end of a casing has been cut off to produce a casing stub, it has been common to machine or otherwise finish the outer surface of the casing stub to provide a smooth, finished surface for a metal-to-metal seal to be installed between the casing stub and the tubing hanger, particularly when a relatively hard metal seal is used.
Installation of a metal seal is furthermore desired to be accomplished without regard to the particular arrangement of the installed casing head, because different casing head arrangements are provided by different manufacturers.
IDENTIFICATION OF OBJECTS OF THE INVENTION
It is a primary object of the invention to provide an apparatus and method for the installation of a relatively soft metal seal which is effective to provide a metal-to-metal seal between the relatively rough outer surface of a casing stub and a tubing head without requiring any special finishing or machining of the exterior of the casing for effective metal-to-metal sealing between the OD of the casing stub and an interior surface of the tubing head.
A further object of the invention is to provide an apparatus and method by which a metal-to-metal seal is provided between the casing stub and the tubing head where the seal is supported solely from the casing stub, and not from the casing head.
SUMMARY OF THE INVENTION
The present invention is directed particularly to an apparatus and method for sealing between the exterior of a casing stub which extends upwardly from a casing head. The casing stub has a generally rough unfinished outer surface. The metal-to-metal seal arrangement of this invention seals between the rough outer surface of the casing stub and an adjacent opposed inner surface of a tubing head which is secured to the casing head. The method and apparatus include a slip assembly which includes a slip ring, a cam bowl member for engaging the slip ring, and a bushing which initially locates the slip ring vertically on the casing stub and supports the slip ring and the cam ring while opposing the force exerted by a hydraulic swaging tool against the cam member while urging the slip ring into tight gripping engagement with the outer surface of the casing. The bushing could serve as a secondary seal or test seal if desired.
The wellhead assembly has an upper housing or casing head which receives the casing coaxially by means of a casing hanger and defines an annulus therebetween. The special slip swaging tool is positioned over the upper end of the casing stub for engaging the cam ring bowl of the slip assembly to force the slip ring to grip the casing with support from below by the supporting bushing. Then, the slip swaging tool is removed with the result that the slip ring, the cam ring bowl and the reaction support bushing remain in position about the casing. The slip ring is in position to act as the sole lower support for supporting and positioning the metal seal on the casing stub.
Next, the tubing head is placed over the cam ring, slip ring and bushing in order to move the bushing downwardly on the casing stub and below the slip ring with the result that the slip ring and cam bowl ring are supported entirely from the casing stub itself and not the casing head. The tubing head is then removed.
Next, a relatively soft metal seal is positioned over the upper end of the casing stub and is moved downwardly until it abuts the cam ring. In this position, a tubing head or similar device, such as a spool or adapter for a Christmas tree, is positioned over the upper end of the casing stub such that it lands on the exterior profile of the seal. A measurement is made of the distance between the bottom surface of the tubing head and the top surface of the casing head. The tubing head is removed, and the seal is removed. A shim is provided over the top end of the cam ring to insure that when the seal is reinstalled and the tubing head is reinstalled, the distance between the upward hub face of the casing head and the bottom hub face of the tubing head is a predetermined distance.
Finally, a connector squeezes a lower flange of the tubing head and an upper flange of the casing head together, thereby causing the flange faces of the tubing head and the casing head to abut each other. During the connecting or squeezing operation, the tubing head moves down by the predetermined distance referred to above while a camming surface of the tubing head drives the soft metal-to-metal seal radially inwardly into the casing stub. The seal is prevented from axial movement along the casing stub, because the slip ring, cam ring and shim cannot move axially due to the fact that the slip ring tightly grips the exterior of the casing stub.
Thus, it is a feature of the present invention to provide an apparatus and method for installing a soft metal seal for sealing between the generally unfinished outer surface of a casing stub which extends upwardly from a casing head and an opposed inner surface of a tubing head which is secured to the casing head and without any special machining or finishing of the exterior of the casing stub required prior to installation of the relatively soft metal seal.
It is a further feature of the invention that an apparatus and method are provided which includes a seal, and a slip arrangement secured to the rough casing before the relatively soft metal seal is positioned over the casing, where the slip arrangement supports the metal seal at a precise position on the casing without any support from the casing head.
Another feature of the invention relates to a swaging tool which is used to position the bushing and the slips at a precise location relative to the hub face of the casing head thereby providing accurate positioning of the slip assembly to insure later adequate energizing of the metal seal on the casing stub after a shimming procedure and after makeup of a connector between the tubing head and the casing head.
Other objects, features, and advantages of the invention will become more apparent upon reference to the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, advantages and features of the invention will become more apparent by reference to the drawings which are appended hereto and wherein an illustrative embodiment of the invention is shown, of which:
FIG. 1 is an enlarged longitudinal sectional view of a casing stub which projects upwardly from the upper surface of a casing head of a wellhead assembly in which a casing is installed with a casing hanger and defines an annulus between the casing and the casing head;
FIG. 2 is a sectional view of a swaging tool for installing a bushing and a slip ring about the casing stub;
FIG. 3 is a sectional view of a swaging tool with a seal bushing installed by means of cap screws and without outer diameter S-seals installed, where the tool is ready to be installed over the casing stub;
FIG. 4 is a sectional view of the swaging tool of FIG. 2 installed over the casing stub and landed on the hub face of the casing head with the bushing snubbed about the exterior of the casing stub;
FIG. 5 is a sectional view of the casing stub after a slip ring and cam ring bowl have been installed over the casing stub and landed on the seal bushing;
FIG. 6 illustrates an energizer ring that has been installed over the casing stub and landed on the cam ring bowl ready for energizing by means of the swaging tool;
FIG. 7 illustrates the swaging tool of FIG. 2 installed over the casing stub, slip ring, cam ring bowl, and energizing ring for energization of the slip ring;
FIG. 8 illustrates hydraulic force being applied to the energizer ring for squeezing the slip ring radially inwardly into the OD of the casing stub, while the bushing is being held in place by cap screws through a wall of the swaging tool;
FIG. 9 illustrates that the swaging tool has been removed and that the bushing has been moved downwardly by a shoulder of the tubing head which has been landed over the casing stub;
FIG. 10 illustrates that the tubing head has been removed and that the area above the cam slip bowl is cleaned without grinding;
FIG. 11 illustrates that a relatively soft metal seal is installed over the casing stub and landed on the cam slip and cam ring bowl;
FIG. 12 shows that the tubing head is reinstalled over the casing stub and landed on the exterior surface of the metal seal in preparation for measuring the stand off between the bottom hub face of the tubing head and the top hub face of the casing head;
FIG. 13 shows that the tubing head has been removed and that a shim has been placed between the bottom of he metal seal and the top of the cam slip bowl and with a gasket installed in an API groove in the top face of the casing hub; S-seals have also been installed on the bushing O.D.
FIG. 14 shows the tubing head installed over the casing stub and seal assembly ready to energize the soft metal seal;
FIG. 15 illustrates a connector clamp installed over flanges of the casing head and the tubing head ready to make up the metal seal; and
FIG. 16 illustrates the connection made up evenly with the metal seal between the casing stub and the tubing head with the metal seal supported solely by the casing stub.
DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a casing string 10 (for example having an O.D. of 95/8") which is supported in a casing head 12 by means of a casing hanger 14. A stub or exterior of the casing string 10 extends above the casing head 12. It is referred to herein sometimes as a casing stub. The height "D" of the casing stub from the top of the casing hub to the hub face 16 is preferably 11.0"±1/4" in a preferred embodiment of the method for running a FX RCMS seal for a 95/8" casing. A preferred FX RCMS seal is of stainless steel AISI 316 and is characterized by a UNS Name of 531600, a Rockwell "B" of 83 HRB Max and a yield strength of 30,000 psi min. The 11" is measured from the top of the hub face 16 and is marked on the casing so that the casing stub 11 is of the proper height above hub face 16. The casing stub 11 should be prepared with a bevel and wire brushed on its OD, preferably with a pneumatic wire brush. The OD should be cleaned to base metal as much as possible, but a grinder should not be used on the casing stub 11 to clean off the scale.
Next the OD tolerance range of stub 11 is determined by using the procedure as outlined in Table 1 below. A 0.15" shim is first used, then gages 1, 2, and 3 are employed to determine bowl, shim and seal particulars consistent with the OD of the stub 11.
TABLE 1__________________________________________________________________________CSG. TOL. RANGE W/CORRESPONDING SLIPS, BOWL, SHIM ANDFX RCMS SEAL LOWCSG TOL GAGE GAGE GAGESIZE SHIM #1 #2 #3 SLIPS BOWL SHIM SEAL__________________________________________________________________________9.721/ NO NO NO NO HIGH #1 HIGH HIGH9.685 GO GO GO GO TOL. TOL. TOL. (1)9.684/ NO GO NO NO HIGH #2 HIGH HIGH9.649 GO GO GO TOL. TOL. TOL. (1)9.648/ GO GO GO NO LOW #3 LOW LOW9.613 GO TOL. TOL. TOL. (1)9.612/ GO GO GO GO LOW #4 LOW LOW9.577 TOL. TOL. TOL.__________________________________________________________________________ NOTE 1: IF GAGE GOES OVER THE CASING, ASSUME THE CASING IS IN THE NEXT LOWER TOLERANCE RANGE. GAGE SIZES: LOW TOL. SHIM ID 9.663"/9.673 GAGE #1 ID 9.686"/9.687 GAGE #2 ID 9.650"/9.651 GAGE #3 ID 9.614"/9.615
Next, as illustrated in FIG. 3, a swaging tool 18 is provided. FS seals 20 are assembled in a reducer bushing 22 which is secured via the bottom end of swaging tool 18 by means of fasteners such as cap screws 24. A generous layer of copper coat grease is applied over the screw threads, the tip of the screws and the locking holes. Preferably, sixteen cap screws are provided which are made up band tight. The screws are considered made up when the bottom of the cap screws head 24 is about one inch from the OD of 18. S-seals on the OD of bushing 22 are not installed at this time in the slots 21 provided for same.
FIGS. 2 and 3 illustrate the swaging tool which includes a lower tool housing 19 having a visual port 26 provided therein. An upper tool housing 28 is threadably secured to lower tool housing 19. Three one hundred sixty degree pad eyes 32 are provided for lifting the swaging tool 18 onto and from casing stub 11. A piston 30 is provided within the upper tool housing 28, and a sealing polypak 36 provides a seal for piston 36 to be reciprocated by pressurized hydraulic fluid. In the method of installation, the piston 30 of the swaging tool 18 is placed as high as possible in the upper tool housing 28. A pipe plug 34 is installed in pressure port 35 to maintain the piston 30 in place.
As illustrated in FIG. 4, the swaging tool 18 is placed over the top and around casing stub 11. A thick layer of clean grease is applied to the FS-seals 20 and to the OD of the casing stub 11. As the tool 18 and seal bushing 22 are installed about casing stub 11, the tool 18 is placed with its bottom face 25 in face-to-face contact with hub face 16. If the weight of the tool 18 is not great enough to bring the tool 18 and bushing 22 to the position illustrated in FIG. 4, a drill collar or other weight may be applied to the top of tool 18 to overcome friction between the seals 20 and the outer surface of casing stub 11 in order that the tool face 25 is placed face-to-face on the hub face 16.
Next, the bushing 22 is unlocked from the tool 18 by fully unscrewing the sixteen one-inch socket head cap screws 24. The tool 18 is then removed by lifting it from the top of casing stub 11. The bushing is not disturbed from its position of FIG. 4. Friction between the FS seals 20 and the casing stub 11 temporarily maintains the bushing 22 in place.
Based on the measurements described above by reference to Table 1, the appropriately sized slips, bowl, FX RCMS seal element and shims are selected.
As illustrated in FIG. 5, a segmented slip ring 40 is installed first about the OD of the casing stub 11, and then the cam bowl 42 is placed about an outer camming surface of slip ring 40.
Next, as shown in FIG. 6, an energizing ring 44 is placed over the top end of casing stub 11 and lowered until it contacts slip bowl 42. The bowl 42 is leveled to a horizontal position by placing a level on the ring 44 at two places spaced ninety degrees apart. The gap between the bottom of bowl 42 and the top of the bushing 22 is preferably between about 0.5" and 0.618".
As shown in FIG. 7, the hydraulic swaging tool 18 is installed over the top of the combined casing stub 11, the slip ring 40, the slip bowl 42, and the energizing ring 44. One of the socket head cap screws 24 on the swaging tool 18 is removed to insure proper alignment with the bushing 22 as the swaging tool 18 is being installed. After alignment, all sixteen of the one-inch socket head screws 24 are inserted and tightened into a corresponding hole of the bushing. The screws 24 are made up hand tight. They are considered made up when the bottom of the cap screw head is approximately one-inch from the OD of the swaging tool 18. Previously, a generous layer of copper coat grease has been applied over the screw threads, the tip of the screws 24 and the sixteen holes in the bushing 22 prior to the installation of the swaging tool 18 If the bushing 22 has not been disturbed after the initial installation as described above, and the screws 24 and the holes of the bushing 22 have been greased properly, most of the screws 24 can be tightened by hand. However, Allen wrenches or other tools may be used to make up the screws 24 if necessary. Proper alignment of the screws 24 with the holes of the bushing 22 prevents damage to the bushing 22. If the bushing has been inadvertently disturbed, its height is adjusted until the holes line up vertically with the socket head cap screws 24 of the swaging tool 18.
Next, referring to FIG. 8, the pipe plug 34 is removed and a hydraulic line (not illustrated) (rated to 5000 psi min) is applied to the pressure port from which the plug 34 is removed. The piston 30 forces ring 44 downward which causes slip ring 40 to be energized, that is, to be forged and locked around the casing 11. Pressure to a maximum level of 4700 psi is applied in increments of 1000 psi. The gap between the bottom of the bowl 42 and the top of bushing 22 is monitored via the four two-inch view ports 26. At 4700 psi, the gap is measured with feeler gages at four places at ninety degrees apart through the view ports 26. The pressure is relieved, and the gap is remeasured with feeler gages.
The pressure is increased as before to 4700 psi until the gap, with pressure relieved, does not change more than 1/32". The gap should stabilize after the third cycle of pressure. The reference to no change greater than 1/32" is merely a short hand way of insuring that the casing slip ring and bowl 42 are energized. A pressure greater than 4700 psi for energization should be avoided.
Next, pressure is relieved from swaging tool 18, and the hydraulic line is removed. The tool 18 is removed by unscrewing the sixteen socket head cap screws 24. The energizing ring 44 is removed. The slip ring 40 and bowl 42 should be fully energized.
Next, referring to FIGS. 9 and 10, with the S-seals still removed from reducer bushing 22, a tubing head 50 is landed over the casing stub 11, slip bowl assembly 42, and reducer bushing 22. As the tubing head 50 moves down onto the lower position, the bushing 22 is pushed down by contact of shoulders 52 between bushing 22 and tubing head 50. The tubing head 50 is then removed with the bushing installed on the casing stub 11. The tubing head is pulled straight up so as not to disturb the position of bowl 42 or ring 40.
Next, as shown in FIG. 11, the selected FX RCMS seal 54 (the selection of which is described above by reference to Table 1) is placed over the casing stub and on the slip bowl 42. The small end of the taper of seal 42 is placed up. As illustrated in FIG. 12, the tubing head 50 is carefully lowered over the casing stub 11, slip ring 40 and bowl 42 and FX RCMS seal 54. The tubing head 50 is leveled, and then the stand off S at the interface between flanges 55 of tubing head 50 and flange 56 of casing head 12 is measured and recorded.
Next, the tubing head 50 and the FX RCMS seal element 54 are removed. Shims 60 that were selected as described above are installed between seal 54 and bowl 42. A stand off gap S of about 0.350" is preferred. The number of shims to install is found by subtracting the measurement recorded above from 0.350" and determining the number of 0.150" and 0.100" shims required for a minimum gap of 0.350".
As shown in FIG. 13, with the sealing area clean and greased, the FX RCMS seal 54 is installed over the casing stub 11 on the slip 40, bowl 42 and shim assembly 60. A layer of copper coat grease is applied to the entire surface of the FX RCMS seal element 54. S-seals 62 are installed on the OD of bushing 22, and a layer of clean grease is applied on the seals. A BX gasket 64 is installed in the API groove 66 of the hub face 16.
As illustrated in FIG. 14, the tubing head 50 is installed over the casing stub 11 and seal assembly. After the tubing head is leveled, the resulting stand off S is measured.
Next, as illustrated in FIG. 15, connector 60 is positioned such that its inclined shoulders 57, 58 are in contact with shoulders 68, 69 of flanges 55 and 56. The connector 60 is then energized to force the hub face 16 and the tubing head face 5 into face-to-face contact. The connection of tubing head 50 and casing head 12 is now ready for testing. When the FX RCMS seal 54 is tested by applying pressure via port 100, 80% of casing collapse pressure should not be exceeded. Alternatively, a 10,000 psi limit should be observed if a cup tester is used in the casing.
If a test procedure were to result in failure, the tubing head 50 is removed and the FX RCMS seal 54 is removed with a power wheel cutter. Care must be taken to insure that the casing stub 11 is not damaged during such operation. The seal surface of the casing is cleaned again with a wire brush and the applicable steps described above are repeated.
While preferred embodiments of the present invention have been illustrated and/or described in some detail modifications and adaptions of the preferred embodiments will occur to those skilled in the art. Such modifications and adaptations are within the spirit and scope of the present invention. | A method and apparatus for installing a metal annular seal (54) between the outer rough surface of a casing member (11) which has had a portion thereof cutaway with a remaining portion projecting upwardly from the upper end of a casing head (12). A slip installation tool (18) mounted on the upper end of the casing head (12) carries a slip assembly which includes segmented slips (42), a bushing (22), and a cam member (42). The slip installation tool (18) secures the slips (40) about the outer rough surface of the casing (11) as shown in FIGS. 7 and 8 with bushing (22) acting as a supporting base or foundation to oppose the forces from the camming action because of support from lock down screws (24). After mounting of the slip assembly about the casing (11), the installation tool (18) is removed, and the metal seal (54), formed of a relatively soft metal material, is mounted over the extending end of the casing (11). Positioning of the tubing head (50) on the casing head (12) as shown in FIGS. 14-16 deforms the metal seal (54) into metal-to-metal sealing relation between the outer rough surface of casing (11) and the inner frusto-conical sealing surface (96) of the tubing head (50). | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional App. 61/151,764 filed Feb. 11, 2009, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to balloon catheter devices used for imaging and treating tissue regions of interest. More particularly, the present invention relates generally to methods and devices for balloon catheters which can be used to image and treat tissue regions of interest, such as a vessel ostium, for various conditions, such as atrial fibrillation, etc.
SUMMARY OF THE INVENTION
[0003] An inflatable balloon catheter having an irrigation sheath may generally comprise two expandable membranes disposed about a catheter. The first inner membrane may be generally or substantially sealed to a catheter and may serve as a balloon to facilitate positioning of the device, e.g., within a lumen. This balloon structure when filled with fluid may expand and become engaged in direct contact with the tissue. A second (outer) membrane may be at least partially positioned over the balloon and may provide a pathway for delivery of fluid at the treatment site. In treating a tissue region with ablation energy, particularly within a body lumen such as a heart chamber, one device in particular may be used as shown and described in detail in U.S. Pat. No. 6,605,055, which is incorporated herein by reference in its entirety. As disclosed, an inflatable balloon which is sealed to a catheter may be advanced within a body lumen, such as within a chamber of a subject's heart, and inflated for contact against a tissue region to be treated.
[0004] A balloon catheter having a primary balloon member disposed about a catheter for inflation within the body, e.g., with the heart, may provide a transmission waveguide for radiation (such as laser radiation) projecting from an optical fiber to the ablation site, e.g., an ostium of a vessel. The catheter is typically an elongated hollow instrument having at least one lumen in communication with the port.
[0005] The outer membrane or sheath may define a distal opening to partially cover the primary balloon such that an irrigating fluid such as saline may be introduced through the annular conduit between the inner and outer membranes and exit through this opening to clear the region of blood between the balloon and the underlying tissue. In phototherapy applications, the removal of blood from the treatment site allows for the unobstructed and uniform delivery of ablative energy. In addition, the irrigating fluid cools the surface of the target site, thereby preventing overheating or burning of the tissue or coagulation. Also, it is noted that removal of blood allows direct visualization of the tissue surface with an appropriate imaging system.
[0006] An imager, e.g., CMOS or CCD electronic image sensor, may be affixed to an inside wall of the primary balloon with an electrical connection leading out of the distal end of the balloon to an image processing system for displaying the image, e.g., on a monitor. Direct visualization of the tissue surface is made possible when blood is flushed out and/or squeezed from the field of view. At least one light source, such as an LED, may also be affixed to an inside wall of the primary balloon coupled to an electrical connection as well. Both the light source and imager may be angled or positioned such that their field of view is directed towards the distal end of the balloon to capture and/or illuminate the underlying tissue region through the transparent balloon.
[0007] Another variation may include a fiberscope, which may be articulatable to control a direction of its distal end, positioned within the interior of the balloon. The distal end of the fiberscope may be articulated from outside the patient's body by the operator to direct an angle of the fiberscope within the balloon to view any region of contacted tissue through the balloon. The fiberscope may be optionally coupled to an imaging system, e.g., CMOS or CCD electronic image sensor, positioned external to the patient's body.
[0008] In yet another variation, an imager, such as an electronic imager, may be positioned upon the distal end of an articulatable member. The articulatable member may be manipulated from outside the patient's body to direct a viewing angle of the imager within the balloon. An imaging system may be located outside the patient's body for communicating with the imager for processing and/or displaying the images of the contacted tissue regions captured within the patient.
[0009] In yet another variation, fluid such as saline may be introduced through the conduit formed between the sheath and balloon. The introduced fluid, particularly an electrolytic fluid such as saline, may also be used to conduct ablative energy into the underlying tissue from the one or more electrodes which may be positioned along an outer surface of the balloon or sheath. The one or more electrodes may be positioned at locations where the fluid exits the conduit and contacts the underlying tissue such that the fluid flowing into contact with the electrodes may conduct any discharged energy, e.g., radio frequency (RF) energy, to ablate the tissue in combination with or exclusive of the ablative radiation energy projected from the optical fiber. The energy delivered via electrodes is not limited to RF energy may but also include any number of other ablative forms of energy such as cryo-ablation, microwave, ultrasonic, etc. Moreover, utilization of ablation energy in contact or in direct proximity to the tissue may provide additional ablative effects should blood obscure the radiation energy. Also, these electrodes may be also used independently from the laser ablation system or may be used to map electric potentials at the tissue surface.
[0010] Another variation of the balloon catheter may include one or more pores defined circumferentially about the distal end of the sheath such that the introduced fluid passing through the conduit may be diffused through the one or more pores into contact against the underlying tissue. The diffusion of the fluid through the pores may facilitate distribution of the ablation energy over the tissue.
[0011] In yet another variation, one or more ultrasound transducers may be positioned near or at a distal end of the balloon and/or sheath for placement in proximity to or in contact against the tissue region of interest. The one or more ultrasound transducers may be actuated to deliver ultrasonic signals into the underlying tissue to detect a thickness of the tissue, e.g., at the locations at which the radiative energy is to be applied. Knowledge of the thickness of the tissue to be ablated may help determine how much energy to provide or to determine, e.g., an appropriate amount of fluid flow needed to cool the tissue surface, etc., amongst other parameters. Tissue thickness detection utilizing ultrasound transducers is described in further detail in U.S. patent application Ser. No. 12/118,439 filed May 9, 2008 (U.S. Pat. Pub. 2009/0030412 A1), which is incorporated herein by reference in its entirety. Various methods may be utilized, e.g., by a controller such as a microprocessor in communication with the ultrasound transducers, for controlling and/or adjusting various parameters of an ablation procedure, e.g., power, laser intensity, flow rate, temperature, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a cross-sectional view of a variation of a balloon catheter apparatus having an imaging system attached to an inside wall of the balloon.
[0013] FIG. 2 shows a cross-sectional view of another variation of a balloon catheter apparatus having an articulatable fiberscope within the balloon and coupled at a proximal end to an imaging system, such as a CMOS or CCD imaging system.
[0014] FIG. 3 shows a cross-sectional view of another variation of a balloon catheter apparatus having imaging sensor, such as an electronic imager, affixed at the distal end of an articulatable member within the balloon.
[0015] FIG. 4 shows a cross-sectional side view of yet another variation illustrating one or more electrodes positioned upon the balloon surface for transmitting energy through a fluid into the underlying tissue.
[0016] FIG. 5 shows a cross-sectional side view of a balloon catheter apparatus which defines a plurality of openings or pores through which energy may be transmitted into the underlying tissue surface.
[0017] FIG. 6 shows a cross-sectional side view of a balloon catheter apparatus having one or more ultrasound transducers positioned along the balloon for detecting a thickness of the underlying tissue.
[0018] FIG. 7 shows an example of a flow chart illustrating one method for controlling parameters of an ablation system in response to detected tissue thickness.
DETAILED DESCRIPTION OF THE INVENTION
[0019] In treating a tissue region with ablation energy, particularly within a body lumen such as a heart chamber, various devices and methods may be utilized for visualizing and treating the tissue. One device is shown and described in detail in U.S. Pat. No. 6,605,055, which is incorporated herein by reference in its entirety. As disclosed, an inflatable balloon which is sealed to a catheter may be advanced within a body lumen, such as within a chamber of a subject's heart, and inflated for contact against a tissue region to be treated.
[0020] FIG. 1 illustrates a cross-sectional side view of a balloon catheter 50 having a primary balloon member 56 disposed about a catheter 14 for inflation (via port 23 ) within the body (e.g., with the heart) to provide a transmission waveguide for radiation 13 (such as laser radiation) projecting from an optical fiber to the ablation site 12 , e.g., an ostium of a vessel. A laser generator 28 may be in optical communication with the optical fiber for delivering the radiation 13 . The primary balloon member 56 may be generally or substantially sealed and can be inflated to position the catheter 14 within the lumen. The catheter 14 is typically an elongated hollow instrument having at least one lumen in communication with the port 23 . The primary balloon 56 is shown engaged in direct contact with a body lumen 52 (e.g., a pulmonary vein) and an outer membrane or sheath 16 may be at least partially disposed about the primary balloon member 56 for providing an irrigation path via the annular conduit 20 formed between the two membranes to the body lumen. Primary balloon member 56 and sheath 16 may accordingly form a respective inner and outer membrane of the balloon assembly.
[0021] The outer membrane or sheath 16 may define a distal opening to partially cover the primary balloon 56 , as shown, such that an irrigating fluid such as saline may be introduced through the annular conduit 20 between the inner and outer membranes and exit through this opening to clear the region of blood between the balloon and the underlying tissue. In phototherapy applications, the removal of blood from the treatment site allows for the unobstructed and uniform delivery of ablative energy 13 . In addition, the irrigating fluid cools the surface of the target site, thereby preventing overheating or burning of the tissue or coagulation. Also, it is noted that removal of blood allows direct visualization of the tissue surface with an appropriate imaging system.
[0022] In this variation, an imager 32 , e.g., CMOS or CCD electronic image sensor, may be affixed to an inside wall of the primary balloon 56 with an electrical connection 34 leading out of the distal end of the balloon to an image processing system for displaying the image, e.g., on a monitor. Direct visualization of the tissue surface is made possible when blood is flushed out and/or squeezed from the field of view. At least one light source 30 , such as an LED, may also be affixed to an inside wall of primary balloon 56 coupled to an electrical connection 36 as well. Both light source 30 and imager 32 may be angled or positioned such that their field of view is directed towards the distal end of the balloon 56 to capture and/or illuminate the underlying tissue region 52 through the balloon 56 which may be optically transparent.
[0023] Another variation is illustrated in the cross-sectional side view of FIG. 2 , which shows a fiberscope 38 , which may be articulatable to control a direction of its distal end, positioned within the interior of balloon 56 . The distal end of fiberscope 38 may be articulated from outside the patient's body by the operator to direct an angle of fiberscope 38 within the balloon 56 to view any region of contacted tissue through the balloon 56 . The fiberscope 38 may be optionally coupled to an imaging system 40 , e.g., CMOS or CCD electronic image sensor, positioned external to the patient's body.
[0024] In yet another variation, FIG. 3 shows an example where an imager, such as an electronic imager 32 , may be positioned upon the distal end of an articulatable member 42 . As previously described, articulatable member 42 may be manipulated from outside the patient's body to direct a viewing angle of imager 32 within the balloon 56 . Imaging system 40 may be located outside the patient's body for communicating with the imager 32 for processing and/or displaying the images of the contacted tissue regions captured within the patient.
[0025] In yet another variation, FIG. 4 shows a cross-sectional side view of a tissue region in proximity to body lumen 52 ablated by projecting radiation 13 from optical fiber 60 positioned within balloon 56 . As previously described, fluid 17 such as saline may be introduced through conduit 20 formed between sheath 16 and balloon 56 . The introduced fluid 17 , particularly an electrolytic fluid such as saline, may also be used to conduct ablative energy into the underlying tissue from one or more electrodes 62 which may be positioned along an outer surface of balloon 56 and/or sheath 16 , e.g., near or at a distal end of the balloon 56 and/or sheath 16 . The one or more electrodes 62 may be positioned at locations where fluid 17 exits conduit 20 and contacts the underlying tissue 52 such that the fluid 17 flowing into contact with electrodes 62 may conduct any discharged energy, e.g., radio frequency (RF) energy, to ablate the tissue 52 in combination with or exclusive of the ablative radiation energy 13 projected from optical fiber 60 . The energy delivered via electrodes 62 is not limited to RF energy may but also include any number of other ablative forms of energy such as cryo-ablation, microwave, ultrasonic, etc. Moreover, utilization of ablation energy in contact or in direct proximity to the tissue may provide additional ablative effects should blood obscure the radiation energy 13 . Also, these electrodes 62 may be also used independently from the laser ablation system or may be used to map electric potentials at the tissue surface.
[0026] Another variation of balloon catheter 50 is shown in the cross-sectional side view of FIG. 5 . This example illustrates a balloon catheter assembly similarly configured to the variation shown in FIG. 4 with one or more electrodes 62 for delivering ablation energy conducted via the discharged fluid 17 . In this variation, however, one or more pores 64 may be defined circumferentially about the distal end of the sheath 16 such that the introduced fluid 17 passing through conduit 20 may be diffused through the one or more pores 64 into contact against the underlying tissue. The diffusion of the fluid 17 through the pores 64 may facilitate distribution of the ablation energy over the tissue.
[0027] In yet another variation, FIG. 6 shows a cross-sectional side view of a balloon assembly having one or more ultrasound transducers 66 positioned near or at a distal end of the balloon 56 and/or sheath 16 for placement in proximity to or in contact against the tissue region of interest. The one or more ultrasound transducers 66 may be actuated to deliver ultrasonic signals into the underlying tissue to detect a thickness of the tissue, e.g., at the locations 12 at which the radiative energy 13 is to be applied. Knowledge of the thickness of the tissue to be ablated may help determine how much energy to provide or to determine, e.g., an appropriate amount of fluid flow needed to cool the tissue surface, etc., amongst other parameters. Tissue thickness detection utilizing ultrasound transducers is described in further detail in U.S. patent application Ser. No. 12/118,439 filed May 9, 2008 (U.S. Pat. Pub. 2009/0030412 A1), which is incorporated herein by reference in its entirety.
[0028] FIG. 7 shows a flowchart 70 with one example of a method for an algorithm that may be utilized, e.g., by a controller such as a microprocessor in communication with the ultrasound transducers 66 , for controlling and/or adjusting various parameters of an ablation procedure, e.g., power, laser intensity, flow rate, temperature, etc. In this example, once the target tissue region has been identified 72 for treatment, such as visually or otherwise, the targeted tissue thickness may be detected 74 , e.g., via the one or more ultrasound transducers 66 . A tissue thickness threshold, e.g., a minimum tissue thickness, may be predetermined and programmed into the device for comparison against the detected thickness 76 to ensure patient safety.
[0029] In the event that the detected thickness fails to meet the threshold level, the operator may be alerted (visual or auditory) of this anomaly 82 prompting the operator to re-measure 84 the tissue thickness. If the re-measured tissue thickness meets the threshold level, the ablation procedure may continue. Otherwise, the operator may manually determine the ablation parameters 86 , e.g., lowering power levels, etc., and begin the ablation procedure 80 . In the event that the re-measured tissue thickness meets the threshold level 76 , the controller may automatically determine the appropriate ablation parameters 78 , e.g., based upon a table of ablation parameters for a given thickness value, and the ablation procedure may begin 80 .
[0030] The applications of the disclosed invention discussed above are not limited to certain treatments or regions of the body, but may include any number of other treatments and areas of the body. Modification of the above-described methods and devices for carrying out the invention, and variations of aspects of the invention that are obvious to those of skill in the arts are intended to be within the scope of this disclosure. Moreover, various combinations of aspects between examples are also contemplated and are considered to be within the scope of this disclosure as well. | Imaging catheters having irrigation capabilities are described herein. Generally, the device may include a first inner membrane which is sealed and serves to position the device within or relative to a lumen. This balloon structure, when filled with fluid, expands and is engaged in direct contact with the tissue. A second (outer) membrane is not completely sealed and instead provides a pathway for delivery of fluid at the treatment site for effecting various treatments. Imaging systems, optionally articulatable, may be positioned within the balloon as well as electrodes positionable upon the balloon may be utilized to facilitate tissue treatments. | 0 |
The invention concerns a textile planar structure as or for paper machine cloths, transport belts, or filtering means, having at least two textile plies of which at least one textile ply is a fabric ply having first structural yarns that run in one direction and having second structural yarns that run transversely thereto, groups of respectively adjacent first structural yarns binding, as binding structural yarns, into at least two textile plies in such a way that in at least one textile ply—and preferably in all textile plies that they join—they alternate when viewed in their extension direction.
BACKGROUND
The existing art has disclosed textile planar structures that are formed from two or more textile plies, arranged one above another and constituted as fabric plies, that fundamentally represent independent woven structures. It is characteristic of these that each fabric ply has intersecting mutually interwoven structural yarns, i.e. first structural yarns, for example warp yarns, and second structural yarns transversely thereto, for example weft yarns. Fabrics of this kind are used, in particular, as forming fabric in the sheet-forming region of a papermaking machine. They are theoretically also suitable, however, for being provided in other sections of a papermaking machine if they are correspondingly adapted or additionally equipped with fiber plies, for example in order to form a fiber felt. They are also suitable, for example, as transport belts or filtering means.
Engineering fabrics made up of two or more independent fabric plies create the possibility of adapting the fabric plies to the particular requirements by selecting the nature, number, thickness, and material of the structural yarns. For example, when such fabrics are used in the papermaking machine sector it is common to manufacture the fabric ply that is intended to support the paper web from fine structural yarns having a weave pattern such that good fiber and filler retention is achieved and marking of the paper web, which is still very sensitive in this region, is prevented, but at the same time so that dewatering is also not substantially impeded. For the machine-side fabric ply it is usual to use a smaller number of structural yarns that have a larger diameter, in order to ensure good abrasion resistance and dimensional stability for the overall structure, i.e. to prevent longitudinal extensions and/or transverse shrinkage under load. Fine-yarn and coarse-yarn fabric plies of this kind can also be of multiple-ply configuration.
A problem that exists with such engineering fabrics, also called composite fabrics, is that of joining the fabric plies to one another. Two fundamentally different joining techniques have been developed in this context.
In the first joining technique, additional binding yarns that bind into two adjacent fabric plies are used. They do not belong the regular fabric weave of either the one fabric ply or the other fabric ply, i.e. do not constitute structural yarns. The binding yarns can run in either the warp or the weft direction (cf. U.S. Pat. No. 4,987,929; U.S. Pat. No. 5,518,042; U.S. Pat. No. 5,709,250; EP-B-0 579 818; U.S. Pat. No. 4,815,499; U.S. Pat. No. 4,729,412, FIG. 1 ). DE-A-42 29 828 and EP-A-0 408 849 also depict and describe binding yarns running in one direction; EP-A-0 408 849 showing a paired arrangement of two binding yarns in each case, which respectively alternate in the fabric plies that are joined by them. Casual mention is made of the possibility of providing binding yarns in both the longitudinal and the transverse direction, but such an arrangement is not explained or shown in further detail. Intersecting binding yarns of this kind are, however, explicitly evident from DE-A-34 11 119 and DE-C-33 01 810. In both cases, the binding yarns join the fabric plies not directly, but indirectly by forming an elastic intermediate layer, between the fabric plies, that is made up exclusively of the two binding yarn systems.
The joining technique described above has the disadvantage that yarns foreign to the structure are woven into the fabric as binding yarns. They engage irregularly into the binding weave and disrupt its uniformity, even if they are arranged respectively in pairs (cf. U.S. Pat. No. 4,987,929; U.S. Pat. No. 5,518,042; U.S. Pat. No. 5,709,250; EPA-0 408 849). This results in inhomogeneities in water removal and markings due to denting (dimpling effect) in the paper-side surface. In order to minimize these effects, relatively thin binding yarns are used. But because the binding yarns are subjected to large forces and moreover to abrasion due to mutual displacement of the fabric plies, a compromise must be found in this regard. This also applies to the number of binding yarns, since too large a number of such yarns would interfere with dewatering.
With the second type of joining technique, the structural yarns of at least one fabric ply are employed to join the fabric plies. These are not additional yarns, but those that are an integral component of the respective fabric ply. Examples of this may be seen in U.S. Pat. No. 4,605,585, U.S. Pat. No. 5,244,543, U.S. Pat. No. 5,564,475, EP-B-0 224 276, U.S. Pat. No. 4,501,303, U.S. Pat. No. Re.35,777, and EP-A-0 794 283. In the four first-named documents, all the structural longitudinal yarns of the paper-carrying fabric ply bind into the ply located therebelow, in some cases in such a way that each two adjacent structural yarns in the paper-carrying fabric ply alternate (cf. U.S. Pat. No. 4,605,585; EP-B-0 224 276). In the fabric according to U.S. Pat. No. Re.35,777, the binding structural yarns run in the transverse direction.
The three last-named documents above describe fabrics in which only a portion of the structural yarns running in one direction form binding structural yarns, by the fact that they bind not only into the paper-carrying fabric ply but also into the machine-side fabric ply. In this context, two binding structural yarns run next to each other in each case, i.e. form a pair of structural yarns, the manner in which they bind in being such that they alternate in the two fabric plies, i.e. when the one binding structural yarn is binding into the first fabric ply, the second binding structural yarn is binding into the other fabric ply. The two binding structural yarns thus intersect within the fabric. The binding-in within the respective fabric ply is such that the portions of the pairs of binding structural yarns and non-joining structural yarns that bind thereinto yield a desired weave pattern.
This joining technique also has disadvantages. If too many or indeed all of the-structural yarns of a fabric layer are bound in as binding structural yarns, the result is a very uneven surface, at least on the outer side of that fabric ply. If only a few structural yarns are employed as binding structural yarns, the joining of the fabric layers is not strong enough, so that relative movements occur between the fabric plies. This in turn results in internal friction, which causes premature wear with the risk of delamination. In addition, the structural binding yarns are then so highly stressed in tension that here again denting results, with the risk that marking in the paper web may occur.
SUMMARY OF THE INVENTION
It is the object of the invention to configure a textile planar structure having at least two independent plies in such a way that on the one hand permanent joining of the plies with high dimensional stability can be achieved, but on the other hand a very homogeneous surface is obtained.
This object is achieved, according to the present invention, in that groups of respectively adjacent second structural yarns bind, as binding structural yarns, into at least two textile plies in such a way that in these groups, the binding structural yarns alternate in at least one textile ply when viewed in their extension direction. A group of binding structural yarns can comprise two, but also three or even more yarns.
The present invention is directed to a textile planar structure for paper machine cloths, transport belts or filtering means that has two or more plies, and structural yarns in both the machine and cross-machine directions that bind at least two plies together, and optionally, structural yarns which do not bind the plies together, but which cooperate with the binding structural yarns to form a uniform weave pattern. At least one ply has a group of adjacent structural yarns running in the same direction that alternate in their position within the planar structure, such that when one yarn binds one ply, another yarn in the same group binds another ply, and vice versa. When a binding structural yarn from an adjacently disposed group crosses from a first ply into an inter-ply space between the plies, another yarn from the same adjacently disposed group crosses from a second ply into the inter-ply space without the binding structural yarns laying under or over each other.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plan view of a portion of the upper ply of a papermaking machine fabric for the sheet-forming region of a papermaking machine, with a smaller portion showing the lower ply;
FIG. 2 ( a ) shows a longitudinal section through the papermaking machine fabric according to FIG. 1, in plane A—A;
FIG. 2 ( b ) shows a longitudinal section through the paper machine fabric according to FIG. 1, in plane A—A, including a nonwoven ply; and
FIG. 3 shows a cross section through the paper machine fabric according to FIG. 1, in plane B—B.
DETAILED DESCRIPTION OF THE INVENTION
The basic idea of the invention is thus to provide groups of binding structural yarns in both directions. The binding-in of these binding structural yarns can, in each case, be limited to two adjacent textile plies. If more than two textile plies are present, however, the binding structural yarns can also bind more intro than two textile plies or even all the textile plies. In all cases, it thereby becomes possible to create a substantially greater number of attachment points between the textile plies, and thereby to distribute the forces on the textile plies more uniformly. This results in a more even surface, which is advantageous in particular for use in a papermaking machine because of the risk of marking that otherwise exists. The strength of the join can be selected, in accordance with the specific requirements, by way of material selection and the manner in which the binding structural yarns are bound in. In any event, relative movement between the textile plies can be greatly reduced by way of a stronger join. This in turn, because of the lower internal friction, results in a substantial lengthening of the service life. Dimensional stability is moreover good in both directions. Durability in response to cleaning with a high-pressure water stream is also improved.
It is further advantageous that because of the distribution of the attachment points in both directions, a substantially improved variability exists in terms of configuring the textile planar structure and the individual textile plies. The planar structure can be optimally adapted to the particular intended application. The requisite mechanical properties of the planar structure can be established largely irrespective of the other application-specific properties conditioned by its use, for example, as a paper machine cloth, filtering means, or the like. For example, in the case of an application as a sheet-forming wire, attention can be paid to good retention and water removal, without thereby needing to accept strength disadvantages.
In an embodiment of the invention, provision is made for the binding structural yarns to alternate in each group, viewed in their extension direction, in the textile plies that they join. All the binding structural yarns are therefore employed to join the textile plies, specifically in such a way that they alternate in all the textile plies.
In a further embodiment of the invention, provision is made for the groups of binding structural yarns extending in one direction to alternate with non-joining structural yarns extending in that direction; a corresponding provision can also be made for the groups of binding structural yarns extending in the other direction. The number of non-joining structural yarns between two groups of binding structural yarns can be adapted to the respective requirements, especially in terms of the strength with which the textile plies are joined, i.e. one or more non-joining structural yarns can be present. It also possible for several groups of binding structural yarns, extending in one direction, to run adjacent to one another. An odd number of binding structural yarns can also be present between two non-joining structural yarns, only a portion of those binding structural yarns constituting a group in the sense described above, i.e. alternating in one fabric ply.
Also belonging to the invention is an embodiment in which the fabric ply or at least one of the fabric plies has, in one direction, exclusively binding structural yarns i.e. no non-joining structural yarns are present in that direction. This allows the manufacturing outlay to be reduced.
According to a further feature of the invention, provision is made for the non-joining structural yarns not to be interwoven with one another in their fabric ply, i.e. for binding into the fabric ply to be accomplished via the binding structural yarns. If the binding structural yarns are omitted, the non-joining structural yarns are present only as a yarn layer. The same can also apply, conversely, to the binding structural yarns, i.e. notional omission of the non-joining structural yarns means that then, again, only one yarn layer remains.
In a preferred embodiment, in the or the at least one fabric ply, the portions of the binding structural yarns and of the non-joining structural yarns binding in there yield a uniform and conforming weave pattern. This is to be understood as a binding-in of the binding structural yarns (constituting a group) that corresponds in the relevant fabric ply to a continuous structural yarn that, together with the weave pattern of the non-joining structural yarns, yields a homogeneous fabric appearance. This has the advantage that the relevant surface of the fabric is of correspondingly homogeneous structure, i.e. it is difficult to detect that in a plane perpendicular to the surface, two or more binding structural yarns alternate, so that in plan view, the impression is given of a single, continuous structural yarn bound in conformingly with the weave. If as smooth as possible a surface is desired, for example on the paper-carrying side of a paper machine cloth or a filter sieve, it is understandable that this type of weave pattern should be effected as the fabric on at least one outer side.
With the textile planar structure according to the present invention, in known fashion all the textile plies can be configured as fabric plies. The possibility also exists, however, of configuring a portion of the textile plies as nonwoven yarn structures, in particular as yarn layers with intersecting structural yarns.
The basic idea of the invention is moreover not limited to specific weaves. All weaves that can be produced for engineering fabrics are possible, for example plain weave, satin weave, twill weave, etc. It is specifically an advantage of the fabric according to the present invention that because of the plurality of attachment points between the textile plies, there is inherently a great deal of freedom for configuring the individual textile plies, especially in terms of weaves.
There are also no limitations in terms of the geometry of the yarns, i.e. structural yarns with round, rectangular, oval, etc. cross sections are possible. It is also not a violation of the basic idea of the invention to use for the binding structural yarns cross-sectional geometries and cross-sectional areas different from those for the non-joining structural yarns. There is also no obstacle to providing a number of attachment points in the one direction which differs from the number in the other direction. The number of structural yarns in the one and the other direction—separately for each fabric ply—can be adapted in accordance with the particular requirements.
It is further understood that the widest variety of structural yarns can be used, for example monofilaments, multifilaments, fiber yarns, etc. They can also be combined with one another in order to bring out the respective dominant properties.
This also applies in similar fashion to the selection of the materials of the structural yarns. The materials possible in this case are all those that have been proposed for yarns in paper machine cloths, conveyor belts, or filter sieves, i.e. thermoplastic yarns in particular. Here again the basic idea of the invention allows every opportunity to discover the material suitable for the particular purpose; different materials can also be combined with one another, for example in such a way that high-strength, low-elongation material is used for the binding structural yarns because of their tensile load, while for the other structural yarns, a material adapted to their specific purpose is used.
The invention is illustrated, with reference to an exemplary embodiment, in the drawings, in which:
Papermaking machine fabric 1 depicted in Figures comprises an upper fabric ply 2 and a lower fabric ply 3 .
The portion that shows upper fabric ply 2 depicts longitudinal structural yarns 4 - 14 that extend in the machine direction (arrow C), i.e. in a direction in which papermaking machine fabric 1 circulates after installation in the papermaking machine. Transverse structural yarns 4 - 14 extend transversely to longitudinal structural yarns 15 - 22 , specifically over the entire width of papermaking machine fabric 1 , only a portion of which is depicted here. Longitudinal structural yarns 4 - 14 and transverse structural yarns 15 - 22 are bound exclusively into upper fabric ply 2 .
Extending between each two longitudinal structural yarns 4 - 14 are groups of longitudinal binding structural yarns, all designated in exemplary fashion in FIG. 1 as 23 , 24 , each group comprising a pair of two longitudinal binding structural yarns 23 , 24 . Running analogously between each two transverse structural yarns 15 - 22 are two transverse structural yarns, forming a group or pair and all designated in exemplary fashion as 25 , 26 . Longitudinal binding structural yarns 23 , 24 and transverse binding structural yarns 25 , 26 bind both into upper fabric ply 2 and into lower fabric ply 3 . The binding into upper fabric ply 2 is such that longitudinal structural yarns 4 - 14 and transverse structural yarns 15 - 22 are present only as a yarn layer if longitudinal binding structural yarns 23 , 24 and transverse binding structural yarns 25 , 26 are notionally removed. This also applies, conversely, to longitudinal binding structural yarns 23 , 24 and transverse binding structural yarns 25 , 26 , i.e. they too form only one yarn layer if longitudinal structural yarns 4 - 14 and transverse structural yarns 15 - 22 are notionally omitted.
In the portion that shows lower fabric ply 3 , upper fabric ply 2 is not drawn in so that lower fabric ply 3 is visible. Longitudinal and transverse structural yarns 23 , 24 , 25 , 26 are also omitted. Lower fabric ply 3 also comprises transverse structural yarns—labeled 27 - 30 in FIG. 1 —and longitudinal structural yarns—labeled 35 - 39 in FIG. 1 .
FIG. 2 a shows the layout of a pair of longitudinal binding structural yarns 23 , 24 in plane A—A as shown in FIG. 1 . Otherwise all that is visible of fabric plies 2 , 3 are transverse structural yarns 15 - 22 of upper ply 2 and transverse structural yarns 27 - 34 of lower fabric ply 3 , as well as the pairs of transverse binding structural yarns 25 , 26 running substantially one above another, whereas longitudinal structural yarns 4 - 14 are omitted. The front longitudinal binding structural yarn 23 (shown as a solid line) binds in respectively in upper fabric ply 2 with two transverse structural yarns 15 - 22 at the top and, in each case between two transverse structural yarns 15 - 22 , with one transverse binding structural yarn 26 at the bottom, before penetrating into the interior of the fabric and binding in with a transverse structural yarn 27 - 34 in lower fabric ply 3 . It then passes again through the interior of the fabric to upper fabric ply 2 , and there binds in again with two transverse structural yarns 15 - 22 and between them with one transverse binding structural yarn 26 . Longitudinal binding structural yarn 24 located behind it (drawn as a dashed line) binds in the same fashion as longitudinal binding structural yarn 23 , but offset in such a way that longitudinal binding structural yarn 24 binds into upper fabric ply when longitudinal binding structural yarn 23 is binding into lower fabric ply 3 . Longitudinal binding structural yarns 23 , 24 thus intersect in the interior of the fabric without being disposed parallel to each other. The portions of longitudinal binding structural yarns 23 , 24 thus alternate regularly in the respective fabric plies 2 , 3 .
A portion of the textile plies may be configured as a nonwoven yarn structure or structures, in particular as a yarn layer with intersecting structural yarns. FIG. 2 b shows that additional longitudinal yarns 47 and crosswise yarns 15 - 22 form a non-woven yarn layer of intersecting structural yarns. Manufacturing this layer is possible with usual textile measures similar to a weave.
The alternation occurs in the two fabric plies 2 , 3 in such a way that in each fabric ply 2 , 3 , the respective portions of longitudinal binding structural yarns 23 , 24 that are bound in there complement one another, specifically so that no overlaps of the portions and also no gaps between the portions occur. The juxtaposed layout of the portions corresponds to the layout of the adjacent longitudinal structural yarns 13 , 14 , but offset in the longitudinal direction in the manner of a plain weave. The portions of longitudinal binding structural yarns 23 , 24 thus conform to the weave, as shown in FIG. 1 . The fact that the portions are constituted by not one but two longitudinal binding structural yarns 23 , 24 is evident in the plan view of FIG. 1 only from the slight transverse offsets of the portions, and is illustrated using different crosshatchings.
In accordance with the plain-weave structure, the profile of transverse binding structural yarns 25 , 26 does not differ from that of longitudinal binding structural yarns 23 , 24 , as is evident from FIG. 3 . Here again, transverse binding structural yarn 25 located at the front alternates, between the two fabric plies 2 , 3 , with transverse binding structural yarn 26 located at the back, i.e. transverse binding structural yarns 25 , 26 , forming a pair, are located substantially one above another and intersect in the interior of the fabric. Each transverse binding structural yarn 25 , 26 binds in with a longitudinal structural yarn 35 - 45 in lower fabric ply 3 , and then passes through the interior of the fabric to upper fabric ply 2 where it binds in with two longitudinal structural yarns 4 - 14 and, between them, with one longitudinal binding structural yarn 23 , 24 . As in the case of longitudinal binding structural yarns 23 , 24 , the portions of transverse binding structural yarns 25 , 26 complement one another in upper fabric ply 2 in such a way that the juxtaposed portions bind in with transverse structural yarns 15 - 22 in a manner that conforms to the weave, i.e. what results, in the plan view according to FIG. 1, is a fabric appearance like that of a plain weave. The fact that the portions are formed from two transverse binding structural yarns 25 , 26 is apparent from the slight longitudinal offsets of the portions, illustrated by different crosshatchings. | A textile planar structure for paper machine cloths, transport belts or filtering means has two or more plies, each of which has structural yarns in both the machine and cross-machine directions that bind at least two plies together, and optionally, structural yarns which do not bind the plies together, but which cooperate with the binding structural yarns to form a uniform weave pattern. At least one ply has a group of adjacent structural yarns running in the same direction that alternate in their position within the planar structure, such that when one yarn binds one ply, another yarn in the same group binds another ply, and vice versa. When a binding structural yarn from an adjacently disposed group crosses from a first ply into an inter-ply space between the plies, another yarn from the same adjacently disposed group crosses from a second ply into the inter-ply space without the binding structural yarns laying under or over each other. | 3 |
FIELD OF THE INVENTION
This invention relates to a wheel construction and, more particularly, relates to a wheel construction wherein the axis of the preassembled bearing housing is located concentric with the outside diameter of the wheel and a moldable, synthetic resin material fills a spacing between the outer periphery of the bearing housing and the inner diameter of a hole through the center of the wheel to effect a securement of the bearing housing to the wheel. This invention also relates to a wheel construction wherein the synthetic resin material is an elastomeric material having a resilient characteristic so that the wheel is movable against the resilient urging of the elastomeric material relative to the bearing housing when shock loads and the like are applied to the support structure for the wheel construction.
BACKGROUND OF THE INVENTION
The life expectancy of wheel constructions, particularly the type adapted for use with a yoke assembly, is continuously being subjected to review. Generally, it can be stated that the failure of such a wheel construction is primarily due to a failure in the ball-bearing assembly. My U.S. Pat. No. 3 807 817 represents a unique bearing assembly which has substantially prolonged the life of wheel constructions. In addition, such bearing assembly has reduced the cost of the total wheel construction.
The bearing assembly illustrated in my aforementioned U.S. Pat. No. 3 807 817 is a type wherein the axle and the sleeve having the bearings located therebetween are preassembled. However, a problem has existed in assembling the preassembled bearing construction into a wheel and having the axis of the bearing construction end up concentric with the outer diameter of the wheel. In addition, a problem continues to exist in protecting the bearing assembly from shock loads which are, from time to time, applied to the support construction, particularly the yoke. It is well known that the life of a bearing, hence of the wheel upon which it is mounted, is materially affected by the amount of looseness or play in the bearing parts thereof. Thus, where bearing parts are assembled with an excess amount of initial play, the useful life of the bearing is shortened in a corresponding manner. That is, unnecessary runout, radial play or axial play in the bearing parts relative to each other, or in the bearing parts relative to the wheel which they support, will tend to induce or accelerate wear which merely increases the play. In a sense, this results from the fact that the loose parts have an opportunity to hammer each other during normal use of the wheel or other structure in which the loose bearing is used. This acceleration in deterioration of loose bearing assemblies is especially noticeable in situations of severe usage, such as in the wheels of castors.
Furthermore, it has been largely taken for granted that looseness or excess play had to be tolerated in return for low cost bearing constructions. Accordingly, it is not uncommon for certain users, such as owners of supermarket shopping carts, to accept bearing failures in a relatively short period of time due to severe shock loading that can occur during normal use thereof. It is a desire, therefore, of this invention to provide a wheel construction utilizing a bearing assembly which has successfully overcome the problem of developing looseness during use thereof in a wheel and assuring that the outer diameter of the wheel is concentric with the axis of the bearing assembly. In addition, it is desirable to provide a wheel construction wherein the shock loads applied to the wheel construction are isolated from the bearing assembly.
Accordingly, it is an object of this invention to provide a wheel construction wherein the axis of the bearing assembly is assured of being concentric with the outer diameter of the wheel.
A further object of the invention is to provide a wheel construction, as aforesaid, which is particularly adaptable for use in the wheels of a castor or the like where the treatment received by the bearing assembly, even under normal conditions of use, is severe by any reasonable standard.
A further object of this invention is to provide a wheel construction, as aforesaid, having a sufficient structural simplicity that it can be assembled rapidly, accurately and inexpensively.
A further object of the invention is to provide a wheel construction, as aforesaid, comprised of a minimum number of parts, each part being of such structural configuration that it is capable of being assembled so that the strength of the assembly is increased during the assembly.
A further object of the invention is to provide a wheel construction, as aforesaid, in which the bearing assembly can be constructed in a variety of sizes and for a variety of specific uses with a minimum of modifications and structural limitations.
A further object of the invention is to provide a wheel construction, as aforesaid, wherein the full effect of shock loads or the like applied to the wheel construction are isolated from the bearing construction.
SUMMARY OF THE INVENTION
In general, the objects and purposes of the invention are met by providing a wheel construction having wheel means with an axially extending hole therethrough, which hole has a first diameter. Bearing housing means having a second diameter less that the first diameter are located inside the hole with the center of the bearing housing means being concentric with the outside diameter of the wheel means. The difference between the first and second diameters defining a spacing therebetween. A moldable synthetic resin material is utilized to fill the spacing to effect a securement of the bearing housing means to the wheel means.
Other objects and purposes of the invention will be apparent to persons acquainted with wheel constructions of this general type upon reading the following specification and inspecting the accompanying drawing, in which:
FIG. 1 is a side elevational view of a complete castor embodying the invention; and
FIG. 2 is a sectional view taken along the line II--II in FIG. 1.
The words "in" and "out", used herein for convenience in reference, will refer to directions toward and away from, respectively, the geometric center of the device and designated parts thereof. Such terminology will include the words above specifically mentioned, derivatives thereof and words of similar import.
DETAILED DESCRIPTION
FIG. 1 illustrates a swivel castor 10, which includes an inverted, U-shaped frame 11 having a pair of parallel legs 12 and 13 (FIG. 2) straddling a wheel 14 and a bearing assembly 17 mounted in the central opening 16 of the wheel. An axle 20 extends through the bearing assembly 17 and has an opening 24 therethrough aligned with a pair of axially aligned openings 18 and 19 in the legs 12 and 13, respectively, of the frame 11.
The bearing assembly 17 is identical to the bearing assembly described and illustrated in my U.S. Pat. No. 3 807 817. The bearing assembly 17 includes a hollow, thermoplastic sleeve 21 which is mounted in the central opening 16 of the wheel 14. Bearings 22 and 23 are positioned, as described in my aforementioned patent, between the axle 20 and the sleeve 21.
The bearing assembly 17, which includes the axle 20, the sleeve 21 and the bearings 22 and 23, is positioned along with the shields 26 and 27, between the legs 12 and 13 of the frame 11 so that the opening 24 through the axle 20 is axially aligned with the openings 18 and 19 in the legs 12 and 13, respectively, of the frame 11. A shaft 29 is inserted through the aligned openings 18, 19 and 24 whereby the wheel 14 and bearing assembly 17 are mounted upon the legs 12 and 13 of the frame 11. The opposite ends 31 and 32 of the shaft 29 are staked, or otherwise enlarged, in order to prevent removal of the shaft 29 from the frame 11.
Referring now to the specific construction of the wheel 14 illustrated in FIG. 2, the central opening 16 has a central rib extending radially inwardly thereof. The surface portions 34 and 36 on opposite axial sides of the radial rib 33 are inclined to the horizontal. In this particular embodiment, the inner surface portion 34 extends radially outwardly from the rib 33 as does the inner surface portion 36.
The outer periphery of the sleeve 21 has a radially outwardly extending central rib 37 thereon. The rib 37 is, in this particular embodiment, radially aligned with the rib 33 in the central opening 16 in the wheel 14.
The outer periphery of the sleeve 21 is less in diameter than the diameter of the central opening 16 in the wheel 14 to define a spacing 38 therebetween. Synthetic resin material 39 is injection molded into the spacing 38 and forms one continuous piece of material from one axial side of the wheel construction to the other. The radially aligned ribs 33 and 37 serve to define a narrow gap 41 therebetween and through which the synthetic resin material 39 extends. The portion of the spacing 38 on opposite axial sides of the radially aligned ribs 33 and 37 have a larger radial dimension than the gap 41. As a result, the synthetic resin material 39 serves to secure the bearing assembly 17 in the central opening 16 of the wheel 14.
In one preferred embodiment, the synthetic resin material 39 is ABS (acrylonitrile-butadiene-styrene). This material is well known as a sturdy and very hard composition. Prior to insertion of the ABS material into the spacing 38, the axis 42 is located so as to be concentric with the outer diameter of the wheel 14. Thus, the insertion of the ABS material in the spacing 38 effects a rigid securement of the wheel 14 to the bearing assembly 17.
In another embodiment of the invention, it is proposed to use an elastomeric material as the synthetic resin material 39 having a resilient characteristic, particularly a material that has a memory and returns to the original condition illustrated in FIG. 2 after an abnormal load has been applied thereto to flex the wheel so that the central plane 43 of the wheel 14 is flexed to a position inclined to the axis 42 of the bearing assembly 17, such as schematically represented by the line 43A. In addition, movements of the wheel 14 are also possible in a direction wherein the central plane 43 remains perpendicular to the axis 42 but is simply shifted axially as schematically represented by the line 43B. In the instance where the wheel 14 is moved to a position wherein the central plane 43 is inclined along the line 43A, the wheel 14, in most instances, will strike at least one of the legs 12 or 13 of the frame 11. This load will occur when, and assuming that the wheel has been installed on a shopping cart, the shopping cart has been shifted sidewardly so that the force applied to the wheel 14 adjacent the outer diameter thereof is perpendicular to the tangent at the outer periphery of the wheel 14, such as is illustrated by the vector F in FIG. 2. In this particular embodiment, the elastomeric material 39 is made of a polyurethane, having a hardness of 80 Shore A Durometer. The effective range of hardnesses for the elastomeric material is in the range of 75 Shore A to 55 Shore D Durometer.
Still another embodiment of the invention incorporates the utilization of the polyurethane material described above for the material of the sleeve 21 in the bearing assembly 17. The resilient characteristics of the sleeve 21 will have the same range of hardness as described above for the elastomeric material, namely 75 Shore A to 55 Shore D Durometer. It is also contemplated to utilze the same elastomeric material for both the sleeve 21 and the material 39 injection molded into the spacing 38. The degree of resilientness of the material of the sleeve and the material in the spacing 38 can be selected to provide the desired amount of flexing of the wheel relative to the bearing assembly 17 to achieve the desired isolation of shock loads applied to the wheel 14 from the bearing assembly 17.
In the embodiment wherein the sleeve 21 is made of a resilient elastomeric material, the material will be adapted to flex radially outwardly to accommodate an encirclement of different combinations of different diameter axle and bearing combinations to thereby result in a variable outside diameter for the sleeve 21 with each different combination. In some instances, the shaft 29 is made of a larger diameter for use in heavy-duty environments. In instances where the shaft 29 is increased in size from 5/16 inch to 3/8 inch, for example, the same sleeve 21 can be utilized for both combinations of shafts. The axle 20 will have a larger diameter to accommodate the increased diameter in the shaft 29 and, as a result, the bearings 22 and 23 will also be increased in size. It has been discovered that the resilient characteristic of the sleeve 21 is sufficient to expand in diameter so that the same sleeve 21 can be utilized for several different size shafts 29 and bearing assemblies 17. Since the outer diameter of the sleeve 21 is altered, the only difference that occurs in the wheel construction is the radial dimension of the spacing 38. Since the synthetic resin material 39 is injection molded into the spacing 38, the only thing that needs to be controlled is the size of the shot of elastomeric material 39 into the gap 38. This simple adjustment permits a simple change in the wheel construction without materially altering the construction of the wheel.
Although particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | A wheel construction having a wheel with an axially extending hold therethrough and having a first diameter. A preassembled bearing housing having a second diameter less than the first diameter is located inside the hole of the wheel. The axis of the bearing housing is concentric with the outside diameter of the wheel. The difference between the first and second diameters defines a spacing therebetween. A moldable synthetic resin material fills the aforesaid spacing and effects a securement of the bearing housing to the wheel. | 5 |
FIELD OF THE INVENTION
The present invention relates to printing inks for the intaglio printing process, also referred to as engraved steel die printing process. In particular, oxidatively curing inks comprising a combination of fusible wax and a UV curing binder component are disclosed. These inks can be printed on a standard printing press and allow to significantly reduce or eliminate the undesired set-off which can occur after printing and stacking the printed sheets. Using the inks of the present invention results in less set-off contaminated printed sheets, allowing for a higher pile-stacking of the printed good, for the use of increased engraving depths, of a more challenging intaglio design, and for the printing on less porous substrates, while enabling the printing on a standard printing press, and offering the possibility of using a lower printing plate temperature.
BACKGROUND OF THE INVENTION
In the engraved steel die printing process, hereafter called intaglio printing process, a rotating engraved steel cylinder, carrying a pattern or image to be printed, and heated to a temperature of the order of 80° C., is supplied with ink by one or more template inking cylinders. Subsequent to the inking, any excess of ink on the plain surface of the printing cylinder is wiped off by a rotating wiping cylinder. The remaining ink in the engraving of the printing cylinder is transferred under pressure onto the substrate to be printed, which may be a paper or plastic material in sheet form, while the wiping cylinder is cleaned by a wiping solution. Other wiping techniques can also be used, such as paper wiping or tissue wiping (“calico”).
One of the distinguishing features of the intaglio printing process is that the film thickness of the ink transferred to the substrate can be varied from a few micrometers to several tens of micrometers by a correspondingly shaped printing plate. This ability to vary the film thickness is a most desirable feature of the intaglio printing process and can be used to produce embossing effects, i.e. to confer tactility to the printed document, as well as to produce shade variations using one and the same ink.
The pronounced relief of the intaglio printing accentuates the problem of “set-off”, which is the transfer of ink from one printed sheet to the back side of the next following printed sheet in a stack, or to the back of the endless sheet in a web. The factors influencing the “set-off” are determined by the printing ink formulation, the engraving depth and evenness, the printing conditions, the printing substrate, the number of stacked sheets per pile, the time between printing and handling of the piles and the way how the printed piles of paper are handled after printing.
The “set-off” caused by the residual tackiness of the printed ink, which adheres to the substrate surface of the back of the next sheet, is aggravated when pressure is applied to a pile of stacked printed sheets. Depending on its extent, “set-off” can irreversibly spoil the printed product affected by it. A classical method to avoid losses of printed good due to “set-off” is to interleave separation sheets between all printed sheets; this leads however to a slowing down of the printing process and also to a more expensive printing.
The problem of reducing set-off in oxidatively curing inks has been addressed in the art in several ways:
by using high molecular weight oxidatively curable binders,
by solvents with relatively low boiling point which would partially evaporate on the printing plate,
by waxes, forming a protective layer on the ink film,
by a high filler to binder ratio which would reduce the residual tackiness of the ink, and
by efficient metal catalysts which ensure the rapid through-curing of the printed ink film.
WO 03/066759 (and the related JP 2002-38065 and JP 01-289876) disclose a dual-curing ink matrix, comprising a UV curable material as the principal component (around 40 wt-%), together with an oxidatively curing alkyd resin as a secondary component (around 5 wt-%), a photoinitiator, and an oxidative polymerization catalyst. The disclosed ink composition does not comprise fusible wax.
This ink is subjected to UV curing immediately following the printing operation, whereupon it instantly dries, at least at the surface, with the consequence that set-off cannot occur. A slower, in-depth post-curing takes place during the following hours and days according to an oxypolymerization mechanism, allowing for a good adhesion of the ink to the substrate even in the presence of UV-opaque pigments or fillers.
The ink according to WO 03/066759 requires particular, e.g. EPDM rubber equipped, printing presses, designed for the printing of UV curing inks; the ink cannot be printed on an Intaglio printing press equipped for printing standard oxypolymerization curing, greasy inks.
WO 01/38445 A1 addressed the “set-off” of intaglio printing inks on polymer substrates. The binder of the therein disclosed intaglio printing ink includes an auto-oxidizable polyester resin having fatty acid residues, and a wax dispersion having a glass transition temperature below the maximum temperature achieved during the printing process. The disclosed printing ink further includes solvents and pigments and can be cured under UV radiation. This printing ink contains no acrylates at all.
The majority of intaglio printing inks used today are still alkyd based, greasy inks, which cure according to a purely oxidative drying mechanism. They traditionally contain hydrocarbon solvents. In consequence, the printing machines in the majority of printing works are equipped with inking systems, printing blankets and wiping cylinders which are specifically designed to resist to the alkyd- and hydrocarbon solvent-based chemistry of these traditional intaglio printing inks, but which, in turn, do not resist to the more polar UV-ink chemistry.
Oxidatively drying alkyds, as compared to UV-curing inks have, however the shortcomings of an inherently slow drying, which results in a lower production rate, of the need to use environment-unfriendly organic solvents (VOC=volatile organic compounds), and of the intrinsic proneness of these inks to produce “set-off” as a consequence of their slow drying. Their main advantage, in turn, is a good in-depth curing provided by the oxidative drying mechanism, resulting in good physical and chemical resistances of the printed and dried product. The printing equipment adapted to print them is furthermore already in place at every printing work.
UV-curing intaglio printing inks, on the other hand, have the advantage of a fast or almost immediate surface drying, eliminating waiting times and allowing for a high production rate. The presence, in the ink formulation, of volatile organic compounds can be avoided, and set-off does not occur due to the instant-drying.
The shortcomings of UV-inks, in turn, are that in-depth curing remains a challenge, in particular in case of a high pigment loading in the ink and/or the presence of pigments which are opaque or which have a high absorbance in the UV spectrum. UV-curable intaglio printing inks are furthermore significantly more expensive than traditional alkyd based inks, and, even more important, the printing equipment needs a major change of all components which come into contact with the UV-curable printing ink, in particular the rollers made of rubber or other polymer materials, which must be redesigned to resist the different chemistry of the UV-inks.
The chemical composition of UV-curing intaglio printing inks is noteworthy entirely different from that of alkyd-/hydrocarbon solvent based intaglio printing inks. When UV-curable intaglio printing inks come in contact with the alkyd-/hydrocarbon solvent-specific rubber components of the inking system, the printing blankets and the wiping cylinders of the printing machine, they can cause a swelling or shrinking of the rubber, which in turn alters the geometry of the rollers and blankets. This results in a low printing quality, as well as in a reduced roller lifetime, altogether increasing the printing and maintenance cost.
In practice, to allow for the printing of UV-curing intaglio inks, the rollers of the printing machine must be made of a special material or protected by a highly resistant compound such as non-polar EPDM rubber (ethylene propylene diene monomer rubber). Thus an additional cost arises for the printer if he changes from traditional alkyd-based intaglio inks to energy-curable intaglio inks, which is caused on the one hand by the more expensive energy-curable (UV-curable) intaglio printing ink itself, and on the other hand by the expensive upgrade of the printing equipment to become UV-ink compliant. A further disadvantage results for the printer who needs to print in both technologies, because each time he changes the type of printing ink (UV-curable or oxidatively curable, respectively), all corresponding parts of the printing machine must be changed accordingly in a time-consuming operation.
It would thus be highly desirable to have available an ink which combines the favorable set-off properties of the UV intaglio inks with the good in-depth curing of the alkyd intaglio inks, which results in high physical and chemical resistances of the printed ink on the document, and which is compatible with (i.e. printable without change on) the existing intaglio printing equipment in place at the printers' premises.
It is the object of the present invention to provide an intaglio printing ink which has very good set-off resistance and in-depth curing values, and which can be printed on the conventional intaglio printing equipment designed for oxidatively curing inks.
SUMMARY OF THE INVENTION
The present invention is related to an intaglio printing ink composition comprising as a principal component an oxidatively curable material, such as an alkyd resin or a modified alkyd resin, and, as an auxiliary component, a combination of a UV curable material and of a fusible wax, characterized in that said composition, after a thermal cycling from 25° C. to 80° C., to 25° C., and after irradiation with a curing dose of UV light, shows an increase in its complex dynamic modulus of at least 50%, preferably at least 100%.
The thermal cycling used in the present invention corresponds to the ink's typical variation of temperature during the conventional intaglio printing process. The temperature of the intaglio plate during the printing operation is traditionally chosen to be around 80° C., and the inks are formulated in consequence as to the melting temperature range of their fusible wax components. The inks of the present invention, having a particular mechanism to increase viscosity after printing, allow for more freedom in choosing the printing plate temperature. In particular, inks containing temperature-sensitive components can be formulated so as to be printable at a lower temperature, such as 60° C. or even 50° C., whilst still obtaining a good set-off resistance of the freshly printed sheets.
According to the present invention, a curing dose of UV light means a dose which would dry-cure a corresponding UV-ink.
Said increase in complex dynamic modulus means that the printed ink is gelling following the UV-irradiation, and in consequence loses much of its initial tackiness. The dynamic modulus is a measure for the ink's rheologic behavior; an increase of this modulus by 50% is highly significant with respect to set-off resistance.
In particular, the ink according to the present invention has, as a principal component, an oxidative curing material in an amount between 20 and 50 wt-% of the total printing ink, which provides it with good in-depth drying properties, and, as an auxiliary component, a combination of fusible wax in amounts up to 10 wt.-%, preferably between 2 and 5 wt-%, and a UV curing material in amounts between 2 and 15 wt-%.
It was found that the said combination of fusible wax and the UV curing component allowed the printed ink to be surface-stabilized through a short UV irradiation following the printing operation, so as to avoid set-off, while still being printable on standard printing equipment at full printing speed, but allowing for a higher stacking of the printed goods. The good in-depth curing and the physical and chemical resistances of traditional oxidatively curing intaglio inks are maintained.
The ink of the invention has chemical properties which are close to the ones of traditional intaglio inks, and it can, for this reason, be printed on a conventional intaglio printing press, without the need for changing the rubber parts on the printing machine which come into contact with the printing ink. The only requirement for the printer is the additional presence of a UV irradiating unit on an otherwise standard intaglio printing press.
The intaglio printing ink of the present invention is principally an oxidatively curing intaglio ink, which in addition to wax, comprises a UV-curable component, preferably in an amount of 2 to 15 wt-%, more preferably of 4 to 8% by weight of the total printing ink composition. Through a UV exposure immediately after the printing operation, the printed ink surface is stabilized, so as to allow a stockpiling (stacking) of the printed sheets, without producing “set-off” even under particularly unfavorable conditions. Significantly higher stacks of printed goods can therefore be envisaged.
The ink of the present invention is, however, not dry after the short UV irradiation following the printing operation. This is evidenced by the fact that, under strong pressure, the printed and UV-irradiated ink of the present invention nevertheless transfers to a second sheet of substrate, whereas a printed and UV-irradiated UV-curing ink does not. The surface and in-depth curing of the ink of the present invention takes place during the hours or days which follow the printing operation, through an oxypolymerization process under the influence of air oxygen, as known for traditional intaglio inks.
The formulation of oxidatively curing inks is known to the skilled person. Such inks comprise an oxidatively curable material and an oxypolymerization catalyst (drier). Oxidatively curable materials, useful as the oxidatively curable component, can be of natural or synthetic origin. Typical oxidatively curing materials of natural origin are oligomers or polymers based on vegetable oils, such as linseed oil, tung oil, tall oil, as well as other drying oils known to skilled person. Typical oxidatively curing materials of synthetic origin are alkyd resins, such as can be obtained, as known to the skilled in the art, for example by the joint condensation (esterification) at 180° C. to 240° C. of
one or more polycarboxylic acids, such as ortho-, iso-, or ter-phthalic acids, ortho-tetrahydrophthalic acid, fumaric acid, maleic acid, or a corresponding anhydride thereof;
one or more polyhydric alcohols, such as glycol, trimethylolethane, pentaerythritol, sorbitol, etc.; and
one or more unsaturated fatty acids, such as linseed oil, tung oil or tall oil fatty acids.
Such oxidatively curable components are present in the ink according to the invention preferably in amounts of 20 to 50% by weight, most preferably of 30 to 45% by weight, of the total printing ink.
The UV-curable material, useful as the UV-curable component, can be selected from the group of acrylate monomers, oligomers or polymers, such as amino acrylates, epoxy acrylates, polyester acrylates, urethane acrylates, self-photoinitiating oligomer acrylates, dendritic acrylates, as well as mixtures thereof. Preferred UV-curable components are acrylate oligomers and polymers.
The intaglio printing ink of the present invention further comprises at least one siccativating agent, i.e. an oxypolymerization catalyst, which may be the salt of a long-chain fatty acid with a polyvalent metal cation, such as cobalt(2+), vanadyl(2+), manganese(2+), or cerium(3+). Salts of the said type are oil soluble and thus compatible with fatty alkyd based inks. The ink may further comprise soaps of calcium and/or zirconium and/or cerium as a co-siccativating agent to further improve the in-depth curing. The siccativating agent is usually present in amounts of up to 5% by weight, preferably of 1 to 3% by weight, of the total printing ink composition.
The intaglio printing ink of the present invention further comprises at least one photoinitiator for initiating the polymerization reaction of the UV-curable components. The photoinitiator is usually present in amounts of up to 5% by weight, preferably of 1 to 3% by weight, of the total printing ink composition. Suitable photoinitiators are known to the skilled person and are e.g. of the acetophenone type, the benzophenone type, the α-aminoketone type, or, preferably, the phosphine oxide type. One suitable photoinitiator is Irgacure 819 from Ciba.
The intaglio printing ink composition may further comprise photoinitiator stabilizers (UV stabilizer) in an amount of up to 3%, preferably of 0.5 to 3%, more preferably of 1.5% by weight of the total printing ink.
The inventors further found out that the simultaneous presence of, on the one hand, fusible wax, which is known to reduce the “set-off” in traditional intaglio printing inks, and, on the other hand, UV-curable acrylates, resulted in a synergistic effect in preventing the “set-off” of the printed intaglio inks of the present invention to a dramatic and unexpected degree, if the inks are subjected to UV irradiation immediately after the printing operation.
The intaglio printing ink of the present invention thus further comprises at least one fusible wax, such as a Montan wax based material, e.g. refined Monatan wax, Montanic-acid, -amides, or -esters; modified or saponified Montan wax, or Carnauba wax, or other similar synthetic long chain ester wax or mixtures thereof. The fusible wax or waxes are comprised in the intaglio printing ink of the present invention in amounts of up to 10% by weight, preferably between 1 to 10%, more preferably between 1 to 5%, and even more preferably between 2 to 5% by weight of the total printing ink.
Within the context of the present invention, fusible wax refers to a wax or a wax mixture having a melting point or a melting interval of the neat product in the range of between 50-120° C., preferably of between 55-100° C., more preferably of between 60-85° C. In the printing ink composition, the corresponding melting points or melting intervals of the wax are lowered due to the presence of other compounds.
The intaglio printing ink composition may further comprise other components such as pigments for providing the color of the ink, fillers, emulsifiers, solvents, e.g. for the viscosity adjustment, as well as special additives and/or markers for security or forensic purposes.
DETAILED DESCRIPTION OF THE INVENTION
The intaglio printing ink composition of the present invention comprises at least one oxidatively curable principal component, preferably in amounts between 20 and 50 wt-% of the total ink composition, at least one UV-curable component, preferably in amounts between 2 and 15 wt-% of the total ink composition, at least one oxypolymerization drier, at least one photoinitiator, and at least one fusible wax, preferably in amounts between 1 to 10 wt-%, of the total ink composition. Optionally, pigments, fillers, additives and solvents, as well as a stabilizing agent for the UV-curing part, may be present.
The oxidatively curable component can be selected from the group consisting of the alkyd resins and the modified alkyd resins of synthetic or natural origin, in particular phenol-, epoxy-, urethane-, silicone-, acryl- and vinyl-modified alkyd resins, neutralized acid alkyds, and siccativating vegetable oils. Typical oxidatively curing materials of synthetic origin are the alkyd resins obtained by esterification of a mixture of one or more polyhydric carboxylic acids or acid derivatives, such as anhydrides and/or their hydrogenated equivalents, and one or more unsaturated fatty acids of natural origin, with one or more polyols, such as ethylene glycol, glycerol, pentaerythritol etc. Examples for such alkyd resins are disclosed in EP 0 340 163 B1, the respective content thereof being incorporated herein by reference, in particular the examples II and III.
The oxidatively curable component is present in amounts of 20 to 50% by weight, preferably of 25 to 40% by weight, and most preferably in an amount of 30 to 35% by weight of the total printing ink.
The siccativating agent (drier), i.e. the oxypolymerization catalyst, is added to promote the in-depth curing of the alkyd under the influence of air oxygen. Said drier is typically based on transition metal salts which are soluble in the oil based printing ink medium. The ions of the chemical elements with numbers 23 to 29, as well as those of certain other chemical elements, are potentially useful in driers. Particularly preferred is a combination of cobalt and manganese carboxylates, or of cobalt, manganese and zirconium carboxylates, wherein the carboxylate is a long-chain carboxylic acid anion. A particularly preferred drier comprises cobalt(II) octoate, manganese(II) octoate, and zircon(IV) octoate in a hydrocarbon solvent. Other suitable driers have been disclosed in co-pending patent application EP07112020.8 of the same applicant. The drier is present in amounts of up to 5%, preferably 0.5 to 5 wt-%, and more preferably of 1 to 3 wt-% of the total printing ink.
The UV-curable component is preferably an acrylate, a monomer or preferably an oligomer or polymer. Said acrylate may be selected from the group consisting of the amino acrylates, the epoxy acrylates, the polyester acrylates, the urethane acrylates, the self-photoinitiating oligomeric acrylates, the dendrimeric acrylates, and mixtures thereof. Examples of suitable UV-components are given in Table 1.
TABLE 1
Resin Type
Trade Name
Supplier
acrylate monomers
TMPTA, HDDA, NPGDA, PETA,
Cytec
and many other products
and many other
from different suppliers
suppliers
amino acrylates
Genomer 5275
Rahn
Uvecryl P115
UCB
epoxy acrylates
Craynor 132
Sartomer
Laromer LR 8765
BASF
polyesters acrylates
Ebecryl 450
Cytec
urethanes acrylates
Photomer 6618
Cognis
Actilane 245
Akzo
Ebecryl 2003
Cytec
Ebecryl 220
Cytec
dendritic acrylates
BDE-1029
IGM Resins
BDE 1025
IGM Resins
Self-photoinitiating
Drewrad 1122
Ashland
oligomer acrylate
Acrylate oligomer
Ebecryl 600
Cytec
The UV-curable component is preferably present in an amount of 2 to 15% by weight, more preferably of 4 to 8% by weight, most preferably of 5 to 7% by weight, of the total printing ink.
The intaglio printing ink of the present invention further comprises at least one photoinitiator. Said photoinitiator is typically present in amounts of up to 5% by weight, preferably of 0.5 to 5% by weight, more preferably in amounts of 1 to 3% by weight, and most preferably of 1 to 2% by weight of the total printing ink.
Suitable photoinitiators can be chosen from the group consisting of the α-aminoketones (e.g. Irgacure 369, Irgacure 907), the α-hydroxyketones (e.g. Irgacure 2959), the phosphine oxides (e.g. Irgacure 819), the thioxanthones (e.g. ITX), the oligomeric thioxanthones (e.g. Genopol TX-1), the oligomeric amino benzoates (Genopol AB-1), the oligomeric benzophenones (e.g. Genopol BP-1). These types of photoinitiators are known to the skilled person; they generate free radicals upon UV irradiation, initiating a radical polymerization reaction of the UV curable component, such as the acrylate.
Fusible waxes suitable to carry out the present invention may be chosen from the group of refined Montan wax, Montanic-acid, -amide, -ester; modified or saponified Montan wax, Carnauba wax, long chain ester wax, and mixtures of these. Examples of suitable waxes are given in Table 2. The melting point or melting range of the fusible wax suitable to carry out the invention is between 50 to 120° C., preferably between 55 to 100° C., more preferably between 60 to 85° C.
TABLE 2 Type of Wax Trade Name Melting Point* Refined Montan wax Licowax U ~86° C. Montanic acids Licowax S ~82° C. Licowax SW ~83° C. Licowax LP ~83° C. Licowax UL ~83° C. Licowax NC ~84° C. Esterified Montanic Licowax E ~82° C. acids Licowax F ~79° C. Licowax KP ~87° C. Licowax KPS ~82° C. Esterified, partly Licowax O ~100° C. saponified Montanic Licowax OP ~100° C. acids Licowax OM ~89° C. Montan based Printwax MM8015 ~95° C. Montan/Carnauba Printwax MX6815 ~90° C.
The indicated melting points are those given by the suppliers for the neat wax.
Licowax is supplied by CLARIANT
Printwax is supplied by DEUREX GmbH, Toglitz
Other type of waxes, such as paraffin, polypropylene, polyethylene amide or PFT waxes and the like, can be further comprised in the printing ink composition of the present invention without disturbing the synergistic effect on the set-off displayed by the simultaneous presence of fusible wax and acrylate under UV irradiation immediately after printing. They may be used for adjusting other properties of the intaglio printing ink, such as rub resistance or rheological behavior, as known to the skilled person.
According to a further aspect of the invention, a photoinitiator-stabilizer (UV-stabilizer) may also be comprised in the ink. Such photoinitiator-stabilizers are known to the skilled person. Useful stabilizers are e.g. Florstab UV-1, supplied by Kromachem, and Genorad 16, supplied by Rahn.
Said photoinitiator-stabilizer is comprised in the ink in an amount of up to 3%, preferably of 0.5 to 3%, more preferably in an amount of 1 to 2%, most preferably in an amount of 1.5% by weight of the total printing ink.
The presence of the UV-stabilizer serves to avoid a premature polymerization during the preparation or during the handling of the ink prior to use on the printing press as well as prior to the radiation-curing step. Furthermore, the UV-stabilizer provides a longer shelf live to the printing ink.
The intaglio ink of the present invention further may comprise pigments and fillers, as well as mineral solvents. The pigment content of intaglio printing ink composition is generally in the range of 3 to 30%, more usually in the range of 5 to 15%, by weight of the total printing ink. Suitable pigments for use in intaglio inks are known to the skilled person.
According to a further aspect of the invention, the filler content of the printing ink composition may be in the range of 5 to 50%, by weight of the total printing ink. The filler can be e.g. of natural origin, such as chalk, china clay, exfoliated mica, or talcum, or synthetically prepared, such as precipitated calcium carbonates, barium sulfate, bentonite, aerosil, titanium dioxide, or also mixtures of some of these.
Suitable mineral solvents for embodying the present inventions are linear or branched organic hydrocarbon solvents with chain lengths of C 10 to C 15 and having a boiling point between 180 and 290° C., such as PKW 1/3, PKW 4/7 AF, PKWF 6/9 neu or PKW 6/9 AF (e.g. from Halternan), as well as fatty acid esters. Oxygenated or polar solvents, such as glycol ethers, may be added as co-solvents.
The viscosity of the ink is adjusted with mineral solvent and additives, e.g. Aerosil, to about 1 to 40 Pa·s, preferably about 3 to 25 Pa·s, more preferably to about 6 to 15 Pa·s, measured on a cone-plate geometry at 1000 s −1 and 40° C.
The intaglio printing ink of the present invention is preferably prepared according to the following process, comprising the steps of:
a) grinding together, preferably on a three-roll mill, at least one oxypolymerization-curable component, such as an alkyd resin, at least one UV-curable component, such as an acrylate, at least one fusible wax, and optional fillers and solvents, to obtain a homogeneous dispersion;
b) grinding together, preferably on three-roll mill, at least one oxypolymerization-curable component, such as an alkyd resin, at least one pigment, and optional fillers and solvents to obtain a homogeneous dispersion;
c) mixing and grinding together the dispersion of step a), the dispersion of step b), an oxidative drier (siccativating agent), a photoinitiator and an optional photoinitiator stabilizer, to obtain the printing ink of the invention.
A first oxypolymerization-curable component, such as an alkyd resin, may be used in step a) and a second, different oxypolymerization-curable component, such as an alkyd resin, in step b), in order to assure best compatibility with the UV-curable acrylate and with the pigment, respectively.
Care must be taken during the mixing together of the printing ink components that the temperature does not exceed 50° C., because the UV curable component, such as an acrylate component, may undergo a premature polymerization reaction, making the ink useless for further application. For this reason, the mixing of the ink components is preferably carried out on an open three roll mill system rather than in a ball mill mixing equipment.
As will be appreciated by the skilled person, the production of the ink according to the present invention is not restricted to the indicated process; however, using the indicated process prevents any uncontrolled heating of the printing ink and therefore offers some guarantees against the premature and uncontrolled polymerization of the acrylic components during the ink manufacturing step.
The inventors have found that there is an inherent correlation between the “set-off” shown by an intaglio printing ink and its internal structural properties, sometimes also referred to as the cohesion force or cohesive strength, which can be considered as the force which is necessary to disrupt an applied coating layer (film splitting).
The complex dynamic modulus G* is a measure for the said cohesive strength of the ink, and is defined as:
G*=G′+iG″
wherein G′ is the elastic modulus (also called storage modulus),
and G″ is the plastic or viscous modulus (also called loss modulus).
The inventors surprisingly found that the simultaneous presence of fusible wax and a moderate amount of UV-curable acrylate oligomer significantly increased G* after thermal cycling, followed by exposure of the ink to UV light. In other words, the internal cohesion of the ink increased, which turned out to strongly decrease the “set-off” tendency of the ink:
Due to the simultaneous presence of the fusible wax and the UV curable component, after irradiation of the printed intaglio ink of the present invention by UV light following the printing operation, involving a thermal cycling of the ink, no “set-off” was observed any more, as is the case for UV-irradiated UV-curing inks. In contrast to UV-curing inks, the ink of the present invention is, however, not “dry” after the UV-irradiation, and only dries through oxypolymerization during the following hours and days. The present ink remains, as to its principal parts, an oxidatively curing intaglio ink having good in-depth drying and long-term mechanical and chemical resistances, which can be printed using standard printing equipment with rubber parts designed for printing greasy alkyd inks, given that a UV-irradiation unit is present on the printing press.
The UV-radiation may hereby be generated by conventional mercury UV-lamps, electron-less bulb UV-lamps, pulsed UV-lamps, UV-light-emitting-diodes (UV-LED's) and the like, capable of emitting UV-A, UV-B, and/or UV-C radiation.
A method of intaglio printing, using an intaglio printing ink according to the present invention, comprises thus the steps of a) intaglio-printing the ink onto a substrate, hereby cycling the ink's temperature from room temperature to printing plate temperature and back to room temperature; b) subjecting the printed document to UV-radiation following the printing operation; and c) storing the printed document for several days, to allow for oxidative curing of the printed ink.
According to the present invention, room temperature is meant to be 25° C. The printing plate temperature is typically 80° C., as described above, but with specific inks can be as low as 50° C.
The features of the disclosed intaglio ink result in a neat advantage for the printer, who can run his standard intaglio press with higher efficiency and versatility. These improvements are reached through the synergistic effect onto the “set-off” tendency of the printed ink of small amounts of both, fusible wax and UV-curable acrylates.
The present invention will now be described in more detail with reference to non-limiting examples and drawings.
FIG. 1 shows a plot of the experimentally determined complex dynamic modulus (G*, Pa), measured before and after heat-cycling (25° C.-80° C.-25° C.) of the ink, against the experimentally determined set-off resistance value (determined according to the method given below on an empirical scale going from 1 (bad) to 6 (excellent)) for four different intaglio inks of the prior art, each without and with a fusible wax component.
FIG. 2 a - c illustrate the synergistic effect of the simultaneous presence of fusible wax and UV-curable acrylate in an intaglio ink to prevent set-off after printing for the following example 1 and comparative examples 1 to 3. In detail:
FIG. 2 a shows a plot of the experimentally determined set-off value versus the complex dynamic modulus G*=G′+iG″ [Pa, as an absolute value]
FIG. 2 b shows a plot of the set-off value versus the elastic component G′ (real part of G*; also called the storage modulus)
FIG. 2 c shows a plot of the set-off value versus the plastic or viscous component G″ (imaginary part of G*, also called the loss modulus).
FIG. 3 shows the intaglio-printed test image used to assess the set-off and drying properties of the inks (shown in FIG. 4 a - d ).
FIG. 4 a - d illustrate the cooperative effect of a UV-curable component and a fusible wax onto the set-off properties of the inks, as exemplified with example 1 and comparative example 1.
EXAMPLE 1
Ink of the Present Invention (“Modified 30”)
An intaglio ink according to the present invention was prepared as follows (the amounts are given as wt.-% with respect to the final ink composition):
A first part of the ink was prepared by combining the following components, and grinding them on a conventional three-roll mill (Bühler SDY-200), as known to the skilled in the art, so as to form a homogenous dispersion:
Part I
Component
Amount (wt.-%)
Neutralized acid alkyd
11
(prepared as disclosed in EP 0 340 163 B1, p.
9, l. 45-51)
Acrylated oligomer
7
(Ebecryl 600, of Cytec)
Surfactant
3
(sodium dodecylbenzene-sulfonate)
Mineral solvent
4
(PKWF 6/9 neu, of Haltermann)
Talcum
2
Polyethylene wax
2
(Ceridust 9615A, of Clariant)
Fusible wax
5
(Carnauba wax)
Mineral filler
24.5
(Sturcal L, of Specialty Minerals)
Total
58.5
A second part of the ink was prepared by combining the following components, and grinding them on a three-roll mill, so as to form of a homogenous dispersion:
Part II
Component
Amount (wt.-%)
Modified alkyd
12.5
(Urotuföl SB650 MO 60, of Reichhold Chemie, or
the alkyd resin of part I)
Phenolic modified rosin based varnish
5.5
(solution of Sylvaprint MP6364 of Arizona
(45%) in PKWF 4/7 (15%) and linseed oil (40%))
Mineral solvent
1
(PKWF 6/9 neu, of Haltermann)
PB 15:3 blue pigment
7
(Irgalite blue GLO, of CIBA)
Mineral filler
9.5
(Sturcal L, of Specialty Minerals)
Total
35.5
The final ink was prepared by combining on a three-roll mill the above parts I and II with the following additional components:
Final ink
Component
Amount (wt.-%)
Part I
58.5
Part II
35.5
Photoinitiator
2
(Irgacure 819, of Ciba)
UV stabilizer
1.5
(Florstab 1, of Floridienne)
Metal drier
2.5
(blend of octa-soligen cobalt (12 parts) and
Octa-soligen manganese (8 parts), of Borchers)
Total
100
The viscosity of the final ink was adjusted with mineral solvent and additives, e.g. Aerosil, to about 1 to 40 Pa·s, preferably about 3 to 25 Pa·s, more preferably to about 6 to 15 Pa·s, measured on a cone-plate geometry at 1000 s −1 and 40° C.
COMPARATIVE EXAMPLE 1
Modified 30 without Wax
The ink was prepared as described above in example 1, except that in part I no fusible wax was added. Instead, the amount of the mineral filler (Sturcal L, of Specialty Minerals) was raised to 29.5 wt.-% (based on the final ink composition) in order to compensate for the lack of fusible wax.
COMPARATIVE EXAMPLE 2
Standard
The ink was prepared as descried in example 1, except that no UV-curable resin was present.
A first part of the ink was prepared by combining the following components, and grinding them on a three-roll mill, so as to form a homogenous dispersion (the amounts are given as wt.-% with respect to the final ink composition):
Part I
Component
Amount (wt.-%)
Neutralized acid alkyd
18
(prepared as disclosed in EP 0 340 163 B1, p.
9, l. 45-51)
Acrylated oligomer
—
(Ebecryl 600, of Cytec)
Surfactant
3
(sodium dodecylbenzene-sulfonate)
Mineral solvent
4
(PKWF 6/9 neu, of Haltermann)
Talcum
2
Polyethylene wax
2
(Ceridust 9615A, of Clariant)
Fusible wax
5
(Carnauba wax)
Mineral filler
24.5
(Sturcal L, of Specialty Minerals)
Total
58.5
A second part of the ink was prepared by combining the following components, and grinding them on a three-roll mill, so as to form a homogenous dispersion (the amount of the alkyd resin and the filler in part II was increased to compensate for the lack of UV-phototinitiator and UV-stabilizer in the final ink):
Part II
Component
Amount (wt.-%)
Modified alkyd
14
(Urotuföl SB650 MO 60, of Reichhold Chemie, or
the alkyd resin of part I)
Phenolic modified rosin based varnish
5.5
(solution of Sylvaprint MP6364 of Arizona
(45%) in PKWF 4/7 (15%) and linseed oil (40%))
Mineral solvent
1
(PKWF 6/9 neu, of Haltermann)
PB 15:3 blue pigment
7
(Irgalite blue GLO, of CIBA)
Mineral filler
11.5
(Sturcal L, of Specialty Minerals)
Total
39
The final ink was prepared by combining on a three-roll mill the above parts I and II with the following additional components:
Final ink
Component
Amount (wt.-%)
Part I
58.5
Part II
39
Photoinitiator
—
(Irgacure 819, of Ciba)
UV stabilizer
—
(Florstab 1, of Floridienne)
Metal drier
2.5
(blend of octa-soligen cobalt (12 parts) and
Octa-soligen manganese (8 parts), of Borchers)
Total
100
The viscosity of the final ink was adjusted with mineral solvent and additives, e.g. Aerosil, to about 1 to 40 Pa·s, preferably about 3 to 25 Pa·s, more preferably to about 6 to 15 Pa·s, measured on a cone-plate geometry at 1000 s −1 and 40° C.
COMPARATIVE EXAMPLE 3
Standard without Wax
The ink was prepared as described above in comparative example 2, except that in part I no fusible wax was added. Instead, the amount of the Mineral filler (Sturcal L, of Specialty Minerals) was raised to 29.5 wt.-% (based on the final ink composition) in order to compensate for the lack of fusible wax.
Measurements
The set-off resistance values were determined as follows: 10 intaglio prints were made on banknote paper (175×145 mm) on a trial press with the exemplary inks, using a standard, heated intaglio plate having fine, medium and deep engravings (up to 120 μm). The 10 printed sheets were immediately stacked on top of each other, with 10 blank interleaving sheets between them, and weight of 2 kg was placed on the stack. After 24 hours, the stack was separated, and the set-off to the interleaving sheets was evaluated on a statistical basis, by comparing each interleaving sheet with a scale of reference set-off sheets. A value between 1 (bad) and 6 (excellent) was attributed to each sheet, and the mean value of the 10 sheets was taken as being representative of the set-off of the ink in question.
The reference set-off sheets represent a standard intaglio image ( FIG. 3 ) in a linear series of photometric graduations, going from perfect copy (set-off value 1) to no copy at all (set-off value 6). Set-off values for practicable inks must be close to 6.
The complex dynamic modulus G* (in Pa) of the inks in question was determined on a AR1000 rheometer from TA Instruments in oscillating mode at 25° C.; cone 4 degree, 2 cm diameter, frequency 1 Hz.
In FIG. 1 , a plot of the experimentally determined complex dynamic modulus G* (in Pa) against the set-off resistance values (as determined above) is shown. FIG. 1 refers to intaglio inks which are formulated as given in Comparative Example 2 (“Standard”) and in Comparative Example 3 (“Standard without wax”), with variations as to the type and the quantity of fusible wax, as well as solvent content. These inks do not contain any UV-curable components. The four inks to the left correspond to comparative example 3 (i.e. inks without wax). The four inks to the right of the graph correspond to Comparative Example 2 and contain different kinds and concentrations of fusible waxes. A first set of complex dynamic modulus values was determined on the freshly prepared inks (otherwise as described above) (triangular points in FIG. 1 ). A second set of set-off resistance values and of complex dynamic modulus values was measured on the same inks after a thermal cycle, in which the ink's temperature was raised to 80° C. (i.e. the temperature of the printing plate) and cooled to 25° C. again (square points in FIG. 1 ). Only the square points represent a (dynamic modulus/set-off) value pair; the triangular points, corresponding to the not thermally cycled inks, do only represent the dynamic modulus values of the corresponding inks before printing and have been extrapolated from the square points with respect to the set/off resistance values. For determining set-off values, the inks must noteworthy be printed, and therefore mandatory pass through a thermal cycling.
A glance at FIG. 1 shows that the inks without fusible wax (points to the left) show only a slight increase in G* after thermal cycling. These inks remain tacky after printing, and correspondingly produce set-off, as indicated by their lower set-off resistance values. The inks with fusible wax (points to the right) show a large increase in G* after thermal cycling. These inks lose their tackiness upon printing, and correspondingly avoid set-off, as indicated by their higher set-off resistance values.
The observed increase in complex dynamic modulus after the heating/cooling cycle is an indicator of the ink's internal structural change upon printing. It can be seen that inks showing a large increase of the complex dynamic modulus G* (i.e. the group of inks to the right of the graph, which comprise fusible wax) upon thermal cycling have higher set-off resistance values than inks showing a small increase of the complex dynamic modulus (i.e. the group of inks to the left of the graph, without fusible wax).
FIG. 2 illustrates the synergistic effect of the combination of fusible wax and UV-curable acrylate in an intaglio ink in preventing set-off after printing. The inks according to example 1 and comparative example 1 to 3 were applied as follows: A 15 micrometer thick layer of the ink in question was applied onto a 80° C. preheated glass plate using a SHINN applicator. The glass plate was placed at 80° C. in an oven for additional 10 seconds, then cooled to 25° C. again. Where indicated, the glass plate was then subjected to UV-irradiation (1 pass, 50 m/min, 150 W/cm, 2 UV lamps); this treatment is designated as “2×100 UV”. The ink layer was subsequently scratched off the glass plate with a spatula and measured on the AR1000 rheometer.
FIG. 2 a shows a plot of the experimentally determined set-off resistance values (determined as described above) versus the complex dynamic modulus G* (in Pa as an absolute value).
FIG. 2 b shows a plot of the set-off value versus the elastic component G′ (real part of G*; also called the storage modulus) of the measured complex dynamic modulus G*.
FIG. 2 c shows a plot of the set-off value versus the plastic or viscous component G″ (imaginary part of G*, also called the loss modulus) of the measured complex dynamic modulus G*.
The ink of example 1, comprising both wax and UV-curable acrylate, and subjected to the above thermal cycle, followed by UV-irradiation (“Modified 30+2×100 UV”), has the highest value of complex dynamic modulus G* (Pa), and also provides the best set-off resistance values of all investigated inks. The set-off properties furthermore correlate in the same way with both components of the complex dynamic modulus, i.e. with the elastic (G′) and with the plastic (G″) modulus; the latter being the more important contributor to the complex dynamic modulus. In particular, an unexpectedly high increase of the set-off resistance value after the above thermal cycle was observed with the ink of example 1. Said increase exceeded the respective increase of the set-off resistance value of the other examined inks by far.
As can be inferred from FIG. 2 a , the UV-irradiation of the ink of the present invention led to a more than twofold increase of the complex dynamic modulus G*. Even for the same ink without wax, an about twofold increase of the complex dynamic modulus G* was observed. On the other hand, for the standard ink, with or without wax, UV-irradiation did not show any noticeable effect on the complex dynamic modulus G*.
The cooperative effect of wax and UV-curable acrylate in preventing set-off was assessed as follows: FIG. 3 shows the intaglio-printed test image used to assess said set-off and drying properties of the inks. This test intaglio plate has different engraving depths, varying from shallow (fine-line pattern in the face and hair part), to middle-deep (hat part), to deep engraving (SICPA guilloches). The deep engraving yields the most sensitive parts on the printed image for assessing the set-off properties. The latter are assessed by subjecting a fresh print covered by a sheet of paper to a weight of 2 kg during 24 hours, then separating the sheet of paper from the print. The set-off image is the reverse of the printed image.
FIG. 4 a - d illustrate the cooperative effect of a UV component and a fusible wax onto the set-off properties of the ink. The ink of example 1 was used in the cases shown in FIGS. 4 b and 4 d , whereas in the cases of FIG. 4 a and FIG. 4 c . the ink of comparative example 1 (i.e. the fusible wax (Carnauba wax) was replaced by 5% mineral filler) was used. In the cases shown in FIGS. 4 c and 4 d , a UV-irradiation as described above was carried out, whereas in the cases shown in FIGS. 4 a and 4 b , no UV-irradiation was carried out.
In the absence of UV-irradiation and wax ( FIG. 4 a , comparative example 1), a bad set-off note (5.44) resulted. The presence of fusible wax ( FIG. 4 b , example 1) already considerably improved the set-off note (5.60). UV-irradiation in the absence of fusible wax ( FIG. 4 c , comparative example 1) gave a similar result (5.66). Set-off was completely absent ( FIG. 4 d , example 1) in the presence of fusible wax after UV-irradiation (note 5.90). | The present invention relates to printing inks for the intaglio printing process, also referred to as engraved steel die printing process. In particular, oxidatively curing inks comprising a combination of fusible wax and a UV curing binder component are disclosed. These inks can be printed on a standard printing press, and, through a short UV irradiation after printing, allow to significantly reduce or eliminate the undesired set-off which can occur after printing and stacking the printed sheets. Using the inks of the present invention results in less set-off contaminated printed sheets, allowing for a higher pile-stacking of the printed good, for the use of increased engraving depths, of a more challenging intaglio design, and for the printing on less porous substrates, while enabling the printing on a standard printing press, and offering the possibility of using a lower printing plate temperature. | 2 |
BACKGROUND
In drilling and completion industries such as hydrocarbon exploration and production, Carbon Dioxide sequestration, etc., tools are often run into the downhole environment for particular purposes requiring locating the tool at a target position. Traditionally an operator will keep track of a length of tubing in the hole and anticipate the specific tool at issue locating upon a feature within the hole. The feature may be a seat, profile, bottom, etc. Such “gauging” of where the tool is occurs in trips into the borehole, trips out of the borehole and movements of the tool in defined areas of the borehole.
For example, an operation in a borehole may require several actions taking place between a downhole most location and an uphole most location for the particular operation. Providing profiles at these locations will provide a guide to the operator to keep the target tool in the target location for the job being done.
While such measures are currently used, tools do not always engage profile properly and effective indication of position at the surface may not be received. Such situations result in lost time, which translates to cost increases.
In order to address the foregoing, a downhole position locating device with fluid metering feature (U.S. Pat. No. 7,284,606, the entirety of which is incorporated herein by reference) was developed. Such a tool or others that function by providing a fluid movement component of their operation, which fluid component has an effect on tool operation such as in the '606 patent wherein the fluid delays an action until the fluid is removed by exhaustion or by movement to another chamber are useful as landing in a sought profile is better verifiable by a pull or push from surface that allows for a slower movement of the string. While the concept generally works well, there is a possibility that the tool experiences restricted movement due to friction, Blow Out Preventer (BOP) contact or other impediments rather than due to an engagement with a profile and fluid movement. In such case, the indication of tool location at surface would be inaccurate. Since accuracy in downhole operations improves efficiency and reduces costs, the industry will well receive improved arrangements supporting these goals.
SUMMARY
A downhole tool with a feedback arrangement including a tool having one or more fluid outflow ports that exhaust fluid during normal operation of the tool; and a feedback arrangement in operable communication with the fluid exhausted from the one or more fluid outflow ports during operation of the tool, the feedback arrangement interacting with exhausting fluid to produce a signal receivable at a remote location indicative of proper tool operation.
A method for confirming operation of a downhole tool including disposing an oscillator within a fluid outflow path; actuating the tool thereby causing fluid to flow in the outflow path; affecting the oscillator with the fluid; and creating a signal with the oscillator representative of tool operation.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several Figures:
FIGS. 1A-C is a representation of one embodiment of a metering tool with feedback arrangement in three distinct positions;
FIGS. 2A-C is a representation of another embodiment of a metering tool with feedback arrangement in three distinct positions; and
FIG. 3 is a plan view of an embodiment of a pulser.
DETAILED DESCRIPTION
It is to be appreciated that while the overall configuration of the metering tool of the '606 patent is utilized to illustrate two embodiments of the disclosed invention, other configurations where fluid movement is a part of the function of the tool will also benefit from the embodiments providing feedback as described herein.
Referring to FIGS. 1A-C , a metering tool 10 is generally depicted with a feedback arrangement including an oscillator 12 . The metering tool 10 is also shown to include an exemplary embodiment where fluid movement is a part of the function of the tool. The illustrated exemplary embodiment includes a mandrel 100 made up of top sub 120 , upper body 140 , lower body 16 and bottom sub 18 . An outer sleeve 200 has a window 22 for each dog 24 that is used. One or more dogs 24 can be used. Dogs 24 have tabs at opposed ends to limit the outward travel of the dogs 24 with respect to window 22 . FIG. 1A shows the dog 24 in section. The dog 24 is generally U-shaped having a pair of inwardly oriented legs 28 and 30 . On the trip into the well, surface 32 on dog 24 may encounter an obstacle. On the trip out of the well, surface 34 on dog 24 may encounter an obstacle. Sleeve 200 is mounted to slide over mandrel 10 . It is biased uphole by spring 36 that bears on surface 38 of bottom sub 18 . Spring 40 bears on surface 42 of top sub 120 and applies an opposing force to sleeve 20 than spring 36 . Spring 40 may be weaker than spring 36 for reasons that will be explained below.
Upper body 140 has three grooves 44 , 46 , and 48 . These grooves are deep enough so that when legs 28 and 30 are in them, outer surface 50 of dogs 24 recedes inside of window 22 . In this manner the tool 10 can pass an obstruction going downhole and can be removed after release going uphole. If an obstruction is encountered by surface 32 going in the hole, the spring 40 is compressed as the sleeve 20 and dogs 24 stop downhole motion. Continued downhole movement of the mandrel 100 not only compresses spring 40 but also positions grooves 44 and 46 in alignment with legs 28 and 30 of dogs 24 to allow them to retract to a position closer to the central axis 52 and within sleeve 200 . At that point the obstruction can be passed and spring 40 can bias the sleeve 200 back into the neutral position shown in FIG. 1A . FIG. 1B shows the legs 28 and 30 getting cammed out of grooves 44 and 46 by the action of spring 40 after the obstruction going downhole is cleared. Note that sloping surfaces 52 and 54 facilitate the exit of legs 28 and 30 from grooves 44 and 46 under the return force of the formerly compressed spring 40 . With the obstacle cleared going downhole, the dogs 24 resume the neutral run in position shown in FIG. 1A .
Between the sleeve 200 and mandrel 100 an upper fluid reservoir 56 ( FIG. 1C ) and a lower fluid reservoir 58 . A fill port 60 allows charging the fluid at the surface. Thermal and hydrostatic effects in this closed system of interconnected reservoirs are fully compensated by a piston that can be biased by Belleville washers, for example, or any other device that is comparable. Those skilled in the art will appreciate the benefit of such compensation on the structure of the device especially when it is deployed at great depths and/or high temperature applications. FIG. 1B best illustrates other features of this reservoir system. There is a flow restrictor 66 that regulates the flow rate from reservoir 58 into reservoir 56 . There is a check valve 68 that permits a bypass of restrictor 66 when the fluid is flowing in the opposite direction from reservoir 56 to reservoir 58 . A pressure relief device 70 is in line with the restrictor 66 so that when fluid is urged in a direction from reservoir 58 to reservoir 56 there will have to be a rise in the driving pressure to cause such flow to a predetermined level before any flow begins.
The fluid system is operative to create a delay as the dogs 24 are in the desired location and a force is applied to the mandrel 100 to create a surface signal for such engagement prior to the release of the dogs 24 from the locating groove (not shown). In the exemplary embodiments further described herein, the feedback arrangement is further provided features to produce an oscillating or pulsating signal that is more easily discernible at a remote location. The system also serves to allow a reduction of the applied pulling force before release to reduce the slingshot effect from release. When used with the optional pressure relief device 70 the tool can be inverted and can be used to apply a load in a predetermined range on a BHA without concern for premature release, such as an offshore drilling application where a heavy compensator system is employed.
FIG. 1A shows the run in position with the dogs 24 having legs 28 and 30 out of any of the grooves 44 , 46 , and 48 . The dogs may be biased into the FIG. 1A position where legs 28 and 30 straddle groove 46 by virtue of spring 36 overpowering spring 40 to move sleeve 200 to the FIG. 1A position. As the tool is brought downhole, an obstacle will first hit surface 32 on dogs 24 . The mandrel 100 will continue downhole as the dogs 24 stop the descent of the sleeve 200 . As grooves 44 and 46 come into alignment with legs 28 and 30 , the dogs 24 will be able to retract sufficiently to allow the tool to continue past the obstacle. The dogs 24 can retract within sleeve 200 as much as necessary to allow the obstacle to be cleared. The advancing of the mandrel 100 with the dogs 24 temporarily stuck on an obstacle, compresses spring 40 . After the obstacle is cleared, spring 40 relaxes to return the tool to the FIG. 1A position from the FIG. 1B position. It should be noted that advancing the mandrel downhole with the dogs 24 stopped by an obstacle will result in sleeve 200 taking dogs 24 against the bias of spring 40 taking the lower end 21 of sleeve 200 away from upper end 23 of sleeve 25 , whose relative movement with respect to the mandrel 100 , at other times, creates movement of fluid between reservoirs 56 and 58 . The amount of this movement to reset the dogs 24 to the FIG. 1A position after clearing the obstacle is also quite short.
When the desired depth is reached, the tool is pulled up until the surface 34 engages a desired locating groove downhole. At that point, further upward pulling on the mandrel 10 from the work string (not shown) will force fluid from reservoir 58 to reservoir 56 through restrictor 66 . This regulates the rate of movement of mandrel 100 as the force is being applied to give surface personnel the time to notice a signal that the desired groove has been engaged and a force that well exceeds the potential drag force from friction of slip/stick effects on the work string in a deviated wellbore are applied. The rig crew can then actually lower the applied pulling force before the actual release happens to reduce the slingshot effect from the release. Release occurs after the mandrel 100 moves a sufficient distance to place grooves 46 and 48 in alignment with legs 28 and 30 to allow the dogs 24 to retract and the tool to be returned to the FIG. 1A position. This occurs because the pulling uphole with the dogs 24 in the locating groove compresses spring 36 as seen in FIG. 1C . Retraction of the dogs 24 allows spring 36 to overcome spring 40 and the tool returns to the FIG. 1A position, ready for another cycle. With the use of the optional relief device 70 the surface personnel are assured that a pulling force up to a predetermined level will not initiate the release sequence. Hence force can be applied and removed any number of times before there is a release. Those skilled in the art will appreciate that the tool can be used in an inverted orientation and function similarly in one application, for example where a range of weight on a BHA is desired in a given range without fear of initiating a release sequence. In such an application, rather than a pulling force uphole, a pushing force downhole is applied with the dogs 24 engaged in a receptacle. Combining with the use of the optional relief device 70 no fluid flow between reservoirs 56 and 58 can happen until a predetermined force is exceeded. This configuration can be used in offshore drilling in conjunction with heave compensators.
The use of the check valve 68 allows the tool to quickly find its neutral position after a release so that the test can be quickly repeated, if desired. The use of the restrictor 66 allows more time at the surface to hold a force before release and further allows lowering the applied force after the passage of time but before release to reduce the slingshot effect from release. The pressure relief device 70 allows application of force for any desired time without fear of release if the force is kept at a level where the relief device remains closed. The fluid used on the reservoirs can be a liquid or gas. The compensator is an optional feature. The tool is serviceable in the well in opposed orientations depending on the intended service. Although four dogs 24 are illustrated one or more such dogs can be used. Biasing of springs 26 and 40 can be accomplished by equivalent devices.
In the embodiment of FIGS. 1A-1C , the feedback arrangement is an oscillator 12 illustrated as a spring mass that is positioned within a fluid outflow through outflow port(s) 14 caused by metering of the metering tool 10 . It is to be understood that although a spring mass is illustrated as oscillator 12 , any mass that can be caused to oscillate due to fluid flow can be used. As will be appreciated from a review of the metering tool in the incorporated by reference '606 patent, fluid is exhausted from chamber 56 to chamber 58 , or from chamber 58 to chamber 56 , during the normal operation of the tool 10 , such as when a dog 24 engages a desired locating groove downhole. Because of the placement of the oscillator 12 within reservoir 58 , the fluid flow through outflow port(s) 14 interacts with the oscillator 12 to cause the oscillator 12 to oscillate. Oscillation of the oscillator 12 produces a signal that can be received at remote locations and is indicative of proper tool operation, such as when the dog 24 engages a desired locating groove downhole. Different forms of oscillation can be transmitted to remote locations for reliable feedback of the operation of the tool. In this case, the spring mass, which may be a coil spring as shown, oscillates against the tool itself creating vibration that is transmitted through a string 16 supporting the tool back to surface or other remote location. The vibration is detectable at the remote location by hand or sensor or auditorily and confirms proper operation of the tool in the downhole environment.
In another embodiment, referring to FIGS. 2A-C , a metering tool 10 with a feedback arrangement includes a pulser 20 mounted proximate a fluid outflow through the outflow port(s) 14 of the tool 10 . Upon fluid outflow, the pulser arrangement will rotate. The pulser, in one embodiment is hence a rotating member. Rotation of the pulser is due to one or more (four shown) openings 22 in the pulser 20 that are configured angularly relative to an axis of the rotatable pulser. Rotation of the pulser 20 results in an alternating pattern of openings and solid sections of the pulser aligning with the fluid outflow of the tool 10 . This alternatingly allows fluid passage and fluid blockage (or at least inhibition). Accordingly, pressure within the fluid downstream of the pulser changes alternatingly at the same rate that the pulser rotates. Pressure downstream of the pulser decreases when fluid flow is inhibited and returns to system pressure with each alignment of the openings 22 . More particularly, when one of the openings (or more of them if there are more fluid outflow ports or if the pulser is configured to align more than one of the openings with the fluid outflow (in the event that the fluid outflow is broader in area than one of the openings 22 plus an adjacent solid portion of the pulser 20 ) is aligned with the fluid outflow, the pressure downstream of the pulser is the same as it is upstream of the pulser. When the pulser rotates to a position where the fluid flow from the outflow port(s) is blocked or inhibited, the pressure in the fluid downstream of the pulser dips. The dip in pressure and subsequent recovery of system pressure can be received and in some cases might actually be measured a substantial distance from the pulser 20 and tool 10 . The pressure change is embodied as an acoustic signal propagating through fluid in the borehole and provides feedback at a remote location or at the surface of fluid outflow from the outflow port(s). Depending upon the length of time a particular tool has a fluid outflow, the acoustic signal may have time to reach a remote location such as the surface to be perceived or the signal may act as a post actuation confirmatory signal. This is because an appreciable amount time is required for signal propagation in a fluid medium. And while clearly the time factor for signal propagation in a fluid medium is directly related to the density of that fluid, (and of course distance is a factor in overall travel time) in virtually all cases of fluid borne acoustic signals from downhole tools, it will be likely that the actuation time causing the fluid outflow will be less than the transit time for the signal hence making such signals confirmatory.
While the foregoing embodiment provides one method for propagating a signal based upon the structure shown, there is another that provides for much less of a time delay. This utilizes the actual work string the tool is disposed in to propagate a vibratory signal. Because the pulser, in addition to what it does as noted above, will also cause pressure variations in the tool that is exhausting fluid, the string itself experiences varying strain that is cyclic. A cyclic change in tensile strain can function as a signal. More specifically, and using the metering tool of the '606 patent as an example, as the tool contacts a locating profile, applied tension displaces fluid through the outflow ports and past the pulser. The flow of fluid rotates the pulser thereby restricting and unrestricting the flow of liquid through the ports. This variance in restriction results in a variance of the pressure within the tool chamber. The variance in chamber pressure in the tool will be manifested as a variance in force between the metering tool and the profile. This force variation is detectable as a variance in tensile force in the workstring upon which the tool has been run and operated. The signal provides increased confidence that the tool 10 is operating properly. One benefit of this embodiment is the speed at which a signal will propagate through metal as opposed to a fluid. In view of this speed increase, the signal is received virtually contemporaneously with the tool actuation.
While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. | A downhole tool with a feedback arrangement including a tool having one or more fluid outflow ports that exhaust fluid during normal operation of the tool. A feedback arrangement in operable communication with the fluid exhausted from the one or more fluid outflow ports during operation of the tool. The feedback arrangement interacting with exhausting fluid to produce a signal receivable at a remote location indicative of proper tool operation. A method for confirming operation of a downhole tool is included. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a portable device for assisting in teaching a proper golf swing.
An ideal golf swing comprises five important elements: proper alignment of the body, a shifting of weight to the right foot in the backswing, maintaining a still head with eyes fixed upon the ball, a shifting of weight to the left foot at the start of the downswing, and clearance of hips to the left prior to impact. These five elements, when practiced together, enhance the effectiveness of a user's golf swing much more than when one or several of the elements are omitted.
Golf training devices are known to assist in improving the swing. Prior art devices in this field address one or several of the above elements, or address different elements. Prior art devices most commonly have operated by teaching a limited number of elements, with the expectation that improvement of other elements not addressed by a particular device will follow. For example, U.S. Pat. No. 3,740,051 to Cross trains a user to adopt and maintain a proper head position during execution of a golf swing. Although a golfer may have perfected his or her swing, and only seeks help with positioning his or her head, because the apparatus addresses only the head, the integrity of the other elements of the swing may be adversely affected.
A golfer who trains on only one element is likely to master that one element to the detriment of others. As a consequence of the limited utility of the prior art devices, a golfer who wishes to improve his or her performance on all desired elements must train on several different machines, all addressed to one or two elements.
Some prior art devices which comprise rigid guides do not accurately simulate playing conditions, where no guides are present. For example, Lopez U.S. Pat. No. 4,688,800 describes a device to be worn around a golfer's waist. A golfer who does not swing a golf club correctly, while wearing the device, will abruptly hit the golf swing guide with his or her elbow and will not be able to complete the swing without severe interference from the guide with his or her elbow. U.S. Pat. No. 3,623,733 to Cavanaugh shows a body "cage" which will touch the golfer's body if he or she unduly sways while taking a swing. The device also comprises a trough-type track from which the ball is hit. If hit improperly, the golfer's club strikes the walls of the trough. A golfer may become dependent on such aids and be unable to perform well in their absence.
U.S. Pat. No. 4,583,738 to Fava discloses a device comprising a guide rail for directing the movement of a golf club in a predetermined swing plane. The device emits a rhythmic tone which corresponds to the movement of the golf club. A golfer that utilizes that device may become dependent on the guide rail and audio signal and be unable to duplicate a proper swing on the golf course.
Further, the training devices of the prior art offer no feedback other than interference by a part of the device during an improper swing. The user is left to guess what he or she did improperly, and attempt to correct it. There is no way to quantify the amount of error.
For example, U.S. Pat. No. 3,138,388 to Herold shows a device which coordinates shoulder and hip movement during a downswing. The ratchet-operated device comprises bars which rest on the golfer's shoulders and buttocks. When, during a downswing, the golfer's shoulders improperly pivot before the hips, the bar resting on the shoulders locks, warning of the impending improper swing. The golfer has no way of knowing exactly what he or she did incorrectly, and as a result, has no way of knowing exactly what to adjust in order to perfect the swing. Operating the device properly, such that the shoulder rest does not lock, is a process of trial and error.
U.S. Pat. No. 3,510,135 to Gentile discloses a means for developing correct positioning only of the head and feet of a golfer, comprising foot markings and a padded knob which rests against the head. The device addresses only these isolated body parts and provides a rough guide, rather than feedback means, for a proper swing.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a portable golf training device which teaches a complete, proper golf swing comprising proper alignment of the body, shifting of body weight to the right foot when beginning a back swing, maintaining a still head with eyes fixed upon the ball throughout the swing, a shifting of body weight to the left foot at the start of a downswing, and clearance of hips to the left prior to impact.
It is another object of the invention to provide a device to assist in teaching a proper golf swing without reliance on rigid guides which are not present on the golf course.
It is still another object of the present invention to provide a golf training device which provides a golfer with feedback of his or her progress.
The present invention is an improvement on the prior art and discloses a novel golf training device which teaches all five of the elements incorporated by professional golfers in execution of a golf swing.
A movable hip guide which comprises movable measurement means to measure right hip movement, an adjustable sighting device, a stationary right knee stop, a left thigh target, and a movable left knee post work together to teach a user proper alignment of the body, proper shifting of body weight during a backswing, maintenance of a still head throughout the swing, proper body weight shifting during a downswing, and clearance of hips to the left prior to impact.
The stops, targets and guides of the device do not force a proper swing, thus creating dependence on them. Rather, they define the outer limits of correct alignment and movement so that a student may memorize the feel of proper body alignment and movement while being left to align and move the body on his or her own, without merely fitting into a guide.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a golf training device in accordance with the present invention.
FIG. 2 is a top plan view of the golf training device in accordance with the present invention.
FIG. 3 is a front elevational view of the golf training device in accordance with the present invention.
FIG. 4 is a rear elevational view of the golf training device in accordance with the present invention.
FIG. 5 is a partial cross-sectional view taken along the line 5--5 in FIG. 1.
FIG. 6 is a partial cross-sectional view taken along the line 6--6 in FIGS. 1 and 2.
FIG. 7 is a partial cross-sectional view taken along the line 7--7 in FIG. 2.
FIG. 8 is a partial cross-sectional view taken along the line 8--8 in FIG. 4.
FIG. 9 is a partial cross-sectional view taken along the line 9--9 in FIG. 4.
FIG. 10 is a partial cross-sectional view taken along the line 10--10 in FIG. 2.
FIG. 11 is a partial cross-sectional view taken along the line 11--11 in FIG. 2.
FIG. 12 is a partial cross-sectional view taken along the line 12--12 in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
Generally, as shown in FIG. 1 of the drawings, the present invention relates to golf training device 10. The device 10 comprises a foot platform 12 and a ball platform 15 attached by center rail 17. Foot platform 12 and ball platform 15 are made of aluminum and in a preferred embodiment are covered with artificial turf.
Center rail 17 connects foot platform 12 and ball platform 15. Center rail 17 is affixed by fasteners 18 to the underside of foot platform 12. As best seen in FIG. 6, center rail 17 is movably attached by fastener 19 to the underside of ball platform 15. Ball platform 15 can be rotated 90° about fastener 19 so that the platform can be positioned with respect to center rail 17. Ball platform 15 also can be moved along center rail 17, which is calibrated, so that ball platform 15 can be adjusted both away from or closer to foot platform 12. When ball platform 15 is at a desired position, it can again be rotated 90° about fastener 19 to be locked into position. As best seen in FIG. 7, tee 36 is attached to ball platform 15 by fastener 37.
One foot 21 is attached to the center of the front edge of ball platform 15. Two other feet 21 are attached to the rear corners of foot platform 12. Thus, the two platforms are supported by three legs. Foot platform 12 is large enough to support most of the components of the device, as well as the user.
Connected near one end of center rail 17, forward of ball platform 15, is sighting device 40. Sighting device 40 extends from support pole 41, which at its lowermost end is seated into channel 43 which runs through the center of center rail 17. As best seen in FIG. 5, pole 41 of sighting device 40 can be moved along channel 43 to cause sighting device 40 to be closer to or further from foot platform 12, depending upon the size of the user. Support pole 41 is connected by fasteners 18 at its uppermost end to head guide 27. Support pole 41 is bent at its lower end at an angle of between 90° and 180° for proper location of head guide 27. Head guide 27 has a viewing port 29 through which a user may view a golf ball 30 placed on tee 36. As shown in FIG. 2, viewing port 29 slides laterally along track 31 and can be adjusted for ease of use and desired body position with respect to the position of foot platform 12. As best seen in FIG. 10, viewing port 29 also slides laterally within head guide 27 to further allow for adjustment with respect to the height of the user.
Most of the guides and stops of the golf training device 10 are located on foot platform 12. As seen in FIG. 2, foot platform 12 has foot guide 42 drawn on it in a contrasting color to aid the user in properly positioning his or her left foot. Two foot guides may be used instead of a single guide.
As seen in FIGS. 1-4, mounted by bracket means to foot platform 12 is right knee brace or stop 46, comprising a U-shaped bar 50. As seen in FIG. 11, in a preferred embodiment, U-shaped bar 50 is covered with cushioned plastic sleeve 52. Knee brace 46 prevents the right knee from straightening during the backswing. A straight leg causes loss of power.
As best seen in FIGS. 1, 2 and 8 right hip guide 54 is mounted on foot platform 12 behind and above right knee brace 46. Hip guide 54 comprises a shaft 56, the top portion 57 of which is at a right angle to the bottom portion, and parallel to foot platform 12. As seen in FIG. 12, movable cushioned plastic sleeve 62 surrounds the top portion 57 of shaft 56, and stop 59 prevents sleeve 62 from disengaging from top portion 57. Movable sleeve 62 is adapted to move freely on top portion 57 and to produce an audible "click" through clicker 63 to signal proper movement of the right hip during the body swing. Movable sleeve 62 returns to the front end of top portion 57 by spring means (not shown) when a user's hip is not in contact with movable sleeve 62.
As seen in FIGS. 3 and 4, left thigh target 66 is located opposite hip guide 54. As seen in FIG. 9, pole 67 supporting left thigh target 66 is fixed by bracket means 68 to the rear of foot platform 12. Left thigh target 66 prevents the left thigh from traveling too far upon completion of the swing and indicates the proper left thigh finishing position.
As best seen in FIGS. 1 and 3, hinged left knee guide 70 is also affixed to foot platform 12 next to foot guide 42. Hinged left knee guide 70 comprises three coincident posts 73, 74, 75. The lower two posts 73, 74 are connected by magnetic latch 72. The top two posts 74, 75 are attached by hinge means 71 to form a pivot. Hinge means 71 enables the left knee guide 70 to bend upon contact with the user's left knee. If the user's left knee pushes the top of knee guide 70 beyond a predetermined range, magnetic latch 72 will release, causing the upper portion of left knee guide 70 to fall over.
In use of the golf training device 10, a user places his or her left foot onto foot guide 42. The user distributes weight evenly among both feet and rests the right hip against right hip guide 54 which has previously been adjusted for the user's body size. The knees are bent slightly. The user places the head of his or her golf club next to golf ball 30 on tee 36 and views golf ball 30 through viewing port 29, which also has been adjusted for the user's body size and club selection. The head is then turned approximately two inches to the right. When these steps have been followed, the user will have achieved proper initial alignment of the body.
The user then turns the hips right, sliding sleeve 62 along the top portion 57 of right hip guide 54, until his or her club is raised and the backswing is completed. A proper swing will cause movable sleeve 62 to emit an audible "click", indicating that weight has shifted to the right foot and a sufficient hip turn is achieved. A swing which is insufficient will not move sleeve 62.
The user must keep the golf ball 30 in view through viewing port 29 throughout the back swing. Concurrently with the backswing, most of the user's weight should be shifted to the right heel. Throughout the backswing, the right leg is slightly bent over right knee brace 46.
After the backswing is completed and the right knee is bent over right knee brace 46, ball 30 is still viewed through viewing port 29, and the golfer begins to shift weight to the left foot to start the downswing.
During the downswing, the hips are turned left to avoid knocking over hinged left knee guide 70 during the downswing.
The user focuses upon the ball 30 through viewing port 29 during the backswing, during the downswing, and until after impact, catching a glimpse of the empty tee 36 through viewing port 29 after impact, thus maintaining a still head throughout his or her entire swing.
In a properly executed complete swing, the swing is finished with the user's left thigh touching left thigh target 66 and missing left knee guide 70, thus insuring that the hips clear left prior to impact and weight has completely shifted to the left foot. If the user follows the proper procedure assisted by the golf training device 10, the golf ball should travel along the correct trajectory.
Although not shown, an optional sound making device could be attached to a user's belt to assist in keeping the right elbow tucked in during the swing.
Although the invention has been shown and described for a right-handed user, the elements could be reversed for a left-handed user. The device shown is appropriate for a standard driver. It could readily be adapted for other clubs.
It should be apparent to those skilled in the art that other modifications could be made in the device without departing from the spirit and scope of the invention. | Portable golf training device for teaching proper golf swing having a ball platform with viewing means, a foot platform with right knee brace, left knee guide, left thigh target and right hip guide with sounding device, to ensure proper hip rotation and weight shift. The device teaches more elements of a golf swing, provides more feedback, and utilizes less rigid guiding equipment to decrease dependence on guides than known training devices.
The device, which can be utilized by a user as a self teaching device, or by an instructor as a teaching tool, comprises adjustable components which enable a user or golf instructor to determine proper adjustments and to adapt the device to a particular user or student. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority benefit under 35 U.S.C. Section 119(e) to U.S. Provisional Patent Ser. No. 61/148,792 filed on Jan. 30, 2009 the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a method and a system for liquefying natural gas. In another aspect, the present invention concerns a method and a system for enhancing the production of liquefied natural gas.
BACKGROUND OF THE INVENTION
The cryogenic liquefaction of natural gas is routinely practiced as a means of converting natural gas into a more convenient form for transportation and storage. Such liquefaction reduces the volume of the natural gas by about 600-fold and results in a product which can be stored and transported at or near atmospheric pressure.
Natural gas is frequently transported by pipeline from the supply source to a distant market. While it is desirable to operate the pipeline under a substantially constant and high load factor, often the deliverability or capacity of the pipeline will exceed demand while at other times the demand may exceed the deliverability of the pipeline. In order to shave off the peaks where demand exceeds supply or the valleys when supply exceeds demand, it is desirable to store the excess gas in such a manner that it can be delivered when demand exceeds supply. Such practice allows future demand peaks to be met with material from storage. One practical means for doing this is to convert the gas to a liquefied state for storage and to then vaporize the liquid as demand requires.
The liquefaction of natural gas is of even greater importance when transporting gas from a supply source which is separated by great distances from the candidate market and a pipeline either is not available or is impractical. This is particularly true where transport must be made by ocean-going vessel. Ship transportation in the gaseous state is generally not practical because appreciable pressurization is required to significantly reduce the specific volume of the gas. Such pressurization requires the use of more expensive storage containers.
In order to store and transport natural gas in the liquid state, the natural gas is preferably cooled to −240° F. to −260° F. where the liquefied natural gas (LNG) possesses a near-atmospheric vapor pressure. Numerous systems exist in the prior art for the liquefaction of natural gas in which the gas is liquefied by sequentially passing the gas at an elevated pressure through a plurality of cooling stages whereupon the gas is cooled to successively lower temperatures until the liquefaction temperature is reached. Cooling is generally accomplished by indirect heat exchange with one or more refrigerants such as propane, propylene, ethane, ethylene, methane, nitrogen, carbon dioxide, or combinations of the preceding refrigerants (e.g., mixed refrigerant systems).
In any natural gas liquefaction process, there will be progressive accumulation of buildup upon the interior surfaces of the cryogenic heat exchanger. Such buildup can be caused by water in the form of ice or relatively heavy hydrocarbons present in the gas feed in solid form. The various sections of the cryogenic heat exchanger operate at different temperatures depending upon what stream is passing through a particular section. For example, one section of the cryogenic heat exchanger can operate at an inlet temperature of −35° F. and an outlet temperature of −50° F., while a nearby or contiguous section can operate at an inlet temperature of −147° F. and an outlet temperature of −103° F., while yet another nearby or contiguous section in the cryogenic heat exchanger can operate at an inlet temperature of −147° F. and an outlet temperature of −204° F. Thus, it can be seen that a specific stream containing materials having various freeze points may pass through one or more sections of the unit without forming a buildup, but the same stream may encounter a separate section operating at a lower temperature than the other section(s), and buildup can ultimately result thus adversely affecting the overall heat transfer efficiency of the unit. Build-up of solids in these cryogenic heat exchangers, control valves and other associated equipment can lead to reduced heat transfer, high pressure drop and/or reduced flow resulting in a decrease in LNG production.
Therefore, a need exists for the removal, or de-riming, of heavy hydrocarbons that precipitate, wax up or freeze in the passages of cryogenic heat exchangers, control valves and other associated equipment.
SUMMARY OF THE INVENTION
In an embodiment of the present invention, a method of removing buildup in a heat exchanger, the method includes: (a) closing a first inlet valve of pumping vessel, wherein the first inlet valve controls a supply of a solvent into the pumping vessel, wherein the pumping vessel is a positive displacement pumping vessel, wherein the solvent is liquid petroleum gas; (b) closing a first exit valve of the pumping vessel, wherein the first exit valve controls a supply of a solvent exiting the pumping vessel; (c) closing a second inlet valve of the pumping vessel, wherein the second inlet valve controls a supply of a method gas into the pumping vessel, wherein the method gas is capable of exiting with the solvent without negatively impacting the integrity of the solvent, wherein the method gas is a high pressure method gas; (d) continuously opening and closing a second exit valve to maintain pressure within the pumping vessel, wherein the second exit valve controls a supply of the method gas exiting the pumping vessel; (e) opening the first inlet valve to introduce the solvent into the pumping vessel, wherein the pumping vessel includes a pumping vessel housing forming a pumping vessel chamber and a moveable float located within the pumping vessel chamber, wherein the moveable float is attached to the pumping vessel chamber by a mechanical linkage; (f) engaging the moveable float by continuously introducing solvent into the pumping vessel chamber until the solvent reaches a predetermined level, wherein upon reaching the predetermined level the mechanical linkage of the moveable float engages to close the first inlet valve, to close the second exit valve, and to open the second inlet valve; (g) opening the first exit valve of the pumping vessel to discharge the solvent, wherein the discharged solvent is injected into the heat exchanger, wherein the solvent is injected into the heat exchanger at a variable rate; (h) closing the first exit valve of the pumping vessel; and (i) closing the second inlet valve of the pumping vessel.
In another embodiment of the present invention, a method of removing buildup in a heat exchanger, the method includes: (a) closing a first inlet valve of pumping vessel, wherein the first inlet valve controls a supply of a solvent into the pumping vessel; (b) closing a first exit valve of the pumping vessel, wherein the first exit valve controls a supply of a solvent exiting the pumping vessel; (c) closing a second inlet valve of the pumping vessel, wherein the second inlet valve controls a supply of a method gas into the pumping vessel; (d) continuously opening and closing a second exit valve to maintain pressure within the pumping vessel, wherein the second exit valve controls a supply of the method gas exiting the pumping vessel; (e) opening the first inlet valve to introduce the solvent into the pumping vessel, wherein the pumping vessel includes a pumping vessel housing forming a pumping vessel chamber and a moveable float located within the pumping vessel chamber, wherein the moveable float is attached to the pumping vessel chamber by a mechanical linkage; (f) engaging the moveable float by introducing solvent into the pumping vessel chamber until the solvent reaches a predetermined level, wherein upon reaching the predetermined level the mechanical linkage of the moveable float engages to close the first inlet valve, to close the second exit valve, and to open the second inlet valve; (g) opening the first exit valve of the pumping vessel to discharge the solvent, wherein the discharged solvent is injected into the heat exchanger; (h) closing the first exit valve of the pumping vessel; and (i) closing the second inlet valve of the pumping vessel.
In yet another embodiment of the present invention, a system for removing buildup in a heat exchanger, the system includes: (a) a pumping vessel, wherein the pumping vessel includes: (i) a pump housing forming a pump chamber, (ii) a moveable float located within the pump chamber, wherein the moveable float is attached to the pump chamber by a mechanical linkage, (iii) a first inlet leading into the pump chamber, wherein the first inlet introduces a solvent into the pump chamber, (iv) a first inlet valve for controlling supply of the solvent into the pump chamber, (v) a first exit, wherein the first exit discharges the solvent from the pump chamber, (vi) a first exit valve for controlling the discharge of solvent exiting the pump chamber, (vii) a second inlet leading into the pump chamber, wherein the second inlet introduces a process gas into the pump chamber, (viii) a second inlet valve for controlling supply of the process gas into the pump chamber, (ix) a second exit, wherein the second exit discharges process gas from the pump chamber, (x) a second exit valve for controlling the discharge of solvent exiting the pump chamber; and (b) a heat exchanger, wherein the first exit and the first exit valve are between the pumping vessel and the heat exchanger, and wherein the heat exchanger is configured to receive the solvent.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is shown by way of example and not by limitation in the accompanying figures, in which:
FIG. 1 is a schematic diagram of one embodiment of the deriming process according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not as a limitation of the invention. 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 illustrated or described as part of one embodiment can be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations that come within the scope of the appended claims and their equivalents.
A cascaded LNG process uses one or more refrigerant systems for sequentially transferring heat energy from the natural gas stream to the environment where different refrigeration systems may use different refrigerants. Each refrigeration system functions as a heat pump by removing heat energy from the natural gas stream as the stream is progressively cooled to lower and lower temperatures. In so doing, the thermal energy removed from the natural gas stream is ultimately rejected (pumped) to the environment via energy exchange with one or more refrigerants.
The design of a cascaded refrigeration process involves the balancing of thermodynamic efficiencies and capital costs. In heat transfer processes, thermodynamic irreversibilities are reduced as the temperature gradients between heating and cooling fluids become smaller, but obtaining such small temperature gradients generally requires significant increases in the amount of heat transfer area, major modifications to various process equipment and the proper selection of flow rates through such equipment so as to ensure that both flow rates and approach and outlet temperatures are compatible with the required heating/cooling duty.
One of the most efficient and effective means of liquefying natural gas is via an optimized cascade-type operation in combination with expansion-type cooling. Such a liquefaction process is comprised of the sequential cooling of a natural gas stream at an elevated pressure, for example about 625 psia, by passage through a multistage propane cycle, a multistage ethane or ethylene cycle, and an open-end methane cycle which utilizes a portion of the feed gas as a source of methane and which includes therein a multistage expansion cycle to further cool the same and reduce the pressure to near-atmospheric pressure. In the sequence of cooling cycles, the refrigerant having the highest boiling point is utilized first followed by a refrigerant having an intermediate boiling point and finally by a refrigerant having the lowest boiling point. As used herein, the term “propane chiller” shall denote a cooling system that employs a refrigerant having a boiling point the same as, or similar to, that of propane or propylene. As used herein, the term “ethylene chiller” shall denote a cooling system that employs a refrigerant having a boiling point the same as, or similar to, that of ethane or ethylene. As used herein, the terms “upstream” and “downstream” shall be used to describe the relative positions of various components of a natural gas liquefaction plant along the flow path of natural gas through the plant.
Various pretreatment steps provide a means for removing undesirable components, such as acid gases, mercaptan, mercury, and moisture from the natural gas feed stream delivered to the facility. The composition of this gas stream may vary significantly. As used herein, a natural gas stream is any stream principally comprised of methane which originates in major portion from a natural gas feed stream, such feed stream for example containing at least 85 percent methane by volume, with the balance being ethane, higher hydrocarbons, nitrogen, carbon dioxide and a minor amounts of other contaminants such as mercury, hydrogen sulfide, and mercaptan. The pretreatment steps may be separate steps located either upstream of the cooling cycles or located downstream of one of the early stages of cooling in the initial cycle. The following is a non-exclusive listing of some of the available means which are readily available to one skilled in the art: (1) acid gases and to a lesser extent mercaptan are routinely removed via a sorption process employing an aqueous amine-bearing solution; (2) a major portion of the water is routinely removed as a liquid via two-phase gas-liquid separation following gas compression and cooling upstream of the initial cooling cycle and also downstream of the first cooling stage in the initial cooling cycle; (3) mercury is routinely removed via mercury sorbent beds and (4) residual amounts of water and acid gases are routinely removed via the use of properly selected sorbent beds such as regenerable molecular sieves.
The pretreated natural gas feed stream is generally delivered to the liquefaction process at an elevated pressure or is compressed to an elevated pressure, that being a pressure greater than 500 psia, preferably about 500 psia to about 900 psia, still more preferably about 500 psia to about 675 psia, still yet more preferably about 600 psia to about 675 psia, and most preferably about 625 psia. The stream temperature is typically near ambient to slightly above ambient. A representative temperature range being 60° F. to 138° F.
As previously noted, the natural gas feed stream is cooled in a plurality of multistage (for example, three) cycles or steps by an indirect heat exchange with a plurality of refrigerants, preferably three. As used herein, the term “heat exchanger” broadly means any device capable of transferring heat from one media to another media, including particularly any structure, e.g., device commonly referred to as a heat exchanger. Thus, the heat exchanger may be a plate-fin, shell-and-tube, spiral core-in-kettle or any other type of heat exchanger. Preferably, the heat exchanger is a brazed aluminum plate-fin type. The overall cooling efficiency for a given cycle improves as the number of stages increases but this increase in efficiency is accompanied by corresponding increases in net capital cost and process complexity. The feed gas is preferably passed through an effective number of refrigeration stages, nominally two, preferably two to four, and more preferably three stages, in the first closed refrigeration cycle utilizing a relatively high boiling refrigerant. Such refrigerant is preferably comprised in major portion of propane, propylene or mixtures thereof, more preferably the refrigerant comprises at least about 75 mole percent propane, even more preferably at least 90 mole percent propane, and most preferably the refrigerant consists essentially of propane.
Thereafter, the processed feed gas flows through an effective number of stages, nominally two, preferably two to four, and more preferably two or three, in a second closed refrigeration cycle in heat exchange with a refrigerant having a lower boiling point. Such refrigerant is preferably comprised in major portion of ethane, ethylene or mixtures thereof, more preferably the refrigerant comprises at least about 75 mole percent ethylene, even more preferably at least 90 mole percent ethylene, and most preferably the refrigerant consists essentially of ethylene. Each cooling stage comprises a separate cooling zone. As previously noted, the processed natural gas feed stream is combined with one or more recycle streams (i.e., compressed open methane cycle gas streams) at various locations in the second cycle thereby producing a liquefaction stream. In the last stage of the second cooling cycle, the liquefaction stream is condensed (i.e., liquefied) in major portion, preferably in its entirety thereby producing a pressurized LNG-bearing stream. Generally, the process pressure at this location is only slightly lower than the pressure of the pretreated feed gas to the first stage of the first cycle.
Generally, the natural gas feed stream will contain such quantities of C 2 + components so as to result in the formation of a C 2 + rich liquid in one or more of the cooling stages. This liquid is removed via gas-liquid separation means, preferably one or more conventional gas-liquid separators. Generally, the sequential cooling of the natural gas in each stage is controlled so as to remove as much as possible of the C 2 and higher molecular weight hydrocarbons from the gas to produce a gas stream predominating in methane and a liquid stream containing significant amounts of ethane and heavier components. An effective number of gas/liquid separation means are located at strategic locations downstream of the cooling zones for the removal of liquid streams rich in C 2 + components. The exact location and number of gas/liquid separation means, preferably conventional gas/liquid separators, will be dependant on a number of operating parameters, such as the C 2 + composition of the natural gas feed stream, the desired BTU content of the LNG product, the value of the C 2 + components for other applications and other factors routinely considered by those skilled in the art of the LNG plant and gas plant operation. The C 2 + hydrocarbon stream or streams may be demethanized via a single stage flash or a fractionation column. In the latter case, the resulting methane-rich stream can be directly returned at pressure to the liquefaction process. In the former case, the methane-rich stream can be repressurized and recycled or can be used as fuel gas. The C 2 + hydrocarbon stream or streams or the demethanized C 2 + hydrocarbon stream may be used as fuel or may be further processed such as by fractionation in one or more fractionation zones to produce individual streams rich in specific chemical constituents (e.g., C 2 , C 3 , C 4 and C 5 +).
The pressurized LNG-bearing stream is further cooled in a third cycle or step referred to as the open methane cycle via contact in a main methane economizer with flash gases (i.e., flash gas streams) generated in this third cycle in a manner to be described later and via expansion of the pressurized LNG-bearing stream to near atmospheric pressure. The flash gasses used as a refrigerant in the third refrigeration cycle are preferably comprised in major portion of methane, more preferably the refrigerant comprises at least about 75 mole percent methane, still more preferably at least 90 mole percent methane, and most preferably the refrigerant consists essentially of methane. During expansion of the pressurized LNG-bearing stream to near atmospheric pressure, the pressurized LNG-bearing stream is cooled via at least one, preferably two to four, and more preferably three expansions where each expansion employs as a pressure reduction means either Joule-Thomson expansion valves or hydraulic expanders. The expansion is followed by a separation of the gas-liquid product with a separator. When a hydraulic expander is employed and properly operated, the greater efficiencies associated with the recovery of power, a greater reduction in stream temperature, and the production of less vapor during the flash step will frequently more than off-set the more expensive capital and operating costs associated with the expander. In one embodiment, additional cooling of the pressurized LNG-bearing stream prior to flashing is made possible by first flashing a portion of this stream via one or more hydraulic expanders and then via indirect heat exchange means employing said flash gas stream to cool the remaining portion of the pressurized LNG-bearing stream prior to flashing. The warmed flash gas stream is then recycled via return to an appropriate location, based on temperature and pressure considerations, in the open methane cycle and will be recompressed.
When the pressurized LNG-bearing stream, preferably a liquid stream, entering the third cycle is at a preferred pressure of about 550-650 psia, representative flash pressures for a three stage flash process are about 170-210, 45-75, and 10-40 psia. Flashing of the pressurized LNG-bearing stream, preferably a liquid stream, to near atmospheric pressure produces an LNG product possessing a temperature of about −240° F. to −260° F.
The liquefaction process may use one of several types of cooling which include but is not limited to (a) indirect heat exchange, (b) vaporization, and (c) expansion or pressure reduction. Indirect heat exchange, as used herein, refers to a process wherein the refrigerant cools the substance to be cooled without actual physical contact between the refrigerating agent and the substance to be cooled. Specific examples of indirect heat exchange means include heat exchange undergone in a shell-and-tube heat exchanger, a core in-kettle heat exchanger, and a brazed aluminum plate-fin heat exchanger. The physical state of the refrigerant and substance to be cooled can vary depending on the demands of the system and the type of heat exchanger chosen. Thus, a shell-and-tube heat exchanger will typically be utilized where the refrigerating agent is in a liquid state and the substance to be cooled is in a liquid or gaseous state or when one of the substances undergoes a phase change and process conditions do not favor the use of a core-in-kettle heat exchanger. As an example, aluminum and aluminum alloys are preferred materials of construction for the core but such materials may not be suitable for use at the designated process conditions. A platefin heat exchanger will typically be utilized where the refrigerant is in a gaseous state and the substance to be cooled is in a liquid or gaseous state. Finally, the core-in-kettle heat exchanger will typically be utilized where the substance to be cooled is liquid or gas and the refrigerant undergoes a phase change from a liquid state to a gaseous state during the heat exchange.
Vaporization cooling refers to the cooling of a substance by the evaporation or vaporization of a portion of the substance with the system maintained at a constant pressure. Thus, during the vaporization, the portion of the substance which evaporates absorbs heat from the portion of the substance which remains in a liquid state and hence, cools the liquid portion.
Finally, expansion or pressure reduction cooling refers to cooling which occurs when the pressure of a gas, liquid or a two-phase system is decreased by passing through a pressure reduction means. In one embodiment, this expansion means is a Joule-Thomson expansion valve. In another embodiment, the expansion means is either a hydraulic or gas expander. Because expanders recover work energy from the expansion process, lower process stream temperatures are possible upon expansion.
As previously discussed the present invention focuses on the removal or deriming of the progressive accumulation of buildup, such as water in the form of ice and relatively heavy hydrocarbons present in the gas feed in solid form, upon the interior surfaces of the cryogenic heat exchanger.
Referring to FIG. 1 , a pumping vessel 20 provides a mechanism for injecting solvent into the cryogenic heat exchanger 10 . The pumping vessel includes a first inlet valve 22 for controlling supply of solvent into the pumping vessel, a first exit valve 24 for solvent exiting the pumping vessel, a second inlet valve 26 for controlling supply of process gas into the pumping vessel, and a second exit valve 28 for process gas exiting the pumping vessel.
The process begins with a minimal amount of solvent in the pump chamber of the pumping vessel. FIG. 1 depicts this minimal amount of solvent via line 11 . The first inlet valve 22 , the second inlet valve 26 , and the first exit valve 24 are all in closed positions, while the process gas exit valve 28 is continuously opening and closing as necessary to maintain appropriate pressure within the pumping vessel 20 . The first inlet valve 22 is then open to allow the solvent to enter the pumping vessel 20 via conduit 2 in an effort to fill the vessel. As the pumping vessel 20 chamber fills with solvent, a float within the pump chamber, not pictured, begins to rise as the amount of deriming solvent increases. When the float reaches a predetermined level, level 12 in FIG. 1 , the float operates as a snap-action mechanical linkage to close the first valve 22 , to then close the second valve 28 , and to then open the second inlet valve 26 allowing for entry of the process gas via conduit 6 in an effort to pressurize the vessel. The snap-action mechanical linkage ensures a rapid changeover from filling to pumping. Thus, as the pressure inside the pump increases above the back pressure, the solvent is forced through the first exit valve 24 and injected into the cryogenic heat exchanger 10 via conduit 12 . After discharge, the first exit valve 24 is closed followed by the process gas inlet valve 26 thus placing the vessel back in pressure control.
In an embodiment, the pumping vessel 20 is a positive displacement pump. In another embodiment, the pumping vessel is a blowcase. In yet another embodiment, the pumping vessel is a steam condensate pump. In a further embodiment, the pumping vessel is a mechanical pressure powered pump.
The process gas utilized in the pumping vessel is capable of co-existing with the deriming solvent without negatively impacting the integrity of the solvent. In an embodiment, a high pressure process gas is utilized.
As previously discussed, the injection of the solvent into the cryogenic heat exchanger assists in the alleviation and elimination of progressive accumulation of buildup within the cryogenic heat exchanger, while allowing the deriming solvent to be delivered to the cryogenic heat exchanger at a variable rate, i.e., continuous or intermittent injection. In an embodiment, the injection can be provided as a slug for high rate injection, i.e., slug deriming. In another embodiment, the injection can be provided as metered into the system. In an embodiment, if the injection is provided as metered into the system a needle valve can be utilized, or a flow control valve can be utilized or any other control system to provide a relatively constant time-averaged rate of injection for continuous deriming of the heat exchanger.
In an embodiment, the solvent is a deriming solvent. In another embodiment, the solvent is liquid hydrocarbon. In another embodiment, the solvent is liquid petroleum gas (LPG). However, other liquid hydrocarbons which can be expected to be suitable for deriming the interior surfaces of the cryogenic heat exchanger are also of significant importance in the practice of this invention. For example, suitable solvent can include liquefied gas mixtures containing varying fraction of approximately 0.1 to approximately 80 volume percent or higher methane, ethane, propane, butane, pentane and hexane from distillation.
The preferred embodiment of the present invention has been disclosed and illustrated. However, the invention is intended to be as broad as defined in the claims below. Those skilled in the art may be able to study the preferred embodiments and identify other ways to practice the invention that are not exactly as described in the present invention. It is the intent of the inventors that variations and equivalents of the invention are within the scope of the claims below and the description, abstract and drawings not to be used to limit the scope of the invention | The invention relates to a method and apparatus relate for the liquefaction of natural gas. In another aspect, the present invention concerns the deriming the interior surfaces of a cryogenic heat exchanger employed in the liquefaction of natural gas. In another aspect, the present invention concerns the utilization of a pump to derim the interior surfaces of a cryogenic heat exchanger. | 5 |
RELATED APPLICATIONS
This application is related to and claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 61/642,205 titled Luminaire with Prismatic Optic filed May 3, 2012, the contents of which are incorporated in their entirety herein.
FIELD OF THE INVENTION
The present invention relates to systems and methods for generating light, and more particularly, a system for effectively distributing light substantially about a light bulb.
BACKGROUND OF THE INVENTION
Achieving nearly uniform light distribution about a light bulb has long been a goal in the lighting industry. Success in this goal has largely depended upon the method of providing light employed by the bulb. Specifically, different methods of light generation produce light with different distributions, which must be compensated for in the construction of the bulb.
Most of the earliest light bulbs were incandescent, which generate light by heating a filament wire until it glows. Due to the relatively sparse nature of the supporting structures necessary for the filament, and due to the 360-degree dispersion of light by the filament, achieving nearly uniform distribution about an incandescent light bulb was not difficult to achieve. However, due to inefficiencies in the method of light production employed in incandescent light bulbs, other methods are desirable.
Fluorescent lamps, specifically compact fluorescent lamps (CFLs), have been steadily replacing incandescent light bulbs in many lighting applications. Similar to incandescent, CFLs produce light in approximately 360 degrees by exciting mercury vapor to cause a gas discharge of light. CFLs are more energy efficient than incandescent light bulbs, but suffer a number of undesirable traits. Many CFLs have poor color temperature, resulting in a less aesthetically pleasing light. Some CFLs have prolonged warm-up times, requiring up to three minutes before maximum light output is achieved. All CFLs contain mercury, a toxic substance that must be handled carefully and disposed of in a particular manner. Furthermore, CFLs suffer from a reduced life span when turned on and off for short period. Therefore, there are a number of disadvantages to using CFLs in a lighting system.
Light emitting diodes (LEDs) are increasingly being used as the light source in light bulbs. LEDs offer greater efficiencies than CFLs, have an increased life span, and are increasingly being designed to have desirable color temperatures. Moreover, LEDs do not contain mercury or any other toxic substance. However, by the very nature of their design and operation, LEDs have a directional output. Accordingly, the light emitted by an LED may not have the nearly omni-directional and uniform light distribution of incandescents and CFLs. Although multiple LEDs can and frequently are used in a single light bulb, solutions presented so far do not have light distribution properties approximating or equaling the dispersion properties of incandescents or CFLs. Accordingly, there is a long felt need for a light bulb that can utilize LEDs as a light source while maintaining uniform and nearly omni-directional light distribution properties.
One issue facing the use of LEDs to replace traditional light bulbs is heat. LEDs suffer damage and decreased performance when operating in high-heat environments. Moreover, when operating in a confined environment, the heat generated by the LED and its attending circuitry itself can cause damage to the LED. Heat sinks are well known in the art and have been effectively used to provide cooling capacity, maintaining an LED-based light bulb within a desirable operating temperature. However, heat sinks can sometimes negatively impact the light distribution properties of the light bulb, resulting in non-uniform distribution of light about the bulb. Accordingly, there is a long felt need for an LED-based light bulb capable of providing uniform light distribution that maintains a desirable operating temperature.
This background information is provided to reveal information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.
SUMMARY OF THE INVENTION
With the foregoing in mind, embodiments of the present invention are related to a luminaire that utilizes a prismatic optic to distribute light from a light emitting element within the luminaire approximately uniformly about the luminaire. The luminaire, according to embodiments of the present invention, can also advantageously combine this prismatic optic with one or more light emitting diodes (LEDs) as a light source, overcoming previous deficiencies in LED-based luminaire designs.
These and other objects, features, and advantages according to the presenting invention are provided by a luminaire including a light source and a prismatic optic. The light source may include one or more LEDs that emit light that is incident upon the prismatic optic. The prismatic optic, in turn, may refract the light substantially about the luminaire, resulting in approximately omni-directional and uniform light distribution. The luminaire may further include a base for connection to a light socket and a heat sink for cooling the light source. The base may be attached to the heat sink, which is, in turn, attached to the light source and the prismatic optic. A surface of the heat sink may have reflective properties configured to reflect light generally towards the prismatic optic. The luminaire may further include a circuit board including circuitry configured to power the light source. The circuit board may be positioned so as to be optimally cooled by the heat sink.
The prismatic optic, according to embodiments of the present invention, may be configured to have specific light refracting properties. Specifically, the prismatic optic may refract light within certain regions with certain uniformities. The light may be refracted within regions of 0 degrees to 135 degrees, 135 degrees to 150 degrees, and 150 degrees to 180 degrees. Furthermore, the light may be of uniform intensity to within a certain percentage of an average intensity, such as within 20%, within 10%, within 5%, or within 1%.
The light source may include a platform upon which one or more LEDs may be attached. The LEDs may be attached to an upper surface and/or a lower surface of the platform, increasing light distribution. Furthermore, the platform may include a section within which the LEDs may be attached that facilitates electric coupling between the LEDs and the circuit board.
A method aspect of the present invention is for using the luminaire. The method may include the steps of generating light and refracting light according to a desired light distribution.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a luminaire according to an embodiment of the present invention.
FIG. 2 is a perspective view of a lower structure of the luminaire presented in FIG. 1 .
FIG. 3 is a perspective view of a prismatic optic of the luminaire presented in FIG. 1 .
FIG. 4 a is a partial top view of the luminaire presented in FIG. 1 .
FIG. 4 b is a partial bottom view of the luminaire presented in FIG. 1 .
FIG. 5 is a partial side sectional view of the prismatic optic of the luminaire presented in FIG. 1 .
FIG. 6 is a perspective view of an upper structure of the luminaire presented in FIG. 1 .
FIG. 7 is a partial side sectional view of the upper section presented in FIG. 6 .
FIG. 8 is a perspective view of a light source used in connection with the luminaire presented in FIG. 1 .
FIG. 9 a is a perspective view of a housing used in connection with the luminaire presented in FIG. 1
FIG. 9 b is a side sectional view of the luminaire presented in FIG. 1 taken through line 9 b - 9 b.
FIG. 10 is a perspective view of a cap used in connection with the luminaire presented in FIG. 1 .
FIG. 11 is a perspective view of the cross section view of the luminaire as presented in FIG. 9 b.
FIG. 12 is a polar graphical illustration representing a light distribution of the luminaire presented in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now 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. Those of ordinary skill in the art realize that the following descriptions of the embodiments of the present invention are illustrative and are not intended to be limiting in any way. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. Like numbers refer to like elements throughout.
Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.
In this detailed description of the present invention, a person skilled in the art should note that directional terms, such as “above,” “below,” “upper,” “lower,” and other like terms are used for the convenience of the reader in reference to the drawings. Also, a person skilled in the art should notice this description may contain other terminology to convey position, orientation, and direction without departing from the principles of the present invention.
An embodiment of the invention, as shown and described by the various figures and accompanying text, provides a luminaire 100 . Referring initially to FIG. 1 , a luminaire 100 according to an embodiment of the present invention is depicted, the luminaire 100 including a base 110 , a lower structure 200 , a prismatic optic 300 , and an upper structure 600 .
The base 110 of the present embodiment of the luminaire 100 is configured to conform to an Edison screw fitting that is well known in the art. However, the base 110 may be configured to conform with any fitting for light bulbs known in the art, including, but not limited to, bayonet, bi-post, bi-pin, and wedge fittings. Additionally, the base 110 may be configured to conform to the various sizes and configurations of the aforementioned fittings.
In the present embodiment, the base 110 of the luminaire 100 may include an electrical contact 111 formed of an electrically conductive material, an insulator 112 , and a sidewall 113 comprising a plurality of threads 114 . The plurality of threads 114 may form a threaded fitting on inside and outside surfaces of the sidewall 113 . The electrical contact 111 may be configured to conduct electricity from a light socket.
Turning to FIG. 2 , the lower structure 200 may have a lower section 201 defining a first end 202 and an upper section 203 defining a second end 204 . The interface between the lower section 201 and the upper section 202 may define a shelf 206 disposed about a perimeter the lower section 201 . The shelf 206 may include one or more attachment sections 207 at which the prismatic optic 300 may attach to the lower structure 200 . The first end 202 may be attached to the base 110 at the sidewall 113 by any means known in the art, including, not by limitation, use of adhesives or glues, welding, and fasteners.
Each of the first section 201 and the second section 203 may include a void that cooperates with each other to define a longitudinal cavity 208 . The shape and dimensions of the longitudinal cavity 208 will be discussed in greater detail hereinbelow. The upper section 203 may include a body member 209 having an outside surface 210 . The outer surface 210 may be configured to reflect light incident thereupon. The outer surface 210 may have a reflection coefficient of at least about 0.1, or about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9, or about 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, or 0.99, or about 1. In one embodiment, the outer surface 210 may act as a substrate and have a layer of reflective paint applied thereto. The reflective paint may advantageously enhance illumination provided by the light source by causing enhanced reflection of the light prior to reaching the prismatic enclosure 300 , which will be discussed in greater detail below. In another embodiment, the outer surface 210 may have a reflective liner applied thereto. Similarly, the reflective liner may be readily provided by any type of reflective liner which may be known in the art.
The upper section 203 may further include one or more channels 212 formed in the outer surface 210 . The channels 212 may be configured to align with the attachment sections 207 and run parallel to the longitudinal cavity 208 , facilitating the attachment of the prismatic optic 300 to the lower structure 200 .
In the present embodiment, the lower structure 200 may be configured to act as a heat sink. Accordingly, portions of the lower structure 200 may be formed of thermally conductive material. Moreover, portions of the lower structure 200 may include fins 214 . In this embodiment, the fins 214 are configured to run the length of the lower section 201 and extend radially outward therefrom. The fins 214 increase the surface area of the lower structure 200 and permit fluid flow between each fin 214 , enhancing the cooling capability of the lower structure 200 . The fins 214 may have a curved vertical profile to emulate the shape of traditional incandescent light bulbs. Optionally, the fins 214 may be configured to conform to the A19 light bulb standard size. Additional information directed to the use of heat sinks for dissipating heat in an illumination apparatus is found in U.S. Pat. No. 7,922,356 titled Illumination Apparatus for Conducting and Dissipating Heat from a Light Source, and U.S. Pat. No. 7,824,075 titled Method and Apparatus for Cooling a Light Bulb, the entire contents of each of which are incorporated herein by reference.
Furthermore, the lower structure 200 may include interior channels formed in the body member 209 . The interior channels may extend from a first opening 216 in an upper surface 222 of the body member 209 to a second opening 218 in an interior surface 224 of the upper section 203 forming the longitudinal cavity 208 . Air may be permitted to flow through the interior channels, providing additional cooling capability. Alternatively, the lower structure 200 may be formed as a substantially solid structure, not including the various structural aspects intended to increase the cooling capacity as described above. The lower structure 200 may further include a recessed region 220 formed in the upper surface 222 of the body member 209 . The recessed region may extend from the void of the upper section 203 to the outside surface 210 .
Referring now to FIG. 3 , a prismatic optic 300 according to an embodiment of the present invention is depicted. In the present embodiment, the prismatic optic 300 may include an upper optic 310 and a lower optic 350 . The upper optic 310 may be attached to the lower optic 350 by any method known in the art, including, but not limited to, threaded coupling, interference fit, adhesives, glues, fasteners, and welding, or combinations thereof. Moreover, in an alternative embodiment, the upper optic 310 and the lower optic 350 may be integrally formed as a single optic. The prismatic optic 300 is configured to define an optical chamber 301 , wherein the optical chamber 301 is configured to permit a light source to be disposed therein.
The prismatic optic 300 may be formed of any transparent, translucent, or substantially translucent material including, but not limited to, glass, fluorite, and polymers, such as polycarbonate. Types of glass include, without limitation, fused quartz, soda-lime glass, lead glass, flint glass, fluoride glass, aluminosilicates, phosphate glass, borate glass, and chalcogenide glass.
Each of the upper optic 310 and the lower optic 350 may include a sidewall 312 , 352 comprising an inner surface 314 , 354 and an outer surface 316 , 356 . Each of the outer surfaces 316 , 356 may comprise a plurality of grooves 318 , 358 formed thereon. Turning to FIGS. 4 a - b , the grooves 318 , 358 are configured to have substantially straight sides 320 , 360 , the sides forming alternating peaks 322 , 362 and valleys 324 , 364 . The angles formed at the peaks 322 , 362 and valleys 324 , 364 , as well as the length of the sides 320 , 360 may be selectively chosen to alter the refraction of light thereby.
Returning now back to FIG. 3 , each of the outside surfaces 316 , 356 may be configured to have a curvature. The degree of the curvature may be selected according to design standards, such as, a curvature that conforms to an A19 light bulb standard, having a diameter of about 2.375 inches. The curvature may also conform to any other industry standard, including, but not limited to, A15 (about 1.875 inches), A21 (about 2.625 inches), G10 (about 1.25 inches), G20 (about 2.5 inches), G25 (about 3.125 inches), G30 (about 3.75 inches), and G40 (about 5 inches). The preceding are provided for exemplary purposes and are not limiting in any way.
The lower optic 350 may include one or more protruding members 366 extending radially inward from a first end the inner surface 354 . The protruding members 366 may be configured to pass through the one or more channels 212 to interface with the attachment sections 207 , which are depicted in FIG. 2 . Each protruding member 366 may be associated with one channel 212 and one attachment section 207 . Each of the protruding members 366 may be attached to an attachment section 207 , thereby attaching the optic 300 to the lower structure 200 . The protruding members 366 may be attached to the attachment sections 207 by any method that can withstand the forces experienced by the luminaire 100 , such as those experienced during installation and removal. Methods of attachment include, but are not limited to, adhesives, glues, welding, and fasteners. Similarly, the upper optic 310 may include protruding members 326 extending radially inward from a first end of the inner surface 314 . The protruding members 326 may be configured to attach to the upper structure 600 described in detail hereinbelow.
Referring now to FIG. 5 , each of the inner surfaces 314 , 354 may include a plurality of generally vertical segments 328 , 368 and a plurality of generally horizontal segments 330 , 370 . Each of the generally vertical segment 328 , 368 may have two ends and may be attached at each end to a generally horizontal segment 330 , 370 , thereby forming a plurality of prismatic surfaces 332 , 372 . It is not a requirement of the invention that the generally vertical segments 328 , 368 be perfectly vertical, nor is it a requirement that the generally horizontal segments 330 , 370 be perfectly horizontal. Similarly, it is not a requirement of the invention that the generally vertical segments 328 , 368 be perpendicular to the generally horizontal segments 330 , 370 . Each of the prismatic surfaces 332 , 372 may be smooth, having a generally low surface tolerance. Moreover, each of the prismatic surfaces 332 , 372 may be curved, forming a diameter of the inner surfaces 314 , 354 .
The variance of the generally vertical segments 328 , 368 from vertical may be controlled and configured to desirously refract light. Similarly, the variance of the generally horizontal segments 330 , 370 from horizontal may be controlled and configured to produce prismatic surfaces 330 , 370 that desirously refract light. Accordingly, the prismatic surfaces 332 , 372 may cooperate with the grooves 318 , 358 , as depicted in FIGS. 3 and 4 a - b , to desirously refract light about the luminaire 100 (shown in FIG. 1 ).
Referring now to FIG. 6 , the upper structure 600 of an embodiment of the present invention is depicted. The upper structure 600 may include a body member 602 having an outer surface 604 . The outer surface 604 may be configured to reflect light incident thereupon. The outer surface 604 may have a reflection coefficient of at least about 0.1, or about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9, or about 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, or 0.99, or about 1. In one embodiment, the outer surface 604 may act as a substrate and may have a layer of reflective paint applied thereto. In another embodiment, the outer surface 604 may have a reflective liner applied thereto.
The upper structure 600 may further include a ridge 606 . The ridge 606 may interface with the prismatic optic 300 , thereby constraining the prismatic optic 300 between the upper structure 600 and the lower structure 200 . Furthermore, the ridge 606 may include one or more attachment surfaces 608 configured to facilitate attachment of the upper structure 600 to the prismatic optic 300 , as shown in FIG. 3 . The protruding members 326 of the upper optic 310 may be attached to the attachment sections 608 by any method that can withstand the forces experienced by the luminaire 100 , such as those experienced during installation and removal. Methods of attachment include, but are not limited to, adhesives, glues, welding, and fasteners.
The upper structure 600 may further include one or more channels 610 formed in the outer surface 604 . The channels 610 may be configured to align with the attachment sections 608 , permitting the passage of protruding members 326 therethrough and facilitating the attachment of the prismatic optic 300 to the upper structure 600 .
In the present embodiment, the upper structure 600 may be configured to act as a heat sink. Accordingly, portions of the upper structure 600 may be formed of thermally conductive material. Moreover, portions of the upper structure 600 may include fins 612 . In the illustrated embodiment, the fins 612 are configured to extend from the ridge 606 generally upwards and towards a longitudinal axis of the upper structure 600 . The fins 612 advantageously increase the surface area of the upper structure 600 and permit fluid flow between each fin 612 , enhancing the cooling capability of the lower structure 600 . The fins 612 may have a curved vertical profile to emulate the shape of traditional incandescent light bulbs. Optionally, the fins 612 may be configured to conform to the A19 light bulb standard size. Those skilled in the art will appreciate that the present invention contemplates the use of various configurations of fins to enhance heat dissipation.
Referring now additionally to FIG. 7 , the body member 602 may further include an inner surface 614 defining an internal cavity 616 . The internal cavity 616 may be configured to cooperate with the longitudinal cavity 208 of the lower structure 200 , defining a continuous cavity. Furthermore, the body member 602 may include a shelf 617 extending radially inward from the inner surface 614 into the internal cavity 616 .
As also illustrated in FIGS. 6-7 , the upper structure 600 may further include a recessed section 618 on the top of the upper structure 600 . The recessed section 618 may include an upper attachment section 620 . The upper attachment section 620 may be configured to attach a housing 900 (described below and illustrated in FIG. 9 ) thereto. The circuit board will be described in greater detail hereinbelow. The attachment section 620 may be configured to permit attachment by any method known in the art, including, but not limited to, fasteners, such as screw and threads, adhesives, glues, and welding. The upper structure 600 may further include a recessed region 622 formed in a lower surface of the body member 602 . The recessed region 622 may be positioned so as to approximately align with the recessed region 220 of the lower structure 200 . Alternatively, the upper structure 600 may be formed as a substantially solid structure, not including the various structural aspects intended to increase the cooling capacity as described above.
Referring now to FIG. 8 , according to an embodiment of the invention, a luminaire including a light source 800 is provided. The present embodiment of the light source 800 employs one or more light emitting elements 802 . The light emitting elements 802 may be disposed within the optical chamber 301 of the prismatic optic 300 , as depicted in FIG. 3 .
The light emitting elements 802 may be oriented to emit light that is incident upon the prismatic surfaces 332 of the upper optic 310 as well as the prismatic surfaces 372 of the lower optic 350 , as depicted, for example, in FIG. 5 . Accordingly, the light emitting elements 802 may be configured to emit light generally radially outward as well as upwards and downwards from the luminaire 100 , as shown in FIG. 1 .
According to the present embodiment of the invention, the light source 800 may include a platform 804 . The platform 804 may include an upper surface 806 , a lower surface 808 , and a void 809 , wherein each of the upper and lower surfaces 806 , 808 are generally flat and configured to permit attachment of the light emitting elements 802 thereto. For example, the light source 800 may include a channel 810 formed into one of the upper surface 806 and the lower surface 808 , or both. The channel 810 may be configured to form a region in the upper surface 806 into which the light emitting elements 802 may be there attached.
The location of the channel 810 on the upper surface 806 may be selectively chosen. In the present embodiment, the channel 810 is formed generally about the periphery of the upper surface 806 , although the channel 810 may be formed in any part of the upper surface 806 . In some embodiments, a plurality of light emitting elements 802 may be distributed within the channel 810 . Each of the plurality of light emitting elements 802 may be selectively distributed, for example, they may be spaced at regular intervals. In an alternative example, the light emitting elements 802 may be clustered in groups. The configuration of the disposition of the light emitting elements 802 may be selected to achieve a desired lighting profile or outcome.
The channel 810 may further include an attachment material disposed within the channel 810 . The attachment material may facilitate the attachment of the light emitting elements 802 within the channel 810 . Furthermore, the attachment material may facilitate the operation of the light emitting elements 802 . For example, where the light emitting elements 802 are LEDs, the attachment material may be formed of an electrically conductive material. Furthermore, the attachment material may be configured to include two or more electrical conduits that are isolated from each other, facilitating the operation of the light emitting elements 802 .
The light source 800 may further comprise a communication section 812 formed adjacent the channel 810 . Accordingly, the communication section 812 may be formed in either of the upper surface 806 and the lower surface 808 , or both. The communication section 812 may contact the channel 810 . Furthermore, the communication section 812 may be formed of an electrically conductive material. Accordingly, the communication section 812 may be in electrically coupled to the channel 810 .
The communication section 812 may include a first terminal 814 and a second terminal 816 . Each of the first and second terminals 814 , 816 may be formed of an electrically conductive material, may contact the channel 810 , and further may be electrically coupled to the channel 810 . Furthermore, where the channel 810 may include an attachment section including two or more isolated electrical conduits, the first terminal 814 may be in communication with a first electrical conduit of the attachment section, and the second terminal 816 may be in communication with a second electrical conduit of the attachment section. For example, and not by limitation, the first terminal 814 may be in communication with a power source conduit, and the second terminal may be in communication with a ground conduit.
Still referring to FIG. 8 , the first and second terminals 814 , 816 may each include a pad 818 , 820 respectively. The pads 818 , 820 may be configured to facilitate attachment of an electrical communication medium thereto. For example, and not by limitation, the dimensions of the pads may be selectively chosen to permit a wire to be soldered thereto. The pads 818 , 820 may be disposed approximately adjacent to the void 809 . Moreover, the pads 818 , 820 may be positioned so as to approximately align with the recessed region 220 of the lower structure 200 and the recessed region 622 of the upper structure 600 . The void 809 may be disposed about approximately the center of the platform 804 . The void 809 may be positioned and dimensioned to approximately align with the longitudinal cavity 208 as shown in FIG. 1 and the internal cavity 616 as shown in FIG. 7 , defining a continuous cavity.
Referring now to FIG. 9 a , a housing 900 according to an embodiment of the invention is presented. The housing 900 may be configured to be disposed substantially about a power source. The housing 900 may include a base section 910 and a monolithic section 950 . The base section 910 may be configured to attach the housing 900 to the base 110 as shown in FIG. 1 . Specifically, the base section 910 may include a body member 911 including plurality of threads 912 configured to cooperate with the threads 114 of the base 110 , wherein the threads 114 are functional on both an inside surface and an outside surface of the base 110 . Alternatively, the base section 910 may be attached to the base 110 by other methods, including, but not limited to, adhesives, glues, fasteners, and welding.
The base section 910 may include an opening (not shown) at a first end 914 . The opening may be configured to have the shape and sufficient dimensions to permit a power source to pass therethrough. The base section 910 may further include a flange 916 extending radially outward from the body member 911 . The base section 910 may still further include a sidewall 918 extending approximately orthogonally from the flange 916 . In one embodiment, the sidewall 918 may be configured to interfere with the fins 214 of the lower structure 200 . In such an embodiment, the housing 900 may be disposed within the longitudinal cavity 208 of the lower structure 200 , and the interference between the sidewall 918 and the fins 214 restricts the translation of the housing 900 beyond the point of that interference. Further, the base section 910 may include one or more ribs 920 that may be attached to the sidewall 918 , the flange 916 , and the monolithic section 950 .
The monolithic section 950 may be configured as a hollow, generally straight, substantially elongated structure. It may include a first end 952 and a second end 954 , with the first end 952 being adjacent the base section 910 and the second end 954 being substantially apart from the base section 910 . The monolithic section 950 may include one or more sidewalls 956 intermediate the first end 952 and the second end 954 , extending generally upward from the base section 910 . The sidewalls 956 may be attached and continuous, so as to define an internal cavity there between. The dimensions of the internal cavity may be sufficient to permit a power source to be at least partially disposed therein, as depicted in FIG. 9 b.
At least one of the sidewalls 956 may include an opening 957 towards the second end 954 . The opening 957 may be configured to facilitate the electrical coupling between a power source and the light source, illustrated in FIG. 8 , and described in greater detail hereinbelow.
At least one of the sidewalls 956 may include one or more vents 958 . The vents 958 may be positioned anywhere along the sidewall 956 . In the present embodiment, the vents 958 are positioned substantially toward the first end 952 . The positioning of the vents 958 , as well as their shape and dimensions, may be selected so as to facilitate the flow of air between the internal cavity defined by the sidewalls 956 and the area surrounding the housing 900 . In one embodiment of the invention, the flow of air may increase the cooling capability of the housing 900 , thereby reducing the operating temperature of a power source disposed within the internal cavity defined by the sidewalls 956 . For example, the vents 958 may be positioned adjacent those parts of a power source that generate the most heat, permitting the rapid transportation of air heated by the power source out of the housing 900 and to heat sinks, such as certain embodiments of the upper structure 200 and the lower structure 600 .
The monolithic section 950 may further include an attachment section 960 located substantially towards the second end 954 . Referring now to FIG. 7 , the attachment section 960 may be configured to attach to the upper attachment section 620 of the upper structure 600 . The attachment section includes a receiving lumen 962 through which a fastener may be disposed and attached thereto. In the present embodiment, a fastener 624 is disposed through the upper receiving section 620 and into the receiving lumen 962 , attaching to the receiving lumen, thereby fixedly attaching the housing 900 to the upper structure 600 . However, alternative embodiments permit the attachment section 960 to attach to the upper attachment section 920 by any method known in the art, including, but not limited to, adhesives, glues, and welding.
Referring now to FIG. 10 , according to an embodiment of the invention, a luminaire including a cap 700 is provided. The cap 700 is configured to cover the recessed section 618 of the upper structure 600 , as depicted in FIG. 7 . The cap 700 includes a domed section 702 and a plurality of tabs 704 extending generally downward and approximately perpendicular to the domed section 702 . One or more of the plurality of tabs 704 may include a catch 706 disposed on one end of the tab 704 . As shown in FIG. 7 , the catch 706 may engage with the shelf 617 of the upper structure 600 , thereby removably coupling the cap 700 to the upper structure 600 .
Referring now to FIG. 11 , a power source according to an embodiment of the present invention is presented. In the present embodiment, the power source may include a circuit board 1000 . The circuit board 1000 may be configured to condition power to be used by the light emitting elements 802 of the light source 800 . Furthermore, the circuit board 1000 may have a first end 1002 and a second end 1004 , wherein the first end 1002 is positioned generally downward and toward the base 110 , and the second end 1004 is positioned generally upward and toward the upper structure 600 . The circuit board 1000 may be dimensioned to permit at least a portion of the circuit board 1000 to be disposed within the internal void of the housing 900 .
The circuit board 1000 may include a first electrical contact 1010 . The first electrical contact may be positioned toward the first end 1002 of the circuit board 1000 . The first electrical contact 1010 may be configured to electrically couple with the electrical contact 111 of the base 110 , thereby enabling the first electrical contact 1010 to supply power to the circuit board 1000 . The circuit board 1000 may further include a second electrical contact 1020 . The second electrical contact 1020 may be positioned toward the second end 1004 of the circuit board 1000 . The second electrical contact 1020 may be configured to electrically couple with the pads 818 , 820 ( 820 not shown) of the light source 800 . The electrical coupling between the second electrical contact 1020 and the pads 818 , 820 enables the circuit board 1000 to deliver power to the light emitting elements 802 .
In one embodiment, the electrical contact 111 conducts power from a light fixture that provides 120-volt alternating current (AC) power. Furthermore, in the embodiment, the light emitting elements 802 comprise LEDs requiring direct current (DC) power at, for instance, five volts. Accordingly, the circuit board 1000 may include circuitry for conditioning the 120-volt AC power to 5-volt DC power.
In a further embodiment, the circuit board 1000 may include a microcontroller. The microcontroller may be programmed to control the delivery of electricity to the light source. The microcontroller may be programmed to, for instance, dim the light emitting elements 802 according to characteristics of the electricity supplied through the electrical contact 111 .
Referring now to FIG. 11 , the light emitted from the light emitting elements 802 may cooperate with the prismatic surfaces 332 , 372 and the grooves 318 , 358 to refract the emitted light substantially about the luminaire 100 . The prismatic surfaces, 332 , 372 and the grooves 318 , 358 may be configured to selectively refract light within desired ranges about the luminaire 100 . Furthermore, the light may be refracted to maintain a uniform intensity within desired ranges about the luminaire 100 .
It is understood that the angles referred to herein are measured according to a polar coordinate system, wherein the angles are measured from the positive Z-axis directed vertically. Moreover, the intensities referred to are in reference to an intensity of the light emitted by the luminaire 100 within a certain angle range. In the present embodiment of the invention, the reference intensity is an average intensity of light emitted within the range of angles between 0 degrees and 135 degrees.
Turning now to FIG. 12 , a graph of ranges of light refraction is presented. Light may be refracted within a first range 1210 about the luminaire. The first range 1210 may include angles within a range between about 0 degrees to about 135 degrees. Furthermore, the light emitted within the first range 1210 may be within about 20%, 10%, 5%, or 1% of the average intensity.
Light may also be refracted within a second range 1220 about the luminaire 100 . The second range 1220 may include angles within a range between about 135 to about 150 degrees. Furthermore, the light emitted within the second range 1220 may be within about 20%, 10%, 5%, or 1% of the average intensity. Light may also be refracted within a third range 1230 about the luminaire 100 . The third range 1230 may include angles within a range between about 150 degrees to about 180 degrees. Furthermore, the light emitted within the third range 1230 may be within about 20%, 10%, 5%, or 1% of the average intensity.
Some of the illustrative aspects of the present invention may be advantageous in solving the problems herein described and other problems not discussed which are discoverable by a skilled artisan.
While the above description contains much specificity, these should not be construed as limitations on the scope of any embodiment, but as exemplifications of the presented embodiments thereof. Many other ramifications and variations are possible within the teachings of the various embodiments. 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 or only mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. 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. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
Thus the scope of the invention should be determined by the appended claims and their legal equivalents, and not by the examples given. | A luminaire with a prismatic optic permits the nearly uniform distribution of light about the luminaire. The prismatic optic permits the use of directional light sources, such as light emitting diodes, while maintaining the uniform light distribution. When light emitting diodes are used, the luminaire further includes a heat sink to maintain a desirable operational temperature without negatively affecting the light distribution properties of the luminaire. | 5 |
FIELD OF THE INVENTION
The invention relates generally to interior wall systems for buildings.
BACKGROUND OF THE INVENTION
Interior wall systems are well known. Such systems are commonly used, for example, to finish the open areas in office buildings. One type of interior wall system is a modular partition wall system which is composed of a number of wall panels in a side-by-side arrangement.
The above interior wall systems constructed using glass wall panels (whether transparent, translucent, or opaque) have become increasingly popular due to their aesthetic qualities. Such wall systems are commonly referred to as “glass walls”. The present invention provides improvements in the wall system of this type.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a leveling assembly for an interior wall system is provided. The wall system is composed of a plurality of wall panels configured for installation in a building having a ceiling and a floor. The assembly comprises:
a) at least one elongate floor channel operatively secured to the floor; b) a floor rail longitudinally disposed within the at least one floor channel, wherein the floor rail is adapted to support at least one of the plurality of wall panels; and c) a plurality of levelers positioned along the at least one floor channel, wherein the plurality of levelers are adapted to vertically space apart the floor rail from the at least one floor channel, wherein the plurality of levelers are adapted to substantially level the floor rail in relation to the floor.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a perspective view of a glass wall system according to a preferred embodiment of the present invention.
FIG. 2 is a partial perspective view of the preferred embodiment showing the ceiling retaining assembly and the floor leveling assembly.
FIG. 3 is a partial elevation view of the preferred embodiment.
FIG. 4 is a cross-sectional view of the ceiling retaining assembly and the floor leveling assembly along line 4 - 4 of FIG. 3 .
FIG. 5 is a lengthwise cross-sectional view of the floor leveling assembly of the preferred embodiment.
FIG. 6 is a cross-sectional view of the floor leveling assembly along line 6 - 6 of FIG. 3 .
FIG. 7 is a cross-sectional view of the ceiling retaining assembly and the floor leveling assembly along line 7 - 7 of FIG. 3 .
FIG. 8 is a cross-sectional view of the floor leveling assembly along line 8 - 8 of FIG. 3 .
FIG. 9 is a partial perspective view of the corner of the glass wall according to a preferred embodiment of the present invention.
FIG. 10 is a lengthwise cross-sectional view of the floor leveling assembly according to a second embodiment.
FIG. 11 is a cross-sectional view of the floor leveling assembly along line 11 - 11 of FIG. 10 .
FIG. 12 is a cross-sectional view of the floor leveling assembly along line 12 - 12 of FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an interior wall system 10 according to a first embodiment of the present invention. The interior wall system 10 illustrated in FIG. 1 includes three glass wall panels 12 a , 12 b , 12 c . The upper edge of each glass wall panel is preferably secured within a ceiling retaining assembly 14 and the lower edge of each glass wall panel is secured within a floor leveling assembly 16 . The glass wall panels are joined to each other at their vertical edges preferably by a transparent adhesive material 18 , such as transparent silicone double-sided tape commercially available from 3M Corporation.
It will be understood by those skilled in the art that it is not essential that the wall panels be made of glass. The wall panels may be made from any other suitable material, whether transparent, translucent, or opaque.
Referring to FIG. 2 , the wall panels (for clarity, only panels 12 b and 12 c are shown in FIG. 2 ) are secured at their upper edges 20 to a ceiling retaining assembly 14 .
Referring now to FIGS. 2 and 4 , the ceiling retaining assembly 14 includes a ceiling channel 24 secured to the ceiling 26 at any suitable interval by a fastener 28 . The type of fastener used depends on the type of ceiling 26 . Ceiling gaskets 30 a , 30 b may be provided between the ceiling channel 24 and ceiling 26 for improved sound attenuation. For longer runs, several ceiling channels 24 may be connected in series.
Continuing to refer to FIGS. 2 and 4 , a ceiling rail 32 is received within the ceiling channel 24 . Ceiling rail 32 is secured to ceiling channel 24 also by fasteners (not shown) at any suitable interval (which is offset from the fasteners 28 ) for securing the ceiling channel 24 to ceiling 26 . Additional ceiling gaskets 30 c , 30 d may be positioned between the ceiling channel 24 and the ceiling rail 32 . Preferably, the ceiling gaskets 30 a - d are made of foam or any other suitable sound absorbing material.
A slot 34 is provided in the ceiling rail 32 to receive the upper edge 20 of the panels 12 a - c (only panel 12 b is shown in FIG. 4 ).
Referring now to FIGS. 2 , 3 , 4 , and 7 , elbow brackets 40 are located at the joints of adjacent glass panels, such as the joint between panels 12 b and 12 c . Preferably, a pair of elbow brackets 40 are positioned facing each other at each joint. Each elbow bracket 40 includes a vertical portion 42 which abuts against the panels 12 b , 12 c and a horizontal portion 44 which is secured by fasteners 46 to the ceiling rail 32 . The elbow brackets 40 assist with retaining the panels in the slot 34 and stabilizing the panels.
Referring now to FIGS. 2-4 , clips 50 are also connected to the ceiling rail 32 by fasteners 52 at predetermined intervals. Preferably, the clips 50 are also positioned in facing pairs. Each of the clips 50 includes a vertical portion 54 to assist with retaining and stabilizing the panels 12 b , 12 c . Ribs 55 are preferably provided to add rigidity to the vertical portion 54 of the clips 50 . Each of the clips include flexible lips 56 a - c into which snaps a flexible ridge 58 of a ceiling trim member 60 . Accordingly, the clips 50 perform a dual function of stabilizing the panels and securing the ceiling trim member 60 . Trim gaskets 62 are provided to improve sound attenuation.
The ceiling trim member 60 may be an aluminum extrusion which provides an esthetically pleasing appearance and hides parts of ceiling retaining assembly 14 .
Referring to FIGS. 2-4 and 6 , the floor leveling assembly 16 includes a preferably U-shaped elongate floor channel 74 which is preferably secured to the floor 75 by fasteners 76 located at predetermined intervals. A floor rail 78 is disposed within the floor channel 74 . Preferably, the floor rail 78 is an elongate tube having a rectangular cross section. A number of holes are provided in the top and bottom surfaces of the floor rail 78 , as described in more detail below.
The floor rail 78 is supported by levelers 80 positioned at intervals along the floor channel 74 . Each leveler 80 includes a base 82 which rests on the floor channel 74 . A threaded rod 84 projects upwardly from the base 82 . An axial opening 85 (shown in FIG. 6 ) is provided in threaded rod 84 to permit turning of the threaded rod by an Allen key or the like.
Nuts 86 are located in openings of the bottom surface of the floor rail 78 . The nuts have a circumferential outer groove 88 which engages the edges of the opening in floor rail 78 to fixedly secure the nuts 86 to floor rail 78 . The threaded inner surface of nut 86 engages the threaded rod 84 , which rotates to adjust the vertical distance between the floor channel 74 and the floor rail 78 .
Referring to FIGS. 2 , 3 , and 8 , panel supports 90 are mounted on the top surface of the floor rail 78 . Each panel support 90 includes a housing 92 located within an opening in the top surface of the floor rail 78 . The housing 92 includes a preferably hexagonal-shaped flange 93 which can be turned with a wrench (not shown) or the like. The flange 93 of housing 92 sits on top of the floor rail 78 and is capable of rotating relative to floor rail 78 . A threaded opening 94 is provided in the housing 92 which receives a bolt 96 . The bolt 96 includes a hat 98 with a channel 100 which engages the bottom edge of the glass panel 12 . The panel supports 90 are capable of providing a fine leveling adjustment for the panels 12 , as described in more detail below.
Referring to FIGS. 2-4 and 6 - 7 , elbow brackets 40 and clips 50 are also provided in the floor leveling assembly 16 and are secured to the floor rail 78 in a similar fashion as described for the ceiling retaining assembly 14 . A floor trim member 110 snaps into the clips 50 connected to the floor rail 78 . Like the ceiling trim member 60 , the floor trim member 110 is preferably an aluminum extrusion which hides the floor leveling assembly 16 and provides an esthetically pleasing appearance.
Referring to FIG. 4 , trim gaskets 62 are also provided between the floor trim member 110 and the panels 12 . A floor gasket 112 is secured to the bottom of the floor trim member 110 and extends between the floor trim member and the floor channel 74 . The floor gasket 112 also provides improved sound attenuation.
FIG. 9 shows a corner assembly 120 , which includes a corner bracket 122 which secures the floor rail 78 to a vertical frame member 124 . The vertical frame member 124 may also include the clips 50 to stabilize the vertical edges of the panel 12 a and to permit snapping connection to a trim member (not shown in FIG. 9 ).
The operation of the first embodiment of the invention will now be described with reference to FIGS. 1-8 .
Referring to FIG. 4 , the ceiling retaining assembly 14 and the floor leveling assembly 16 are secured to their desired locations in the ceiling 26 and floor 75 , respectively. The ceiling channel 24 is secured to ceiling 26 by fasteners 28 . The ceiling rail 32 is then secured to the ceiling channel 24 in the same manner.
The floor channel 74 is secured to the floor 75 by fasteners 76 . The levelers 80 are then located at intervals along the floor channel 74 such that that the threaded rod is aligned with the position of the corresponding nut 86 located in the floor rail 78 . The floor rail 78 is then placed within the floor channel 74 , and the vertical distance between the floor rail 78 and floor channel 74 is adjusted by turning the threaded rod 84 in nuts 86 using an Allen key (not shown). The floor rail 78 is adjusted such that it is level to the horizontal. Any suitable means, such as a conventional bubble or laser level may be used to guide the leveling of the floor rail 78 . An exemplary position of the floor rail 78 relative to floor channel 74 is illustrated in FIG. 5 .
Referring to FIGS. 4 and 8 , the panels 12 a - c are then lifted into the slot 34 of ceiling rail 32 and then dropped onto panel supports 90 . In particular, the panels 12 a - c are fitted in channel 100 of hat 98 . If necessary, fine leveling adjustment may be provided by turning the flange 93 with a wrench, which in turn, adjusts the height of the bolt 96 .
Referring now to FIGS. 2 and 3 , each panel 12 a - c is further secured by mounting the clips 50 in both the ceiling and floor assemblies 14 , 16 , respectively. As additional panels are installed in the same manner as described above, elbow brackets 40 are mounted to the ceiling and floor assemblies 14 , 16 at the joint of adjacent panels. Also, the adhesive material 18 is applied along the adjacent vertical edges of the panels. Finally, the ceiling trim member 60 and floor trim member 110 are snapped onto the clips 50 .
FIGS. 10-12 show a second embodiment of the present invention, which is particularly suited for floor surfaces with greater slope, such that greater leveling is required. In this second embodiment, two or more nested floor channels may be provided. For clarity, only two floor channels 74 a , 74 b are illustrated. The uppermost floor channel 74 b supports the floor rail 78 . Levelers 80 are provided between the floor channels 74 a , 74 b , and between the uppermost floor channel 74 b and floor rail 78 . In other respects, the second embodiment is similar to the first embodiment.
While the present invention as herein shown and described in detail is fully capable of attaining the above-described objects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and thus, is representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural and functional equivalents to the elements of the above-described preferred embodiment that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it is to be encompassed by the present claims. | A leveling assembly for an interior wall system is disclosed. The wall system is composed of a number of wall panels configured for installation in a building having a ceiling and a floor. The assembly includes at least one elongate floor channel secured to the floor and a floor rail longitudinally disposed within the floor channel. The floor rail supports one or more of the wall panels. A number of levelers are positioned along the floor channel. The levelers permit the floor rail to be vertically spaced apart from the floor channel. The levelers are adjustable to level the floor rail in relation to the floor. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention discloses an animal trap that is particularly well-suited for destroying moles in their burrows.
2. Description of the Related Art
Traps for destroying moles are well known in the art. Conventional traps include spring-loaded jaws and a trigger. Many traps are set so that the jaws are positioned on either side of a mole burrow or tunnel. A trigger is positioned on the ground above the burrow. When a mole travels between the jaws, vibrations caused by the mole's movement release the trigger so that the jaws close and destroy the mole. Representative examples of such traps are found in U.S. Pat. Nos. 472,038; 1,296,407; 1,923,039 and 2,525,383.
Conventional spring-loaded traps can be unstable when placed in the ground. Particularly after a rain shower, a trap can settle and shift so that a jaw is exposed in the mole burrow, thereby minimizing the chance that a mole will pass between the jaws. Also, the trap may shift so that a mole can pass through the burrow without being caught by the trap. Furthermore, conventional traps can be pushed too far into the ground during installation, thereby decreasing the effectiveness of the trap. Oftentimes, the ground elevation at a mole burrow is rough and uneven. The effectiveness of conventional traps can be decreased as the ground settles away from the trigger.
Consequently, a need exists for improvements in mole traps. It is desirable that a mole trap include an element to stabilize and prevent the trap from shifting after it has been set. It is also desirable that a trap include a trigger which is adjustable to accommodate all types of ground terrain.
SUMMARY OF THE INVENTION
The present invention includes a mole trap that is stabilized on the ground when the trap is set. A platform, connected to the trap, rests on the ground and prevents the trap from being pushed too far into the ground. The present trap also includes a trigger which can be adjusted to accommodate various ground elevations. Once set, the trap cannot be removed from the ground until it is released. The trap has a low profile and shields the trigger from accidental releases. The present mole trap is extremely effective, durable, inexpensive and easy to operate.
In a preferred embodiment, the present invention includes a mole trap having a pair of spring-loaded jaws. A platform is connected to the jaws to limit the travel of the trap into the ground and to stabilize the trap on the ground when it is set. A lever assembly forces the jaws open and sets the trap when a lever reaches an off-center position. An adjustable trigger mechanism is positioned on the ground above a mole borrow. The vibration of a mole traveling beneath the trigger causes the lever assembly to move upwardly from the off-center position so that the jaws close and destroy the animal.
Other features and advantages of the present invention will become more fully apparent from the following detailed description of the preferred embodiment, the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the mole trap of the present invention shown in the closed position.
FIG. 2 is a side elevational view of the mole trap of FIG. 1 shown set in the ground adjacent a mole burrow.
FIG. 3 is a side elevational view of the present mole trap after the trap has been released.
FIG. 4 is a detailed view of a first embodiment of the adjustable trigger mechanism of the present mole trap.
FIG. 5 is a detailed view of the trigger mechanism of FIG. 4 wherein the trigger rod is mounted on a support bar of the second lever.
FIG. 6 is a detailed view of a second embodiment of the adjustable trigger mechanism.
FIG. 7 is a detailed side elevational view of a first embodiment of a spring retainer.
FIG. 8 is a detailed side elevational view of a second embodiment of a spring retainer.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A preferred embodiment of the mole trap of the present invention, indicated generally at 10, is illustrated in FIGS. 1-3. The mole trap 10 includes a first angled member 12 and a second angled member 14. Angled member 12 terminates in a support end 12A and an opposite blade end 12B. Near the mid-point of the angled member 12, member 12 is angled or bent to form an angle greater than 90°. However, other angular configurations for angled member 12 are within the scope of the present invention. In a similar manner, angled member 14 includes a support end 14A and a blade end 14B. Angled members 12 and 14 are hinged together by fastener 20 to form a first jaw 15.
Mole trap 10 also includes angled members 16 and 18 which are hinged together about fastener 22 to form a second jaw 19. A lever assembly 25 is connected to the support ends 12A, 14A, 16A, and 18A of the first and second jaws 15 and 19 to load and set the trap 10. The lever assembly 25 includes a first connecting rod 26 which is secured to support ends 12A and 16A. A second connecting rod 28 is secured to support ends 14A and 18A. A first lever 30 is pivotally connected at its first end 30A to the first connecting rod 26. A second lever 32 is pivotally connected at its first end 32A to the first connecting rod 28. A support bar 34 is pivotally connected to the first lever 30 near the second end 30B of the first lever 30. The second end 32B of the second lever is pivotally connected to the support bar 34. It is preferred that lock washers 33 be used to secure support bar 34 to the first lever 30.
Coil springs 40 and 42 are secured to the first and second connecting rods 26 and 28 on opposite sides of the first and second levers 30 and 32. As illustrated in FIG. 1, spacers 44A through 44D are inserted between the springs 40 and 42 and the levers 30 and 32 to hold the springs 40 and 42 in place. A detailed view of the installation of spacer 44B is illustrated in FIG. 7, wherein spacer 44B is inserted between spring 40 and the first end 32A of the second lever 32. The springs 40 and 42 are selected so that they are not in tension when the first and second jaws 15 and 19 are closed. It is understood that other types of springs can be utilized with the present trap 10. Also, it is possible to incorporate only one spring with the trap 10.
A trigger mechanism, indicated generally at 50, is pivotally connected to the support bar 34. Trigger mechanism 50 includes a trigger rod 52 pivotally connected at its upper end 52A to the support bar 34. As illustrated best in FIGS. 4 and 5, the lower end 52B of trigger rod 52 is threaded. A sleeve nut 54 is secured to a plate 56. As is described below, the sleeve nut 54 is adjusted on the threaded portion 52B of the trigger rod 52 so that the plate 56 rests on the ground. As described below, it is preferred that a loose fit be provided between the trigger rod 52 and the support bar 34.
As illustrated in FIG. 5, it is preferred that an elongated slot 58 be provided in the second end 32B of the second lever 32. The slot 58 guides the trigger rod 52 when the trap 10 is set.
An alternate embodiment of the trigger mechanism 50A is illustrated in FIG. 6. A trigger rod 59 includes a flattened, upper portion 59A pivotally connected to the support bar 34. Other elements of trigger mechanism 50A are the same as trigger mechanism 50. As illustrated, it is desirable that a loose fit be provided between the trigger rod 59 and the support bar 34.
An alternate embodiment of securing spring 40 on connecting rod 28 is illustrated in FIG. 8. A groove 60 is provided in the outer surface of the connecting rod 28 near support end 14A. The end of the spring 40 is secured in groove 60. A cotter pin 62 is inserted in the connecting rod 28 to hold the first end 32A of the second lever 32 in place. Likewise, a second cotter pin (not shown) is placed along the opposite side of the lower end 32A of the second lever 32 to secure the lever 32 on the connecting pin 28.
A platform, indicated generally at 70 is secured to the mole trap 10 by fasteners 20 and 22. A preferred embodiment of the platform 70 is a rectangular structure which includes a planar surface 72 and side elements 74A-74D, as illustrated in FIGS. 1-3. Each side element 74A-74D includes a vertical sidewall 75A-75D. In the embodiment illustrated in FIGS. 1-3, the planar surface 72B and 72D is provided only on side elements 74B and 74D, respectively. However, it is understood that the planar surface 72 can also be provided on side elements 74A and 74C, as desired. The planar surface 72 can extend any desired width so long as it does not interfere with the operation of the first and second jaws 15 and 19.
Sidewalls 75A and 75C are flattened so as to form tops 76A and 76C, respectively. Top 76A and 76B are parallel to planar surfaces 74B and 72D. It will be understood that tops can also be provided on sidewalls 75B and 75D if desired. During installation, force can be applied only at tops 76A and 76C to position the trap 10.
It is preferred that the platform 70 be pivotally connected to the first and second jaws. As illustrated in FIG. 1-3, fasteners 20 and 22 are inserted through sidewalls 75A and 75C. The fasteners 20 and 22 are snugly tighted, thereby permitting the platform 70 to pivot with respect to the remainder of the trap 10.
The installation and operation of the mole trap 10 is illustrated in FIGS. 2 and 3. A force is applied on the second end 30B of the first lever 30 to open the first and second jaws 15 and 19. As a force is applied downwardly, the first and second levers 30 and 32 provide a lever action to force the connecting rods 26 and 28 away from each other against the force of springs 40 and 42. As the first lever 30 approaches an approximate horizontal orientation, the lever 30 is off-center and locks in place so that the first and second jaws 15 and 19 are opened. The jaws 15 and 19 are inserted into the ground 80 on either side of a mole burrow 82. As the trap 10 is inserted into the ground, the platform 70 prevents the trap 10 from being pushed too far into the ground, so that the hinge points 20 and 22 remain above the ground. The planar surfaces 72B and 72D provide a contact surface between the trap 10 and the ground. The platform 70 can be tilted about fasteners 20 and 22 to achieve a desired orientation. Furthermore, the platform 70 stabilizes the trap 10 and prevents the trap 10 from shifting when the trap 10 is set in the ground.
Once the trap 10 is set into position, the sleeve nut 54 is adjusted so that the plate 56 comes into contact with the ground 80 above the mole burrow 82. The loose fit provided between the trigger rod 52 and the support bar 34 permits angular movement so that the plate 56 can be oriented to accommodate various ground terrains.
When a mole travels in the mole burrow 82, vibrations are transmitted through the ground to the plate 56. As the plate 56 is nudged upwardly, the first and second levers 30 and 32 are forced upwardly and out of a locked position. Springs 40 and 42 immediately close the first and second jaws 15 and 19 to destroy the animal. In FIG. 3, the trap 10 is shown in a closed position in the mole burrow 82.
When set (see FIG. 2), the trap 10 has a low profile close to the ground 80. When set in the ground 80, the trap 10 cannot be removed until the trap 10 is released since the blade ends 12B, 14B, 16B and 18B have pushed soil away from the burrow 82 but not above their locked position. The ground 80 above the blade ends 12B, 14B, 16B and 18B has not been distributed and prevents the trap 10 from being removed until the trap 10 is released.
As illustrated in FIG. 2, the trigger mechanism 50 is shielded by support ends 12A, 14A, 16A and 18A and levers 30 and 32. Therefore, the upper construction of the trap prevents any accidental releases of the trap 10.
It is preferred that a stop be provided on the angled members 12, 14, 16 and 18 to limit the range of motion when the jaws 15 and 19 are closed. A flange 66 is provided near the mid-point of angled member 12. In a similar manner, a flange 68 is provided on angled member 18. Flanges 66 and 68 are oriented so as to be perpendicular with angled members 14 and 16, respectively. When the jaws are not open, the range of closure is limited as flanges 66 and 68 engage angled members 14 and 16, respectively, thereby preventing injury to fingers or hands that are between support ends 12A, 14A, 16A and 18A. It is understood that flanges can be provided on angled members 14 and 16 in orientation so as to engage angled members 12 and 18, if desired. Also, it is understood that only one flange may be used if desired.
It is preferred that the mole trap 10 be constructed from stainless steel to resist weather and corrosion. Furthermore, it is difficult for a mole to smell the stainless steel thereby making the animal unaware that the trap is set in place about its burrow.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | The present invention includes a mole trap having a pair of spring-loaded jaws. A platform is pivotally connected to the jaws to limit the travel of the trap into the ground and to stabilize the trap on the ground when it is set. A lever assembly forces the jaws open and sets the trap when the lever reaches an off-center position. An adjustable trigger mechanism is positioned on the ground above a mole borrow. The vibration of a mole traveling beneath the trigger causes the lever assembly to move upward from the off-center position and the jaws to close and destroy the animal. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to methods of a preparing compound semiconductor crystal and to compound semiconductor crystals, and particularly to methods of preparing a carbon-containing, compound semiconductor crystal and compound semiconductor crystals obtained thereby.
[0003] 2. Description of the Background Art
[0004] It has been conventionally well known that as for an LEC method using a stainless chamber there is a correlation between the CO gas concentration provided in the chamber and the carbon concentration of a GaAs crystal in a high-pressure Ar gas ambient.
[0005] [0005]FIG. 3 is a graph of carbon concentration in a GaAs crystal versus CO gas concentration in a LEC furnace found in Advanced Electronics Series I -4 Bulk Crystal Growth Technology , Keigo Hoshikawa, BAIFUKAN, p.184, Fig. 7.22. FIG. 3 shows that carbon concentration in a GaAs crystal and CO gas content in the LEC furnace are correlated by a straight line. In the LEC method, the correlation represented in the graph is applied to the adjustment of carbon concentration in a GaAs crystal. The carbon concentration in a GaAs crystal can be controlled by adjusting the CO gas content in the ambient gas using a CO gas cylinder and an Ar gas cylinder for dilution connected to the stainless chamber.
[0006] [0006]FIG. 4 shows an exemplary GaAs crystal growth equipment for the LEC method disclosed in Japanese Patent Laying-Open No. 1-239089. Referring to FIG. 4, Japanese Patent Laying-Open No. 1-239089 discloses a method of preparing a single crystal of compound semiconductor by placing in a predetermined gas ambient a raw-material housing portion housing a raw-material melt, detecting at least the concentration of one of H 2 , O 2 , CO 2 and CO corresponding to components of the ambient gas, and controlling the detected concentration of a component at a predetermined value to keep over the entirety of an ingot a predetermined concentration of a residual impurity mixed into a resulting single crystal.
[0007] This method can, however, not be applied in preparing a compound semiconductor crystal in a gas-impermeable airtight vessel incapable of supplying a gas from outside the airtight vessel, such as a quartz ampoule.
[0008] Japanese Patent Laying-Open No. 3-122097 discloses a method of preparing a GaAs crystal in a quartz ampoule wherein a carbon source is arranged internal to the ampoule and external to a crucible in fluid communication with a polycrystalline compound provided as a raw material to allow the GaAs crystal to be doped with carbon. “Fluid communication” means a free flow of vapor and heat between the inside and outside of the crucible which allows carbon to be transferred into the crucible and thus to a melt. In accordance with the method, a carbon disk is arranged on an opening of a cap. It discloses that the ingots of various doped levels can be provided by varying the amount of carbon arranged external to the opening and/or the crucible.
[0009] With this method, however, a large amount of carbon source is placed above the melt. Thus fine powder of carbon falls thereon and can thus vary the carbon concentration thereof. Particularly, the controllability can be poor at a slight carbon concentration corresponding to a level of 0.1×10 15 cm −3 to 2×10 15 cm −3 .
[0010] Japanese Patent Laying-Open No. 64-79087 discloses a method of preparing a single crystal of GaAs doped with carbon to reduce dislocation, using a reactor or a boat for crystal growth at least partially formed of carbon. It discloses that when a graphite boat is used, a part of the carbon boat changes into a gas (CO or CO 2 ) due to oxygen derived from a small amount of As 2 O 3 , Ga 2 O or the like remaining in the quartz reactor and the gas is thus added to the single crystal of GaAs in synthesis reaction or in single-crystal growth.
[0011] In accordance with this method, however, it is difficult to control the carbon concentration in the crystal due to the difficulty of controlling the amount of As 2 O 3 , Ga 2 O or the like remaining in the quartz reactor. In particular, the controllability can be poor at a slight carbon concentration corresponding to a level of 0.1×10 15 cm −3 to 2×10 15 cm −3 .
[0012] Japanese Patent Laying-Open No. 2-48496 discloses a method of preparing a Cr-doped, semi-insulating GaAs crystal wherein a quartz boat or a quartz crucible is used to grow the crystal under the existence of nitrogen oxide or carbon oxide. It discloses that when a GaAs crystal is grown under the existence of nitrogen oxide or carbon oxide, the oxide serves as an oxygen doping source to reduce the Si concentration of the grown crystal so that a semi-insulating crystal is reliably provided.
[0013] However, this method contemplates control of oxygen concentration and does not describe control of carbon concentration.
SUMMARY OF THE INVENTION
[0014] One object of the present invention is to provide a method of preparing a compound semiconductor crystal allowing the compound semiconductor crystal to be doped with carbon in high reproducibility, and a compound semiconductor crystal prepared thereby.
[0015] In one aspect of the present invention, a method of preparing a compound semiconductor crystal includes the steps of sealing carbon oxide gas of a predetermined partial pressure and a compound semiconductor provided as a raw material in a gas-impermeable airtight vessel, increasing the temperature of the airtight vessel to melt the compound semiconductor material sealed in the airtight vessel, decreasing the temperature of the airtight vessel to solidify the melt compound semiconductor material to grow a compound semiconductor crystal containing a predetermined amount of carbon.
[0016] The carbon oxide gas includes at least one type of gas selected from the group consisting of CO gas and CO 2 gas.
[0017] In growing the crystal, preferably the melted compound semiconductor material is at least partially kept into contact with boron oxide (B 2 O 3 ).
[0018] In growing the crystal, more preferably the melt compound semiconductor material has its upper surface entirely covered with boron oxide (B 2 O 3 ).
[0019] Preferably, the boron oxide (B 2 O 3 ) has a water content of no more than 300 ppm, more preferably no more than 100 ppm.
[0020] Preferably, variation of the water content of the boron oxide (B 2 O 3 ) is controlled to fall within a range from +20% to −20%.
[0021] In accordance with the present invention, the carbon oxide gas sealed in the airtight vessel preferably has a partial pressure of 0.1 to 100 Torr at 25° C.
[0022] In accordance with the present invention, carbon oxide gas is preferably sealed in an airtight vessel according to an expression:
C CARBON =a×P 0.5 (1),
[0023] wherein C CARBON (cm −3 ) represents carbon concentration in a compound semiconductor crystal, P (Torr) represents partial pressure of the carbon oxide gas, and a represents any coefficient.
[0024] In expression (1) coefficient a preferably ranges from 0.25×10 15 to 4×10 15 cm −3 /Torr, more preferably 0.5×10 15 to 2×10 15 cm −3 /Torr.
[0025] In accordance with the present invention, preferably the step of subjecting the airtight vessel to a vacuum heat treatment is also provided before the step of sealing carbon oxide gas in the airtight vessel.
[0026] The vacuum heat treatment is preferably provided at a temperature of no more than 350° C.
[0027] In accordance with the present invention, at least the internal wall of the airtight vessel and at least the outer surface of the contents of the airtight vessel other than the compound semiconductor material and the boron oxide are preferably formed from a material which does not contain carbon.
[0028] The material which does not contain carbon includes at least one material selected from the group consisting, e.g., of quartz, silicon nitride, boron nitride, pyrolytic boron nitride and alumina.
[0029] In accordance with the present invention, the gas-impermeable airtight vessel can at least partially be formed from quartz.
[0030] Preferably, the portion formed from quartz has a thickness of no less than 1.5 mm.
[0031] In growing the crystal, preferably the portion formed from quartz is controlled to have a temperature of at most 1270° C.
[0032] In accordance with the present invention, in growing the crystal a space behind a raw-material melt of melted compound preferably has its most heated portion and its least heated portion with a temperature difference of no more than 300° C. therebetween.
[0033] In accordance with the present invention, the space behind the raw-material melt is preferably larger, more preferably no less than twice larger in volume than the space on the side of the raw-material melt.
[0034] A method of preparing a compound semiconductor crystal in accordance with the present invention is applicable to preparing a compound semiconductor crystal of GaAs.
[0035] In another aspect, the present invention provides a compound semiconductor crystal prepared in accordance with the above-described method of preparing a compound semiconductor crystal, having a carbon concentration of 0.1×10 15 cm −3 to 20×10 15 cm −3 .
[0036] In accordance with the present invention, the compound semiconductor includes GaAs.
[0037] The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] [0038]FIG. 1 shows preparation of a GaAs crystal as one example of a method of preparing a compound semiconductor crystal in accordance with the present invention.
[0039] [0039]FIG. 2 shows a position of a sample for FTIR measurement in a crystal.
[0040] [0040]FIG. 3 is a graph of carbon concentration in a GaAs crystal versus CO gas concentration in a LEC furnace.
[0041] [0041]FIG. 4 shows one example of a GaAs crystal growth equipment for the LEC method.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] The present invention is based on a method of preparing a compound semiconductor crystal in a sealed system (a system incapable of supplying a gas from outside an airtight vessel) using a gas-impermeable airtight vessel.
[0043] In accordance with the present invention, carbon oxide gas of a predetermined partial pressure as well as a compound semiconductor provided as a raw material are sealed in a gas-impermeable airtight vessel, the temperature of the airtight vessel is increased to melt the compound semiconductor material and the temperature of the airtight vessel is then decreased to solidify the melt compound semiconductor material to grow a compound semiconductor crystal to thereby allow the compound semiconductor crystal to be doped with carbon in high reproducibility.
[0044] As the carbon oxide gas, a stable CO or CO 2 gas can be used to allow the crystal to be doped with carbon in particularly high reproducibility.
[0045] In growing the crystal, preferably at least a portion of the melt of the compound semiconductor material can be kept into contact with boron oxide (B 2 O 3 ) and more preferably the upper surface of the melt can be entirely covered with boron oxide (B 2 O 3 ) to prevent other elements of impurities from being introduced into the melt so as to further enhance the reproducibility of the carbon concentration of the crystal.
[0046] To reduce an influence of the water contained in B 2 O 3 to control the carbon concentration of the crystal in high reproducibility, B 2 O 3 preferably has a water content of no more than 300 ppm, more preferably no more than 100 ppm. To reduce an influence of variation of the water content of B 2 O 3 to control the carbon concentration of the crystal in high reproducibility, the variation of the water content of B 2 O 3 is preferably controlled to fall within a range from +20% to −20%.
[0047] To obtain a practical carbon concentration for a compound semiconductor crystal, i.e., 0.1×10 15 cm −3 to 20×10 −15 cm −3 , carbon oxide gas requires a partial pressure of 0.1 to 100 Torr at 25° C., substantially establishing the relation: (carbon concentration in a compound semiconductor crystal)=a×(partial pressure of carbon oxide gas) 0.5 , wherein a represents any coefficient and is preferably 0.25×10 15 to 4×10 15 cm −3 /Torr, more preferably 0.5×10 15 to 2×10 15 cm −3 /Torr.
[0048] In conventional art, ambient gas is represented in concentration. For example, an ambient gas for GaAs crystal growth typically has a pressure of 1 to 30 atm. When an ambient gas of 1 atm and that of 30 atm which have the same gas concentration are converted in partial pressure, the partial pressure of the latter is 30 times larger than that of the former.
[0049] The inventors of the present invention have found that in a method of preparing a compound semiconductor crystal in a sealed system (a system incapable of supplying a gas from outside an airtight vessel) using a gas-impermeable airtight vessel, the carbon concentration in the crystal is correlated to the partial pressure of the carbon oxide gas sealed in the airtight vessel rather than the concentration of the carbon oxide gas sealed in the airtight vessel.
[0050] Herein the carbon oxide gas sealed in the airtight vessel is represented in the partial pressure at 25° C., since the partial pressure of the carbon oxide gas increases as the temperature of the airtight vessel is increased in growing a crystal. Since a GaAs crystal has a melting point of approximately 1238° C., the partial pressure of the carbon oxide gas sealed at a room temperature (of 25° C.) is considered to be increased by approximately five times during the crystal growth.
[0051] While in accordance with the present invention, carbon oxide gas having a predetermined partial pressure is sealed in an airtight vessel, carbon oxide gas may be sealed together with another gas, which can include inert gases, such as helium, neon, argon, krypton, xenon, and nitride gas. When carbon oxide gas is only sealed, it has a concentration of 100%. When carbon oxide gas is sealed, e.g., together with any of the above gases of 50%, the carbon oxide gas has a concentration of 50%. It should be noted, however, that if carbon oxide gas is thus sealed together with any of the above gases, the expression: (carbon concentration in a compound semiconductor crystal)=a×(partial pressure of carbon oxide gas) 0.5 is sufficiently satisfied by the coefficient a preferably having the value of 0.25×10 15 to 4×10 15 cm −3 /Torr, more preferably 0.5×10 5 to 2×10 15 cm −3 /Torr.
[0052] Removal of water absorbed in the airtight vessel further enhance the reproducibility of the carbon concentration in the crystal. Accordingly it is preferable to apply a vacuum heat treatment to the airtight vessel before it is sealed. The vacuum heat treatment applied immediately before the vessel is sealed is applied preferably at no more than 350° C., at which temperature B 2 O 3 does not soften or deform.
[0053] To control the carbon concentration of the crystal in high reproducibility, at least the internal wall of the airtight vessel and at least the outer surface of the contents of the vessel other than the compound semiconductor as a raw material and boron oxide are preferably formed from a material which does not contain carbon, so that further generation of carbon oxide gas can be prevented in the vessel. More specifically, the airtight vessel is preferably formed from a material which does not contain carbon, or the vessel preferably has its internal wall coated with a material which does not contain carbon. It is also preferable that the contents of the airtight vessel other than the compound semiconductor material and boron oxide be formed from a material which does not contain carbon or that the contents have the outer surface coated with a material which does not contain carbon. The material which does not contain carbon is preferably quartz, silicon nitride, boron nitride, pyrolytic boron nitride or alumina.
[0054] Furthermore, the gas-impermeable airtight vessel of the present invention can at least partially be formed from quartz, since quartz has superior airtightness and hardly reacts with elements forming the compound semiconductor or carbon oxide gas.
[0055] In accordance with the present invention, carbon oxide gas having a predetermined partial pressure is sealed in a gas-impermeable airtight vessel. However, when the airtight vessel is deformed and its internal volume is changed, the partial pressure of the sealed carbon oxide gas is changed and the carbon concentration of the resulting compound semiconductor crystal will deviate from a targeted carbon concentration.
[0056] The strength of quartz is reduced at high temperature and is significantly reduced at a temperature at which a GaAs crystal is grown, i.e., 1238° C. If a gas-impermeable airtight vessel is at least partially formed from quartz, the difference between the pressure internal to the vessel and that external to the vessel deforms the quartz portion of the vessel and thus changes the internal volume of the vessel. The inventors of the present invention have found that as the vessel's quartz portion is increased in thickness, deformation of the quartz portion is reduced at high temperatures and variation in the vessel's internal volume is thus reduced. The inventors have also found that the quartz portion of the vessel preferably has a thickness of no less than 1.5 mm, more preferably no less than 2.0 mm, still more preferably no less than 2.5 mm.
[0057] The inventors have also found that as temperature is decreased, deformation of quartz is reduced and variation in the vessel's internal volume is reduced. The inventors have also found that the quartz portion of the vessel preferably has a temperature of at most 1270° C., more preferably at most 1260° C., further still more preferably at most 1250° C.
[0058] In accordance with the present invention, carbon oxide gas of a predetermined partial pressure is sealed in a gas-impermeable airtight vessel. When the temperature of the airtight vessel varies, however, the partial pressure of the sealed carbon oxide gas changes and the carbon concentration of the resulting compound semiconductor crystal thus deviates from a targeted carbon concentration.
[0059] In particular, the space on the side of the raw-material melt, more specifically, the space located below the interface (labeled A in FIG. 1) of raw-material melt 2 and boron oxide 4 , i.e., the space on the side of the seed crystal has its temperature reduced as crystal growth proceeds. When the space on the side of the raw-material melt is large in volume, the average temperature and hence partial pressure of the carbon oxide gas in the airtight vessel are reduced significantly.
[0060] In contrast, the temperature of the space behind the raw-material melt, i.e., that located above interface A can be controlled regardless of crystal growth. Thus, controlling the temperature of the space behind the raw-material melt, can prevent reduction of the average temperature of the carbon oxide gas in the airtight vessel and reduce reduction of the partial pressure of the carbon oxide gas in the vessel. Reducing the temperature difference between the most and least heated portions of the space behind the raw-material melt can reduce reduction of the partial pressure of the carbon oxide gas in the vessel. The temperature difference between the most and least heated potions of the space behind the melt is preferably no more than 300° C., more preferably no more than 200° C., still more preferably no more than 100° C.
[0061] When the space behind the raw-material melt that is larger in volume than the space on the side of the raw-material melt can further reduce the reduction of the partial pressure of the carbon oxide gas in the vessel that is caused when the average temperature of the gas in the vessel is reduced. The space behind the raw-material melt is preferably no less than twice, more preferably no less than three times, still more preferably no less than four times larger in volume than that on the side of the raw-material melt.
[0062] Furthermore, the method of the present invention is particularly applicable to preparation of GaAs crystal.
[0063] Hereinafter, an example of actual preparation of a GaAs crystal in accordance with the present invention will now be described in detail.
[0064] [0064]FIG. 1 shows an exemplary method of preparing a compound semiconductor crystal in accordance with the present invention, using a gas-impermeable airtight vessel formed from quartz (referred to as a “quartz ampoule” hereinafter) to prepare a GaAs crystal.
[0065] Referring to FIG. 1, a GaAs seed crystal 3 of orientation <100>, 5 kg of GaAs 2 as a raw material, and 50 g of boron oxide 4 (referred to as “B 2 O 3 ” hereinafter) with a water content of 70 ppm were initially placed in a crucible 5 formed from pyrolytic boron nitride (referred to as “pBN” hereinafter) and having an inner diameter of 80 mm and also having a cylindrical portion of approximately 30 cm in length, and crucible 5 was housed in a quartz ampoule 8 of 2.5 mm thick. The space behind the raw-material melt placed in quartz ampoule 8 , i.e., that located above the interface denoted by arrow A in FIG. 1 was adapted to be four times larger in volume than the space on the side of the raw-material melt, i.e., that located below interface A).
[0066] Quartz ampoule 8 was vacuumed to 1×10 −6 Torr and also heated to 300° C. to remove water adsorbed on the internal wall of ampoule 8 and the raw material. Then, CO 2 gas 7 of 3 Torr was introduced and sealed in ampoule 8 . Ampoule 8 was mounted on a support 9 and thus set internal to a vertical heater 6 provided in a chamber 10 , and the temperature of heater 6 was increased to melt GaAs material 2 and an upper portion of seed crystal 3 .
[0067] Then the temperature profile of the heater was adjusted to decrease the temperature from the side of the seed crystal 3 and the entirety of raw-material melt 2 was thus solidified to grow a crystal. In the crystal growth, the highest temperature of ampoule 8 was also controlled not to exceed 1250°. Furthermore, the temperature of an upper portion of ampoule 8 was controlled so that the space located behind the raw-material melt, i.e., that located above interface A shown in FIG. 1 had its most heated portion and its least heated portion with a temperature difference of no more than 100° C. therebetween.
[0068] The temperature was reduced to a room temperature and quartz ampoule 8 was then cut and opened to separate a GaAs crystal from crucible 5 .
[0069] The resulting GaAs crystal had a diameter of 80 mm, and the portion having the diameter of 80 mm was approximately 18 cm long. A sample of 5 mm thick for measurement of carbon concentration was cut out at the position of a shoulder of the crystal (fraction solidified: g of 0.1). FIG. 2 shows the position of the shoulder of the crystal from which the sample was cut out. Fourier Transform Infrared Spectroscopy (FTIR) was used to measure the concentration of the carbon substituted at an arsenic site (referred to as “C As ” hereinafter). The measured C As concentration was 2.1×10 15 cm −3 .
[0070] The C As concentration in the crystal grown under a different partial pressure of sealed CO 2 was similarly measured. The measured results are provided in Table 1.
TABLE 1 Partial pressure of sealed CO 2 gas and C As concentration in GaAs crystal Partial pressure of sealed CO 2 gas C As concentration in GaAs crystal (Torr) (cm −3 ) 0.5 0.8 × 10 15 3.0 (embodiment) 2.1 × 10 15 4.5 2.7 × 10 15 6.0 3.1 × 10 15 10.0 4.0 × 10 15 30.0 6.5 × 10 15 60.0 10.0 × 10 15 100.0 13.2 × 10 15
[0071] It has been found from the results presented in Table 1 that the relation: (carbon concentration in a compound semiconductor crystal)= a×(partial pressure of carbon oxide gas) 0.5 can be substantially established, wherein a≈1.25×10 15 cm −3 /Torr under the conditions of the first embodiment.
[0072] As a result of experimentally growing a crystal under various conditions, it has been revealed that to obtain a value of a practical carbon concentration in a compound semiconductor crystal, i.e., 0.1×10 15 to 20×10 15 cm −3 , a preferable partial pressure of carbon oxide gas is 0.1 to 100 Torr at 25° C., substantially establishing the relation: (carbon concentration in a compound semiconductor crystal)=a×(partial pressure of carbon oxide gas) 0.5 and that coefficient a preferably ranges from 0.25×10 15 to 4×10 15 cm −3 /Torr, more preferably 0.5×10 15 to 2×10 15 cm −3 /Torr, since the coefficient can vary with the conditions of the experiment carried out.
[0073] It has also been found as a result of an experiment using B 2 O 3 with its water content varied from 30 to 1000 ppm that the carbon concentration in the crystal can be controlled in higher reproducibility when the water content of B 2 O 3 is lower and has less variation. Satisfactory reproducibility of the carbon concentration in crystal is achieved when the water content of B 2 O 3 is no more than 300 ppm, particularly no more than 100 ppm and the variation of the water content of B 2 O 3 is controlled to fall within a range from +20% to −20% With CO 2 gas replaced with CO gas, a similar result has also been obtained in a similar manner,.
[0074] Thus, the present invention can provide a method of preparing a compound semiconductor crystal in a sealed system (a system incapable of supplying a gas from outside an airtight vessel) using a gas-impermeable airtight vessel to allow the compound semiconductor crystal to be doped with carbon in high reproducibility.
[0075] Furthermore, carbon oxide gas of a predetermined partial pressure sealed in the gas-impermeable airtight vessel together with compound semiconductor provided as a raw material allows a compound semiconductor crystal with a desired carbon concentration and hence with a desired electrical characteristic to be prepared in high reproducibility, since the electrical characteristic of the compound semiconductor crystal depends on the carbon concentration of the crystal.
[0076] Thus the present invention can provide satisfactory crystal yield.
[0077] Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims. | There is provided a method of preparing a compound semiconductor crystal, allowing the compound semiconductor crystal to be doped with carbon in high reproducibility. The method includes the steps of sealing carbon oxide gas of a predetermined partial pressure and compound semiconductor material in a gas-impermeable airtight vessel, increasing the temperature of the vessel to melt the compound semiconductor material sealed in the vessel, and decreasing the temperature of vessel to solidify the melted compound semiconductor material to grow a compound semiconductor crystal containing a predetermined amount of carbon. With this method, a compound semiconductor crystal with a carbon concentration of 0.1×10 15 cm −3 to 20×10 15 cm −3 is also prepared in high reproducibility. | 2 |
This application claims the benefit of U.S. Patent Application Serial No. 60/266,354, filed on Feb. 2, 2001 which is specifically incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to an endoscopic system and method of use and, more particularly, an endoscopic system and method useful in eye surgery for illuminating, viewing, lasing and washing an area of an eye of a patient to be operated upon.
DESCRIPTION OF THE BACKGROUND ART
The use of endoscopes and other surgical devices of known designs and configurations is known in the prior art.
By way of example, the prior art includes U.S. Pat. No. 5,093,719 to Prescott entitled Endoscopic Gradient Index Optical Systems. This patent discloses gradient index endoscopic or borescopic systems in forms ranging from basic to more complex depending on the optical task. The basic form comprises a gradient index objective of less than a quarter period in length followed by a gradient index relay whose length is at least one-quarter period longer than the distance of the first image of the object into the relay. The numerical aperture of the objective is preferably larger than that of the relay to provide a wide angle endoscope with an entrance aperture tunnel preceding the objective. In one embodiment with a line-of-view prism, the entrance tunnel is placed in the most restricted aperture within the prism thus minimizing or eliminating vignetting of the field of view. A second embodiment of this subsystem is an endomicroscope wherein the entrance pupil moves and changes size as the ocular focus of the system is changed. The endoscope retains the maximum possible Lagrangian of the system as limited by the numerical aperture and diameter of the relay for all foci. The prior art also includes U.S. Pat. No. 5,095,887 to Leon entitled Microscope-Endoscope Assembly Especially Usable in Surgery. This patent relates to an optical assembly comprising a microscope including a binocular with a pair of oculars, an optical body and an objective lens and an optical path; and an endoscope provided with an extension, an outlet ocular, and an optical path. A commutating modulus is disposed between the binocular and the optical body of the microscope and the outlet ocular of the endoscope so as to enable an observer whose eyes are located at each ocular of the microscope to observe selectively either (a) the optical path of the microscope or (b) the optical, or electronic, path of the endoscope or (c) both optical paths simultaneously to scan an object to be investigated.
In this respect, the endoscope system of the present invention departs substantially from the conventional concepts and designs of the prior art, and in so doing provides a method and apparatus with selectively uncouplable and couplable components primarily developed for the purpose of illuminating and/or viewing and/or lasing and/or washing an area of a patient, such as en eye, to be operated upon.
SUMMARY OF THE INVENTION
The present invention comprises a new and improved endoscope system and method of use for illuminating, viewing, lasing, and washing an eye area of a patient being operated upon comprising, in combination a distally positioned needle component in a generally cylindrical configuration. The needle portion has a distal face and a centrally located tubular needle with a major bore extending distally therefrom and a generally planar proximal face. The major bore has four minor bores axially aligned within the major bore. The proximal face has a plurality of proximally extending tubes including an enlarged viewing tube with an observation bore axially aligned with the major bore of the needle and with two supplemental tubes extending proximally from the proximal face. Each supplemental tube has a bore and an additional tube extending laterally from the needle component. The additional tube is couplable proximal to a source of washing fluid. The first minor bore is in axial alignment with the observation bore with a first lens within the first minor bore and observation bore with the first lens adapted to transmit optical images from the distal end of the needle to the proximal end of the observation tube. The second minor bore and a supplemental tube are coupled through a first angled transistion bore and contain first optical strands for effecting illumination at the distal end of the needle. The third minor bore and the other supplemental tube are coupled through a second angled transistion bore and contain a second optical strand for lasing or fluid infusing. A proximally positioned handle component has a proximal end and an essentially flat distal end with a plurality of axially aligned bores therethrough. It includes a central bore in axial alignment with the observation bore of the needle portion for the receipt of the main tube terminating at the proximal end with internal threaded recess for the removable receipt of a viewing instrument. A second lens is located within the central bore in optical communication with the first lens of the needle component and illumination fibers within one of the supplemental bores in optical alignment with the illumination fibers of the needle component. A lasing fiber or infusion tube is located in the other of the supplemental bores in optical alignment with the lasing fiber of the needle component. The bores at the distal end of the handle component are sized for the receipt of the observation tube and supplemental tubes of the needle component. A bayonet type connector enables rapid separation of the needle component to the handle component. A pivotable locking level prevents separation of the components during use. The handle includes an electric motor-driven focusing assembly to enable the user to rapidly change focus while using the device. Also included is the method of using an endoscope system which includes the step of providing the components as described above including the further step of uncoupling and coupling the needle and handle components as may be required for a particular application.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
It is therefore an object of the present invention to provide a new and improved endoscope system and method which has all the advantages of the prior art surgical devices of known designs and configurations but with added capabilities.
It is another object of the present invention to selectively uncouple and couple components of an endoscope system to meet the requirements of a particular application.
It is a further object of the present invention to provide a new and improved endoscope system which is of a durable and reliable construction.
Still yet another object of the present invention is to tailor miniaturized surgical systems for illuminating and/or viewing and/or lasing and/or cleaning as needed for a required observation or treatment.
Still another object of the present invention is to illuminate, view, lase and wash an area of a patient to be operated upon.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated the preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an exploded perspective illustration of the preferred embodiment of the endoscope system constructed in accordance with the principles of the present invention;
FIG. 2 is a cross-sectional view of the device shown in FIG. 1 taken axially along the length thereof along line 2 — 2 with the needle component and handle component being coupled for operation and use;
FIGS. 3 and 4 are cross sectional views taken along lines 3 — 3 and 4 — 4 respectively of FIG. 1, FIG. 3 being greatly enlarged;
FIGS. 5 and 6 are end elevational views taken along lines 5 — 5 and 6 — 6 respectively of FIG. 1;
FIG. 7 is an exploded perspective view similar to FIG. 1 but taken from the opposite side thereof;
FIG. 8 is a cross-sectional view of an endoscope in accordance with one embodiment of the present invention;
FIG. 9 is an enlarged view of the handle assembly of FIG. 8;
FIG. 10 is an enlarged view of the probe end of the endoscope of FIG. 8; and
FIGS. 11 a and 11 b are end views of the handle of FIG. 9 showing the handle to probe coupling system.
Similar reference characters refer to similar parts throughout the several views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 through 7, thereof, an example of one existing form of endoscope system is shown. The endoscope 10 includes a distally positioned needle component 14 as one of its two primary components. See FIGS. 1, 2 and 7 . At least a portion of the needle component is preferably formed in a generally cylindrical configuration. The needle component has a distal face 16 and a centrally located tubular needle 18 extending distally from the center of the distal face. The needle has a major bore 20 extending axially and centrally located within the entire length of the needle. The needle component is formed with a generally planar proximal face 22 . As can best be seen with reference to FIG. 3, the major bore of the needle has four minor bores 24 , 26 , 28 , 30 axially oriented within the major bore for purposes as will be later described. The proximal face 22 of the needle component has a plurality of proximally extending tubes. Such tubes include an enlarged viewing tube 32 with an observation bore 34 axially aligned with, and an extension of, the centrally oriented first minor bore 24 of the needle. The proximally extending tubes also include, in the preferred embodiment, two supplemental tubes 36 , 38 extending proximally from the proximal face. Each supplemental tube has a bore 40 , 42 . Further, an additional tube 42 extends laterally and proximally from the needle component. The additional tube is couplable proximally to a source of washing fluid, not shown.
The first minor bore 24 of the needle is in axial alignment with the observation bore 34 of the viewing tube. A first lens 48 is located within the first minor bore and the observation bore 34 . The first lens 48 is the first optical component and is adapted to transmit optical images from the distal end of the needle to the proximal end of the viewing tube.
As can be best seen in FIG. 2, the second minor bore 26 and the first supplemental tube 36 are optically coupled through a first angled transition bore 50 and contain a second optical element, strands 52 for effecting illumination of the area to be viewed adjacent to the distal end of the needle. The optical strands are located within the major bore of the needle in regions other the locations of the other optical elements. Such regions are considered the second minor bore. The third minor bore 28 and the second supplemental tube 38 are coupled through a second angled transistor bore 54 . Note again FIG. 2 . Such bores and tube contain a third optical element, an optical strand 56 . Such optical strand functions for lasing at the area being viewed.
The fourth minor bore 30 is directly coupled to a source of pressurized fluid through the additional tube 44 . Such bore and tube are in operative communication, one with the other, and are normally empty except when a fluid from the pressurized source, not shown, is employed to inject a washing or irrigation fluid against the area of the patient being viewed and/or operated upon.
A proximally positioned handle component 58 constitutes the second major component of the endoscope system. Such handle component has an essentially flat distal end 60 . It also has a proximal end 62 . The proximal end includes a plurality of axially parallel bores 64 , 66 , 68 therethrough. Such bores include an enlarged central bore 64 in axial alignment with the viewing tube 52 of the needle portion for the receipt of the viewing tube. Bores 66 and 68 at their distal ends are sized and positioned for the receipt of the supplemental tubes 36 , 38 of the needle component. Compare FIGS. 1, 6 and 7 . The handle component terminates at its proximal end with a centrally located, internal threaded recess 70 for the removable receipt of a viewing instrument, not shown. Additionally, two supplemental tubes 72 , 74 extend through the handle component from the distal end to and beyond the proximal end. Such tubes terminate proximally with threaded ends 76 , 78 .
A second lens 80 is located within the central bore adjacent to the proximal end of the handle component in optical communication with the first lens 48 located adjacent to the distal end of the needle component. Such lenses function together to transmit images from the distal end of the needle to the proximal end of the handle component and rearwardly thereof to the viewing instrument. In addition, illumination strands 82 are located within the first supplemental tube 72 in operative alignment with the strands 52 of the second minor bore of the needle. A lasing strand 84 is located in the second of the supplemental tube 74 in axial alignment with the lasing strand 56 of the third minor bore of the needle.
The threaded ends 76 , 78 of the supplemental tubes 72 , 74 are adapted to be coupled to a source of illumination and to a laser source, respectively, when the needle component and handle component are coupled together for operation and use. Neither the source of illumination nor the laser source nor the above-referred to source of pressurized fluid are shown since such are essentially conventional in their constructions. Typical conventional constructions are described and referred to in the aforementioned U.S. Pat. No. 5,03,719 to Prescott.
The bores 64 , 66 , 68 at the distal end of the handle component are sized for the separable receipt of the viewing tube 52 and supplemental tubes 30 , 32 of the needle component. This arrangement allows for the use of various needle components having various optical elements with various handle components having corresponding optical elements. For example, one needle component may be used with a variety of handle components. Conversely, one handle component may be used with a variety of needle components. In addition, the separability of the needle and handle components allows for different first and second lenses to be utilized one with another for tailoring a lens system for a particular application.
A threaded radial bore 86 is located in the handle component. An associated set screw 88 is threadedly received within the radial bore. The radially end of the set screw is located to be positioned within an annular recess 90 formed in the exterior surface of the viewing tube during operation and use of the system. These features are best seen in FIGS. 2 and 4. This allows for the selective separation of the major components as well as for the secure coupling between the needle component and the handle component as may be needed for a particular application.
A collar 92 is also located at the distal end of the handle component. The collar extends distally from the distal end of the handle component, circumferentially around the entire handle component for 360 degrees. The collar functions to receive and properly position the proximal end of the needle component to the distal end of the handle component during operation and use of the system. A collar extending around less than 360 degrees has also been found to function properly.
While the endoscope shown in FIGS. 1-7 is a substantial improvement over other endoscopes, it has been found that additional improvements are needed to simplify exchanging probes to handles during operations on patients when the fragile GRIN lens is often broken and also to enable better focusing of the viewing camera during such operations. FIGS. 8-11 illustrate such an improved endoscope.
The present invention is an improved form of the endoscope described above. Turning now to FIG. 8, is shown a cross-sectional view of an endoscope incorporating the teachings of the present invention. The endoscope comprises a handle portion 100 and a detachable probe portion 102 . A needle 104 containing the optical and other components described above with regard to FIGS. 1-7 extends from the end of the endoscope. FIG. 9 is an enlarged view of the handle portion 100 . Within the handle portion 100 there is a camera 106 having a front imaging lens 108 . Immediately forward of the camera lens 108 is a spring loaded lens assembly 110 including a lens barrel 112 and lens 114 . The lens assembly 110 is positioned within a fitted cylindrical cavity 116 and is biased towards the forward end of the cavity 116 by spring 118 . At the top of the cavity 116 is a slot 120 for receiving a pin 122 downward into engagement in a circumferential groove 115 in the lens barrel 112 . The slot and pin are so designed that the lens barrel can move longitudinally within the cavity 116 to achieve focusing of the camera on the viewing optics. The pin 122 is fastened to a follower nut 124 which rides on a lead screw 126 . The lead screw 126 is driven by a coupler 128 , which coupler is attached to a small gear motor 130 . An opposite end of the lead screw is supported in a fixed brass bearing member 131 . The end of the coupler 128 attached to the lead screw includes a bore in which a spring 132 is seated. An end of the lead screw 126 extends into the bore and is biased outwardly by the spring 132 . The coupler includes a slot which engages a flange on the lead screw and allows the motor 130 to drive the lead screw through the coupler and cause the follower nut 124 to move longitudinally within the handle 100 . The movement of the follower nut 124 correspondingly moves the lens assembly 110 allowing the user to focus an image appearing at the window end 134 of the handle onto the lens 108 of the camera 106 .
One of the advantages of the present design is that the drive mechanism for the lens assembly 110 is capable of being over driven in either direction without becoming inoperative. The threaded portion of the lead screw 126 is less than the length of the follower nut 124 and may be, for example, about ⅛ inch in length. The threaded portion of the nut 124 is also short but selected to be at least as long as is needed to achieve focus for all uses of the endoscope. If the nut 124 is overdriven, the follower nut 124 can actually separate from the threaded portion of the lead screw 126 , such as by the drive motor 130 being energized to rotate in one direction for an extended time. If the nut 124 is driven towards and into engagement with bearing member 131 , lead screw 126 will be driven in an opposite direction such that coupler 128 further depresses spring 132 . Spring 132 maintains a force on lead screw 126 so that the threads of the screw and those of nut 124 are urged towards one another. Consequently, when the motor 130 reverses direction, the threads engage and allow the nut to move on the lead screw. If the lead screw is driven in the reverse direction for an extended time, nut 124 will drive off the opposite end of the threaded portion of the lead screw 126 . In that event, the spring 118 exerts a force through pin 122 via lens assembly 110 to urge nut 124 in an opposite direction so as to engage the threads of the nut and lead screw when the motor drive reverses.
In the embodiment of FIG. 8, the primary functions of imaging and lighting from the end of the endoscope are handled through the length of the handle 100 so that there are no protruding tubes or wires to interfere with the use of the endoscope. However, there is one additional probe input that protrudes through the probe end 102 . Referring to FIG. 10, the end of the handle 100 is shown in engagement with the probe 102 with the handle rotated so as to illustrate positioning of one external guide rod 140 for passage of air or fluid for use in eye surgery. One of the advantages of the present invention is that the probe end 102 separates from the handle 100 by merely depressing a locking lever 142 . When the lever 142 is depressed, the probe assembly can be rotated and separated from the handle assembly. The arrangement of the contacts within the probe assembly are such that positive locking is established between the probe assembly and handle. Referring to FIGS. 11 a and 11 b , there are shown end views of the handle with the mating elements of the probe in an insert position and in a locked position illustrating how the probe rotates using a bayonet type of connection to quickly attach or remove a particular probe and yet assure positive alignment between the probe and handle. The handle 100 has three cantilevered and tilted flanges 150 a , 150 b and 150 c which extend radially inward. Probe portion 102 incorporates three mating flanges 152 a , 152 b and 152 c . When probe portion 102 is pressed into engagement with handle 100 , the flanges 152 fit into spaces intermediate flanges 150 . Rotation of probe portion 102 allows flanges 152 to rotate under flanges 150 . Since flanges 150 are tilted or angled circumferentially, such rotation tightens the engagement between probe portion and handle and pulls the two sections together. The locking lever 142 establishes the final engagement position by slipping into a slot 154 in probe portion 102 . A cam surface 156 on probe portion 102 is used to raise the lever 142 as the probe portion is rotated. The slot 154 is located at the end of the cam surface 156 . The locking lever 142 fits into the slot 154 in the probe when the probe is properly positioned with regard to the handle so as to accurately place the probe onto the handle. While the locking lever is illustrated as having a substantially rectangular cross section, it will be appreciated that the end which engages into the probe to assure proper positioning with respect to the handle could in fact be tapered to assure exact placement of the angular orientation of the probe 102 with respect to the handle 100 .
The present invention also includes the method of use of an endoscope system. Such method includes the steps of providing the components as described above as well as the steps of illuminating and/or viewing and/or lasing and/or washing with such components and the further step of uncoupling and coupling the needle component and handle component and interchanging such components for a particular application. | An endoscope for eye surgery incorporates a handle having a camera and an electric motor driven lens assembly for enabling a user to focus the camera during surgery without manually adjusting the focus. The endoscope includes a probe attached by a rotatable bayonet type connector with a simple pivoting lever to release the probe from the handle. The motor drive system incorporates spring biasing to compensate for overruns of a drive nut on a lead screw when the user attempts to exceed the focal range of the lens assembly. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a controlling apparatus for an air conditioner. More particularly, the present invention relates to a controlling apparatus for an air conditioner including the improved structure of an interface circuit adapted to exhibit excellent properties when a remote controller is attached to a main body of the air conditioner. Further, the present invention relates to electric circuit for the controlling apparatus which assures that each switch disposed separately from the main body of the air conditioner can effectively be actuated.
2. Background Art
A typical conventional controlling apparatus of the foregoing type employable for an air conditioner is disclosed in an official gazette of Japanese Patent Laid-Open Publication No. 3-233247. According to the prior invention, the controlling apparatus is constructed such that it is mounted on a main body of the air conditioner and an operation to be performed by the air conditioner is controlled by actuating a selection switch disposed on the controlling apparatus in response to an operation command signal outputted from the controlling apparatus for the air conditioner in association with a compressor and a blower.
With the conventional controlling apparatus for an air conditioner constructed in the above-described manner, because of the fact that the selection switch is disposed on the main body of the air conditioner, when an operation of the air conditioner is started, it is necessary that a user walks to the main body of the air conditioner with his own feet.
In the case that the selection switch is separated from the main body of the air conditioner and then disposed at the position where each user can conveniently actuate the selection switch, it is necessary that components such as relays, transformers or the like are additionally arranged for the air conditioner to improve the structure of each electric circuit. Consequently, there arises a problem that manhours required in association with electrical works conducted for installing the air conditioner increase.
In addition, in the case that an operation to be performed by the air conditioner is controlled by utilizing signals outputted from the existent temperature controlling unit, when a plurality of semiconductor elements for controlling the compressor and others incorrectly match with signals outputted from the temperature controlling unit, there arises another problem that the air conditioner is erroneously operated.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of the aforementioned background.
An object of the present invention provides a controlling apparatus for an air conditioner which assures that correct matching can be maintained between semiconductor element in the controlling apparatus and a series of signals outputted from a temperature controlling unit when the existing temperature controlling unit is employed for the controlling apparatus as it is.
Another object of the present invention is to provide a controlling apparatus for an air conditioner which assures that a restricting circuit arranged in the controlling apparatus can prevent the air conditioner from being erroneously operated due to the presence of an electric current flowing through the restricting circuit.
According to a first aspect of the present invention, there is provided a controlling apparatus for an air conditioner including a refrigerating cycle which is constructed by a compressor, a heat exchanger on a heat source side, an expansion device, and a heat exchanger on a utilization side, wherein the controlling apparatus comprises a relay serving to feed electricity to the compressor therethrough in response to the feeding of electricity to a magnetizing coil thereof, a semiconductor element including a controlling terminal so as to control the feeding of electricity to the magnetizing coil of the relay therewith in response to a signal applied to the controlling terminal, a thermostat for changing the connected state between contact pieces thereof to another one depending on a preset temperature value and a detected temperature value, a heating section adapted to generate heat by receiving a small quantity of electricity while the contact pieces of the thermostat are connected to each other, the heating section serving to provide a differential every time when the connected state of the thermostat is changed to another one, and at least one electricity transmitting path serving to feed the electricity fed from the contact pieces of the thermostat to the controlling terminal of the semiconductor element in the form of a signal to be applied to the latter, whereby the semiconductor element feeds electricity to the magnetizing coil in response to the feeding of the small quantity of electricity while preventing an operation of the compressor from being started.
In addition, according to a second aspect of the present invention, there is provided a controlling apparatus for an air conditioner including a refrigerating cycle which is constituted by a compressor, a four-way valve, a heat exchanger on a heat source side, an expansion device, and a heat exchanger on a utilization side, the air conditioner performing a cooling operation and a heating operation with the aid of the heat exchanger on the utilization side while the present operative state of the four-way valve is changed to another one and further including an electric heater serving for the purpose of auxiliary heating, wherein the controlling apparatus comprises a relay for the compressor serving to feed electricity to the compressor in response to the feeding of electricity to a magnetizing coil thereof, a relay for the electric heater serving to feed electricity to the electric heater in response to the feeding of electricity to a magnetizing coil thereof, a semiconductor element for controlling the compressor, said semiconductor element controlling the feeding of electricity to the magnetizing coil of the relay for the compressor in response to a signal applied to a controlling terminal thereof, a semiconductor element for controlling the electric heater, said semiconductor element controlling the feeding of electricity to the magnetizing coil of the relay for the electric heater in response to a signal applied to a controlling terminal thereof, a thermostat for controlling the compressor, said thermostat serving to change the connected state between contact points thereof to another one depending on a first preset temperature value and a detected temperature value, a thermostat for controlling the electric motor, said thermostat serving to change the connected state between contact points thereof to another one depending on a second preset temperature value and a detected temperature value, a heating section adapted to generate heat by receiving a small quantity of electricity while the contact points of each of the thermostats are connected to each other, said heating section serving to provide a differential every time when the connected state of the contact points of each thermostat is changed to another one, electricity transmitting paths each serving to feed the electricity fed from the contact points of the thermostat to the controlling terminal of each of the semiconductor elements in the form of a signal to be applied to the controlling terminal of each of the semiconductor elements, and restricting circuits disposed in the electricity transmitting paths, each of the restricting circuits restricting the feeding of the small quantity of electricity to each of the semiconductor elements, whereby each of the semiconductor elements feeds electricity to the magnetizing coils in response to the feeding of the small quantity of electricity while preventing an operation of the compressor and/or feeding of electricity to the electric heater from being started.
Additionally, according to third and fourth aspects of the present invention, it should be noted that properties of a Zener diode are employed for each restricting circuit.
Furthermore, according to a fifth aspect of the present invention, there is provided a controlling apparatus for an air conditioner including a refrigerating cycle which is constituted by a compressor, a heat exchanger on a heat source side, an expansion device, and a heat exchanger on a utilization side, the air conditioner further including an electric motor for blowing an air air-conditioned in the heat exchanger on the utilization side to a regulating unit, wherein the controlling apparatus comprises a first relay for controlling the feeding of electricity to the compressor, a second relay for controlling the feeding of electricity to the electric motor, a temperature controlling circuit for controlling at least an operation of each of the first and second relays depending on a detected temperature value and a preset temperature value, a switch for forcibly stopping at least the feeding of electricity to the compressor and the electric motor irrespective of an operation of the temperature controlling circuit, and an electric circuit for making it possible to feed electricity to the electric motor irrespective of the actuation of the switch, causing the temperature controlling circuit to be effectively controlled relative to the electric motor.
With the controlling apparatus for an air conditioner constructed in the above-described manner, correct matching can be maintained between a plurality of semiconductor elements in the controlling apparatus and a series of signals outputted from a temperature controlling circuit at all times while preventing the controlling apparatus from being erroneously operated, even in the case that the existent temperature controlling unit includes a heat generating section for the purpose of temperature compensation.
Other objects, features and advantages of the present invention will become apparent from reading of the following description which has been made in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated in the following drawings in which:
FIG. 1 is a partially exploded perspective view of an air conditioner including controlling apparatus constructed according to an embodiment of the present invention;
FIG. 2 is an electric circuit diagram which shows the structure of a part of an electric circuit employable for the air conditioner shown in FIG. 1;
FIG. 3 is an electric circuit diagram which shows the structure of other part of the electric circuit employable for the air conditioner shown in FIG. 1;
FIG. 4 is an electric circuit diagram which shows the structure of another part of the electric circuit employable for the air conditioner shown in FIG. 1; and
FIG. 5 is an electric circuit diagram which shows the structure of further another part of the electric circuit employable for the air conditioner shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail hereinafter with reference to the accompanying drawings which illustrate a preferred embodiment thereof.
FIG. 1 is a perspective view of a partially exploded perspective view of an air conditioner including a controlling apparatus constructed according to the embodiment of the present invention wherein the air conditioner is shown with a casing removed therefrom. In the drawing, reference numeral 1 designates a bottom plate on which the air conditioner is mounted. The bottom plate 1 is made of a metallic plate by way of the steps of bending and others. Reference numeral 2 designates a compressor. The compressor 2 constitutes a refrigerating cycle in cooperation with a heat exchanger 7 on an internal side (i.e., a heat exchanger on a utilization side), a heat exchanger 10 on an external side (i.e., a heat exchanger on a heat source side), a four-way valve 4 and an expansion device.
In the case that the heat exchanger 7 on the internal side serves as an evaporator and the heat exchanger 10 on the external side serves as a condenser, when an operation of the compressor 2, a blower 6 on the internal side and a blower 12 on the external side is started, a cooling operation is performed for a room to be air-conditioned. On the contrary, in the case that the heat exchanger 7 on the internal side serves as a condenser and the heat exchanger 10 on the external side serves as an evaporator by changing the four-way valve 4 to another location, a heating operation can be performed for the room to be air-conditioned.
Reference numeral 3 designates a partition wall for dividing the inner space of the air conditioner into two sections, one of them being a space section on the external side and the other one being a space section on the internal side. The compressor 2, the blower 12 on the external side (i.e., a propeller fan), the heat exchanger 10 on the external side, a fan casing 11 and other associated components are accommodated in the space section on the external side. Reference numeral 13 designates an electric motor mounted in the space section on the external side. As the electric motor 13 is rotationally driven, environmental air is introduced into the space section on the internal side via a rear surface grill and then flows along both the side surfaces of the heat exchanger 10 on the external side, and thereafter, it is blown to the heat exchanger 10 on the external side via the rear side of the fan casing 11.
Reference numeral 26 designates a frosting detector which is disposed adjacent to the heat exchanger 10 on the internal side. The frosting detector 26 determines whether or not a phenomenon of frosting appears on an electrical circuit to be described later by detecting the temperature of the heat exchanger 10 on the external side.
The blower 6 on the internal side (i.e., a scirocco fan), the heat exchanger 7 on the internal side and an electric heater 9 and other associated components are accommodated in the space section on the internal side. The blower 6 on the internal side and the blower 12 on the external side are fixedly mounted on opposite output shafts of the electric motor 13. Thus, as the electric motor 13 is rotationally driven, both the blowers 6 and 12 are simultaneously rotated by the electric motor 13, whereby air introduced into the room to be air-conditioned via a suction grill on the internal side is cooled or heated by the heat exchanger 7 on the internal side, and subsequently, after it is heated by the electric heater 9, it is blown to the room to be air-conditioned via a blowing grill on the internal side. It should be noted that the suction grill and the blowing grill are formed through a cabinet molded of a synthetic resin and secured to the bottom plate 1.
Reference numeral 19a designates a temperature switch (serving as a protective switch) of which contacts pieces are parted away from each other when the temperature of the electric heater 9 detected thereby is elevated in excess of a predetermined protective temperature, and reference numeral 19b designates an electric current fuse adapted to be molten when an intensity of electric current flowing through the electric heater 9 is increased in excess of a predetermined electric current value. The temperature switch 19a and the electric current fuse 19b are electrically connected to the electric heater 9 in series.
Reference numeral 16 designates an electrical instrument box. A controlling unit inclusive of a base board for electrical instruments is accommodated in the electrical instrument box 16. Reference numerals 21 and 22 designate switches, respectively, each of which serves to feed a signal to the controlling unit. The switch 21 is designed in the form of a selection switch for sequentially changing the present mode of air conditioning to one of other ones (a COOL (strong) mode for a cooling operation, a COOL (weak) mode for the same, a FAN mode for performing an air blowing operation for the room to be air-conditioned, an OFF mode for stopping the operation of the air conditioner, a HEAT (strong) mode for a heating operation, and a HEAT (weak) mode), and the switch 22 is actuated in association with a thermostat for detecting the room temperature. Reference numeral 25 designates a power source cord for feeding electricity into the electrical instrument box 16.
The foregoing thermostat for detecting the room temperature is disposed to detect the temperature of environmental air introduced into the room to be air-conditioned by rotating the fan 6 arranged on the primary side of the heat exchanger 7 on the internal side, i.e., the temperature of the roll to be air-conditioned.
Reference numeral 28 designates a temperature detector. The temperature detector 28 is disposed at the position located in the vicinity of the thermostat 27. A preset temperature of the temperature detector 28 is kept unchangeable, and contact pieces of the temperature detector 28 are closed when the room temperature is lowered in excess of a preset temperature (e.g., -3° C.).
Reference numeral 29 designates a thermostat for preventing a phenomenon of frosting from appearing. The thermostat 29 serves to detect the temperature of the heat exchanger 7 on the internal side. In practice, the appearance of the phenomenon of frosting is detected when the temperature of the heat exchanger 7 on the internal side is lowered in excess of a preset temperature of -7° C.
Reference numeral 30 designates a connector for making connection to a remote controller (not shown), and reference numeral 31 designates a connector for connecting cables extending from a central controlling unit to the electrical instrument box 16.
Reference numeral 32 designates a fan cycle switch. When this switch 32 is changed to the FC side, ON/OFF of the compressor 2 can be associated with ON/OFF of the electric motor 13. Incidentally, while the switch 32 is changed to the CONT side, the electric motor 13 is continuously rotationally driven regardless of ON/OFF of the compressor 2.
Reference numeral 33 designates a change switch. While this switch 33 is changed to the a side, an operation of the air conditioner is controlled in response to an operation command signal (generated on receipt of a DC voltage) from the remote controller connected to the connector 30. On the contrary, while the switch 33 is changed to the b side, the operation of the air conditioner is controlled in response to an operation command signal (generated on receipt of a DC voltage) outputted from the selection switch 21.
Reference numeral 34 designates a power source switch for the air conditioner.
FIG. 2 to FIG. 5 show by way of electric circuit diagrams the structure of an electric circuit employable for controlling the air conditioner shown in FIG. 1.
FIG. 2 is an electric circuit diagram which shows the structure of a part of the electric circuit associated with the selection switch 21, and the foregoing part of the electric circuit includes change contact pieces 35 and 36 each adapted to be changed on actuation of the selection switch 21 and a fan cycle switch 32. Terminals associated with the selection switch 21 represent six operation modes as designated from the left-hand side, i.e., a COOL (strong) mode, a COOL (weak) mode, a FAN mode, an operation stop mode, a HEAT (weak) mode, and a HEAT (strong) mode.
The foregoing part of the electric circuit is electrically connected to a connector 38 shown in FIG. 3 via a connector 37 in such a manner that terminal numbers on the connector 37 are coincident with those on the connector 38. Similarly, a connector 39 is electrically connected to a connector 40 shown in FIG. 4 in such a manner that terminal numbers on the connector 39 are coincident with those on a connector 40. It should be noted that the connector 39 is electrically connected to the connector 40 when it is required that the selection switch 21 is effectively utilized for the foregoing part of the electric circuit shown in FIG. 2.
In FIG. 2, reference numeral 41 designates a variable resistor. An operation of the compressor is controlled depending on a magnitude of the voltage which has been preset by the variable resistor 41.
Referring to FIG. 3, while the selection switch 21 is changed to assume a COOL position, a voltage of 9 V appears on a terminal NO. 1 on the connector 38, causing electricity to be fed to a switching transistor 42. An ON/OFF operation of the transistor 42 is controlled by a transistor 43.
The electric circuit shown in FIG. 3 includes a connector 44 of which terminal NO. 1 and terminal NO. 2 have the thermostat 22 (i.e., a thermistor having negative properties) connected thereto at the position located therebetween, and a divisional voltage divided due to variation of a resistor value of the thermistor is fed to one of input terminals on each comparators 46 and 47 via a resistor 45. Reference numerals 48 and 49 designate bias resistors, respectively, each of which serves to bias the thermistor.
Reference numerals 50, 51, 52 and 53 designate resistors, respectively, each of which serves to divide a certain voltage into divisional voltages. Each divisional voltage obtained by dividing a voltage of +9 V is fed to the other terminal of each of the camporee 46 and 47. The voltage applied to the latter terminal of the comparator 46 is preset such that the voltage applied to the former terminal of the comparator 47 is higher than the voltage applied to the latter terminal of the same.
For this reason, when the temperature detected by the thermistor connected to the connector 44 is lowered, causing the voltage applied to the former terminal of the comparator 47 to be higher than the voltage applied to the other terminal of the same, an output from the comparator 47 is held at a L level. In addition, when the temperature detected by the thermistor is lowered, causing the voltage applied to the former terminal of the comparator 46 to be higher than the voltage fed to the other terminal of the same, an output from the comparator 46 is likewise held at a L level.
If an output from the comparator 47 is held at a H level (which represents that the temperature detected by the thermistor is kept high) when electricity is fed from a terminal NO. 1 on the connector 38 (while maintaining a COOL mode), both the transistors 43 and 42 are turned on, causing the voltage held at a H level to be applied to one terminal of a comparator 54 via a diode 50, a resistor 51, a diode 52 and a resistor 53.
In addition, if an output from the comparator 47 is held at a L level (which represents that the temperature detected by the thermistor is kept low) while electricity is fed from a terminal NO. 2 on the connector 38 (during a heating operation), a transistor 55 is turned on, causing the voltage held at a H level to be applied to the one terminal of the comparator 54 via a diode 56, the resistor 51, the diode 52 and the resistor 53.
When the temperature detected by the thermistor is lowered, causing an output from the comparator 46 to be held at a L level, a potential appearing between the resistor 51 and the diode 52 via a diode 57 is lowered to reach a L level. Thus, there is no possibility that the voltage to be outputted at a H level fed at a time when the transistor 55 is turned on is fed to the one terminal of the comparator 54.
The comparator 54 constitutes a timer circuit which is composed of a resistor 58, a capacitor 59, diodes 60 and 61, a capacitor 62, resistors 63, 64 and 65 and others. This timer circuit serves to convert an output from the comparator 54 into a voltage having a H level when a certain voltage having a H level is applied to one terminal of the comparator 54, and thereafter, forcibly hold the output from the comparator 54 at a L level for a predetermined period of time after the voltage applied to the one terminal of the comparator 54 is varied to a voltage having a L level. In other words, although the voltage having a H level is applied to the one terminal of the comparator 54 again for the predetermined period of time, the output from the comparator 54 is unchangeably held at a L level until the predetermined period of time elapses. This predetermined period of time is coincident with the time that elapses until the voltage of the capacitor 62 is discharged to assume a voltage having a H level or less, and the foregoing predetermined period of time is preset mainly depending on a capacity of the condenser 62 and a value of the discharging resistor 63.
Incidentally, when the output from the comparator 54 is converted into a voltage having a H level, the compressor 2 starts its operation. In addition, when the transistor 55 is turned on, an electric current is caused to flow through the electric heater 9.
A thermistor 26 having unspecified properties (serving as a frosting detector) for detecting the temperature of the heat exchanger 10 on the external side is electrically connected to terminals NO. 1 and NO. 2 on the connector 66, and when the thermistor 26 is biased by a resistor 67, the voltage corresponding to the temperature of the heat exchanger 10 on the external side is applied to one terminal of a comparator 69 via a resistor 68. When this voltage is increased in excess of the divisional voltage preset by resistors 70 and 71, an output from the comparator 69 is converted into a voltage having a L level, and moreover, a potential appearing between the diode 52 and the resistor 53 is reduced to assume a voltage having a L level, resulting in the operation of the compressor 2 being stopped.
In other words, when the temperature on the heat exchanger 10 on the external side is lowered in excess of the temperature corresponding to the foregoing divisional voltage, an output from the comparator 69 is converted into a voltage having a L level. Incidentally, the resistor 72 is provided in the form of a resistor which serves to determine a differential when the H level of the comparator 69 is changed to the L level of the same, and vice versa. In FIG. 3, reference numeral 73 designates a diode employable for the purpose of restricting.
In addition, the electric circuit shown in FIG. 3 includes a connector 74 of which terminals NO. 1 and NO. 2 are electrically connected to the thermistor 29 having unspecified properties (serving as a thermostat for preventing an occurrence of freezing) for detecting the temperature of the heat exchanger 9 on the internal side, and when the thermistor 29 is biased by a resistor 75, a voltage corresponding to the temperature of the heat exchanger 9 on the internal side is applied to one terminal of a comparator 77 via a resistor 76. When this voltage is increased in excess of the divisional voltage preset by resistors 78 and 79, an output from the comparator 77 is converted into a voltage having a L level, and a potential appearing between the diode 52 and the resistor 53 is reduced to assume a voltage having a L level, resulting in the operation of the compressor 2 being stopped.
Specifically, when the temperature of the heat exchanger 9 on the internal side is lowered in excess of the temperature (e.g., -7° C.) corresponding to the divisional voltage, an output from the comparator 77 is converted into a voltage having a L level. Incidentally, a resistor 80 is provided in the form of a resistor which serves to determine a differential when the H level of the comparator 77 is changed to the L level of the same, and vice versa. Reference numeral 81 designates a diode which serves for the purpose of restricting.
A capacitor 82 and resistors 83 and 84 are components each constituting a delay circuit which serves to mask an output of the L level voltage from the camporee 69 and 77 for a period of time until the potential of the capacitor 82 is lowered therewith while preventing the compressor 2 from being erroneously operated at the time of starting of an operation of the same.
The electric circuit shown in FIG. 4 is electrically connected to the electric circuit shown in FIG. 3 via a plurality of lines L1 to L7. In FIG. 4, reference numerals 101 to 107 designate a plurality of auxiliary relays, i.e., an auxiliary relay for changing a speed of the electric motor 13, an auxiliary relay for executing start/stop of the electric motor 13, an auxiliary relay for feeding electricity to the electric heater 9, an auxiliary relay for controlling the operation of a drain pump (not shown), an auxiliary relay for controlling the operation of the compressor 2, and an auxiliary relay for controlling the four-way valve 4.
Reference numerals 108 to 114 designate inverted buffers for driving the aforementioned auxiliary relays, respectively. When a voltage having a H level is applied to the input side of each of the buffers, an output from each buffer is converted into a voltage having a L level, whereby electricity is fed to each of the auxiliary relays 101 to 107.
While the air conditioner is operated while maintaining the COOL (weak) mode or the HEAT (weak) mode, an output from the buffer 112 is converted into a voltage having a L level, causing electricity to be fed to the auxiliary relay 101 for changing the speed of the electric motor 13 to another one. At the same time, electricity is fed to the auxiliary relay 102 for executing start/stop of the fan via a diode 118. Also when electricity is fed to the auxiliary relay 103 for the electric heater 9, electricity is simultaneously fed to the auxiliary relay 102 for executing start/stop of the fan via a diode 117. A diode 116 is used for preventing the air conditioner from being erroneously operated.
Reference numeral 115 designates a humidity detector which is electrically connected to a terminal NO. 1 and a terminal NO. 2 on a connector 119 at the position located therebetween. When a humidity in the room to be air-conditioned is lowered in excess of a predetermined value, contact pieces of the humidity detector 115 are kept closed, enabling a pump for elevating the present level of humidity in the room to be air-conditioned to be operated. An effect for additionally supplying moisture, i.e., water droplets to the room to be air-conditioned can be obtained by spraying water over the heat exchanger 7 on the interior side by driving the foregoing pump.
Reference numerals 120 and 121 designate connectors, respectively. Both the connectors 120 and 121 are electrically connected to each other in such a manner that terminal numbers on the connector 120 are exactly coincident with those on the connector 121. Reference numeral 122 designates a connector which is electrically connected to terminals NO. 5 and NO. 6 of the connector 122. A switch 127 for the central controller is electrically connected to the connector 121. The electric circuit shown in FIG. 5 (i.e., an electric circuit for the remote controller arranged separately from a main body of the air conditioner) is electrically connected to the connector 30. In addition, the connector 30 is electrically connected to a connector 123 shown in FIG. 5 in such a manner that terminal numbers on the connector 30 are exactly coincident with those on the connector 123.
When the connector 123 is electrically connected to the connector 30, a connector 124 is electrically connected in such a manner that terminal numbers on the connector 40 are exactly coincident with those on the connector 124 so as to enable electricity of DC of 24 V to be fed to the electric circuit shown in FIG. 5. In other words, in the case that the remote controller is practically used, the connector 39 is removed from the electric circuit.
Referring to FIG. 5 again, reference numerals 201 and 202 designate working contact pieces for thermostats respectively for controlling the compressor and for controlling the electric heater, wherein the thermostats being arranged in the electric circuit shown in the drawing, respectively. So-called two stage thermostat may be used for such purpose instead of the above. The working contact pieces 201 and 202 are changed to the C side or the H1 side as well as to the open side or the H2 side depending on a magnitude of each preset temperature and a magnitude of each detected temperature. The working contact piece 202 is designed to be actuated at a temperature lower than that of the working contact piece 201 by a predetermined quantity. Reference numerals 203, 204 and 205 designate electric heaters (heating sections), respectively. When the working contact pieces 201 and 202 are changed to the H1 side and the H2 side, electricity is fed to the electric heaters, causing the working contact pieces 201 and 202 to be actuated to provide a differential therebetween.
Reference numeral 206 designates a change switch adapted to be actuated so as to selectively determine one of operation modes (HEAT, OFF, COOL) employable for the air conditioner at present. Reference numerals 206 and 207 designate change contact pieces adapted to be actuated in operative association with each other corresponding to the present operation mode employed for the air conditioner, respectively. When the change contact pieces 206 and 207 are changed to the HEAT (heating mode) side, electricity is fed to the working contact pieces 201 and 202 via the change contact piece 206. If the detected temperature is lower than a preset one, this means that the working contact piece 201 is changed to the H1 side. Thus, a DC voltage signal of +24 V (i.e., a signal representing that the compressor 2 is turned on) obtained from a terminal NO. 6 on the connector 123 is outputted to a terminal NO. 3 on the same. In addition, when the detected temperature is reduced to be lower than a predetermined one, this means that the working contact piece 202 is changed to the H2 side. Thus, a DC voltage signal of +24 V (i.e., a signal representing that the electric heater 9 serving as an auxiliary heat source is turned on) is outputted from a terminal NO. 4 on the connector 123 in the same manner as mentioned above. Additionally, a DC voltage signal of +24 V (i.e., a signal representing that the four-way valve 4 is changed) is always outputted from a terminal NO. 1 on the same.
When the change pieces 206 and 207 are changed to the COOL (cooling mode) side, electricity is fed to the working contact piece 201 via the change contact piece 207. If the detected temperature is higher than a preset one, this means that the working contact piece 201 is changed to the C side. Thus, a signal generated by a DC voltage of +24 V is outputted to the terminal NO. 3 on the connector 123.
Reference numeral 208 designates a fan control switch. When this switch 208 is changed to the ON side (automatic side), a signal generated by a DC voltage of +24 V (i.e., a signal representing that the electric motor 13 is driven) is outputted from a terminal NO. 2 on the connector 123 in synchronization with the DC voltage signal outputted from the terminal NO. 3 on the same. In other words, a signal for bringing an operation of the cross flow fan 8 in association with ON/OFF of the compressor 13 is outputted from the terminal NO. 2 on the connector 123. When the fan control switch 208 is changed to the OFF side (continuous operation side), a signal generated by a DC voltage is continuously outputted from the terminal NO. 2 on the connector 123 regardless of ON/OFF of the compressor 2.
Referring to FIG. 4 again, when a DC voltage of 24 V is outputted from a terminal NO. 1 on the connector 120 (i.e., during a heating operation), this voltage of 24 V is divided by resistors 128 and 129, and an output derived from the thus divided voltage is fed to the buffer 108 via a Zener diode 130, causing the auxiliary relay 107 for changing the four-way valve 4 to be turned on.
At this time, the Zener diode 130 serves to prevent the voltage lower than a Zener voltage from passing therethrough. In addition, the leak voltage induced attributable to the generation of noise and the arrangement of electric heaters 203, 204 and 205 is not permitted to pass through the Zener diode 130.
When a voltage of 24 V is outputted from a terminal NO. 2 on the connector 120 (in response to a signal instructing that the fan is rotated), the voltage of 24 V is divided by resistors 131 and 132, and subsequently, an output from the resistors 131 and 132 is fed to the buffer 110, causing the auxiliary relay 103 for rotating the blowers 6 and 12 to be turned on.
When a voltage of 24 V is outputted from a terminal NO. 3 on the connector 120 (in response to a signal instructing that the compressor 2 is operated), the voltage of 24 V is divided by resistors 133 and 134, and subsequently, an output from the resistors 133 and 134 is fed to the comparator 54 shown in FIG. 3 via a Zener diode 135, switching transistors 136 and 137 and a resistor 138, causing the auxiliary relay 106 for operating the compressor 2 to be turned on.
At this time, the Zener diode 135 prevents the voltage lower than a Zener voltage from passing therethrough. In addition, the leak voltage induced attributable to the generation of noise and the arrangement of the electric heaters 203, 204 and 205 is not permitted to pass through the Zener diode 135.
At the same time, a switching transistor 140 is turned off with the aid of a diode 139 while preventing electricity from being fed to the electric heater 9.
When a voltage of 24 V is outputted from a terminal NO. 4 on the connector 120 (in response to a signal instructing that the compressor 2 is operated), the voltage of 24 V is divided by resistors 141 and 142, and subsequently, the output derived from the thus divided voltage is fed to the buffer 113 via a Zener diode 143, switching transistors 144 and 140 and a resistor 145 in the form of a voltage having a H level, causing the auxiliary relays 103 and 104 for activating the electric heater 9 to be turned on.
At this time, the transistor 144 is turned on, and a potential appearing between a diode 52 and a resistor 43 shown in FIG. 2 is lowered to assume a H level, whereby an operation of the compressor 2 can forcibly be stopped in the same manner as mentioned above. The Zener diode 143 serves to prevent the voltage lower than the Zener voltage of the Zener diode 143 from passing therethrough, and moreover, the generation of noise as well as the generation of leak electricity attributable to the arrangement of the electric heaters 203 to 205 are shut out also in the same manner as mentioned above.
In FIG. 4, reference numeral 147 designates a temperature switch which is used for preventing the room to be air-conditioned from being frozen. The temperature switch 147 is electrically connected to a connector 146. Contact pieces of the temperature switch 147 are closed when the temperature of the room to be air-conditioned is lowered to reach a level of about 3° C. When the contact pieces of the temperature switch 147 are closed, a voltage having a H level is applied to the buffer 113, causing electricity to be fed to the electric heater 9. Thus, a heating operation is started so as to prevent a malfunction of excessive cooling of the room to be air-conditioned such as firm closing of doors in the room due to a phenomenon of freezing or the like from arising due to the foregoing phenomenon of freezing.
A connector 125 is electrically connected to a connector 126, thereby a jumper line 149 is also connected in the electric circuit. Once the connector 125 and the connector 126 are electrically connected to each other, it is possible to perform only an air blowing operation while the switch 127 in the central controller is kept open. Incidentally, since electricity is fed via a diode 151 while the switch 127 is kept opened, this makes it possible to rotationally drive the fan even when the connector 125 is disconnected from the connector 126.
Provided that the connector 126 is electrically connected to the connector 125 and it is preset that a cooling operation and a heating operation are performed with the aid of the control circuit shown in FIG. 2 or the control circuit show in FIG. 5 while the switch 127 is kept open, electricity can be fed to each of the auxiliary relays 101 and 102 so as to substantially perform only an air blowing operation. It should be noted that a normal air conditioning operation can be performed, if the switch 127 is kept closed.
In the case that it is preset that a cooling operation and a heating operation can be performed with the aid of the controlling circuit shown in FIG. 2 or the controlling circuit shown in FIG. 5, electricity can not be fed to the auxiliary relays 101 and 102 when the connector 126 is disconnected from the connector 125 and the switch 127 is kept open, resulting in any air-conditioning operation failing to be achieved any longer.
Referring to FIG. 4 again, VDD is electrically connected to a DC supply source to receive DC electricity from the latter.
With the controlling apparatus of the present invention constructed in the above-described manner, there does not arise a malfunction that each controlling circuit is erroneously operated when a small quantity of electric current leaks from the electric heater 9 operable for the purpose of temperature compensation.
In addition, since the controlling apparatus includes an electric circuit which makes it possible to effectively rotationally drive the electric motor 13 at all times without a necessity for asking for any aid given by the switch for the central controlling unit, an operator can confirm that the air conditioner is properly operated irrespective of actuation of each of the switches.
While the present invention has been described above with respect to a single preferred embodiment thereof, it should of course be understood that the present invention should not be limited only to this embodiment but various change or modification may be made without any departure from the scope of the present invention as defined by the appended claims. | A controlling apparatus for an air conditioner includes a relay serving to control the feeding of electricity to a compressor, a semiconductor element including a controlling terminal to control the feeding of electricity to a magnetizing coil of said relay, a temperature controlling mechanism for changing the connected state between contact points thereof to another one depending on a preset temperature value and a detected temperature value, a heating section adapted to generate heat by feeding a small quantity of electric current while performing temperature compensation in association with the changing operation with the contact points in the temperature controlling mechanism connected to each other, electricity transmitting paths each serving to feed the electricity fed from the contact points in the temperature controlling mechanism to the controlling terminal of each of the semiconductor elements therethrough, and a restricting circuit for allowing the semiconductor elements disposed in the electricity transmitting paths to restrict the feeding of electricity to the magnetizing coil in response to the feeding of a small quantity of electricity. | 6 |
FIELD OF THE INVENTION
[0001] The field of the invention is electron beam systems, in particular, systems for electron beam lithography.
BACKGROUND OF THE INVENTION
[0002] In the field of particle beam systems, such as those used for lithography, it is necessary to measure the total current in the beam. High gain (efficient) electron detectors developed for microscopy applications are prone to local saturation (meaning that the relation of output signal to input current changes significantly) when directly impacted by the beam of a lithography system. The high gain possible with scintillator/photomultiplier tube, diode/pre-Amp and microchannel plate detectors is necessary to obtain optimal signal to noise ratios in lithography systems because the total beam current is relatively low at 0.1-1.0 μA.
[0003] In situations where the beam is dispersed, these detectors have performed very well. All three of the detector types listed have been successfully employed as backscatter detectors. When the electron beam in a lithography tool is focused, or nearly focused however, the current density can be as high as 100 A/cm2. Even though the total current is low, the concentrated nature of the beam can lead to local saturation effects in the detector.
[0004] Once the detecting medium has saturated, additional beam current produces no more light (scintillator), electron-hole pairs (diode) or photoelectrons (microchannel plate) and additional current in the beam will not produce any increase in the current output from the detector. This reduces the useful operating range of the detector in critical applications like knife edge beam blur measurements, where the output current of the detector must be proportional to the input current in order to preserve data integrity. For this reason lower gain detectors (e.g. unity gain Faraday cups) are often used as transmission detectors on e-beam lithography tools.
[0005] The most common alternative solution is to use a low gain detector with supplemental amplification, but the signal to noise characteristics of such an arrangement are inferior to those obtained with a higher gain detector that requires less subsequent amplification. Others have also attacked this problem by locating the detector far from the target image plane. However, in order to achieve a reasonable degree of defocusing a few hundred millimeters of separation is required for a typical beam with a semi-angle on the order of 10 mRAD. This much separation is generally not available and would place unreasonable constraints on the system mechanical designers.
[0006] In summary, the art has sought a compact system for measuring low total beam current in beams having a high current density.
SUMMARY OF THE INVENTION
[0007] The subject invention relates to the use of a high gain transmission detector located behind a diffusing member that spreads the electron beam current over the surface of the detector. A feature of the invention is the use of a thin diffusing member that absorbs only a small fraction of the incident beam.
[0008] Another feature of the invention is the use of a small drift distance between the diffusion member and the detector, so that the detection system can fit in a confined space.
[0009] Another feature of the invention is that the diffusing member functions as a pellicle, protecting the detector from particulate contamination and deposition of cracked hydrocarbons from the ambient that would build up and require detector replacement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 shows, in partially pictorial, partially schematic form, a system employing the subject invention.
[0011] [0011]FIG. 2 shows a cross section of a diffusing membrane used with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] Referring now to FIG. 1, a simplified drawing of a shaped-beam lithography system comprises a source 10 for generating an electron beam 5 and directing it along axis 101 toward first shaping aperture 20 , which forms a beam with a square cross section. Deflectors 25 move beam 5 in two orthogonal transverse directions with respect to second shaping aperture 30 to form a rectangle of the desired shape. The invention applies as well to Gaussian (probe-forming) systems that generate a beam covering only a single pixel and electron projection lithography systems that project an image from a reticle to the workpiece.
[0013] Lens 50 forms an image of aperture 30 on workpiece 200 . Deflectors 55 move the rectangular beam around on the workpiece within a deflection range to stitch together a number of such rectangles to form the pattern. Workpiece 200 , which may be a semiconductor wafer, lithography mask substrate, a reticle for a projection lithography system, a portion of a hard disk drive head substrate, or other workpiece being micromachined, will be generally mounted on a mechanical stage to cover a broader area than can be covered by deflectors 55 .
[0014] Typically, a deflector assembly would be located along the beam axis 101 beneath workpiece 200 and associated translation stage. Alternatively, deflectors 55 or supplementary deflectors could deflect beam 5 away from the workpiece to strike beam detector assembly 100 . It is an advantageous feature of the invention that it does not matter if the distortion in the beam increases for such a large deflection, because only the total beam current is of interest.
[0015] Within detector 100 , a thin, reasonably conductive membrane 120 is placed a relatively short drift distance 122 in front of the surface of detector 140 . Illustratively, membrane 120 is formed from boron-doped silicon and has a thickness in the area through which the beam passes of about 2 μm. Membrane 120 may be formed by implanting a standard silicon wafer of thickness about 625 μm on one side with a dopant that resists etching, then etching the wafer from the other side. A cross section of a membrane is shown in FIG. 2.
[0016] In FIG. 2, a cross section of membrane substrate 120 shows an SOI wafer having a buried oxygen-doped layer 123 formed in substrate 125 . Layer 123 is illustratively formed by oxygen implantation in a SIMOX (Separation by Implantation of OXygen) process. Since the wafer need not support transistors, the annealing steps that are required in a conventional SIMOX process to produce a wafer qualified for integrated circuit production may be eliminated. Above layer 125 , layer 124 is illustratively doped with Boron to a concentration of 1×1018 cm3. An ohmic level of doping is not required—only that the top layer have enough conductivity that it will not trap charge. An aperture 128 has been etched from the back in a wet etch using standard KOH chemistry, to etch the bulk silicon wafer and stop on the SIMOX layer. Optionally, the SIMOX layer has been etched using wet etching with HF chemistry in a region denoted with bracket 126 , to expose a region of doped layer 124 big enough to accept the beam (illustratively about 1 μm in diameter) even if it has been deflected off axis by up to a millimeter.
[0017] Since the area of the thin membrane of layer 124 is only about 5 mm square, strength of the membrane is not an issue.
[0018] The thickness of membrane 120 is chosen so that a relatively minor portion (meaning less than about 10%) of beam 5 is absorbed, both to give a more accurate reading of beam current and to reduce the heat load on the membrane. With the illustrative thickness of 2 μm, a 50 keV beam will have approximately 5% of its electrons absorbed in the membrane.
[0019] The electrons that pass through membrane 120 will be scattered, so that the local intensity in the beam is reduced. It has been found that for a detector system comprising a YAG crystal of thickness 1 mm and a photomultiplier tube (Thorn EMI, 9794B) a total beam current of 0.8 μA is spread over a diameter of 12 mm at a drift distance denoted by bracket 122 of 10 mm.
[0020] In an experiment, the scintillator output saturated at approximately 0.5 μA of electron beam current when no diffusing membrane was used. When the silicon membrane was approximately 40 mm above the surface of the YAG scintillator, the spread beam overfilled the 20 mm diameter crystal, charging up the exposed surface of the leaded glass vacuum window beneath the scintillator. When the drift distance was reduced to 10 mm, the beam spread out over the surface of the scintillator crystal filling approximately 50% of the surface area. With this arrangement currents in excess of 4.0 μA have been detected without saturation.
[0021] While the invention has been described in terms of a single preferred embodiment, those skilled in the art will recognize that the invention can be practiced in various versions within the spirit and scope of the following claims. | An electron beam system employs a non-saturating detector for measuring total beam current that comprises a thin membrane of only a few microns thickness placed before a detector and separated from the detector by a drift space of about 10 mm, so that electrons in the beam are not absorbed to any significant extent, but are scattered transversely to spread the beam and avoid local saturation of the detector. | 7 |
This is a division, of application Ser. No. 548,283 filed Feb. 10, 1975 now U.S. Pat. No. 4,006,209.
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for the preparation of reinforced or filled synthetic resins by extrusion.
It is known in industry that the physical, chemical and other properties of extruded and injection molded synthetic resins may be enhanced by the incorporation in these resins of one or more of certain other materials, hereinafter called additives. One of these additive materials comprises filamentary reinforcing, such as glass fibers, another comprises a resin different from the primary resin, and others comprise materials for other purposes, such as fillers of low cost materials to provide a lower cost of product.
In the contents of these specifications and claims, the word "extruder" is understood to include both an extruder, having a rotating screw, used for the heat plastifying and extrusion of plastics materials and a reciprocating screw plasticizer, having a rotating and reciprocating screw, as used on injection molding machines and as is disclosed in U.S. Pat. No. 2,734,226. The word "resin" is understood to include any thermoplastic or thermosetting plastics materials that are capable of being extruded in the conventional single or multiple screw extruder or reciprocating screw plasticizer wherein the resin is introduced into the extruder or plasticizer through a feed opening, is melted and mixed by a rotating screw or screws and is discharged under pressure as a molten material through a discharge orifice. The word "additive" is understood to mean any material which is added to and mixed with the resin in the carrying out of the process of the present invention.
One method for incorporation of additives into the resin is to premix the resin and additive in a mixer or blender and then feed the mixture to a feed opening of a conventional extruder. Disadvantages of this method include: first, the requirement of a separate batch mixing operation with the associated equipment; second, the inability to change or adjust the proportion of additive to resin during the running of the extruder; third, the difficulty of feeding the extruder with the mixer, especially when the mixture consists of a high proportion of additive to resin; and, fourth, the fact that the additive must undergo the same conditions of temperature, pressure and mixing required to melt and mix the resin which in the case of many additives results in thermal or physical degradation of the additive.
An improvement to the above method is disclosed in U.S. Pat. No. 3,520,027 wherein both the resin and additive are separately fed to a common feed section of an extruder, or fed to a continuous mixer which then discharges to a common feed section of an extruder. This improvement alleviates somewhat the first and second disadvantages of the aforementioned method but the third and fourth disadvantages remain.
U.S. Pat. No. 3,304,282 discloses that the resin may be supplied in powder or granulate form through the feed inlet of an extruder and melted in the kneading zone. After the last melting and kneading operation in the kneading zone, glass fibers of short length are added and mixed with the melt. However, no method or apparatus is disclosed for introducing the fibers into the resin, and it is specifically pointed out in the patent that it is difficult technically to meter in these fibers uniformly.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus to carry out such method which overcomes the problem of nonuniformity of additive feed and which also provides additional advantages to prior art methods, including the ability to feed a very high percentage of various additives in addition to glass fibers to the resin.
Briefly, the invention comprises melting and mixing the resin in the first stage of an extruder screw and introducing the additive material into the primary material in a low pressure zone in the second stage of the screw by means of an additive screw feeder.
DRAWINGS
FIG. 1 is a central longitudinal sectional view through a plastics extruder barrel incorporating the present invention.
FIG. 2 is a longitudinal sectional view through 2--2 of FIG. 1 and showing the screw feeder for additives.
DESCRIPTION OF PREFERRED EMBODIMENT
In FIG. 1, 10 represents a single screw plastics extruder comprising a barrel 11, a feed end closure 12, a discharge closure 13 having a discharge orifice 14 and a resin feed opening 15. Positioned within barrel 11 is an extrusion screw 16 having an axial extension 17 which is adapted to be coupled to a rotary drive means (not shown).
As is shown in the illustrated embodiment of the invention, extruder screw 16 is preferably a three stage screw having a first melting stage comprising a feed section A, a transition section B and a metering section C. The second or mixing stage comprises low pressure section D, second transition section E, second metering section F and preferably a mixing section G. It will be noted that the channel depth, that is, the distances from the root radius of the screw to the outside diameter of the screw, is greater in the low pressure section than in the metering section. By suitable design of the screw and selection of the channel depths as is well known in the art, the resin pressure in the low pressure section will be maintained at atmospheric or substantially atmospheric pressure. Mixing section G, if used, is preferably of the type disclosed in U.S. Pat. No. 3,411,179; but other known extruder screw mixing sections may be used. The third or venting and discharge stage comprises second low pressure section H, third transition section I and third metering section J.
Surrounding the barrel 11 are conventional heating means 18. At a location corresponding to the second low pressure section H is vent opening 19 in the barrel which, if desired, may be connected to vacuum means in a manner well known in the art. At a location corresponding to the first low pressure section D is provided additive feeder 20 shown in further detail in FIG. 2. Additive feeder 20 comprises a barrel 21 mounted to extruder barrel 11 so that the bore of the additive feeder barrel intersects the bore of the extruder barrel. At the feed end of additive feeder barrel 21 is provided feed end closure 22 and additive feed opening 23. Positioned within the additive feed barrel is feeder screw 24 having an axial extension 25 which is adapted to be coupled to a rotary drive means (not shown). It is preferred that the drive means for the extruder screw and the feeder screw shall each be capable of being adjusted in speed independently of each other. Surrounding the feeder barrel 21 between the feed opening and the extruder barrel are conventional heating means 26.
In operation in the embodiment shown, resin is supplied to extruder feed opening 15 in the form of granules, pellets, flakes, powder, or other form. The rotation of the extruder screw 16 conveys the resin through the first stage A, B, and C wherein the resin is melted by means of the heat supplied by heaters 18 and the frictional heat developed by the shearing and mixing of the resin between the rotating screw and the barrel. The resin pressure is raised above atmospheric pressure in transition section B and metering section C due to the decreased channel depths in these sections. The molten resin is thence conveyed into low pressure section D of the second stage wherein the resin pressure is decreased to atmospheric or substantially atmospheric pressure. At this location the additive, which has been supplied to the feed section 23 of the additive feeder and conveyed in the direction of the extruder barrel by the additive feeder screw 24, is introduced into the extruder and combines with the molten resin in a continuous operation. Since the resin is at low pressure at the location at which the resin and additive combine, the additive feeder is not required to exert any more than a minimum pressure on the additive to introduce it into the extruder.
The combined resin and additive is conveyed then through the second stage sections D, E and F of the extruder screw where they are partially mixed and raised to a higher pressure. Passing through the mixing section G of the second stage, the resin and additive are thoroughly mixed and conveyed to the second low pressure section H of the third stage where the pressure is again lowered and any volatiles in the mixture are removed through the vent opening 19. The mixture of resin and additives then is conveyed through the third metering section J where the pressure is raised and the mixture is discharged under pressure through the extruder discharge orifice 14, which may be in the form of a die for forming the extrudate into whatever shape is desired.
For some types of plastics materials, it is desirable to apply heat to the portion of the additive feeder barrel nearest the extruder barrel, as by means of heaters 26 of FIG. 2, in order to maintain the elevated temperature of the extruder barrel in the vicinity of its junction with the additive feeder barrel. This prevents any solidification of the molten resin due to cooling at the point at which the additive is introduced.
For certain additives it is required that a blanketing gas be provided to exclude contact with atmospheric oxygen. For this purpose the additive feeder barrel is provided with one or more ports 27 for the introduction of the blanketing gas to the additive in the feeder barrel. These ports also may be used to introduce a gas desired as a catalyst for the additive or the resin.
The invention may be used in the same manner in conjunction with reciprocating screw plasticizers with the additional requirement that the low pressure section of the screw corresponding to section D of FIG. 1 be of sufficient length so that the additive will always be fed into this low pressure section at all axial positions of the reciprocating screw.
In some instances it may be desirable to provide control means for the drive means for the extruder and feeder which allow the operator to raise or lower the speeds of both extruder and feeder simultaneously. However, it is essential that these speeds may also be adjusted independently of each other so that the proportion of additive may be changed by changing the speed of the additive feeder in relation to the extruder speed. In normal operation under steady state conditions, it has been found desirable to maintain the extruder speed constant and to adjust the speed of the feeder to obtain the desired porportion of additive to resin. This also allows the changing of the proportion at any time during operation.
It can be seen that in the practice of the present invention the resin is fed to the extruder screw, is transformed to a molten condition by the application of heat and by extensive shearing and is mixed, all in the first stage of the extruder screw, before the additive is added to the resin. Thus, in contrast to prior art methods, where the additive is fed into the feed opening of the extruder along with the resin, the additive is not required to undergo extensive working under high temperature and, therefore, is not subject to degradation which might be caused by such working.
Although the preferred method and apparatus uses a three stage screw as described, the invention is not limited to the use of a three stage screw. For example, some materials may be processed without the need for venting, in which case the materials can be satisfactorily processed in a two stage screw and the third stage comprising sections H, I and J omitted. In other cases, the venting stage may be located upstream of the additive addition stage so that only the resin volatiles are removed by venting. Other arrangements are possible, and it is important only that in any arrangement the additive is introduced into the resin at a low pressure location such as the first low pressure section D of the second stage of the extruder screw.
EXAMPLES
An Egan vented extruder of 31/2" inside barrel diameter with an effective length/diameter ratio of 36/1 was used to extrude various resins, as tabulated below. The nominal 31/2" diameter extruder screw was configured as shown in FIG. 1 and as described in the foregoing specification.
The additive feeder comprised a barrel of about 31/4" diameter with an effective length of about 30 inches. The nominal 31/4" diameter feeder screw was configured as shown in FIG. 2.
The following materials were processed under the conditions shown.
EXAMPLE I
Run--1359-14B
Resin--Celanese Plastics Company Nylon 1000-1
Additive--PPG Industries glass fiber 1/8", #3531
Extruder Screw RPM--75
Feeder Screw RPM--14.5
Output--320 pounds per hour
Percentage of Additive--40% by weight
Remarks--On analysis the product was found to be of a quality comparable and in some respects to surpass the commercial products produced by prior art means.
EXAMPLE II
Run--1359-10B
Resin--Celanese Plastics Company Nylon 1000-1
Additive--Du Pont Surlyn
Extruder Screw RPM--75
Feeder Screw RPM--10
Output--258 pounds per hour
Percentage of Additive--27.5% by weight
Remarks--Extrudate showed some unmelted lumps, believed to be the Surlyn additive. Otherwise, quality was good.
EXAMPLE III
Run--1372-4
Resin--Polyester PLT
Additive--Calcium metasilicate (Wollastonite F-1)
Extruder Screw RPM--36
Feeder Screw RPM--18.5
Output--101 pounds per hour (resin only)
Percentage of Additive--61.5 by weight
EXAMPLE IV
Run--1371-5A
Resin--Tennessee Eastman PTMT Polyester
Additive--Owens Corning 1/8" chopped glass X53
Extruder Screw RPM--100
Feeder Screw RPM--16
Output--702 pounds per hour
Percentage of Additive--27.8 by weight | A method and apparatus for feeding an additive, such as glass fibers, fillers, etc., to a plastic resin in an extruder is disclosed. The additive is fed by means of a screw type feeder into the barrel of a plastics extruder or reciprocating screw plastifier at a location where the resin is molten and the resin pressure is low. | 1 |
[0001] This application claims priorities from Korean Patent Application Nos. 10-2003-0040404 and 10-2003-0061845, filed on Jun. 20, 2003 and Sep. 4, 2003, respectively, with the Korean Intellectual Property Office, and U.S. Provisional Patent Application No. 60/477,036 filed on Jun. 10, 2003 with the United States Patent and Trademark Office, the disclosures of which are incorporated herein in their entireties by reference.
BACKGROUND
[0002] 1. Field of Invention
[0003] The present invention relates, in general, to data copy protection, and more particularly, to a system and a method for protecting Audio/Video (hereinafter referred to as “AV”) contents from illegal copying thereof, by use of copy control information (hereinafter referred to as “CCI”) contained in an AV streaming data (hereinafter referred to as “AV data”).
[0004] 2. Description of the Related Art
[0005] With the development of digital signal processing technologies, various kinds of digital recording apparatuses and media have been widely popularized. However, digital data contained in these apparatuses and media are available for repeated playing and copying. In this regard, if recording media containing illegally copied data are distributed in the market, interests to copyrighters or authorized venders, etc. of various contents of music, movies, etc. are liable to be damaged. Recently, a variety of methods to prevent illegal copying of the digital data have been introduced. Among them is a method of using copy control information.
[0006] Usually, AV data contains therein copy control information indicating a state of copy control of content in the AV stream. The copy control information indicates whether or not AV data processing systems, for example, a recorder implemented by hardware or software, has an authorization to copy the content contained in AV data received from a transmitting medium, and the recorder determines decryption of the content depending on a value of the copy control information.
[0007] The copy control information may be indicated with bits as predetermined within the AV data, usually with a 2-bit code. It is possible to establish 4 types of modes as listed in Table 1. As in Table 1, the modes capable of constituting the copy control information are as follows.
TABLE 1 Operation modes of an AV apparatus according to CCI information CCI code and status of AV stream Description 00 ‘copy free’ Contents are not encrypted, so copying thereof is indefinite 01 ‘copy free Contents are encrypted but copying thereof but encrypted’ is indefinite 10 ‘copy one Contents are encrypted, and only one generation’ copying thereof is allowed. After copying, CCI information is changed to ‘no more copy’ 11 ‘no more copy Contents are encrypted, and no copying or copy never’ thereof is allowed
[0008] [0008]FIG. 1 illustrates a schematic structure of AV data. The AV data 100 comprises a content field containing therein contents and an information field containing therein information on the contents.
[0009] The information field has a section 110 for copy control information to be used to control the copying operation of the AV apparatus, and comprises information on a variety of contents contained in the AV stream. The content field is sectioned into n sub-unit sections, that is, ‘Content_unit — 1,’ ‘Content_unit — 2,’ . . . ‘Content_unit_n.’
[0010] The section 110 for copy control information contained in the information field (hereinafter referred to as “first copy control information”) is divided into sections as many as the number of the sub-units described above. In each of the divided sections, values of copy control information such as ‘11’ and ‘10,’ etc. relative to the sub-units and location information to indicate locations of the sub-units are included. The location information may comprise physical or logical addresses relative to the sub-units, or time information when the contents in the sub-units are played. FIG. 1 refers to the location information as ‘unit — 1_ptr,’ ‘unit — 2_ptr,” . . . ‘unit_n_ptr.”
[0011] A sub-unit can be divided into one or more sections. By way of example, the sub-unit included in the content field may be divided into three small sections of ‘Sub — 2 — 1,’ ‘Sub — 2 — 2” and “Sub — 2 — 3,” and each of the small sections may include the copy control information 130 proper thereto.
[0012] The copy control information included in each sub-unit of the content field (hereinafter referred to as “second copy control information”) is mainly used so as to generate a decryption key to decrypt the contents, and thus, if it is illegally modified, the contents cannot be decrypted. However, the first copy control information 110 is used so as to control an operation as to whether to copy the contents, and thus, illegal copying of the contents becomes possible since a third party is allowed to change the first copy control information 110 .
[0013] [0013]FIG. 2 illustrates a conventional system for AV stream data copy protection to protect contents from being illegally copied.
[0014] The AV stream data copy protection system 200 to decrypt encrypted AV data comprises an AV data receive unit 210 , a control unit 220 , a decryption key generation unit 230 , and a content interpret unit 240 . The AV data receive unit 210 receives AV data. The control unit 220 receives a control signal to control an operation of an apparatus for processing AV data, inputted externally: the control signal may comprise a command signal to play an AV content, a command signal to copy the AV content, etc. At this time, the control signal may include a content playing command, a content copying command, etc. The control unit 220 receives the first copy control information 110 as depicted in FIG. 1, transmitted from the AV data receive unit 210 , and transmits a control signal corresponding to a value of the first copy control information to the decryption key generation unit 230 and the content interpret unit 240 .
[0015] If the description key generation unit 230 receives a command to generate the decryption key from the control unit 220 , it generates a decryption key with the use of second copy control information and other information for key generation inputted from the AV data receive unit 210 and transmits the decryption key to the content interpret unit 240 . The content interpret unit 240 decrypts the content field in the AV data received by the AV data receiver part with the use of the decryption key received from the decryption key generation unit 230 and transmits the decrypted content to an output device 250 .
[0016] An operation of the conventional AV data processing system to decrypt the AV data is described hereinbelow.
[0017] The AV data receive unit 210 receives AV data, and transmits to the control unit 220 the first copy control information 110 included in AV data as depicted in FIG. 1.
[0018] The control unit 220 receives a control signal inputted externally to control an operation of an AV apparatus. Where the control signal is a command signal to copy the content, the control unit 220 checks an encryption status of the AV content in the AV data received by the AV data receive unit 210 by use of the first copy control information 110 .
[0019] Where a value of the first copy control information 110 is ‘copy free,’ there is no need to generate a decryption key, and thus, the control unit 220 allows the content interpret unit 240 to transmit the AV data to an output device 250 as they have been received by the AV data receiver part.
[0020] If a value of the first copy control information 110 is any one of ‘no more copy or copy never,’ ‘copy free but encrypted’ and ‘copy one generation,’ data is required to be decrypted. For this purpose, the decryption key generation unit 230 receives the first copy control information 110 transmitted from the control unit 220 , generates a decryption key by use of the second copy control information and other information required for generating the description key as inputted from the AV data receive unit 210 , and transmits the decryption key to the content interpret unit 240 . The content interpret unit 240 decrypts the content field in the AV data received by the AV data receive unit 210 , by use of the decryption key as transmitted, and transmits the decrypted AV contents to an output device 250 , such as a storage medium or a displaying apparatus.
[0021] The conventional AV data copy protection system 200 uses the first copy control information so as to check whether an AV apparatus has an authorization to copy the contents. However, this is problematic because the first copy control information can be easily modified for illegal copy of data. If ‘no more copy or copy never (11)’ or ‘copy one generation (10)’ is modified to ‘copy free but encrypted (01)’ or ‘no more copy or copy never (11)’ is modified to ‘copy one generation (10)’ as illustrated in Table 1 and AV data are received by the AV data receive unit 210 , the control unit 220 may falsely confirm that copying of the AV data has been allowed, and therefore, illegal copying of the concerned contents can be made in an easy manner.
SUMMARY OF THE INVENTION
[0022] The present invention is conceived to solve the aforementioned problems. An object of the present invention is to provide a method for effectively preventing decryption of contents due to illegal modification and illegal copying of the copy control information by utilizing a first copy control information where a key for encryption or decryption of data is generated.
[0023] To achieve the above and/or other objects of the present invention, there is provided a system for preventing copying of AV data, comprising a copy control information inspection unit receiving a first copy control information from AV data including an AV content information section having the first copy control information and an AV content section having second copy control information, and transmitting the first copy control information and a control command corresponding to the first copy control information, a key generation unit generating a decryption key with the use of the first copy control information and predetermined information for the decryption key generation according to the control command, and a decryption unit decrypting the AV data with the use of the decryption key.
[0024] According to another aspect of the present invention, there is provided a system for preventing copying of AV data, comprising a copy control information inspection unit receiving a first copy control information from AV data including a AV content information section having the first copy control information and an AV content section having a second copy control information, and transmitting the first copy control information and a control command corresponding to the first copy control information, a key generation unit generating an encryption key with the use of the first copy control information and predetermined information for the encryption key generation according to the control command, and an encryption unit encrypting the AV data with the use of the encryption key.
[0025] According to still another aspect of the present invention, there is provided a method for preventing copying of AV data, comprising the steps of receiving first copy control information from AV data including an AV content information section having the first copy control information and an AV content section including second copy control information, determining a control state of the first copy control information and transmitting the first copy control information and a control command corresponding to the copy control state, generating a decryption key with the use of the first copy control information and predetermined information for the decryption key generation according to the control command, and decrypting the AV data with the use of the decryption key.
[0026] According to still further another aspect of the present invention, there is provided a method for preventing copying of AV data, comprising the steps of receiving first copy control information from AV data including an AV content information section having the first copy control information and an AV content section including second copy control information, determining a control state of the first copy control information and transmitting the first copy control information and a control command corresponding to the copy control state, generating an encryption key with the use of the first copy control information and predetermined information for the encryption key generation according to the control command, and encrypting the AV data with the use of the encryption key.
[0027] Preferably, the copy control information may indicate multiple modes of copy control states by predetermined bit information, comprising a first mode in which no copy is allowed, a second mode in which contents are encrypted and one copy thereof is allowed (said second mode, is modified into the first mode after one copy), a third mode in which contents are encrypted but copying thereof is indefinitely allowed, and a fourth mode in which contents are not encrypted and copying thereof is indefinitely allowed. Also preferably, the information for encryption key generation may include the second copy control information.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The above and other objects and features of the present invention will become apparent from the following description of exemplary embodiments given in conjunction with the accompanying drawings, in which:
[0029] [0029]FIG. 1 is a schematic diagram illustrating a configuration of an AV stream;
[0030] [0030]FIG. 2 is a diagram illustrating a configuration of a conventional AV data processing system to prevent illegal copy of contents;
[0031] [0031]FIG. 3 is a block diagram illustrating an AV data protection system to encrypt the contents according to an exemplary embodiment of the present invention;
[0032] [0032]FIG. 4 is a diagram illustrating an AV data protection system to decrypt the contents according to an exemplary embodiment of the present invention;
[0033] [0033]FIG. 5A through 5C are diagrams illustrating media for providing AV data according to an exemplary embodiment of the present invention; and
[0034] [0034]FIG. 6 is a flow chart depicting a process for preventing illegal copying of AV data according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Hereinafter, a system and a method for AV stream data copy protection according to exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.
[0036] A content protection system according to an embodiment of the present invention may extract contents from an AV data storage medium to play them, or decrypt encrypted contents to store them in another type of storage medium such as a hard disk and so on. Further, the content protection system may encrypt the contents so as to store them in an AV data storage medium. Accordingly, the content protection system will be described in view of two cases: to encrypt and record the contents, and to decrypt and copy the decrypted contents.
[0037] [0037]FIG. 3 is a block diagram illustrating an AV data protection system to encrypt the contents according to an embodiment of the present invention. As illustrated therein, the content protection system comprises a copy control information inspection unit 310 for inspecting a status of a first copy control information and generating a control signal in response to the inspection result, and a content processing unit 320 for generating an encryption key according to the control signal and encrypting the contents. The content protection system 300 operates linked with a CPU memory 330 receiving the AV data and a CPU 340 processing the AV data stored in the CPU memory.
[0038] Hereinbelow, a process of encrypting the contents and recording them on the AV data storage medium will be described.
[0039] If the AV data is loaded on the CPU memory 330 , the CPU 340 extracts key generation information and contents comprising first copy control information 110 and second copy control information 130 as illustrated in FIG. 1 and transmits them to the content protection system 300 .
[0040] The copy control information inspection unit 310 receives a control signal relative to an operation mode of the content protection system 300 from a user 360 . At this time, the operation mode comprises a mode of encrypting and recording the received AV data on the AV data storage medium 350 (‘a first mode’), a mode of decrypting the received AV data (‘a second mode’). The embodiment illustrated in FIG. 3 is operated under the first mode.
[0041] The copy control information inspection unit 310 receives the first copy control information from the CPU memory 330 and inspects a status of the copy control. The copy control status has been represented in Table 1 (shown above).
[0042] Where a copy control status of the first copy control information is ‘11,’ no copy of contents is allowed. In this regard, the copy control information inspection unit 310 controls a key generation unit 322 of a content processing unit 320 not to be operated, thereby allowing the received AV contents not to be recorded on the AV data storage medium 350 .
[0043] Where a copy control status of the first copy control information is ‘00,’ the contents are not encrypted and copying thereof is free, and thus, there is no need to generate a key to encrypt the AV data. Therefore, the copy control information inspection unit 310 allows the content processing unit 320 to record the received contents on the AV data storage medium 350 without encrypting them. At this time, the first copy control information and the key generation information are together recorded.
[0044] Where a copy control status of the first copy control information is ‘0’ or ‘10,’ a key to encrypt the received contents is to be generated. The key generation unit 322 generates the key for encryption of the contents by use of the key generation information received from the CPU memory 330 and the first copy control information received from the copy control information inspection unit 310 . At this time, the key generation information includes second copy control information. In addition to the second copy control information, the key generation information includes information on a device comprising the content protection system 300 , a value of a common key or a secret key existing in the device, a common key or a secret key according to the AV data storage medium 350 , and a seed value generated randomly for key generation.
[0045] If the key to encrypt the contents is generated by the key generation unit 322 , encryption/decryption unit 324 encrypts the contents received from the CPU memory 330 , by use of the key. Then, the encrypted contents are recorded on the AV data storage medium 350 .
[0046] [0046]FIG. 4 is a diagram illustrating an AV data protection system to decrypt the contents according to an embodiment of the present invention.
[0047] Referring to this figure, the content protection system 400 comprises a copy control information inspection unit 410 inspecting a status of the first copy control information and generating a control signal according to the inspection result, and a content processing unit 420 generating a decryption key according to a control signal and decrypting the contents. The content protection system 400 operates linked with a CPU memory 430 receiving AV data from the AV data storage medium, and a CPU 440 processing the AV data stored in the CPU memory 430 .
[0048] Hereinbelow, a process of decrypting the contents by use of the content protection system will be described.
[0049] If AV data is loaded on the CPU memory 430 from the AV data storage medium 450 , the CPU extracts the first copy control information 110 shown in FIG. 1 and key generation information including second copy control information 130 from the AV data and transmits them to the content protection system 400 .
[0050] The copy control information inspection unit 410 receives a control signal relative to an operation mode of the content protection system 400 , from a user 460 . FIG. 4 shows that it is operated under the second mode (discussed above).
[0051] The copy control information inspection unit 410 receives the first copy control information from the CPU memory 430 and inspects a status of the copy control. The copy control status is indicated on Table 1.
[0052] Where the copy control status of the first copy control information is ‘11,’ no copy of the contents is allowed. Since the copy control information inspection unit 410 allows the key generation unit 422 of the content processing unit 420 not to be operated, the received AV data is not decrypted.
[0053] Where the copy control status of the first copy control information is ‘00,’ the contents are not decrypted and copy of the contents is free, and thus, there is no need to generate a key for decryption of the AV data. Therefore, the copy control information inspector part 410 outputs the AV contents received by the content processing unit 420 .
[0054] Where a copy control status of the first copy control information is ‘0’ or ‘10,’ a key to decrypt the received contents is to be generated. The key generation unit 422 generates the key for decryption of the contents by use of the key generation information received from the CPU memory 430 and the first copy control information received from the copy control information inspection unit 410 . At this time, the key generation information includes second copy control information. In addition to the second copy control information, the key generation information includes information on a device comprising the content protection system 400 , a value of a common key or a secret key existing in the device, a common key or a secret key according to the AV data storage medium 450 , and a seed value generated randomly for key generation.
[0055] If the key for decryption of the contents is generated by the key generation unit 422 , encryption/decryption unit 424 decrypts and outputs the contents received from the CPU memory 430 , by use of the key.
[0056] During the above-described operational processes, if the first copy control information is illegally modified and integrated into the copy control information while the AV data is loaded on the CPU memory 330 or the first copy control information is transmitted to the copy control information inspection unit 310 from the CPU memory, a different key from the key used to encrypt the data stored in the AV data storage medium 450 may be generated. Thus, the received AV data is not decrypted.
[0057] [0057]FIGS. 5A through 5C are diagrams illustrating media for providing AV data according to an embodiment of the present invention, wherein the CPU memory 430 can receive the AV data through an interface unit 510 corresponding to data transmission mediums 520 , 530 and 540 .
[0058] [0058]FIG. 5A represents a wireless medium for a WLAN (Wireless-LAN) based on 802.11a or 802.11b, Bluetooth, a wireless asynchronous transfer mode (ATM), Digital Terrestrial Communication or Digital Satellite Communication.
[0059] [0059]FIG. 5B represents a wired medium for Ethernet, fiberoptic digital data interface (FDDI) or high-speed serial communication such as IEEE1394.
[0060] [0060]FIG. 5C represents a storage media such as an optical storage medium, a magnetic storage medium or a mobile storage medium.
[0061] [0061]FIG. 6 is a flow chart depicting a process for preventing illegal copying of AV data according to an embodiment of the present invention.
[0062] If AV data is received S 605 , a first copy control information is extracted from the AV data so as to inspect a status of the copy control information S 610 .
[0063] If the status of the first copy control information is ‘11’ as indicated in Table 1, copying of the contents is prevented, and thus, a copying process is terminated S 640 .
[0064] If the status of the first copy control information is ‘00’ as indicated in Table 1, there is no need to decrypt the contents, and thus, the AV data is output as received, without passing through a decryption process S 615 .
[0065] Where the status of the first copy control information is ‘01’ or ‘10’ as indicated in Table 1, at least one copy will be performed. Thus, a decryption key is generated by a command to play, with the use of the first copy control information S 625 . At this time, the decryption key includes the second copy control information in addition to the first copy control information. The decryption key may further include a value of a common key or a secret key existing within the device, a common key or a secret key according to the medium storing therein AV data or providing the AV data, or a seed value generated randomly for the key generation.
[0066] After the decryption key is generated, the AV data received with the use of the decryption key is decrypted and then output S 630 and S 640 .
[0067] As described above, the present invention provides a means for preventing illegal copying of AV contents due to modification of copy control information and an easy application thereof to digital electronic apparatuses for household purpose and other purposes, all of which are used in storing or copying the AV data containing copy control information, thereby contributing to content protection.
[0068] It is understood that those skilled in the art can make various substitutions, changes and modifications to the embodiments of the present invention described above without departing from the technical spirit and scope of the invention, and thus, the present invention is not limited to the embodiments illustrated in the drawings. | A system for preventing copying of audio/video (AV) data, including a copy control information inspection unit receiving first copy control information from AV data including an AV content information section having the first copy control information and an AV content section having second copy control information, and transmitting the first copy control information and a control command corresponding to the first copy control information, a key generation unit generating a decryption key using the first copy control information and predetermined information for the decryption key generation, according to the control command, and a decryption unit decrypting the AV data with the use of the decryption key. | 6 |
RELATED APPLICATIONS
[0001] This application makes reference to, claims priority to, and claims the benefit of U.S. Provisional Patent Application Ser. No. 61/237,925, entitled “Mascara Applicator and Method of Use” (Attorney Docket 20945US01), filed Aug. 28, 2009, the complete subject matter of which is hereby incorporated herein by reference in its entirety.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] [Not Applicable]
MICROFICHE/COPYRIGHT REFERENCE
[0003] [Not Applicable]
BACKGROUND OF THE INVENTION
[0004] The present mascara applicator and method of use generally relates to the field of cosmetics. More specifically, the present mascara applicator and method of use relates to devices used to apply eye makeup, particularly mascara to eyelashes.
[0005] Mascara is typically applied to eyelashes in layers. However, mascara is a liquid. Thus, the person must wait between applications for the mascara to dry before applying the next layer. The person may flutter their eyelids in an attempt to speed the drying of the mascara, but this will likely take longer than desired. The mascara is then applied after the drying process.
[0006] The goal when applying mascara is to make a person's eyelashes appear fuller and longer than their natural lashes. Existing mascara products are marketed as making lashes appear thicker and fuller for various reasons. For example, some products are marketed as offering thicker and fuller lashes because of the composition of the mascara used. Others are marketed as using a two-step process where the first step supposedly will define and smooth the lashes, and the second step will then supposedly build the lash volume. Still other products are marketed as having superior brush applicators. For instance, some products employ a rotating or oscillating brush that will supposedly create longer looking lashes.
BRIEF SUMMARY OF THE INVENTION
[0007] The present mascara applicator provides dramatically fuller and longer eyelashes than existing methods. A fan is incorporated into the mascara applicator that may be used to blow air over a user's eyelashes after applying mascara. The airflow quickly dries the mascara on the eyelashes as the mascara brush moves outward and upward, which reduces the waiting time between applications of mascara and results in a uniformly thicker coating of mascara on the eyelashes. By repeating this process, the user will then enjoy longer, fuller, and up to 200% more dramatic eyelashes.
[0008] One embodiment of the mascara applicator comprises a housing, the housing having a top, a bottom, and a sidewall; a mascara reservoir, the mascara reservoir configured to be at least partly housed in the housing; a cap, the cap configured to sealingly attach to the mascara reservoir; a mascara brush, the mascara brush configured to fit within the mascara reservoir; a fan attached to the mascara applicator, the fan having a suction side and discharge side; a battery, the battery electrically connected to the fan; a switch, the switch configured to electrically connect the battery and the fan to operate the fan; an air chamber, the air chamber having a diameter; wherein the fan blows air through the air chamber and out of the housing near the top of the housing.
[0009] In some embodiments, the housing may be made of plastic. Some embodiments may include a battery access that covers the battery. The battery access may in turn include a vent for airflow to the fan.
[0010] A method of applying mascara to a user's eyelashes using a mascara applicator may include a the mascara applicator, the mascara applicator comprising a housing, a mascara reservoir; a cap, the cap configured to sealingly attach to the mascara reservoir, a mascara brush, the mascara brush configured to fit within the mascara reservoir, a mascara applicator fan, the fan attached to the housing, a switch, the switch configured to electrically connect the fan to a battery and operate the fan. The method may comprise: applying a light coat of mascara to the user's eyelashes using long, upward strokes of the mascara brush; operating the mascara applicator fan; and then directing airflow from the fan at the user's eyelashes to dry the mascara quickly
[0011] Additional objects and advantages of the invention are set forth in, or will be apparent to those of ordinary skill in the art from the detailed description herein. Also, it should be further appreciated that modifications and variations to the specifically illustrated and discussed features or materials hereof may be practiced in various embodiments and uses of this invention without departing from the spirit and scope thereof, by virtue of present reference thereto. Such variations may include, but are not limited to, substitution of equivalent means and features or materials for those shown or discussed, and the functional or positional reversal of various parts, features or the like.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0012] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0013] FIG. 1 is a perspective view of an embodiment of the present mascara applicator;
[0014] FIG. 2 is a sectional view of the mascara applicator of FIG. 1 along section A-A;
[0015] FIG. 3 is a sectional view of the mascara applicator of FIG. 1 along section B-B;
[0016] FIG. 4 is an exploded view of an embodiment of the mascara applicator.
[0017] Repeat use of reference characters throughout the present specification and appended drawings is intended to represent same or analogous features or elements of the invention. While the present mascara applicator and method of use is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Reference now will be made in detail to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used on or with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations. Other objects, features and aspects of the present invention are disclosed in or are apparent from the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention.
[0019] FIG. 1 depicts a preferred embodiment of the present mascara applicator 50 . Mascara applicator 50 includes a housing 14 , which in this embodiment houses a mascara tube 24 , a fan 10 , and a battery 2 (these are best seen in FIG. 4 ). Housing 14 includes a top 19 , bottom 21 , and sidewall 16 . Mascara tube 24 holds the liquid mascara. Cap 18 of mascara tube 24 is seen near the top 19 of housing 14 . Battery 2 is located near the bottom 21 of housing 14 . Housing 14 may have an ergonomic and or aesthetically pleasing shape. For example, housing 14 may be ribbed, stepped, grooved, etc. to provide an ergonomic and or aesthetically pleasing look, and include shapes that are cylindrical, cylindraceous, square, rectangular, etc. Housing 14 is assembled in two parts in this embodiment, but could also be manufactured as a single part (not shown). Housing 14 includes vents 6 through which air is drawn by fan 10 . The location of the vents 6 is not critical. Vents 6 could easily be located elsewhere on the housing 14 . Housing 14 is preferably made from a lightweight material, such as plastic.
[0020] Switch 8 activates fan 10 (best seen in FIG. 4 ). However, a variety of readily available switches may be used. For example, and not by way of limitation, while a single-pole sliding switch is depicted in this embodiment, the present mascara applicator and method of use may employ a variety of switch types, including a multiple pole switch enabling multiple fan speeds, or a push-button switch rather than a sliding switch.
[0021] Turning now to FIGS. 2 and 3 , fan 10 has a suction side 9 for drawing in air and a discharge side 11 for discharging air. A presently preferred fan is a 5V fan made by Sunon, part number GM0502 PFV1-8, but other fans may also be used. Fan 10 is powered by battery 2 . A presently preferred battery is the Energizer A544 alkaline battery, but other batteries may also be used. Battery access 4 is located near the bottom of housing 14 , and covers battery 2 . Alternatively, battery access 4 may be located elsewhere, such as on the side of housing 14 (not shown). Battery access may be secured to housing in a variety of ways, including the use of fasteners, such as screws, hinges, tabs, etc. Battery access 4 may also include vents. Air drawn through vents 6 in the housing and/or battery access may also serve to cool battery 2 . Battery access 4 may also be omitted entirely. For instance, a multi-part housing may be used where battery 2 can be accessed by opening the multi-part housing. Battery access 4 may also be omitted where the device is intended to be disposable. Of course, battery 2 may be located outside the housing in a nearby attached compartment. In other embodiments, fan may be attached to the exterior of housing 14 (not shown), or to a removable cover (not shown) that mates with housing 14 . In those embodiments, vents 6 may not be necessary.
[0022] A mascara reservoir in the form of mascara tube 24 may be fitted in housing 14 with an interference fit at the bottom of the housing 14 such that cap portion 18 of mascara tube 24 protrudes above housing 14 . Alternatively, housing 14 may include a flexible sleeve (not shown) within or on top of housing 14 to accept and hold mascara tubes 24 of varying sizes. Users may then refill Mascara applicator 50 with mascara tubes 24 of various brands and manufacturers. Mascara applicator 50 may thus be reusable. Mascara applicator 50 may also be disposable, in which case mascara tube 24 may be of a non-standard size and configuration, and be fitted in housing 14 with a more secure arrangement, such as a snap-fit latch, c-ring collar, or the like (not shown).
[0023] Cap 18 may be attached to mascara brush 22 by stem 20 . Alternatively, cap 18 may be separate from mascara brush 22 , in which case mascara brush 22 may have a separate handle (not shown) configured to fit within cap 18 . Mascara brush 22 is not limited to the size, thickness or shape shown in FIGS. 2 and 4 . Bristles of the mascara brush 22 , for example, may vary in size, shape, length and width.
[0024] Air chamber 12 may be formed between the sidewall 16 of mascara tube 24 and housing 14 . In this embodiment, air chamber 12 decreases in size from the bottom of mascara tube 24 to the top. This provides accelerated airflow from the top of mascara applicator 50 when fan 10 is activated by switch 8 to ensure that the mascara applied to the user's eyelashes dries quickly, e.g. in one to two seconds versus six to ten seconds. However, air chamber 12 need not decrease in size if fan 10 is sized such that the airflow from the top of mascara applicator 50 is sufficient to quickly dry the mascara applied to the user's eyelashes. Air is drawn into fan 10 through vents 6 and past battery 2 , and blown into air chamber 12 . Battery access 4 covers battery 2 , which is electrically connected to fan 10 through switch 8 .
[0025] Cap 18 may be configured to cover air chamber 12 opening at the top of housing 14 . For example, and not by way of limitation, FIG. 2 depicts an air chamber protector 26 that extends radially outward from cap 18 and covers air chamber 12 opening at the top of housing 14 . Alternatively, the cap 18 may be configured to extend radially to cover air chamber 12 opening. Air chamber protector 26 is intended to prevent the entry of significant debris, such as lint, etc., into air chamber 12 . FIG. 4 depicts an exploded view of mascara applicator 50 . A two-piece housing 14 is configured to house mascara tube 24 , fan 10 , battery 2 , and battery terminal 3 . Housing 14 includes airflow vents 6 . Battery access 4 is connected to housing 14 when the two halves of housing 14 are attached to each other. The two halves can be attached in a variety of ways, including a snap fit, fasteners, such as clips, screws, tabs, etc. Mascara cap 18 may be secured to mascara tube 24 with a threaded connection, although any readily removable, sealing connection will suffice. Stem 20 and mascara brush 22 are thereby enclosed in mascara tube 24 . Of course, if mascara applicator is made disposable, mascara tube 24 may be replaced with a mascara reservoir (not shown) located in the housing 14 .
[0026] In operation, mascara applicator 50 may be carried on the person of a user, e.g., in a purse or pocket, until used. When used to apply mascara, the user removes cap 18 , which is attached to mascara brush 22 in this embodiment, and thus removes mascara brush 22 from mascara applicator 50 . The user also operates switch 8 to activate fan 10 . This is not done in any particular order, e.g. the user could activate fan 10 before removing cap 18 . The user then applies a light coat of mascara to the user's eyelashes using long, upward strokes with the mascara brush 22 . After mascara application, the user then directs airflow from mascara applicator 50 at the user's eyelashes to dry the mascara quickly. This will create a “false lash” look or fuller and longer-looking lashes, giving the user up to a 200% fuller lash look.
[0027] Although preferred embodiments of the invention have been described using specific terms, devices, and methods, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or the scope of the present invention, which is set forth in the following example claims. In addition, it should be understood that aspects of the various embodiments may be interchanged either in whole or in part. Therefore, the spirit and scope of the appended example claims should not be limited to the description of the preferred versions contained therein. | A novel mascara applicator blows air over a user's eyelashes after mascara is applied, wherein brushing of the mascara as it dries results in the appearance of fuller and longer eyelashes. The mascara applicator includes a housing that houses a mascara tube and brush, a fan and a battery. The housing has a vent and is configured to form an air chamber between the housing and the mascara tube. The fan blows air through the air chamber and out of the top of the housing, which is directed at the user's eyelashes after mascara is applied with the brush. The blowing air in conjunction with the upward and outward action of the mascara brush produces fuller, longer, and 200% more dramatic eyelashes. | 0 |
[0001] The present disclosure relates to subject matter contained in priority Japanese Patent Application No. 2001-61790, filed on Mar. 6, 2001, the contents of which is herein expressly incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method and apparatus for attaching a pouch-shaped separator to an electrode plate of a battery.
[0004] 2. Description of Related Art
[0005] A prismatic battery is constituted by placing an electrode plate group and an electrolyte in a battery case. The electrode plate group is composed of a plurality of square negative and positive electrode plates that are alternately superimposed one upon another with a separator interposed therebetween. In connection with this, as a method for inserting a separator between negative and positive electrode plates, there is known a technique whereby negative and positive electrode plates are alternately superimposed one upon another under a state where a pouch-shaped separator is attached to the positive or negative electrode plate.
[0006] An example of methods for attaching a pouch-shaped separator to an electrode plate will be described below. Firstly, as shown in FIG. 6A, a sheet-like separator 2 is so arranged as to cover both surfaces of an electrode plate 1 . Subsequently, as shown in FIG. 6B, an ultrasonic bonding tool 31 is applied to a to-be-bonded edge of the separator 2 . The ultrasonic bonding tool 31 has a width which is so set as to correspond to a width of a bonded portion 3 . Thereby, the separator 2 receives, while being pressurized, ultrasonic vibration in a direction of a sheet surface thereof so as to be ultrasonically bonded. Lastly, as shown in FIG. 6C, a cutter 32 is applied to the central part of the bonded portion 3 to cut off the separator 2 . In this way, the electrode plates 1 to which the pouch-shaped separator 2 is attached are consecutively produced.
[0007] In the conventional separator attaching method, the separator 2 made of a synthetic resin fiber cloth is subjected to ultrasonic bonding. However, in order for a fibrous material to be melted down by frictional heat resulting from ultrasonic vibration, application of ultrasonic vibration of large amplitude is required. This leads not only to an undesirable increase in running cost but also to the following problems. During bonding process, ultrasonic vibration is transmitted to the electrode plate 1 . This causes active substances to fall off from the electrode plate 1 , resulting in occurrence of minute short circuiting. Furthermore, whenever the cutter 32 is used to cut the bonded portion 3 , a resin component contained in the separator 2 adheres to the blade of the cutter 32 . This degrades the cutting capability of the cutter 32 in a short period of time and thus shortens its service life. Consequently, the amount of indirect materials tends to increase, and frequent halts of operations for cutter replacement are inevitable. This is undesirable from a cost standpoint.
SUMMARY OF THE INVENTION
[0008] The present invention has been made in light of the above stated problems with the conventional art, and accordingly it is an object of the present invention to provide a method and apparatus for attaching a separator to an electrode plate, the method and apparatus being free from a fear of minute short circuiting caused by the falling off of active substances from an electrode plate during the time a separator is shaped like a pouch by bonding, the method and apparatus being capable of cutting a bonded portion stably for a longer period of time without tool replacement, and requiring lower cost.
[0009] To achieve the above object, according to one aspect of the present invention, a method for attaching a separator to an electrode plate includes: a separator arrangement step for arranging a sheet-like separator so as to cover both surfaces of an electrode plate; a separator bonding step for thermally welding the separator by applying a first heating plate along a to-be-bonded edge of the separator adjacent to the electrode plate, the first heating plate having a width which is so set as to correspond to a width of a bonded portion of the separator; and a cutting step for cutting off the separator by pressing a second heating plate against substantially a central part of the bonded portion. In this method, since bonding of the separator is performed by thermal welding, no vibration occurs. This prevents active substances from falling off from the electrode plate, and thus prevents the possibility of minute short circuiting. Moreover, the separator is cut off by subliming its resin component through local heat transfer with use of a heating plate. Thus, cutting of the bonded portion is stably performed for a longer period of time without tool replacement, resulting in cost reduction.
[0010] According to another aspect of the invention, an apparatus for attaching a separator to an electrode plate, the apparatus that bonds a to-be-bonded edge, adjoining an electrode plate, of a separator which is so arranged as to cover both surfaces of the electrode plate and that cuts a central part of a bonded portion of the separator, includes: a bonding and cutting member composed of a heating plate with a width which is so set as to correspond to a width of the bonded portion, and having a cutting protrusion formed in one part thereof facing substantially the central part of the bonded portion. With this construction, bonding is performed without causing minute short circuiting, and further cutting of the bonded portion is stably performed for a longer period of time without tool replacement, which results in cost reduction. In addition, bonding and cutting are performed in combination in one process. This helps reduce the number of assembly man-hours, so that the cost is reduced greatly.
[0011] According to still another aspect of the invention, an apparatus for attaching a separator to an electrode plate, the apparatus that bonds a to-be-bonded edge, adjoining an electrode plate, of a separator which is so arranged as to cover both surfaces of the electrode plate and that cuts a central part of a bonded portion of the separator, includes: a heating plate for bonding having a width which is so set as to correspond to a width of the bonded portion; and a heating plate for cutting that cuts substantially the central part of the bonded portion.
[0012] While novel features of the invention are set forth in the preceding, the invention, both as to organization and content, can be further understood and appreciated, along with other objects and features thereof, from the following detailed description and examples when taken in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a longitudinal sectional front view showing a separator attaching process according to a first embodiment of the present invention;
[0014] [0014]FIG. 2 is a longitudinal sectional front view showing another bonding and cutting member employed in the first embodiment;
[0015] [0015]FIGS. 3A and 3B are longitudinal sectional front views showing the separator attaching process according to a second embodiment of the present invention;
[0016] [0016]FIG. 4 is a longitudinal sectional front view showing a separator bonding process according to a third embodiment of the present invention;
[0017] [0017]FIG. 5 is a longitudinal sectional front view showing the separator bonding process according to a-fourth embodiment of the present invention; and
[0018] [0018]FIGS. 6A, 6B, and 6 C are longitudinal sectional front views showing a conventional separator attaching process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
[0019] Hereinafter, with reference to FIGS. 1 and 2, a first embodiment of the method and apparatus for attaching a separator to an electrode plate according to the present invention will be described. Note that, in the first embodiment, the process for attaching a separator 2 to an electrode plate 1 is basically the same as that of the conventional example described with reference to FIGS. 6A to 6 C, except the bonding and cutting process. Thus, in the following description, the components that play the same or corresponding roles as in the conventional example will be identified with the same reference symbols, and overlapping descriptions will be omitted.
[0020] As shown in FIG. 1, in the first embodiment, both of bonding and cutting of the separator 2 is performed by a single-unit heating plate 11 . The heating plate 11 , serving as a bonding and cutting member, has a width which is so set as to correspond to a width of a bonded portion of the separator 2 , and has a cutting protrusion 12 formed in substantially the central part thereof. As a material used for the heating plate 11 , aluminum or aluminum alloy is preferable, because these materials are excellent in thermal conduction. Further, from the viewpoint of service life, high-strength duralumin-base metal is most desirable. The heating plate 11 has, for example, such a configuration that the protrusion 12 is 0.2 mm in width and 0.2 mm in height; the shoulder portions on both sides of the protrusion 12 is each 0.6 mm in width; and the entire width is 1.4 mm.
[0021] In the foregoing construction, by pressing the heating plate 11 along a to-be-bonded edge of the separator 2 , the separator 2 is thermally welded to be bonded. Then, the protrusion 12 locally transfers heat to the central part of the bonded portion 3 to sublime a resin component contained in the separator 2 , so that the separator 2 is cut off.
[0022] In this way, since bonding of the separator 2 is performed by thermal welding, no vibration occurs. This prevents active substances from falling off from the electrode plate, and thus prevents the possibility of minute short circuiting. Moreover, since the separator 2 is cut off by the heating plate 11 , cutting of the bonded portion 3 is stably performed for a longer period of time without tool replacement, which results in cost reduction. Further, bonding and cutting are performed in combination in one process. This helps reduce the number of assembly man-hours, so that the cost is reduced greatly.
[0023] While in FIG. 1, an example is shown in which the heating plate 11 consisting of a single member is employed, using a heating plate 13 shown in FIG. 2 as a bonding and cutting member may also be preferable. The heating plate 13 is composed of a heating plate for cutting 14 with a cutting protrusion 12 and heating plates for bonding 15 , arranged on both sides of the heating plate 14 , that are formed integrally with one another via a heat insulating material 16 . In this heating plate 13 , the heating plate for cutting 14 and the heating plate for bonding 15 may be individually heated by their respective heaters 17 and 18 . As the heat insulating material 16 , asbestos or foam glass is suitably used. The former is excellent in heat resistance and has sufficiently high maximum allowable working temperature (ranging from 400 to 600 degrees centigrade), and the latter exhibits lower thermal conductivity.
[0024] In such a heating plate 13 , the temperature settings of the heating plate for cutting 14 and the heating plate for bonding 15 are individually made by the heaters 17 and 18 . This facilitates performing bonding and cutting properly in a single process.
Second Embodiment
[0025] While the first embodiment deals with the case where bonding and cutting are performed in combination in one process by a single-unit heating plate ( 11 or 13 ), as shown in FIGS. 3A and 3B, bonding and cutting may also be separately performed with use of a heating plate for bonding 19 and a heating plate for cutting 20 . In this case, the operation is made in two steps. In the first process shown in FIG. 3A, the separator 2 is subjected to bonding by the heating plate for bonding 19 to form a bonded portion 3 . Then, in the second process shown in FIG. 3B, the central part of the bonded portion 3 is subjected to cutting by the heating plate for cutting 20 .
[0026] The heating plate for bonding 19 has a width which is so set as to correspond to a width of the bonded portion 3 (1.4 mm, for example), and has, in the widthwise central position on its front-end surface, a concave groove 19 a for securing contact surface pressure. A temperature of the heating plate for bonding 19 is, though it varies according to the thermal conductivity of the heating plate material or the material of the separator 2 , preferably set to a range of 200 to 240 degrees centigrade. If the setting temperature is too low, the resin component cannot be melted sufficiently, causing imperfect welding and/or reduction in the bonding strength. By contrast, if the setting temperature is too high, the resin component is melted thoroughly, with the result that the welded surface may become lost, or part of the separator 2 adjacent to the bonded portion 3 may be cut off by radiant heat emitted from the heating plate. Moreover, it is preferable that a pressing force of the heating plate for bonding 19 be set to a range of ca. 2.8 to 4.2 Mpa in terms of surface pressure, and that duration of time that the separator 2 is being pressed be set at ca. 0.6 sec. In this embodiment, bonding is performed under the following conditions: setting temperature: 240° C.; pressing force: 4.2 Mpa; and pressing time duration: 0.6 sec.
[0027] The heating plate for cutting 20 is 0.2 mm in width dimension and its temperature is, though it varies according to the thermal conductivity of the heating plate material or the material of the separator 2 , preferably set to a range of ca. 300 to 340 degrees centigrade. Moreover, a pressing force of the heating plate for cutting 20 should preferably be set to a range of ca. 4.2 to 4.9 Mpa in terms of surface pressure. In this embodiment, cutting is performed under the following conditions: setting temperature: 310° C.; pressing force: 4.9 Mpa; and pressing time duration: 0.2 sec.
Third Embodiment
[0028] While the second embodiment deals with the case where the separator 2 is supported simply at its back face, as shown in FIG. 4, it is also preferable that the separator 2 be supported at its back face via a cushioning member 21 made of, for example, a tape material having high heat resistance.
[0029] This arrangement allows the separator 2 to make good contact with the heating plate for bonding 19 , so that the quality of the bonded portion 3 improves.
[0030] While in this description, an example is shown in which the cushioning member 21 is used in the bonding process performed by the heating plate for bonding 19 of the third embodiment, the cushioning member 21 may also be used in the bonding/cutting process performed by the heating plate 11 of the first embodiment or the heating plate 13 of the second embodiment. In these cases, by supporting the separator 2 via the cushioning member 21 in a similar manner, substantially the same effect is attained.
Fourth Embodiment
[0031] In the bonding process according to the second embodiment, the heating plate for bonding 19 and the separator 2 make direct contact with each other. Alternatively, as shown in FIG. 5, it is also preferable that a protective tape 22 having high heat resistance be interposed between the heating plate for bonding 19 and the separator 2 .
[0032] In FIG. 5, the protective tape 22 is wound on a supply reel 23 which is so designed as to pay out the protective tape 22 under a certain tension. The protective tape 22 unreeled from the supply reel 23 is, through the front-end surface of the heating plate for bonding 19 , wound up on a take-up reel 24 by a motor (not shown). The protective tape 22 is taken up by the take-up reel 24 by several millimeters at regular intervals.
[0033] In this way, the protective tape 22 is interposed between the heating plate for bonding 19 and the separator 2 , and the protective tape 22 is moved at regular intervals so as for its fresh surfaces to be used for bonding operations at all times. This arrangement prevents degradation in the quality of the bonded portion 3 caused by the adhesion of a burnt or melted residue of the separator 2 to the front-end surface of the heating plate 19 due to the repetition of thermal welding, eliminates the need to clean the surface of the heating plate 19 on a regular basis, and improves the capacity utilization ratio.
[0034] In the method and apparatus for attaching a separator to an electrode plate according to the present invention, since bonding of a separator is performed by thermal welding and cutting is performed by pressing a heating plate against substantially a central part of the bonded portion of the separator, no vibration occurs. This prevents active substances from falling off from the electrode plate and thus prevents the possibility of minute short circuiting. Moreover, the separator is cut off by subliming its resin component through local transfer of heat carried out by a heating plate. Consequently, cutting of the bonded portion is stably performed for a longer period of time without tool replacement, which results in cost reduction.
[0035] Although the present invention has been fully described in connection with the preferred embodiment thereof, it is to be noted that various changes and modifications apparent to those skilled in the art are to be understood as included within the scope of the present invention as defined by the appended claims unless they depart therefrom. | A sheet-like separator is so arranged as to cover both surfaces of an electrode plate, and a heating plate is applied along a to-be-bonded edge of the separator, thereby achieving bonding by thermal welding. The heating plate has a width corresponding to a width of a bonded portion of the separator. Then, by pressing a protrusion of the heating plate or a heating plate for cutting against substantially the central part of the bonded portion, local heat transfer takes place to sublime a resin component, whereby the separator is cut off. Thereupon, the pouch-shaped separator is attached to the electrode plate. | 1 |
RELATED APPLICATION
This application replaces Provisional Application Ser. No. 60/045,821 filed on May 05, 1997 and entitled "Adhesive Compositions for Corrugated Boxes".
BACKGROUND OF THE INVENTION
This invention relates to the manufacture of novel starch-silicate adhesive compositions. In particular this invention concerns the formulation of adhesives for the manufacture of corrugated board by the use of improved mixtures of starches and alkali metal silicates.
The art of using soluble alkali silicates as adhesives for paper and box board has been known for many years. Alkali silicates are inexpensive, fire resistant, vermin resistant, recyclable and provide excellent strength to the products in which they are used. Among other applications these compounds find use as adhesives for paper products and plywood, as well as paper cores and tubes. Alkali silicates do however have a number of disadvantages which have resulted in the discontinuation of their use in certain industrial applications.
A primary disadvantage of silicate based adhesives is that the adhesive bond forms relatively slowly. This is a serious problem in the high speed corrugating machines employed today which require the formation of a strong "green bond" within a very few seconds of the linerboard and the corrugating medium being brought into contact. Another disadvantage of alkali silicates is that they are prone to deposit a tough, intractable glass on any surfaces upon which they are allowed to dry.
Because starch exhibits performance properties which are superior in quick bond formation and does not form a tough deposit, starch has almost completely replaced alkali silicates in the manufacture of corrugated boxboard some years ago. Starch itself, however, is not a perfect adhesive for this application. For one thing, the maximum solids content of such adhesive compositions usually attainable is in the range of 25-30%. Thus some 75% of the adhesive formulation applied to the boxboard consists of water, the removal of which reduces the operational speed of the corrugating equipment, and increases the energy costs associated with water evaporation. The higher water content of the adhesive also contributes to loss of paper strength as well as quality problems during the manufacture of boxes such as warping, blistering or a "washboard" effect.
It has also long been known that the edge crush strength of boxes glued with starch based adhesives is not as high as that which can be attained by use of silicate. These strength properties are now of considerable importance, owing to the fact that the specification of boxes is now based on their edge crush strength (Alternate Freight Regulations Rule 41, as described in Tappi test methods T811) rather than basis weight (as was the case in the past). Use of silicates in the adhesive thus opens the possibility of manufacturing boxes of equivalent edge crush strength either by using paper of a lower basis weight or by using recycled paper of poor quality.
A number of attempts have been made to combine alkali silicates and starch in adhesives for the fabrication of corrugated paperboard boxes and similar applications, in order to realize the benefits described. Thus U.S. Pat. No. 2,669,282 (Kreyling) discloses an adhesive mixture of starch, clay and sodium silicate. U.S. Pat. No. 2,772,996 (Sams) teaches a method of producing such an adhesive by mixing silicate, starch and borax. More recently, Canadian Patent No. 1,056,107 (Falcone, 1979) discloses a class of starch-silicate adhesives in which some of the starch in conventional starch-based adhesive compositions is replaced by alkali silicate, but the total solids content of the adhesive compositions is not appreciably changed.
To date, however, none of the compositions or methods to combine starch and silicate for the manufacture of corrugated boxboard has found commercial application because none has proved to be capable of meeting the demanding requirements of modern high speed corrugating equipment, none of the previous starch and silicate combinations having demonstrated the ability to impart higher edge crush. The principal requisites for such performance features are, firstly, formulation of adhesives so that their viscosity, rheology properties, gelation temperature and speed of "green-bond" formation are all within a very tight range. It is thus essential that the finished adhesive have low thixotropy and a viscosity of between 20-60 Stein-Hall seconds in order to achieve a smooth and rapid transfer of the adhesive from the holding tanks to the corrugator adhesive applicator stations.
A second essential aspect of starch based adhesive formulations is the temperature at which gelation of starch occurs. This usually occurs at a temperature between 60 and 70° C. (140-160° F.), operation of modern corrugating equipment not generally being possible if the gelation temperature is outside this range. Although the aforementioned Falcone patent reveals that addition of sodium silicate to starch leads to a dramatic increase in gel temperature, no teaching has yet been provided of how to formulate satisfactory starch/silicate compositions having gel temperatures low enough to be within an allowable operating range or a viscosity stability over time at elevated temperature, i.e. above 50° F. (120° F.).
There is yet another aspect of starch gelation of pertinence to this invention. During the normal operating procedure the starch based adhesive is maintained in the storage tank at a temperature of between 38-40° C. (100-104° F.). The stability of conventional starch based adhesives is such that this material is prone to premature gelation due to fluctuations in the temperature of the operating environment, and these starch based adhesives can not be stored longer than about 3 days.
We have discovered that by modifying starch-based adhesives by the addition of alkali silicate, in addition to other ingredients such as caustic soda and borax commonly used in starch adhesives, in a precisely controlled and ordered manner, that it is possible to realize all the known advantages of alkali silicates without incurring the problems with viscosity or elevated gelation temperatures which prevented the commercialization of the earlier disclosures.
These formulations are also found to exhibit unusually good high temperature stability. The discovery of high temperature stability has allowed for higher temperature storage which has help offset the higher gel temperature.
Moreover we also discovered, to our surprise, that the methods here described allow the preparation of starch based adhesives with very much higher solids content than previously attainable. As will be demonstrated in the examples below, this discovery increases the solids content of such compositions from the 25-30% range achievable using the conventional technology, to around 45% solids. As mentioned above, reduction of the water content in this manner leads to significant benefits in the operation of corrugating equipment by reducing the strength loss in the liner and mediums caused by water addition from the adhesive, the amount of steam energy required to evaporate the water and the production of boxes with improved dimensional stability.
As the examples given below will show, the invention herein described also lead to improvements both in the strength of the adhesive bond, and in the box itself. The examples also demonstrate that these formulations are entirely compatible with a wide range of operational variables commonly encountered and well known to those skilled in the art.
Formulations according to the present invention are: (i) applicable to raw and modified starches from a wide variety of sources; (ii) compatible with insolubilizing resins such as the cross-linked polymers of melamine-formaldehyde, urea-formaldehyde and ketone-aldehyde commonly used to impart water resistance to starch based adhesives; and (iii) amenable to preparation using conventional techniques for preparing starch-based adhesives, such as the "two-stage" (Example 8, below), "no carrier" (Example 9, below), and "carrier-no carrier" manufacturing processes.
Although most of the examples presented reveal the preparation of the adhesives using liquid ingredients, Example 10 is also presented to demonstrate that similar results can be obtained if only dry ingredients are employed, this being of potential advantage in the commercialization of these materials.
Example 11 below is presented to demonstrate that when these formulations are prepared using recycled water from the corrugating print station (so-called "flexo" water), the concentration of soluble copper in the adhesive is reduced to an unexpectedly low level. The importance of this observation arises from the fact that although the use of flexo water in the preparation of starch based adhesives is an increasingly popular method of recycling waste streams, the conventional starch based compositions employed until now have not been found capable of reducing the solubility of toxic copper ions or other metal ions present in the waste water. The specific reduction of copper observed in the compositions here disclosed is to be attributed to the well known sequestering properties of alkaline silicates.
Although the focus of this disclosure is directed towards manufacture of corrugated boxes, it should also be noted that this is but one of numerous area of potential application of the silicate-starch compositions herein described. Adhesives according to the invention may be used with other cellulosic materials, such as wood and other paper products.
SUMMARY OF THE INVENTION
With a view to providing improved adhesives for the manufacture of boxes and other industrial wood and paper products, based on combinations of silicate and starch but affording the requisite control of adhesive viscosity and gel temperature to permit use of the adhesives in corrugating equipment, the invention is directed in one aspect to adhesive compositions having solids content of 30 to 45% by weight and consisting essentially of:
(i) 12 to 35% by weight of a starch;
(ii) 1.5 to 12% of soluble alkali metal silicate;
(iii) 0.25 to 2.5% by weight of alkali hydroxide;
(iv) optionally, up to 2% borax (anhydrous or hydrated form) or boric acid); and
(v) 55 to 70% water by weight, and in another aspect, to processes for preparing improved starch-silicate adhesives of this kind.
In the present invention, "starch" refers to the carbohydrate reserve of a plant. It is generally deposited in the form of minute granules 1 to 100 microns and swells in water at 55 to 80° C. While starches are found throughout the plant world, those of particular commercial advantage for use in the present invention are corn, wheat and potato starches, although others could be used, including modified starches. An example of a preferred starch is the cornstarch sold as 3005 by Corn Products International, Ill.
Soluble alkaline silicates useful in carrying out the present invention include materials in solution as well as hydrated solids and anhydrous silicates, exhibiting molar ratios of SiO 2 to M 2 O in the range of 1.5 to 4.0 where M is preferably either sodium or potassium. The disclosure of Canadian Patent No. 1,056,107 is hereby incorporated by reference for its general teaching of alkali metal silicates used in starch-silicate adhesive compositions. A particular silicate found useful in the present invention is N® brand sodium silicate manufactured by the PQ Corporation (valley Forge, Pa.), which exhibits a weight ratio of SiO 2 to Na 2 O of 3.2.
DETAILED DESCRIPTION OF THE INVENTION
Compositions according to the present invention are illustrated in Examples 2 and 3 in which modified and unmodified carrier starches respectively are employed to prepare adhesive compositions according to the invention, which exhibit superior bond and paper strength when used in the manufacture of corrugated boxes.
There is provided a demonstration of the superior heat stability of this composition (Example 4), and a method of varying the gelation characteristics including gel temperature of the starch-silicate adhesives of the invention by changing the relative quantities of caustic soda and borax used in their preparation (Example 5), this being of particular importance to ensure that the gelation characteristics are compatible with the operation of modern corrugating equipment.
The prior art relating to starch-silicate adhesive combinations is limited to total solids content in the range of 15 to 30%, a limit dictated by the high viscosity, instability and gel temperature which were observed in the formulations contained within these earlier disclosures. According to a further advantage afforded by the present invention, however, a silicate-starch adhesive may be manufactured at a solids content as high as 45%. (Example 6). This grants a number of significant advantages including:
(i) realization of energy savings as a result of a reduction of the amount of water requiring evaporation;
(ii) lower warpage of glued boxboard product, again because of lower initial water content;
(iii) faster machine speeds; and
(iv) less liner and medium strength loss due to water from the adhesive.
A currently preferred embodiment of the process of the invention, comprises the following steps for preparing new and useful starch silicate adhesives:
(a) preparing a gelled carrier portion by addition of 1.5 to 10% starch by weight of the final adhesive composition to 20 to 45% by weight of water, mixing until the starch is dispersed in the water, and then adding of 0.25 to 2.5% by weight of sodium or potassium hydroxide, after which the composition is mixed or preferably sheared, until a complete gel and constant viscosity of this carrier portion is obtained;
(b) adding 10 to 30% by weight of liquid sodium or potassium silicate to the carrier portion and shear mixing until homogeneous;
(c) optionally, adding to the mixture produced in step (b) up to 2.5% by weight of sodium or potassium hydroxide, after which the material is mixed or sheared until homogenous;
(d) optionally, adding up to 2% by weight of borax followed by mixing or shearing to constant viscosity;
(e) adding of 3 to 20% by weight of water and mixing or shearing until homogenous; and
(f) adding 2 to 35% starch by weight and shear mixing to constant viscosity to produce the final adhesive composition.
As will also be shown in the examples which follow, these compositions are also compatible with various other chemicals and industrial processes well known to those skilled in the art of adhesive manufacture, such as insolubilizing resins (Example 7); the "two-stage" addition process (Example 8) and "no-carrier" methods well known to those skilled in the art (Example 9).
According to a further aspect of this invention, silicate-starch adhesives of this type can be prepared as a pre-mixed dry blend by the use of a dry form of alkali silicate (Example 10). Finally, a still further aspect of this invention illustrated in Example 11, reveals that use of recycled "flexo" water results in a composition containing significantly lower levels of soluble copper.
Those skilled in the art will also be aware that the formulating procedures herein described also apply to other types of starches (such as acid-stable starches) as are commonly used in adhesive compositions. Nor are these examples meant to preclude the use of other common additives such as surfactants, or polymers such as polyvinyl alcohol which are used from time to time to enhance the performance of such adhesives.
EXPERIMENTAL EXAMPLES
In the following examples, certain embodiments of the invention are illustrated and compared to the prior art. All proportions used in the examples are parts by weight (pbw) unless otherwise noted. The ratios of the silicates are weight ratios of SiO 2 /Na 2 O, sodium generally being the alkali metal of choice.
The first example shown illustrates the preparation of a typical starch based adhesive commonly used in industrial applications, the method of preparation of this standard composition which will be used as a control is as follows:
Example 1
Preparation of conventional starch based adhesive for use in the manufacture of corrugated boxes.
The carrier portion of a pure starch adhesive is prepared by combining 39.2 pbw water with 5.2 pbw modified corn starch (manufactured by Corn Products International under the name Surebond®) followed by 1.1 pbw sodium hydroxide (50% solution). The resulting slurry is held at 45° C. (115° F.) and is allowed to gel while mixing under high shear. Upon reaching a stable viscosity, 0.39 pbw of borax (pentahydrate) is added to gel mixture and mixed to a stable viscosity. 31.41 pbw water is added to the mixture and mixed until homogeneous. 22.7 pbw prime (unmodified) corn starch (Corn Products International, 3005) is added to the mixture and mixed until homogeneous.
Initial Stein-Hall Viscosity--25-35 seconds at 38° C. (100° F.)
gel temperature--61° C. (142° F.)
Example 2
An adhesive composition prepared under commercial conditions using a modified carrier starch. The adhesive composition demonstrates superior bond strength and edge crush strength of corrugated board made with starch/silicate.
The carrier portion of the starch/silicate adhesive is prepared by combining 36.1 pbw water with 4.9 pbw modified corn starch (Corn Products International, Surebond®) followed by 1.0 pbw caustic (50%). The resulting slurry was held at 55° C. (131° F.) and is allowed to gel under low shear mixing. Upon reaching a stable viscosity, 18.9 pbw sodium silicate (Silicate N®, PQ Corporation) is added and mixed until homogenous. 1.4 pbw caustic (50%) is added to the mixture and mixed until homogeneous. 0.37 pbw borax (pentahydrate) is added to the mixture and mixed to a stable viscosity. 15.7 pbw water is added and mixed until homogeneous. 21.6 pbw prime (unmodified) corn starch (Corn Products International, 3005) is added to the mixture and mixed to steady viscosity. Upon completion the temperature of the starch/silicate adhesive is 45° C. (113° F.).
Results
Initial Stein-Hall viscosity--35s @ 51° C. (124° F.)
gel temp.--71° C. (160° F.)
solids--35%
______________________________________Edge Crush of Production Board starch starch silicatebox type adhesive example #2______________________________________light weight 27.5 lb/in 37.9 lb/inmedium weight 34.5 49.2heavy weight 53 73.3______________________________________
Example 3
The formula in Example 2 was used to prepare a lab sample to test greenbond strength (duplication of the bond strength immediately off the single facer) The lab prepared sample demonstrated significantly higher green bond strength.
control (example #1)--332 grams of force
starch/silicate (example #3)--449 grams of force
Example 4
Preparation of silicate-starch adhesive demonstrating high temperature stability.
The carrier portion of the starch/silicate adhesive is prepared by combining 36.0 pbw water with 3.0 pbw modified corn starch (Corn Products International, Surebond®) followed by 1.0 pbw caustic (50%). The resulting slurry is held at 60° C. (140° F.) and is allowed to gel under high shear mixing. Upon reaching a stable viscosity, 20.0 pbw sodium silicate (Silicate N®, PQ Corporation) is added and mixed until homogeneous. 1.5 pbw caustic (50%) is added to the mixture and mixed until homogeneous. 0.37 pbw borax (pentahydrate)is added to the mixture. Upon reaching a stable viscosity 11.13 pbw water is added and mixed until homogeneous. 27.0 pbw prime (unmodified) corn starch (Corn Products International, 3005) is added to the mixture and mixed to steady viscosity.
Initial Stein-Hall Viscosity--23 seconds @ 45° C. (113° F.).
gel temperature--72.5° C. (162° F.)
solids content--39.1%
______________________________________Viscosity Stability 60 min 120 min 4 hrs 7 hrs @ @ @ @initial 55° C. 55° C. 55° C. 55° C.______________________________________example #1 50 s @ 40° C. 118 s 342 s >10 min NAexample #4 23 s @ 55° C. 22 s 22 s 23 s 22 s______________________________________
Example 5
A method of varying the gelation characteristic of silicate-starch adhesives by changing the quantities of caustic soda and borax used in their preparation. Adhesive was prepared using unmodified starch as the carrier.
The carrier portion of the starch/silicate adhesive is prepared by combining 39.2 pbw water with 3.7 pbw prime (unmodified) corn starch (Corn Products International, 3005) followed by 0.78 pbw caustic (50%). The resulting slurry is held at 45° C. (113° F.) and is allowed to gel under high shear mixing. Upon reaching a stable viscosity, 20.0 pbw sodium silicate (Silicate N®, PQ Corporation) is added and mixed until homogeneous. Caustic (50%) is added to the amount shown in the Table, and mixed until homogeneous, after which borax (pentahydrate)is added to the mixture as shown in the Table. Upon reaching a stable viscosity 12.2 pbw water is added and mixed until homogeneous. 23.7 pbw prime (unmodified) corn starch (Corn Products International, 3005) is added to the mixture and mixed to steady viscosity. Gelation characteristics are determined using a Brabender instrument.
______________________________________BRABENDER RESULTS elapsed start time to2.sup.nd of maximumNaOH borax gel viscosity brabender gel(pbw) (pbw) (minutes) (minutes) Visc. slope______________________________________starch 0 0.25 13.5 18.5 560 112adhesivestarch/ 0.875 0.25 14.5 22 550 73.3silicatestarch/ 1.75 0.25 13.0 20 920 131.4silicatestarch/ 1.75 0 14.0 21 660 94.3silicate______________________________________
Example 6
A process for preparing a stable adhesive composition having a very high solids content.
The carrier portion of the starch/silicate adhesive is prepared by combining 36.0 pbw water with 3.0 pbw modified corn starch (Corn Products International, Surebond®) followed by 1.00 pbw caustic (50%). The resulting slurry is held at 60° C. (140° F.) and is allowed to gel under high shear mixing. Upon reaching a stable viscosity, 22.0 pbw sodium silicate (Silicate N®, PQ Corporation) is added and mixed until homogeneous. 1.5 pbw caustic (50%) is added to the mixture and mixed until homogeneous. 0.40 pbw borax (pentahydrate)is added to the mixture. Upon reaching a stable viscosity 4.1 pbw water is added and mixed until homogeneous. 32.0 pbw prime (unmodified) corn starch (Corn Products International, 3005) is added to the mixture and mixed to steady viscosity.
initial Stein-Hall viscosity--39 seconds @45° C. (113° C.)]
gel temp--73° C. (163° F.).
solids--44.9%
Example 7
Compatibility and effectiveness of silicate-starch compositions with water proofing resins.
The carrier portion of the starch/silicate adhesive is prepared by combining 36.1 pbw water with 4.3 pbw modified corn starch (Corn Products International, Surebond®) followed by 1.00 pbw caustic (50%). The resulting slurry is held at 55° C. and is allowed to gel under high shear mixing. Upon reaching a stable viscosity, 18.9 pbw sodium silicate (Silicate N®, PQ Corporation) is added and mixed until homogeneous. 1.4 pbw caustic (50%) is added to the mixture and mixed until homogeneous. 0.37 pbw borax (pentahydrate)is added to the mixture. Upon reaching a stable viscosity 15.83 pbw water is added and mixed until homogeneous. 22.1 pbw prime (unmodified) corn starch (Corn Products International, 3005) is added to the mixture and mixed to steady viscosity.
Two of the more common water proofing resins, a melamine-formaldehyde resin (Corn Products International, Coragum®) and a ketone-formaldehyde resin (Cellbond Inc., Watertite®) were post added to the prepared starch/silicate adhesive. As is the common practice in the corrugating industry, the post addition of resin is measured as a percentage of starch solids.
Starch/silicate showed no compatibility problems with either Coragum® or Watertite®. In the specific case of Coragum®, the viscosity was monitored for 24 hrs.
______________________________________Stability of Starch/Silicatewith 6% Coragum ® post added initial 24 hour visc @ visc @ 45° C. 45° C.______________________________________starch/silicate 24 s 21 sstarch/silicate + 30 s 23 s*melamine-formaldehyderesin______________________________________ *sample was shear mixed for 1 minute
The water resistance of starch/silicate with resin was measure two ways:
Starch/silicate with 6% post added Coragum® was tested by gelling the adhesive samples, submersing the samples under water and then observing the rate of breakdown of the gelled samples. Results showed a much slower rate of gel breakdown of starch/silicate with Coragum®.
i. Starch/silicate with 5% post added Watertite® was tested using TAPPI T812 and passed with equal resistance over 24 hrs as that of the starch adhesive with 5% post added Watertite®.
Example 8
Starch/silicate adhesive prepared using the two-stage Stein-Hall method.
This method is conventionally used in preparing starch-only adhesives for making corrugated boxboard. We have found that it can readily be adapted to the making of starch-silicate adhesives according to the present invention by process steps such as the following:
The first stage is prepared by combining 13.31 pbw water with 3.63 pbw modified corn starch (Corn Products International, Surebond®) followed by 1.03 pbw caustic (50%). The resulting slurry is held at 57° C. (135° F.) and is allowed to gel under high shear mixing, after which 9.70 pbw water is mixed into the gel.
The second stage is prepared by combining 34.87 pbw water with 15.98 pbw sodium silicate (Silicate N®, PQ Corporation) followed by 0.73 pbw caustic (50%) and then 0.41 pbw borax (decahydrate)and finally 20.34 pbw prime (unmodified) corn starch (Corn Products International, 3005).
The first stage mix is dropped into the second stage mix over a 20 minute time period. The combined mixes are stirred to steady viscosity
initial Stein-Hall Viscosity--62s @34° C. (94° F.)
gel temperature--68° C. (154° F.)
solids content--31.2%
green bond strength--475 grams of force
Example 9
The "No carrier" technique used in manufacturing starch adhesives is characterized by the fact that controlled swelling of all of the starch is determinative of the finished adhesive viscosity. As adapted to the preparation of starch-silicate adhesives according to the present invention, viscosity increase is terminated by the addition of a second portion of silicate.
The starch/silicate adhesive is prepared by combining 40.0 pbw water with 9.5 pbw sodium silicate (Silicate N®, PQ Corporation) followed by 2.5 pbw caustic (50%)and then 0.37 pbw borax (pentahydrate). To the resulting solution is added 25.0 pbw prime (unmodified) corn starch (Corn Products International, 3005) under agitation. Upon reaching a viscosity of .sup.˜ 7000 cps @ 35° C. (95° F.) the viscosity advancement is halted by the addition of 10.5 pbw sodium silicate (Silicate N®, PQ Corportation). 12.13 pbw water is added to further reduce viscosity.
Initial viscosity--21s @ 36° C. (97° F.)
18 hr viscosity (stored at 50° C. )--21s @ 45° C. (113° F.)
gel temperature--74° C. (165° F.)
Example 10
Silicate-starch adhesives prepared as a dry blend by the use of a solid form of alkali silicate.
Prior to making the adhesive mix, a dry blend is prepared by combining 72.29 pbw prime (unmodified) corn starch (Corn Products International, 3005) with 26.50 pbw sodium silicate powder (Silicate G®, PQ Corporation) and 1.21 borax (pentahydrate).
The carrier portion of the starch/silicate adhesive is prepared by combining 36.1 pbw water with 4.3 pbw modified corn starch (CPC surebond®) followed by 1.0 pbw caustic (50%). The resulting slurry is held at 55° C. (131° F.) and is allowed to gel under high shear mixing. Upon reaching a stable viscosity the gel is diluted with 26.22 pbw water. To the diluted gel is added 30.57 pbw of the previously prepared of starch/sodium silicate/borax dry mix. After thoroughly mixing until homogeneous, 1.81 pbw high alkaline sodium silicate (metso pentabead®, PQ Corportation) is added to the mixture and mixed to steady viscosity.
Initial Stein-Hall viscosity--35s at 45° C. (113° F.)
gel temperature--73° C. (163° F.)
pH--11.2
solids--37.2%
Example 11
Preparation of silicate-starch adhesives using recycled water from corrugator print station. ie. "flexo" water.
The carrier portion of the starch/silicate adhesive is prepared by combining 36.1 pbw "flexo" water with 4.3 pbw modified corn starch (CPC surebond®) followed by 1.0 pbw caustic (50%). The resulting slurry is held at 55° C. and is allowed to gel under high shear mixing. Upon reaching a stable viscosity, 18.9 pbw sodium silicate (Silicate N®, PQ Corporation) is added and mixed until homogeneous. 1.4 pbw caustic (50%) is added to the mixture and mixed until homogeneous. 0.37 pbw borax (pentahydrate)is added to the mixture. Upon reaching a stable viscosity 15.83 pbw flexo water is added and mixed until homogeneous. 22.1 pbw prime (unmodified) corn starch (CPC 3005) is added to the mixture and mixed to steady viscosity.
Initial Stein-Hall Viscosity--24 seconds @ 45° C. (113° F.)
24 hour viscosity at 120F--29 seconds @ 45° C. (113° F.)
gel temperature--72° C. (162° F.)
pH--11.2
solids--35.1%
This results in a composition containing lower levels of soluble copper as measured by atomic absorption spectrometry.
Starch/silicate--31 ppm measurable copper
"flexo" water*--56 ppm measurable copper | Novel starch-silicate adhesive compositions are disclosed which are of particular advantage in the manufacture of corrugated board. By the controlled combination of starch, alkali silicate and, optionally, caustic soda and borax it has been found possible to produce useable adhesives having much higher levels of solids content than conventional starch-based adhesives, thereby allowing for lowered energy costs in use of the adhesive formulation to manufacture boxboard, as well as improved product quality. The formulation of starch-silicate adhesives according to the invention allows viscosity, rheological characteristics--in particular gelation temperature--and the speed of "green-bond" formation to be controlled and adapted to the requirements of modern high-speed corrugating equipment. | 2 |
FIELD OF INVENTION
[0001] The present invention refers to a method and apparatus for indoor rapid and cost-effective tests of mobile tracking antennas for satellite (or terrestrial) communications.
[0002] In particular, the invention concerns a low cost antenna test range based on a standard off-the-shelf reflector antenna, a mobile environment simulation device, and a source of an actual modulated satellite signal or a simulated satellite (or another type) signal to the test antenna. The tracking and recognition capabilities of a mobile antenna terminal may be tested in a compact indoor environment. The disclosed method and apparatus permits a rapid assessment and diagnosis, including final production tests, of receive only or two-way (receive and transmit) mobile antenna terminals for broadband satellite (or terrestrial) communications. The invention permits a simple test set-up requiring minimal training of personnel.
BACKGROUND OF THE INVENTION
[0003] Designs and techniques for an indoor antenna test facility, using an antenna reflector test range that simulates far field range (sometimes called “compact range”), are disclosed in many technical reports, textbooks and articles [for example “Compact Antenna Test Range Without Reflector Edge Treatment and RF Anechoic Chamber by Chang D., Liao C. and Wu C., IEEE Antennas & Propagation Magazine, Vol. 46, No4, August 2004 pp 27-37]. The main principle of operation for such facilities is based on the use of a shaped reflector to produce a plane wave in the area where the antenna under test is situated in order to correctly measure the antenna's far field performance. Such compact range facilities typically require a very precise reflector surface for the accurate measurement of the antenna parameters, resulting in high cost. Furthermore, highly skilled personal are typically needed to perform the tests, which are time consuming thereby making impractical such ranges for a mass production testing environment.
[0004] Thus, one objective of the invention is to provide a system, method and apparatus set up for simple, rapid, low cost indoor functional tests of mobile satellite (or terrestrial) antenna terminals.
SUMMARY OF THE INVENTION
[0005] The invention concerns a test system and method for indoor testing of a mobile antenna terminal having a first antenna with a first aperture of a first size and, preferably, operable in a receive-only mode and/or a transmit and receive mode. The system uses a second antenna having a dual port feed and a reflector, the second antenna having a second aperture of a second size, which is two or more times the first size, and being operative to form a plane wave. The first antenna is mounted to a test platform that is positioned within the second aperture and is operative for a programmed rotating and tilting movement of the antenna to simulate movement on a vehicle. The test system uses a source of RF test signals and communications test equipment coupled to at least the first antenna, as well as a processor for determining a performance of the mobile antenna terminal.
[0006] The invention is described in accordance with multiple exemplary embodiments, but is not limited to the details or even common features thereof. The exemplary embodiments are provided in order to provide an indication of the broad range of applications for the invention.
[0007] According to one exemplary embodiment of the invention, a simple off the shelf reflector antenna is used to generate a plane wave in the area where the antenna terminal under test is situated. The diameter of the reflector is chosen to be larger than the antenna under test in order to ensure relatively uniform amplitude and phase distribution of the electromagnetic field over the test area. A reflector with an off set geometry is preferable in order to minimize shadowing and to ensure better planarity of the wave in the near field plane wave region. An off-the-shelf reflector may be used with the present invention, since the objective is to conduct final system tests (for example acquisition and tracking antenna capabilities) or to determine antenna parameters required by a defined specific acceptance test procedure.
[0008] The plane wave is properly modulated to present the test terminal with an actual or realistically simulated satellite (or another type) signal. In a case when a satellite communication antenna is under test, this is accomplished by using a standard satellite reflector antenna, which is mounted outside and has direct line of site view to a selected geostationary satellite having one or more transponders. A low noise block (LNB), down converts the signals of the chosen satellite transponder. This signal is then fed to an upconverter and thereafter to the antenna reflector test range feed. The modulated plane wave falling over the antenna under test is adjusted to have the intensity (field strength) and has modulation identical to the case when the antenna terminal under test is situated in the open space, directed toward the selected satellite and tuned to the selected transponder.
[0009] In another exemplary embodiment, a digital video broadcast (DVB) signal could be provided using the DVB streamer to reproduce initially recorded baseband DVB streams and a DVB modulator. This way of forming the test signal may be used when a clear line of sight to an actual satellite is not possible or in case when other types of test signals are required.
[0010] Given the presence of the properly modulated plane wave from the antenna reflector test range, the rotation platform upon which the antenna terminal under test is mounted, can be put in operation and the antenna tracking and recognition capabilities under simulated vehicle motion scenarios can be tested, for example, for different speeds of rotation at different elevation angles. The system parameters such as signal to noise ratio, bit error rate (BER), maximal tracking speed, and initial time for recognition and satellite locking can be measured and compared with desired specifications. Additionally a very simple pass/fail final functional test can be applied by direct comparison with a proper “reference” antenna, verifying at the end of the production process the antenna terminal's capability to recognize and track the satellite.
[0011] In another exemplary embodiment of the invention, the system can be used for two-way mobile terminals tests. In such embodiment, it is preferable to use a feed comprising an orthomode device supporting two orthogonal linear polarizations. One of the orthomode inputs could be used in transmit mode to provide a plane wave modulated by the proper DVB (or another type) signal, supplied by one of the embodiments described above, in order to test acquisition and tracking capabilities of the antenna under test in receiving mode. The second orthomode input, operating in receive mode, may be used to test the effective isotropically radiated power (EIRP) transmitted by the antenna under test while operating in transmit mode.
[0012] Another exemplary embodiment of the invention provides a capability to test mobile antennas, which support data communication and at the same time reception of TV programs from a DBS satellite located at the same orbital position with the FSS satellite providing data communication service.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates the geometry of a low cost antenna reflector test range according to an exemplary embodiment of the invention.
[0014] FIG. 2 illustrates a block diagram of the test set up for receive only antenna tests in accordance with another exemplary embodiment of the invention.
[0015] FIG. 3 Illustrates flow chart of the disclosed method in accordance with an embodiment of the invention.
[0016] FIG. 4 illustrates a block diagram of the test set up for two-way antenna tests in accordance with a further exemplary embodiment of the invention FIG. 5 illustrates block diagram of the test set up for the test of a mobile antenna, which is able to support data communication service and at the same time reception of TV programs.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The claims alone represent the metes and bounds of the invention. The discussed implementations, embodiments and advantages are merely exemplary and are not to be construed as limiting the present invention. The description of the present invention is intended to be illustrative, and is not intended to limit the scope of the claims. Many alternatives, modifications and variations will be apparent to those skilled in the art.
[0018] The present invention may be exemplified by several applications of the methods and system embodying low cost facilities for indoor testing of mobile antennas for broadband satellite (or terrestrial) communications using an antenna reflector test range with plane wave supplied by a standard off-the-shelf reflector antenna and an actual or simulated satellite (or other type) signal provided by either an auxiliary antenna or a DVB streamer.
[0019] One exemplary embodiment of the low cost antenna reflector test range configuration is illustrated in FIG. 1 . The, a conventional antenna 1 , which may be an off the shelf reflector antenna 1 , preferably has a preferred size of the antenna aperture needed to form the plane wave 40 selected to be at least 2 times larger that the aperture of the antenna under test 3 . In the case of a specific application the reflector diameter is selected to be 2.4 meters for testing of an antenna with an aperture size of around 0.8 meters. The reflector antenna 1 is selected to have offset configuration in order to avoid shadowing and to achieve more uniform phase and amplitude distribution around the antenna under test 3 . The antenna under test is mounted on a rotating platform (pedestal) 5 , which can be programmed to automatically move the antenna under test 3 with specified angular range and speed around the defined rotation axes. In one specific embodiment the angle for rotation in elevation could be between 20 and 70 degrees while keeping full 360 degrees rotation in azimuth.
[0020] A further understanding of the basic features of the invention can be obtained from the exemplary test system applicable to testing of receive only antennas, as illustrated in FIG. 2 . The illustrated test system comprises two sets of equipment: a transmit set 31 and a receive set 30 .
[0021] The transmit set 31 includes: outdoor standard receive antenna 18 , Low noise block (LNB) 16 , IF/RF system up converter 14 , attenuator 15 , RF switch 17 , interface circuit 13 , power supply units 19 and 20 , and reflector range feed horn 2 . In another exemplary embodiment, a DVB streamer 21 and QPSK modulator (or another proper type of modulator) 22 is used.
[0022] The receive test set 30 includes: indoor unit 6 ; reference antenna 4 ; attenuator 7 ; RF switch 10 ; test receiver 12 ; interface circuit 11 and power supply unit 9 . The computer system 8 is used to control both transmit and receive sets of equipment.
[0023] The test system 3 is connected to the indoor unit block 6 , which provides power supply to the antenna terminal under test 3 , enables satellite recognition function and ensures proper interface with the test receiver 12 and the controlling computer 8 . Power supply unit 9 provides DC bias to the indoor unit 6 and antenna terminal under test 3 . An attenuator 7 is connected between the indoor unit 6 and the test receiver 12 in order to adjust the proper signal level and to ensure good isolation and matching. An RF switch 10 , controlled by the computer system 8 through the interface circuit 11 , is connected in order to switch the test receiver 12 between the antenna under test and a reference antenna 4 (with well defined performance) for comparison.
[0024] An RF test signal is formed in the transmit set 31 . In one embodiment the primary source of the test signal is a standard off the shelf reflector antenna 18 , connected to the Low Noise Block (LNB) 16 , which down converts the DVB RF signal, coming from the selected satellite transponder and then up converted again by the IF/RF upconverter 14 . The antenna 18 is mounted outside, in the open space, having clear line of sight with the geostationary satellite 34 that is selected for communication.
[0025] In another embodiment the test signal could be provided by a standard DVB streamer 21 and a QPSK modulator 22 (or another suitable modulator). The DVB streamer 21 comprises DVB stream recorder and DVB player sets. The DVB stream recorder may be used to record suitable DVB data streams that are needed for appropriately testing the acquisition and tracking capabilities of the mobile system under test 3 . The recorded data (DVB streams) are then reproduced by the DVB player and then provided to the QPSK modulator 22 (or another suitable modulator) in order to form a baseband test signal at the output of the modulator 22 . The baseband test signal is transferred through the attenuator 15 in order to adjust properly the level of the baseband signal and then is upconverted using the IF/RF upconverter 14 , forming in that way an RF test signal at the output of the IF/RF upconverter 14 . The RF switch 17 is used to deliver the RF test signal to any one of the two inputs of the feed 2 situated at the focal point of the antenna test range reflector 1 . Each one the feed 2 inputs is dedicated to one of two polarizations. The polarizations could be Left Hand Circular (LHCP) and Right Hand Circular (RHCP) Polarizations or Horizontal (HP) and Vertical (VP) Linear Polarizations depending on the specifications of the system under test. The feed 2 comprises feed horn, orthogonal mode transducer (orthomode) and polarizing devices in order to form the RF test signal with appropriate polarization simultaneously, illuminating properly the test range reflector 1 . Power supply units 9 , 19 and 20 provide the necessary supply voltages to the indoor unit (IDU) 6 , IF/RF upconverter 14 and RF switch 17 respectively. The dedicated computer system 8 provides control to the IDU 6 , and switches 10 and 17 through the interface circuits 11 and 13 .
[0026] The foregoing arrangement may be used to implement a method of indoor testing of a mobile antenna terminal having an antenna with an aperture of a desired size. According to a first step (S- 1 ) of the method, as illustrated in FIG. 3 , a second antenna, which has at least a feed and a reflector, is provided for forming a plane wave, and is oriented to allow the wave to encompass the mobile antenna terminal. As previously noted, the second antenna has a second aperture of a size, which is two or more times the of the aperture of the antenna on the mobile antenna terminal. In a second step (S- 2 ), an RF test signal, properly modulated by a base band test signal (BBTS) and formed by a transmit set of equipment 47 , which simulates signals with respect to a repeater in open space, is provided to the feed of the second antenna for radiation onto said second antenna reflector. The RF test signal is reflected onto the antenna of the terminal under test. In a third step (S- 3 ), the antenna in the mobile terminal is moved within the second aperture by automatically changing rotation and tilt, such that movement of the first antenna simulates movement in the field of the mobile antenna terminal with respect to a remote repeater, such as a satellite transponder. In a fourth step (S- 4 ), the signal received by the first antenna is analyzed by a receive equipment test set 48 in order to determine the performance of the mobile antenna terminal.
[0027] While the above method is described for a receive function of the terminal, the method can be expanded to cover testing of both transmit and receive functions. In such case, a predetermined transmit signal would be provided to the terminal for radiation by the antenna to the reflector of the second antenna, or reception by the feed.
[0028] In another exemplary embodiment of the invention as illustrated in FIG. 4 , the foregoing method may be applied to the final test of a two-way (receive/transmit) mobile antenna for data communication (for example Internet). In case of this specific embodiment, it is convenient to use a feed 2 comprising horn and orthomode device, which has two independent ports dedicated to two orthogonal linear polarization (for example horizontal H and vertical V). To one of the ports a proper RF signal modulated by a proper base band test signal is provided in order to test the acquisition and tracking capabilities of the antenna under test 3 in receive mode. The RF signal is formed by test set up comprising computer 44 , modem 43 , IF/RF upconverter 14 and power supply 19 . The test RF signal is then radiated by the feed 2 and reflected by the test range reflector 1 in order to form a proper plane wave over the place where the antenna under test 3 is situated. The RF signal, reflected by the reflector 1 is then received by the antenna under test 3 and is transferred through the indoor unit 41 , which comprises a modem device, and the demodulated test signal is provided to the computer or to another proper equipment capable to measure the communication speed and the link system parameters 42 . A power supply unit 9 provides DC bias for the indoor unit 41 and antenna under test 3 .
[0029] At the same time, the signal (which has linear polarization orthogonal to the polarization of the test RF signal) transmitted by the antenna under test 3 , working in transmit mode, is reflected by the test range reflector 1 and received by the feed 2 . The transmit CW or modulated signal, reflected by the test range reflector 1 , appears at the second port of the feed 2 connected to the power meted or another suitable equipment 45 in order to measure the power level of the signal transmitted by the antenna under test 3 and then to compare this measured level to the one defined by the specifications.
[0030] A complete test of a mobile two-way antenna terminal could be performed following the test procedure described above. The capabilities of the antenna under test 3 to acquire and track the signals coming from a communication satellite, while rotating with required speed in azimuth and elevation (simulating vehicle movement), could be tested first, using the plane wave formed by the compact test range reflector 1 , modulated by the proper RF signal and then when the test signal is locked properly and the transmission mode is allowed by the Central Processing Unit (CPU) of the antenna under test 3 , to enable the transmit mode and to test the level of the transmit power.
[0031] In another exemplary embodiment illustrated in FIG. 4 , the method may be applied to final tests of mobile antennas, which could provide a capability of two-way data communications through selected FSS satellite (for example Internet) and at the same time reception of TV programs from a DBS satellite located at the same orbital position. In case of this specific embodiment, it is convenient to use a feed 2 , comprising a horn and an orthomode device, which has two independent ports dedicated to two orthogonal linear polarization (for example horizontal H and vertical V). To one of them a proper DVB signal is provided in order to test the acquisition and tracking capabilities of the antenna under test 3 in a receive mode. The DVB signal is formed by one of the two methods, described previously, using signal received by a standard reflector antenna 18 , mounted outside on a place having clear line of sight with a geostationary satellite 34 , selected for communication or by a standard DVB streamer 21 and a QPSK modulator 22 (or another suitable modulator). At the same time, the signal (which has linear polarization orthogonal to the polarization of the test DVB signal) transmitted by the antenna under test 3 , working in transmit mode, is reflected by the compact range reflector 1 and received by the feed 2 . The transmit signal, reflected by the test range reflector 1 , appears at the second port of the feed 2 connected to the power meter or another suitable equipment 45 in order to measure the power level of the signal transmitted by the antenna under test 3 and then to compare this measured level to one defined by the specifications.
[0032] Following the test procedure described above, a complete test of such type of mobile two-way antennas could be performed. The capabilities of the antenna under test 3 to acquire and track the signals coming from a communication satellite, while rotating with required speed in azimuth and elevation (simulating in that way vehicle movement), could be tested first, using the plane wave formed by the compact test range reflector 1 , modulated by the proper DVB signal and then when the test signal is locked properly and the transmission mode is allowed by the central processing unit (CPU) of the antenna under test 3 , to enable the transmit mode and to test the level of transmit power.
[0033] The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present invention. The description of the present invention is intended to be illustrative, and is not intended to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. | A test system and method for indoor testing of a mobile antenna terminal having a first antenna with a first aperture of a first size and, preferably, operable in a receive-only mode and/or a transmit and receive mode. The system uses a second antenna having a dual port feed and a reflector, the second antenna having a second aperture of a second size, which is two or more times the first size, and being operative to form a plane wave. The first antenna is mounted to a test platform that is positioned within the second aperture and is operative for rotating and tilting movement of the antenna to simulate movement on a vehicle. The test system uses a source of RF test signals and communications test equipment coupled to at least the first antenna, as well as a processor for determining a performance of the mobile antenna terminal. | 6 |
This is a division of application Ser. No. 214,744 filed July 1, 1988, now U.S. Pat. No. 4,846,590.
BACKGROUND OF THE INVENTION
The present invention relates to a spherical bearing for use in, for instance, transmission and steering wheel portion of an automobile, and a link motion mechanism of various automation machines, and more particularly to an oilless spherical bearing and a method of production thereof.
Hitherto, as a spherical bearing of this type, for instance, one shown in FIG. 11 is known (refer to the Japanese Patent Publication No. 42569/1976). Referring to FIG. 11, an inner ring 100 has an outer peripheral surface formed spherically, and the inner ring 100 is slidably fitted with an outer ring 101 whose inner peripheral surface is similarly formed spherically. In addition, a liner 102 formed of fluoride resin or the like is interposed between the inner ring 100 and the outer ring 101 to realize an oilless spherical bearing.
As illustrated in FIG. 12, such a spherical bearing is arranged as follows. The surface of the inner ring 100 is coated with a self-lubricating thin plate 103 formed of a low-friction high-polymer material, and the thus prepared inner ring 100 is accommodated in a mold 104 like a core, the mold 104 having a configuration that matches with that of the outer ring 101. A low-melting-point alloy is cast into a cavity therebetween, which completes the formation of the outer ring 101 and, at the same time, the assembly. In addition, sliding surfaces are formed between an outer surface of the inner ring 100 and the above-described self-lubricating thin plate 103 secured to the outer ring 101 at the time of casting.
Furthermore, since the free rotation of the inner ring 100 is hampered as a result of the shrinkage of the outer ring 101 during cooling and hardening, the outer ring 101 is compressed in the axial direction after casting, as shown in FIG. 13, so that the outer ring 101 is subjected to slight plastic deformation in the form of a chevron in which a central part thereof is bent in terms of its vertical cross section, and a slight gap required is hence formed between the thin plate 103 and the inner ring 100.
In such a prior art, however, bonding between the self-lubricating thin plate 103 and the outer ring 101 is effected by fusing the surface of the thin plate 103, which is brought into contact with the molten metal during casting, to the inner surface of the outer ring 101 by means of heat thereof. However, the affinity between resin and metal is generally poor, the bonding strength is weak if they are simply fused to each other, and there is a possibility that the thin plate 103 may become exfoliated due to a shearing force acting on the bonded surfaces, causing the position of the thin plate 103 to be offset. When the position of the thin plate 103 is offset, the metal surface of the outer ring 101 is exposed, and the metallic portion is brought into direct contact with the inner ring 100, which results in increased sliding resistance and causes rattling due to the partial wear of the sliding surface.
In addition, since the liner 102 is formed of a resin, the compressive strength thereof is low, and has the possibility of becoming damaged if the compressive load applied to the inner ring 100 becomes large. Moreover, even if damage does not result, there is a problem in that crip deformation may occur, making it impossible to bear a large load.
Furthermore, since the fluoride-based resin has a small conductivity, the fluoride-based resin is unable to allow the heat generated by friction with the inner ring 100 during use to escape effectively, so that there has also been the problem of the sliding surface becoming overheated and seized.
Meanwhile, in production, the thin plate 103 is coated on the surface of the inner ring 103, but, during casting of the outer ring 101, it is necessary to prevent the molten metal from flowing to the side of the inner ring 100. Namely, if the molten metal enters between the thin plate 103 and the inner ring 100, the molten metal hardens, with the result that a metallic foreign substance is interposed between the thin plate 103 and the inner ring 100 and the surface of the inner ring 100 becomes worn by the metallic foreign substance during use. In addition, the thin plate 103 also becomes damaged by wearing powders, so that the characteristics of the bearing are lost.
This problem would be satisfied with a technique that the thin plate 103 is held in close contact with the outer surface of the inner ring 100 during casting, but since the outer surface of the inner ring 100 is spherically shaped, it has been difficult in terms of molding to hold the sheet-like thin pate 103 in close contact with such a spherical portion. For instance, even if the thin plate 103 is formed into a spherical shape in advance, if an attempt is made to insert the inner ring 100 into such a spherically formed one, the inner ring 100 cannot be inserted since its central portion is expanded. If an attempt is made to insert it forcedly, there has been the problem that the thin plate 103 becomes broken. In addition, if the thin plate 103 is formed into the shape of a strip and if the thin plate 103 is wound around the outer surface of the inner ring 100, and the both ends of the wound thin plate 103 are provisionally attached to each other by means of an adhesive tape, there has been the problem that the molten metal flows round to the side of the inner ring 103 from the seam of the thin plate 103.
On the other hand, in a conventional example, since a very small gap is formed between the thin plate 103 and the inner ring 100 by applying an axial external force to the shrunk outer ring 101, it has been impossible to form this small gap uniformly. In other words, the outer ring 101 has been bent into the chevron shape by an external force, the very small gap is large at the central portion of the inner peripheral surface of the outer ring 101 and is small at edge portions 101a, 101a. For that reason, the swinging resistance of the inner ring 100 becomes nonuniform, and the smooth movement of the inner ring 100 is hampered. In addition, since the gap is nonuniform, the edge portions of the thin plate 103 are partially brought into contact with the outer surface of the inner ring 100 when the load is applied. As a result, the contact area between the thin plate 103 and the inner ring 100 is narrowed, and a concentrated load is applied to the vicinity of the edge portions, making it impossible to bear a high load. In addition, there have also been such problems that partial wear is likely to occur at the edge portions, resulting in play. Furthermore, it has been unavoidable to increase the very small gap in order to prevent the partial contact between the thin plate 103 at the edge portions 101a, 101a and the inner ring 100, so that there has been another problem that this results in a weakness against an impact load as well as a large amount of play, possibly causing a delay in the transmission of a force in, for instance, a link mechanism.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to substantially eliminate defects or drawbacks encountered to the conventional technique described above and to provide an improved spherical bearing capable of increasing the bonding strength between a liner and an outer ring, increasing the strength of the liner itself and making uniform a small gap between the liner and the inner ring.
Another object of this invention is to provide an improved spherical bearing which facilitates a molding process for forming the same, has a good heat conductivity and a long life and makes it possible to prevent molten metal from flowing round to the side of the inner ring.
A further object of this invention is to provide a method of manufacturing a spherical bearing of the superior characteristic features described above.
These and other objects can be achieved according to this invention in one aspect by providing a spherical bearing comprising an outer ring, an inner ring located inside the outer ring to be slidable, and a liner disposed between the outer and inner rings, the liner comprising a liner body made of resin and a metallic mesh member embedded in the liner body, the metallic mesh member partially biting an inner peripheral portion of the outer ring so as to achieve firm engagement of the liner with the outer ring.
In another aspect of this invention, there is provided a method of manufacturing a spherical bearing in which an inner ring is slidably fitted in an outer ring through a liner comprising the steps of coating an outer surface of the inner ring to be coated with a resin made sheet, embedding a metallic mesh member in the coated resin made sheet, disposing the inner ring in a mold, preparing a molten metal and casting the molten metal around the resin-made sheet coated on the inner ring to mold the outer ring, filling the molten metal in meshes of the mesh member so as to bond the resin-made sheet to the outer ring, and pressing the outer ring against an outer surface of the inner ring and spreading the same by applying a radially inwardly-oriented external force to the outer ring of a molding removed from the mold after cooling and hardening, thereby forming a very small gap between the resin-made sheet bonded to an inner periphery of the outer ring and the outer surface of the inner ring.
According to the spherical bearing of the character described above and the method of manufacturing the same, the liner is firmly bonded to the outer ring by means of the mesh member and is not exfoliated by frictional resistance or the like during use. In addition, the strength of the liner is reinforced by the metallic mesh member, and the mesh member functions as a core and permits molding into a desired shape. Furthermore, the frictional heat during use is allowed to escape through the mesh member, and the sliding surface of the inner ring is cooled effectively. Moreover, even if a resin portion of the liner becomes worn and the mesh member is exposed as a result, favorable self-lubricating function is maintained since the meshes of the mesh member are filled with the resin.
Meanwhile, since the sheet made of the resin is held in close contact with the outer surface of the inner ring due to the deformation of the mesh member before casting of the outer ring, the molten metal does not enter between the inner ring and the sheet. In addition, if the outer ring which has shrunk after cooling and hardening is spread by applying an external force thereto inwardly in the radial direction, the inner periphery of the outer ring is spread along the outer surface of the inner ring, and the mesh member bonded to the inner periphery of the outer ring expands by a portion in which the outer ring has been spread. Furthermore, as the mesh member is expanded, the resin portion of the resin-made sheet is also stretched, so that a uniform, very small gap is formed between the resin-made sheet and the outer surface of the inner ring over the entire periphery thereof.
The preferred embodiments of this invention will be described in detail hereunder with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a vertical cross-sectional view of a spherical bearing in accordance with an embodiment of the present invention;
FIG. 2 is an enlarged cross-sectional view of a bonded portion between a liner and an outer ring both shown in FIG. 1;
FIG. 3 is a perspective view of the liner taken out;
FIG. 4 is a schematic perspective view of the bearing shown in FIG. 1;
FIG. 5 is a vertical cross-sectional view of an inner ring;
FIGS. 6A and 6B are views illustrating a resin-made sheet to be preprocessed;
FIG. 7 is a vertical cross-sectional view illustrating a mouth portion to be throttled of the resin-made sheet coated on the inner ring;
FIG. 8 is a vertical cross-sectional view of the inner ring for which the mouth-portion throttling process has been completed;
FIG. 9 is a schematic vertical cross-sectional view of a mold in a casting process;
FIG. 10 is a schematic vertical cross-sectional view of the bearing in a gap forming process after casting;
FIG. 11 is a vertical cross-sectional view of a conventional spherical bearing;
FIG. 12 is a vertical cross-sectional view of the mold in a process of casting the outer ring of the bearing of FIG. 11; and
FIG. 13 is a schematic vertical cross-sectional view of the apparatus illustrating a process of forming a very small gap after the casting of the outer ring of FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereafter, the present invention will be described on the basis of an embodiment illustrated in the accompanying drawings. FIGS. 1 to 4 illustrate a spherical bearing in accordance with an embodiment of the present invention. In the drawings, an inner ring 1 has an outer surface formed into the form of a spherical strip, and the inner ring 1 is slidably engaged with an inner periphery of an outer ring 3 via a liner 2. The inner ring 1 is spherically shaped, and a through hole 4 for mounting a journal therein is formed in the direction of a central axis thereof.
Meanwhile, the outer ring 3 has a configuration of a flat cylinder, and its inner peripheral surface is formed into a spherical shape whose diameter is slightly larger than that of the above-described inner ring 1.
In addition, the liner 2 is a cylindrical member which is expanded into the shape of a spherical strip matching with the configuration of the inner periphery of the above-described outer ring 3, and is constituted by a liner body 21 made of resin and a metallic mesh member 22 embedded in this liner body 21. As the liner body 21, a resin which has a low coefficient of friction and excels in frictional resistance and also excels in heat resistance is employed. In this embodiment, a fluoride-based resin such as tetrafluoroethylene resin is used, which has a high load resistance and a large thermal conductivity in addition to the aforementioned characteristics, and its coefficient of thermal expansion is small. In addition, as the mesh member 22, bronze, stainless steel, or the like which is flexible and rigid is used.
As for a state in which the mesh member 22 is embedded, the mesh member 22 is embedded in such a manner that a sliding surface side S which is brought into contact with the inner ring 1 has a thick resin portion, while the side of its surface contacting the outer ring 3 is thin.
Meanwhile, the inner surface of the outer ring 3 is joined to the liner 2 in a state in which the inner surface bites into the inside of the meshes 22a of the aforementioned mesh member 22.
As for the mesh member 22, wires constituting the same are welded together at a seam, and the meshes do not become loose even if a high load (4,000 kg/cm 2 or thereabout) is applied thereto, and the mesh member 22 firmly binds and holds the resin layer to prevent the deformation or flow thereof. In addition, the mesh member 22 has a property of speedily radiating heat which is generated on the surface of the bearing.
A method of producing the spherical bearing having the above-described arrangement will be described with reference to FIGS. 5 to 10.
First, the inner ring 1 is produced, as shown in FIG. 5. The inner ring 1 is finished after quenching, and a spherical portion la is finished by lapping.
The process of coating with a sheet 5 made of a resin will be described with reference to FIGS. 5 to 8. First, the resin-made sheet 5 is formed in advance into a cylindrical shape, as shown in FIG. 6A. Next, the resin-made sheet 5 is cut in round slices at predetermined widths by a portion to be coated on the inner ring 1, and this portion is applied on the outer surface of the inner ring 1. Further, as shown in FIG. 7, both end portions of the sheet 5 are throttled by using press dies 6, 7, and, as shown in FIG. 8, the sheet 5 is made to be closely adhered to the outer surface of the inner ring 1 over the entire periphery thereof.
Furtherore, as shown in FIG. 9, the inner ring 1 is inserted into a mold 8 and die casting is effected. The mold 8 is a split type to be splittable into two parts along a perpendicular line Y which passes through a central point O of the inner ring 1 and is perpendicular to a central axis X thereof. Inside the mold 8, an annular empty chamber 9 for forming the outer ring 3 is formed around the inner ring 1, and the outer ring 3 is formed as molten metal is poured from a casting channel 10 which communicates with this empty chamber 9.
As for the molding material of the outer ring 3, zinc (melting point: 400° C.), aluminum (melting point: 600° C.), or the like is used. It should be noted that a specific alloy for a bearing may not be used as the material of the outer ring 3.
According to the present invention, since the resin-made sheet 5 is held in close contact with the outer surface of the inner ring 1 in a preprocessing process, it is possible to completely prevent the molten metal from flowing round from the end portions of the sheet 5 to the side of the inner ring 1 during casting.
Owing to the heat of the molten metal poured, the contact surfaces of the resin sheet 5 and the molten material are fused by the heat, and the metal enters the meshes 22a of the mesh member 22, with the result that the sheet is firmly bonded to the inner peripheral surface of the outer ring 3.
Subsequently, after the internal molten material has been cooled and hardened, the mold is opened to take out the molded product.
Furthermore, after the molded product is removed from the mold 8, the shrunk outer ring 3 is spread by applying an external force to the outer periphery thereof inwardly in the radial direction, as shown in FIG. 10, so as to form a very small gap d between the sheet 5 and the outer surface of the inner ring 1. Namely, the inner surface of the outer ring 3 is pressed against the outer surface of the inner ring 1 by the external force, so that the inner surface of the outer ring 3 is spread by conforming to the outer spherical surface of the inner ring 1. The mesh member 22 bonded to the inner peripheral surface of the outer ring 3 is expanded by the portion in which the outer ring 3 has spread, and the resin portion of the resin-made sheet 5 is also spread by the spreading of the mesh member 22, so that the very small gap d with a uniform width is formed between the resin-made sheet 5 and the outer surface of the inner ring 1 over the entire periphery thereof.
Finally, the outer peripheral surface and the both end surfaces of the outer ring 3 are subjected to cutting to remove flashes and the like, and surface finishing is provided, thereby completing the processing.
According to the thus formed spherical bearing, since the metal for the outer ring 3 bites into the meshes 22a of the mesh member 22 of the liner 2, the resin-made sheet 5 does not become offset by the pressure or movement of the pressure molten metal, and the liner 2 can be formed at a predetermined position of the outer ring 3 with a high degree of accuracy. In addition, since the liner 2 is thus bonded firmly, there is no possibility that the liner 2 is offset with respect to the outer ring 3 or removed by a shearing force acting on the bonding portion when the spherical bearing is used under high load and at high speed.
Meanwhile, even if a large load is applied from the inner ring 1 to the liner 2, since the liner 2 is reinforced by the metallic mesh member 22, the liner 2 is not crushed by a compressive load. In addition, the creep deformation of the resin portion is prevented by the location of the mesh member 22.
The frictional heat generated on the bearing surface during use is allowed to escape to the outer ring through the metallic mesh member 22, and the sliding portion is cooled efficiently. Furthermore, even if the resin portion of the liner 2 becomes worn and the mesh member 22 is exposed as a result, since the meshes 22a are filled with the resin, the resin powders loaded in the meshes 22a are the mesh member, the bonding strength can be made far stronger than a case where a resin-made thin plate is directly fused to the outer ring, as in the conventional case, and the reliability can be enhanced. In addition, since the liner itself is reinforced by the mesh member, its strength is high, and its load resisting capability can be improved. Furthermore, the heat generated on the bearing surface during use is transmitted speedily from the mesh member to the outer ring, and the cooling efficiency of the bearing can be enhanced. Moreover, even if the resin portion of the liner becomes worn, the resin powders loaded in the meshes of the mesh member are spread in the form of a film over the entire sliding surface as a lubricant, so that the lubricating performance can be maintained and a long life can be ensured.
Meanwhile, in the present invention, since a resin-made sheet is applied to the spherical surface of the inner ring in a closely adhered state prior to the casting of the outer ring, it is possible to completely prevent the molten metal from flowing round to the side of the inner ring during the casting of the outer ring, it is possible to protect the sliding surfaces of the liner and the inner ring, and the reliability of the product can be improved. In addition, as an external force is applied to the outer ring inwardly in the radial direction, it is possible to spread in the form of a film as a lubricant over the entire sliding surface during the rotation of the inner ring 1, so that a favorable self-lubricating function is maintained.
Furthermore, since the gap d between the liner 2 and the inner ring 1 is formed by compressing the outer ring 3 inwardly in the radial direction and by spreading the outer ring 3 by conforming with the outer peripheral surface of the inner ring 1, a uniform size is obtained over the entire sliding surface. Accordingly smooth movement of the inner ring 1 is ensured, and since the contacting area is large, it is possible to bear a high load, and the load resisting capability is kept to be high. In addition, partial wear does not occur, and it is hence possible to prevent rattling or the like resulting from the partial wear.
It should be noted that, although, in the present invention, a description has been given of a spherical bearing having a cylindrical outer ring, the present invention is also applicable to one having a rod, as in the case of a conventional example, i.e., a rod end bearing.
The present invention is constituted by the above-described arrangement and operation, and since a liner is bonded to an outer ring by using a liner with a metallic mesh member embedded therein and by embedding the inner peripheral surface of the outer ring in the meshes of uniformly form the very small gap formed between the resin-made sheet and the inner ring, so that smooth movement of the inner ring can be ensured. Also, since the inner ring is not brought into partial contact with the liner, it is possible to provide large contacting areas, making it possible to increase the load resisting capability and to prevent the occurrence of partial wear. In addition, since the very small gap can be made uniform, the size of the gap can be made as small as possible. This results in improved shock resistance and smaller play between the inner ring and the liner, and it is possible to improve the response characteristics of transmission of a force when the spherical bearing is used in, for instance, a link mechanism. Thus, the present invention makes it possible to obtain various effects. | A spherical bearing comprises an outer ring and an inner ring located inside the outer ring to be slidable, the outer ring is prepared by casting molten metal around a resin-made sheet to be coated on the inner ring. A liner disposed between the inner and outer ring comprises a liner body and a metallic mesh member embedded in the liner body, and the molten metal is filled in meshes in the mesh member so as to partially bite the inner peripheral portion of the outer ring to achieve the firm engagement of the liner with the outer ring. | 8 |
BACKGROUND OF THE INVENTION
The present invention is directed at an improved method for producing α-(3,4-disubstituted aryl) cyclic ketones. More specifically, the present invention is directed at a method for preparing (±) - (1R,S)-1-(4-chloro-3-methoxyphenyl)-3,4-dihydro-2(1H)-naphthalenone.
A method for producing this compound has been disclosed in European Patent Publication No. 0 230 270, which is directed at fused benzazepines useful in the treatment of psychoses, pain and/or depression. This publication discloses α-(3,4-disubstituted aryl) cyclic ketones as intermediate XVIII and also discloses a method for producing same. This publication discloses that intermediate XVIII can be prepared by first reacting a 3,4-disubstituted 1-(magnesium halide) phenyl with aryl ketones. The resulting compound is dehydrated using acid catalysts with continuous removal of water. The dehydrated compound then may be converted to a compound of formula XVIII by the sequential use, for example, of m-chloroperbenzoic acid, an alkali metal hydroxide, and then a strong mineral acid. Formula I of the present invention includes the compound of formula XVIII of this publication.
While the process disclosed above produces the desired compounds, the process has the disadvantage of being a multi-step process that proceeds in moderate overall yields.
M. Kosugi, et. al. in J. Chemical Society, Chemical Communications page 344 (1983) and references cited therein disclose a method for α-phenylation of ketones utilizing a palladium catalyst system and stannyl enolates generated "in situ" from enol acetates and tri-n-butyltin methoxide.
M. A. Cuifolini in J. Organic Chemistry, Volume 53, page 4149 (1988) discloses palladium-catalyzed displacement of halide from aromatic substrates by "soft" enolates (pKa<15). This publication describes the formation of benzo-fused five-or-six-membered rings via intramolecular cyclizations.
I. Kuwajima, et. al. in J. Am. Chem. Soc., Volume 104, page 6831 (1982) disclose a method for palladium catalyzed α-phenylation of α-stannyl ketones generated "in situ" from silyl enol ethers and tri-n-butyl tin fluoride. However, each of these three publications utilizes different substrates than those of the presently desired compounds, i.e. the aromatic and ketone portions of the substrates of the subject compounds differ from these publications.
Accordingly, an object of the present invention is a less costly method for producing the compounds of formula I below. ##STR6##
SUMMARY OF THE INVENTION
This invention discloses a method for producing a compound of the formula. ##STR7## wherein:
R 1 , R 11 and R 12 may be the same or different and each is hydrogen or alkyl;
Q is methylene, --O-- or --S--;
m and n are independently variable and may each have a value of 0, 1 or 2;
X is hydrogen, halo, alkyl, alkylthio, alkylsulfinyl, alkylsulfonyl, hydroxy, alkoxy or trifluoromethyl;
Y is hydrogen, hydroxy, alkoxy, ##STR8## -N(R 1 ) 2 , ##STR9## where R 1 is as defined above; ring represents a fused thiophene or fused benzene ring, fused benzene ring optionally being substituted with a substituent Z as defined below;
R 2 and R 3 are independently hydrogen, alkyl, aralkyl, cycloalkyl, aryl, hydroxyalkyl, or alkoxyalkyl;
in addition, when one of R 2 and R 3 is as defined above, the other may be --R 4 NR 5 R 6 {wherein R 4 is alkanediyl, R 5 is hydrogen or alkyl and R 6 is alkyl or R 5 and R 6 together with the nitrogen atom form a 1-azetidinyl, 1-pyrrolidinyl, 1-piperidinyl, 1-(4-alkylpiperazinyl), 4-morpholinyl or 1-(hexahydroazepinyl) group};
in further addition, R 2 and R 3 together with the nitrogen atom may form a 1-azetidinyl, 1-pyrrolidinyl, 1-piperidinyl, 4-morpholinyl, 1-(4-alkylpiperazinyl), 1-(4-alkoxyalkylpiperazinyl), 1-(4-hydroxyalkylpiperazinyl), 1-(3-hydroxyazetidinyl), 1-(3-alkoxyazetidinyl), 1-(3-hydroxypyrrolidinyl), 1-(3-alkoxypyrrolidinyl), 1-(3- or 4-hydroxypiperidinyl), 1-(3- or 4-alkoxypiperidinyl), 1-(4-oxopiperidinyl) or 1-(3-oxopyrrolidinyl) ring;
in still further addition, when R 2 is hydrogen, R 3 may be --CHR 7 CO 2 R 8 , wherein R 7 and R 8 are independently hydrogen, alkyl or aralkyl;
R 9 is alkyl, aralkyl, aryl, alkoxyalkyl, aryloxyalkyl, aralkoxyalkyl, cycloalkylalkyl, alkoxycarbonylalkyl, cycloalkyl, 1-adamantyl, cycloalkoxyalkyl, alkoxy, aralkoxy, cycloalkoxy, aryloxy or --CHR 7 NHR 8 {wherein R 7 and R 8 are as defined above}; and
Z is X as defined above, amino, alkylamino or ##STR10## {wherein R 10 is hydrogen, alkyl or aryl } comprising reacting a compound of the formula II or III: ##STR11## with a compound of the formula ##STR12## wherein Hal is a halogen;
R 13 is acetyl, or Si(R 14 ) 3 where each R 14 independently is alkyl or aryl
with suitable hydroxy and amino protecting groups utilized where necessary.
The reaction preferably is catalyzed by an organo transition metal, such as nickel or palladium, preferably a palladium complex. Preferably, X and Hal are not both bromine.
In preferred embodiments of the present invention:
ring is a fused benzene;
Q is --CH 2 --;
m is zero;
n is 1;
R 11 and R 12 are H;
X is halogen, particularly chlorine;
Y is methoxy; and
Hal is halogen, particularly bromine.
When R 13 is an acetyl a preferred catalyst system comprises:
Pd(OAc) 2 and (o-tolyl) 3 P; (n-Bu) 3 SnOMe is used to generate the stannyl enolate "in situ". Toluene is the preferred solvent, and the preferred reaction temperature is 105°-110° C.
When Si(R 14 ) 3 represents
Si(Me) 3 or
Si(tBu)Me 2 , the catalyst system preferably comprises PdCl 2 [(ο-tolyl) 3 P] 2 ; (n-Bu) 4 NF is preferred for generating the enolate. The preferred solvent is DMF and the preferred reaction temperature is 80°-100° C.
With compound II, the catalyst system preferably comprises:
Pd(OAc) 2 and
(ο-tolyl) 3 P; NaH is the preferred base to generate the enolate at 0°-25° C. The preferred solvent is DMF, and the preferred reaction temperature is 100°-135° C.
DETAILED DESCRIPTION OF THE INVENTION
When utilized herein and in the appended claims, the following terms, unless otherwise specified, have the following scope:
halo-represents fluoro, chloro, bromo or iodo;
alkyl (including, for example, the alkyl portions of alkylthio, alkoxy, aralkyl, alkoxyalkoxy, etc.) - represents straight or branched carbon chains having 1 to 6 carbon atoms;
cycloalkyl groups (including the cycloalkyl portion in cycloalkoxy groups) - represents saturated carbocyclic rings having 3 to 7 carbon atoms;
alkanediyl - represents a divalent, straight or branched hydrocarbon chain having from 1 to 6 carbon atoms, the two available bonds being from the same or different carbon atoms thereof, e.g., methylene, ethylene, ethylidene, --CH 2 CH 2 CH 2 --, --CH 2 CHCH 3 , --CHCH 2 CH 3 , etc.; and
aryl (including, for example, the aryl moiety in aralkyl or aralkoxy groups) - represents unsubstituted phenyl and phenyl mono substituted by alkyl, hydroxy, alkoxy, halo or trifluoromethyl.
As used herein "hydroxy protecting group" and "amino protecting group" mean any groups conventionally used for these purposes, with the only requirements being compatibility during protection and deprotection reactions with conventional reagents for this purpose which will not adversely affect the structure of the compounds. Typical of such groups are those listed in Green, "Protecting Groups in Organic Synthesis" John Wiley and Sons, New York, NY (1981). Examples of "hydroxy protecting groups" are ethers such as methyl, methoxymethyl, methylthiomethyl, 2-methoxyethoxymethyl, tetrahydropyranyl, tetrahydrothiopyranyl, 4-methoxytetrahydropyranyl, 4-methoxytetrahydrothiopyranyl, tetrahydrofuranyl, tetrahydrothiofuranyl, 1-ethoxyethyl, 1-methyl-1-methoxyethyl, 2-(phenylselenyl)ethyl, t-butyl, allyl, benzyl, triphenylmethyl, alpha naphthyldiphenylmethyl, paramethoxyphenyldiphenylmethyl, trimethylsilyl, isoamyldimethylsilyl, isopropyldimethylsilyl, t-butyldimethylsilyl, t-butyldiphenylsilyl, tribenzylsilyl, and triisopropylsilyl, as well as esters such as adamantoate, 2,4,5-trimethylbenzoate, N-phenylcarbamate and the like. Examples of "amino protecting groups" are carbamates such as methyl, 2-trimethylsilylethyl, 1,1-dimethylpropynyl, 1-methyl-1-phenylethyl, 1-methyl-1-(4-biphenylyl)ether, t-butyl, cyclobutyl, 1-methylcyclobutyl, 1-adamantyl, vinyl, cinnamyl, 8-quinolyl, benzyl and 9-anthrylmethyl, amides such as N-acetyl, N-picolinoyl, N-benzoyl and N-phthaloyl as well as special protecting groups such as N-allyl, N-methoxymethyl, N-benzyloxymethyl, N-tetrahydropyranyl, N-benzyl, N-o-nitrobenzyl, N-triphenylmethyl, N-(p-methoxyphenyl)diphenylmethyl, N-benzylidene, N-p-nitrobenzylidene, N-diphenylphosphinyl, N-2,4,6-trimethylbenzenesulfonyl, N-toluenesulfonyl and the like.
A "suitable inert organic solvent" can be any organic solvent or combination of solvents that is unreactive in the reaction being conducted and is a solvent for the reactants. Typical solvents include tetrahydrofuran (THF), dimethylformamide, dimethylsulfoxide, and toluene.
The term "enolate generator" can be any organic or inorganic base that will generate the enolate of compounds of formula II. Examples of organic base enolate generators include the alkylamines such as triethylamine, 1,8-diazabicylo[5.4.0]unde-7-ene, diethylisopropylamine and lithium diisopropylamide. Examples of inorganic base enolate generators include NaH, KH, LiH and KOtBu.
The reactions are carried out neat or in suitable inert organic solvent, e.g., toluene, DMF or DMSO at temperatures ranging from 0° C.→135° C. When a compound of formula II is used, an organic or inorganic base, e.g., TEA, NaH, KH, or KOtBu may be used to generate the enolate; and with compounds of formula III, (R 15 ) 3 SnOMe or (R 16 ) 4 NF are used to generate the enolate wherein each R 15 and R 16 independently is alkyl or aryl.
The catalyst system is comprised of an organo transition metal complex, preferably either a nickel or palladium complex with either phosphine or phosphite ligands. These ligands may be various alkyl- or arylphosphines or alkyl-or arylphosphites such as PPh 3 , P(o-tolyl) 3 , P(m-tolyl) 3 , P(p-tolyl) 3 , (2-furyl) 3 P, P(OEt) 3 , P(OPh) 3 , P(O-o-tolyl) 3 as well as bidendate ligands such as 1,2-bis(diphenylphosphino)ethane, (R)-(+)-2,2,bis (diphenylphosphino)propane, (R)-(+)-2,2'-bis (diphenylphosphino)-1,1'-binaphthyl and the like.
Also R, R 1 , R 11 , R 12 , X, Y and Z groups in formula I may be varied by appropriate selection of starting materials from which the compounds are synthesized or by reacting a compound of formula I with a suitable reagent to effect the desired conversion of the substituent to another R, R 1 , R 11 , R 12 , X, Y and Z group. The latter procedure is particularly applicable for changing the substituents X. For example, a chlorine substituent may be added in place of hydrogen by reaction with a chlorinating agent such as sulfuryl chloride in a non-reactive solvent A hydroxymethyl substituent in the X position may be added in place of hydrogen by reaction with formaldehyde in a suitable solvent system, e.g., in a mixed solvent system consisting of dimethoxyethane and aqueous potassium hydroxide, preferably at an elevated temperature. Such a hydroxymethyl substituent may be reduced to an X methyl group by reaction with a catalyst such as palladium hydroxide in a hydrogen atmosphere under pressure. Methoxy substituents may be converted to hydroxy, e.g., by refluxing in a mixture of sodium hydride, DMF and ethanethiol, or by reaction with concentrated hydrobromic acid. Other substitutions may be accomplished using standard techniques. In the case where there is a hydroxy or amino group that may interfere with the reaction, these groups may be protected with either a "hydroxy protecting group" or an "amino protecting group".
Examples I-IV below disclose methods for the preparation of (±)-(1R,S)-1-(4-chloro-3-methoxyphenyl)3,4-dihydro-2(1H)-naphthalenone.
EXAMPLE I ##STR13##
(A) Preparation of 2-acetoxy-3,4-dihydronaphthalene
Charge a nitrogen-flushed 12-L round bottomed flask equipped with a mechanical stirrer and reflux condenser with β-tetralone (1,308.0 grams, 8.947 moles), triethylamine (1,089.0 grams, 10.763 moles), acetic anhydride (1,104.0 grams, 10.810 moles) and 1 L methylene chloride. Cool in an ice/water bath and add 4-dimethylamino pyridine (55.03 grams, 0.4501 moles) portionwise over a 10 minute period (slight exotherm noted). Stir for 23 hours at RT and then add 1 L methylene chloride, wash with 1×2 L 5% HCl solution, 1×1 L water, 1×1 L saturated sodium bicarbonate solution, 1×1 L saturated salt solution, dry over magnesium sulfate, concentrate on a Buchi rotavapor and distill (118°-123° C., 1 Torr) to obtain pure product.
1 H NMR: (CDCl 3 ), δ=6.9-7.20 (m,4 H); 6.21 (s, 1 H); 2.97 (t, 2H, J=7.0 Hz); 2.52 (t, 2H, J=7.0 Hz); 2.18 (s, 3H).
(B) Preparation of (±)-(1RS)-1-(4-Chloro-3-methoxyphenyl)-3,4-dihydro-2(1H)-naphthalenone (7)
Charge an oven dried, argon flushed 3-L 3-necked round bottomed flask equipped with a mechanical stirrer and reflux condenser with 2-acetoxy-3,4-dihydronaphthalene (100.69 grams, 0.5349 moles), 4-bromo-2-methoxy-1-chlorobenzene (116.81 grams, 0.5274 moles), palladium acetate (1.19 grams, 0.0053 moles), tri (ο-tolyl)phosphine (3.24 grams, 0.0107 moles), tri-n-butyltin methoxide (172.83 grams, 0.5383 moles) and 1 L toluene. Place in an oil bath pre-heated to 100°-105° C. for 20 hours. Distill off about 750 mL toluene, cool to RT, add 500 mL 5% HCl and 250 mL ethyl acetate, stir for a few minutes, filter through a pad of celite and wash the celite pad with 5×250 mL ethyl acetate. Separate the layers, extract the aqueous layer with 1×250 mL ethyl acetate, wash the combined organic layers with saturated sodium bicarbonate solution followed by saturated salt solution, dry over magnesium sulfate and concentrate on a Buchi rotavapor. Kugelrohr treat the resulting oil (heated to about 130° C., 1 Torr) to remove the more volatile by-products to yield product. An analytical sample can be prepared by flash chromatography (5-30% ethyl acetate/hexanes) followed by recrystallization (ethyl acetate/hexanes).
1 H NMR: CDCl 3 ), δ=7.23-7.30 (m,4 H); 7.00 (d, 1 H J=7.0 Hz); 6.76 (d, 1H, J=1.9 Hz); 6.53 (dd, 1H, J=1.8, 8.0 Hz) 4.72 (s, 1H), 3.83 (s, 3H); 3.00-3.20 (m, 2H); 2.55-2.68 (m, 2H). mp 77°-78.5° C.
EXAMPLE II
Preparation of (±)-(1RS)-1-(4-Chloro-3-methoxyphenyl)-3,4-dihydro-2(1H)-naphthalenone (7) ##STR14##
Charge an oven dried, argon flushed 25-mL two-necked round bottomed flask equipped with a stirring bar with β-tetralone (1.3095 grams, 8.9575 mmoles) and 5 mL dry dimethylformamide. Cool to 0° C. with an ice bath, add sodium hydride (0.4299 grams, 8.9575 mmoles, 50% oil dispersion) and stir for 25 minutes. Filter the solution through a 5 mL syringe equipped with a bed of celite (dried in an oven) via a double-ended needle into an oven dried, argon flushed 25-mL round bottomed flask equipped with a stirring bar and reflux condenser which had been charged with 4-bromo-2-methoxy-1-chlorobenzene (1.5871 grams, 7.166 mmoles), palladium acetate (0.0079 grams 0.0350 mmoles) and tri(ο-tolyl)phosphine (0.0213 grams, 0.070 mmoles). Heat at about 125° C. (oil bath) for 21 hours, cool to RT and add ethyl acetate and 2N HCl. Separate the layers, extract the aqueous layers with two portions of ethyl acetate, wash the combined organic layers with saturated sodium bicarbonate solution followed by saturated salt solution, dry over magnesium sulfate and concentrate using a Buchi rotavapor to produce the named product.
EXAMPLE III ##STR15##
(a) Preparation of 2-Trimethylsilyloxy-3,4-dihydronaphthalene (18)
Charge an oven dried, nitrogen flushed 100-mL round bottomed flask equipped with a stirring bar with β-tetralone (4.977 grams, 0.0340 moles), triethylamine (6.970 grams, 0.0689 moles), 4-dimethylamino pyridine (0.219 grams,0.0018 moles), trimethylsilyl chloride (7.704 grams, 0.0709 moles) and 30 mL methylene chloride. Stir at RT for 20 hours, filter, wash the solid with 1×20 mL methylene chloride, wash the combined organic layers with 1×5 mL saturated sodium bicarbonate solution, 1×5 mL water, dry over magnesium sulfate, concentrate on a Buchi rotavapor and distill (96°-99° C., 1 Torr) to yield the product as a viscous oil.
1 H NMR: (CDCl 3 ), δ=6.90-7.16 (m,4 H); 5.71 (s, 1 H); 2.90 (t, 2H, J=7.0 Hz); 2.38 (t,2H, J=7.0 Hz); 0.28 (s, 9H).
(b) Preparation of (±)-(1RS)-1-(4-chloro-3-methoxyphenyl)-3,4-dihydro-2(1H)naphthalenone
Charge an oven dried, argon flushed 25-mL 2-necked round bottomed flask equipped with a stirring bar and reflux condenser with 2-trimethylsilyloxy-3,4-dihydronaphthalene (0.4247 grams, 1.9449 mmoles) and tetra-n-butylammonium fluoride (2.3 mL, 2.30 mmoles, 1 M in tetrahydrofuran), stir for a few minutes and then add 4-bromo-2-methoxy-1-chlorobenzene (0.4336 grams, 1.9577 mmoles) dichlorobis(tri-ο-tolyl-phosphine)palladium (0.0154 grams, 0.0196 mmoles) and 5 mL dimethylformamide. Heat the reaction mixture for 18 hours (oil bath temperature about 90° C.), cool to RT and add 5 mL water and 10 mL t-butylmethyl ether. Separate the layers, extract the aqueous layers with 3×5 mL t-butylmethyl ether, wash the combined organic layers with water and saturated salt solution, dry over magnesium sulfate and concentrate using a Buchi rotavapor to yield the final product.
EXAMPLE IV ##STR16##
(a) Preparation of 2-t-Butyldimethylsilyloxy-3,4-dihydronaphthalene (19)
Charge an oven dried, nitrogen flushed 125-mL round bottomed flask equipped with a stirring bar with β-tetralone (4.977 grams, 0.0340 moles), triethylamine (6.970 grams, 0.0689 moles), 4-dimethylamino pyridine (0.217 grams, 0.0018 moles), t-butyldimethylsilyl chloride (10.701 grams, 0.0709 moles) and 40 mL methylene chloride. Stir for 72 hours, filter, wash the filtrate with 1×5 mL saturated sodium bicarbonate solution, 1×5 mL water, dry over magnesium sulfate, concentrate using a Buchi rotavapor and distill (142°-145° C., 1 Torr) to obtain the named compound
1 H NMR (CDCl 3 ), δ=6.86-7.16 (m,4 H); 5.7 (s, 1 H); 2.90 (t, 2H, J=7.0 Hz); 2.36 (t, 3H, J=7.0 Hz); 0.94 (s, 9H); 0.22 (s, 6H).
(b) Preparation of (+)-(1RS)-1-(4-chloro-3-methoxyphenyl)-3,4-dihydro-2(1H)-naphthalenone
Charge an oven dried, argon flushed 25-mL 2-necked round bottomed flask equipped with a stirring bar and reflux condenser with 2-t-butyldimethylsilyloxy-3,4-dihydronaphthalene (0.5007 grams, 1.9224 mmoles) and tetra-n-butylammonium fluoride (2.3 mL, 2.30 mmoles, 1 M in tetrahydrofuran), stir for a few minutes and then add 4-bromo-2-methoxy-2-chlorobenzene (0.4287 grams, 1.9356 mmoles), dichlorobis(tri-o-tolyl-phosphine)palladium (0.0154 grams, 0.0196 mmoles) and 5 mL dimethylformamide. Heat the reaction mixture for 18 hours (oil bath temperature about 90° C.), cool to RT and add 5 mL water and 10 mL t-butylmethyl ether. Separate the layers, extract the aqueous layers with 3×5 mL t-butylmethyl ether, wash the combined organic layers with water and saturated salt solution, dry over magnesium sulfate and concentrate using a Buchi rotavapor to yield the product. | A method for producing a compound of the formula ##STR1## wherein: R 1 , R 11 and R 12 may be the same or different and each is hydrogen or alkyl;
Q is methylene, --O-- or --S--;
m and n are independently variable and may each have a value of 0, 1 or 2;
X is hydrogen, halo, alkyl, alkylthio, alkylsulfinyl, alkylsulfonyl, hydroxy, alkoxy or trifluoromethyl;
Y is hydrogen, hydroxy, alkoxy, ##STR2## --N(R 1 ) 2 , ##STR3## where R 1 is as defined above; ring t represents a fused thiophene or fused benzene ring, said fused benzene ring optionally being substituted with a substituent Z as defined below; and
Z is X as defined above, amino, alkylamino or ##STR4## {wherein R 10 is hydrogen, alkyl or aryl}, comprising reacting a compound of formula II or formula III ##STR5## with a compound of the formula where Hal is a halogen; and
R 13 is acetyl, or Si(R 14 ) 3 where each R 14 independently is alkyl or aryl is disclosed. | 2 |
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
This invention relates to nuclear reactor systems and, more particularly to pressurized water nuclear power reactor systems in which the heat exchanger is attached to a pressure vessel containing the core and which can be selectively disassembled.
2. DESCRIPTION OF THE PRIOR ART
Proposals have been advanced through the years to attached a pressure vessel containing a nuclear reactor core and associated pressurized water to a secondary coolant heat exchanger section to form a system capable of supplying heat energy for power generation or other purposes. A number of significant benefits are attainable through this structural configuration, especially if it is applied to shipboard and to land based electric power process energy uses.
One particular prior art reactor system of this nature has a heat exchanger in which the tubes are bent through 180° to produce a "U" shape. This specific heat exchanger design requires the ends of the bent tubes to be secured in a tube sheet that is extremely thick, unwieldy and difficult to manufacture.
This "U" tube heat exchanger, moreover, is positioned directly above the reactor core. In these circumstances, this configuration of heat exchanger tends to require unorthodox control rod drive systems and undesirable coolant circulating pump arrangements.
In this respect, the operation of the nuclear reactor is regulated by means of control rods which are inserted into and withdrawn from the reactor core in response to power demands. Control rod drive motors, mounted on the exterior surface of the cylindrical portion of the pressure vessel transmit power through a 90° angle to drive these control rods in desired directions relative to the reactor core. Not only is this a mechanically awkward arrangement, but it also increases the vulnerability of the control rod drive mechanism to potential malfunctions.
The coolant circulating pumps are mounted externally on "stalks" which are difficult to manufacture. Furthermore, these stalks, which consist of concentric piping of relatively large diameter, tend to compromise the intrinsic safety of an integrally arranged pressurized water reactor system due to the possibility (though remote) of their failure.
Clearly, there is a need for an integral reactor and heat exchanger system that reduces the thickness of the tube sheet and makes the reactor core more readily accessible for inspection and refueling, in addition to providing a less complicated, and hence more reliable control rod drive mechanism.
The above complications also tend to limit the thermal power range of this system to levels below 100 megawatts. By contrast, it is the intent of this invention to provide an integral pressured water reactor system capable of power levels to at least 1500 thermal megawatts.
SUMMARY OF THE INVENTION
These and other problems that have characterized the prior art are overcome, to a great extent, through the practice of the invention. Illustratively a generally cylindrical pressure vessel is provided not only with a transverse separation in a plane between the reactor core and the heat exchanger, but also with a selectively detachable closure that supports the control rod drive mechanism.
More particularly, control rod drive motors and guide tubes are mounted on one of the arcuate pressure vessel closures. This closure is bolted to an adjacent transverse flange on the generally cylindrical portion of the steam generator section. The control rod guide tubes pass straight through the main body of this assembly and can be removed from the system with relative ease as a single closure unit. Because these tubes pass straight through the main body of this assembly, the need to transmit control rod drive power through a 90° angle that has characterized the prior art is eliminated, along with the attendant possibilities for mechanical difficulty.
Closure removal also exposes a portion of the heat exchanger to facilitate inspection and maintenance. The heat exchanger, moreover, can be entirely removed from the core containing pressure vessel structure through disconnecting the cylindrical portion that composes the heat exchanger section from the portion which encloses the reactor core at the transverse pressure vessel separation between the reactor core and the heat exchanger. In this circumstance, the reactor system is disassembled with relative ease into three essentially manageable segments that expose the control rods, heat exchanger and reactor core for inspection.
This triple segmented system, moreover, increases the plant layout flexibility, enabling the circulating pumps for the pressurized water to be positioned in the system for maximum efficiency and safety. This increased plant layout flexibility also manifests itself in a lower primary water inventory, greater freedom in the arrangement of the heat exchanger with respect to the pressure vessel, and significant reductions in construction costs and time.
More specifically, one illustrative embodiment of the invention disposes the heat exchanger in a hollow cylindrical space between the inside surface of the adjacent segment of the pressure vessel and the vessel's longitudinal axis. This particular arrangement enables the secondary coolant in the heat exchanger to flow in countercurrent relationship with the pressurized water. In these circumstances, the primary coolant, or pressurized water recirculating pumps can be mounted on the pressure vessel closure that is adjacent to the reactor core.
Mounting the pressurized water recirculating pumps in this location provides a number of noteworthy improvements. Perhaps, most important, is the higher plant efficiency that can be anticipated with this system. This improvement is expected because the recirculating pumps are located at that position in which the pressurized water is at its lowest temperature in the entire cycle, thereby decreasing the possibility of destructive cavitation and permitting the system to use a higher pressurized water temperature at the reactor core discharge, and in this manner to increase over-all plant power output. This pump location, moreover, adds an increased safety factor in the event of an accident in which a great deal of the pressurized water drains out of the pressure vessel. In this respect, as long as fresh cooling water can enter the pressure vessel from any source, the pump location adjacent to and below the reactor core will assure that this fresh cooling water will be pumped into that core. During those times, moreover, in which the power reactor system must be shut down for refueling, this structural arrangement provides a further advantage in that the pumps and their connections need not be disconnected because the pumps are mounted on that pressure vessel closure which is not removed.
Because the tubes that are used in the heat exchanger, or steam generator, that characterizes this embodiment of the invention are straight, these individual tubes are of relatively short length in comparison with the "U" tube configurations that characterize the prior art. This feature permits considerably thinner tube sheets to be used in the apparatus under consideration, in contrast to prior art tube sheets that may be more than double that thickness.
In another embodiment of the invention, the heat exchanger fills the entire volume of the segment of the pressure vessel that is separably connected to the portion of the vessel which houses the reactor core. The control rod drive lines in this embodiment also pass straight through the heat exchanger structure to regulate the operation of the control rods within the reactor core, hollow shrouds arranged parallel to the heat exchanger tubes being provided to house these drive lines. In this embodiment, moreover, the pressurized water and the secondary coolant both flow in the same direction (i.e. "parallel flow") in one portion of the heat exchanger in order to permit the pressurized water pump to recirculate primary coolant water that is at a lower temperature, thereby permitting a higher peak primary coolant temperature to be attained and thus increasing the power generating capacity of the entire system.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this specification. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawing and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front elevation in full section of a typical embodiment of the invention; and
FIG. 2 is a front elevation in full section of another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For a more complete appreciation of the invention, attention is invited to an illustrative embodiment that is shown in FIG. 1 of the accompanying drawing. More specifically, a hollow and generally cylindrical pressure vessel 10 has a longitudinal axis 11. Transverse ends 12, 13 of the pressure vessel are sealed by means of closures 14, 15, respectively. Typically, these closures are forged, or otherwise suitably formed, into shapes that are portions of the surface of a sphere.
The closure 14 supports schematically illustrated control rod drive apparatus 16. Drive lines 17, 20, 21 of the control rod apparatus 16 penetrate the closure 14 and pass through the pressure vessel 10 in a direction that is parallel to the longitudinal axis 11 in order to penetrate a reactor core 22 that is mounted in the pressure vessel 10 adjacent to but longitudinally spaced from the closure 15. The reactor core 22, moreover, has a longitudinal axis that is generally coincident with the longitudinal axis 11 of the pressure vessel 10. The closure 14, moreover, has an annular flange 23 that bears upon a matching flange 24 which forms the transverse end 12 of the pressure vessel 10. A circumferential array of studs or bolts 25 joins the closure 14 to the cylindrical body of the pressure vessel 10 to permit selective removal of the closure 14 and the attached control rod drive apparatus 16 as a single unit in accordance with one of the principal features of the invention. This separation, removal and replacement characteristic of the invention is exceptionally useful during those times in which the system is shut down for reactor core reloading and routine maintenance.
As shown in FIG. 1, the cylindrical portion of the pressure vessel 10 also is separably joined about a pair of mutually abutting flanges 26, 27 at a transverse midplane. The flanges 26, 27 generally divide the pressure vessel into two individual cylinders, a heat exchanger enclosure 30 and a reactor core support and enclosure 31.
The heat exchanger enclosure 30 forms a pressure vessel about an annular bundle of longitudinally disposed straight tubes 32. The ends of each of the tubes in the bundle are received in respective inwardly disposed tube sheets 33, 34 that are in the same planes as, and configuous with, the flanges 24 and 26, respectively. A longitudinally oriented hollow cylindrical shroud 35 forms a water and pressure tight enclosure for the tube bundle 32. This construction, moreover, is provided with concentric feedwater inlet and steam outlet pressure vessel penetrations 36 in which feedwater inlet tubes 37 and 40 are nested within respective enclosing steam discharge conduits 41, 42, thereby reducing thermal shocks and stresses to the enclosure 30 that otherwise might be caused by major temperature differences between the incoming feedwater and the operational temperature of the enclosure 30. However, exposure of the steam generator shell in this reactor system arrangement will also permit use of separate steam and feedwater connections. This is not true of some integral reactor arrangements where the steam generator is enclosed inside the primary coolant envelope.
As shown in FIG. 1, the open ends of the tubes in the bundle 32 that are secured in the tube sheets 33, 34 establish fluid communication through the heat exchanger for pressurized water that flows within the pressure vessel 10 as described subsequently in more complete detail. The secondary coolant, in contrast, is discharged into the portion of the heat exchanger that is defined by and the inner surfaces of the enclosure 30, the shroud 35 and the tube sheets 33, 34.
Bolts 43, or equivalent fasteners, join the opposing surfaces of the flanges 26, 27 together to permit the heat exchanger enclosure 30 to be selectively disengaged from the reactor core support and enclosure 31. This feature of the invention permits the heat exchanger and its enclosure 30 to be completely dismounted from the pressure vessel, exposing both of the tube sheets 33, 34 and the inner surface of the shroud 35 to visual inspection, as well as permitting each of the individual tubes in the tube bundle 32 to be inspected through ultrasonic techniques or other suitable methods without interfering with reactor core refueling operations. The relatively short, straight lengths of tube that comprise the bundle 32, moreover, are much less susceptible to stress-corrosion cracking and require less massive tube sheets than the longer lengths of bent tubes that have characterized prior heat exchangers.
The reactor core 22 is supported within a hollow, cylindrical core barrel 44. As shown in the drawing the reactor core 22 is lodged near one of the longitudinal ends of the barrel 44. The opposite end of the barrel 44, however, terminates in an outwardly disposed flange 45 that rests upon a mating groove that is formed on the inner periphery of the flange 27 of the reactor core enclosure 31. This construction supports the barrel and reactor core assembly. In order to promote pressurized water flow from the discharge end of the tubes that are received in the tube sheet 34 into an annular downcomer 46 that is formed between the inner wall of the reactor core support and enclosure 31 and the outer wall of the core barrel 44, longitudinally oriented perforations are formed in the core barrel flange 45. Thus, the core barrel 44 not only provides structural support for the reactor core 22, but it also provides a baffle that directs the pressurized water flow within the vessel 10 toward recirculating pump impellers 47, 50.
In accordance with a principal feature of this embodiment of the invention, the impellers 47, 50 are positioned inside the pressure vessel 10 adjacent to the transverse end closure 15. Motors 51, 52 for driving the impellers 47, 50 respectively, are mounted on the exterior surface of the closure 15 and are coupled to the associated impellers by means of individual shafts that penetrate the closure 15. The impellers 47, 50 discharge the pressurized water to enable the recirculating water to flow into a cavity that is formed by a longitudinally disposed skirt 53 that is positioned between the reactor core 22 and the interior surface of the closure 15.
In operation, pressurized water is discharged from pump impellers 47, 50 and flows, in the direction of arrows 54, parallel to the longitudinal axis 11 of the pressure vessel 10 through the reactor core 22. The water that flows through the reactor core 22 absorbs a great deal of heat from the effects of the fission processes that take place within the core. This heated and pressurized water then continues to flow in a direction that is parallel to the pressure vessel's longitudinal axis 11 through the central portion that is defined by the core barrel 44 and the heat exchanger shroud 35. On reaching the closure 14, the pressurized water flow is conducted through a 180° turn in order to flow through the tubes that form the tube bundle 32 in the annular heat exchanger. Within the heat exchanger, the pressurized water transfers its heat to a secondary coolant which rises into steam. The secondary coolant steam flows out of the heat exchanger through the discharge conduits 41, 42.
Having transferred heat to the secondary coolant, the temperature of primary coolant is decreased, and a colder primary coolant flows from the tube bundle 32, through the perforations in the core barrel flange 45 and through the annular downcomer 46 to the impellers 47, 50. It is important to note that the temperature of the pressurized water is at its lowest point, or at least close to its lowest point at the recirculating pump inlets. This feature of the invention leads to a number of advantages. The pumps circulating colder pressurized primary coolant water, which has a relatively lower threshold for cavitation which tends to destroy the impellers, permit higher primary water outlet temperatures, which, in turn, enhances steam generator performance. Positioning the pumps on the closure 15 also increases the reactor's safety margin, should the system lose much of the primary coolant through a leak, or the like. With the recirculating pump impellers 47, 50 located in the position shown in FIG. 1, however, cooling water can be pumped into the reactor core 22 from any source. During routine refueling operations power, instrument and cooling water connections for these pumps do not have to be disturbed, in contrast to the need to perform this additional work for pumps that are located at some other place in the pressurized water cycle.
Attention now is invited to FIG. 2 of the drawing which shows a further embodiment of the invention. As illustrated, pressure vessel 55 has two generally hollow cylindrical enclosures, a heat exchanger enclosure 56 and a reactor core enclosure 57. The enclosures 56, 57 abut in a common transverse plane and are separably joined together by means of studs 60 that penetrate opposing transverse flanges 61, 62 which are formed on the exterior end surfaces of the enclosures 56, 57, respectively in the common plane.
The transverse end of the enclosure 56 that is opposite from the end with the flange 61 terminates in a bulbous portion 63. The portion 63 has a transverse flange 64 that circumscribes the circular opening in this end of the heat exchanger enclosure. An adjacent end closure 65 that is shaped in the form of a portion of a sphere also has a peripheral flange 66 that rests upon the bulbous portion flange 64. Bolts 67 in the flanges 64, 66 separably join the closure 65 to the heat exchanger enclosure 56.
As illustrated in connection with this embodiment of the invention, a penetration 70 in the bulbous portion 63 provides a journal for a pump shaft 71. The longitudinal axis of the shaft 71 is oriented in a direction that is generally perpendicular to longitudinal axis 72 of the pressure vessel 55. Within the bulbous portion 63, the pump shaft 71 terminates in an impeller 73 for recirculating the pressurized primary coolant water within the vessel 55 as described subsequently in more complete detail.
The end closure 65 also has guide tubes 74 for the reactor control rod drive lines.
Within the heat exchanger enclosure 56, and at the transverse plane of intersection between the cylindrical and bulbous portions there is a transversely disposed tube sheet 75 that accommodates two tube banks, each of different diameter tubing. As shown, there is an outer annular array of large diameter straight tubes 76 which establish fluid communication between the fluid discharge from the impeller 73 that is adjacent to the tube sheet 75 and the discharge side of a tube sheet 77 which is transversely positioned in the end of the enclosure 56 that is adjacent to the reactor core enclosure 57. The extreme longitudinal ends of the tubes in the bank that form the annular large diameter array 76 are, of course, anchored in mating apertures in the tube sheets 75, 77.
Secondary coolant is admitted to the heat exchanger through a feedwater inlet tube 80 that is nested within and concentric with steam discharge conduit 81. Within the bank of large diameter tubes 76 the feedwater inlet tube 80 is bent through a 90° angle in order to discharge the inwardly flowing secondary coolant liquid within a hollow cylindrical sleeve 82 that is open at both ends and that is nested within the array of large diameter tubes 76. The steam discharge conduit 81, in contrast, merely establishes fluid or vapor communication with the interior volume of the heat exchanger enclosure 56. Naturally, a number of sleeve and inlet tube combinations can be located at intervals in the annular tube array. Furthermore, a portion of inlet tube 80 can be designed to be replaceable by incorporation of a suitable joint in the vertical portion just below the 90° bend.
Smaller diameter straight tubes form a central bank of tubes 83 that are positioned in parallel alignment with the longitudinal axis 72 of the pressure vessel 55 between the tube sheets 75, 77. This centrally disposed bank of smaller diameter tubes 83 is enclosed by a hollow, cylindrical, and longitudinally positioned shroud 84. As illustrated, the shroud 84 has secondary coolant inlet ports 85 formed in the end of the shroud that is near to the tube sheet 77. Within the central tube bank 83 moreover, provision is made for control rod drive line guide tubes 86 which permit the control rod drive lines to pass straight through the central tube bank 83 as well as the tube sheets 75, 77.
The reactor core enclosure 57 has a hemispherical closure 87 that is joined to the open transverse end of the cylindrical portion of the closure which is opposite to the end that has the flange 62. Within the enclosure 57, a peripheral groove 90 is formed in the flange 62 in order to support an annular flange 91 on a hollow, cylindrical and longitudinally oriented core barrel 92. The longitudinal axis of the core barrel 92 is coincident with the longitudinal axis 72 of the pressure vessel 55. The transverse outer diameter of the core barrel 92, however, is less than the inner diameter of the reactor core enclosure 57. This difference in respective diameters provides an annular clearance between the core barrel 92 and the enclosure 57 that serves as a downcomer 93 which directs recirculating pressurized water from the annular array of larger tubes 76 toward the hemispherical closure 87.
As illustrated in FIG. 2, reactor core 94 is supported within the portion of the core barrel 92 that is adjacent to the hemispherical closure 87. Transversely disposed grid structures 95 are positioned under the reactor core 94 to bear the weight of the reactor core, to transfer this weight to the core barrel 92 and to balance the pressurized water flow distribution within the reactor core.
In operation, as hereinbefore mentioned, pressurized primary coolant water flows through the downcomer 93. The shape of the interior surface of the hemispherical closure 87 redirects the pressurized water, causing it to flow in the opposite direction and through the reactor core 94. Within the reactor core 94, the pressurized water absorbs heat and continues in its travel parallel to the longitudinal axis 72 through the central bank 83 of smaller diameter tubes. Heat is transferred from the pressurized water flowing within the smaller diameter tubes to the secondary coolant that immerses a portion of the tubes in this centrally disposed bank. This secondary coolant rises into steam and flows out of the pressure vessel through the steam discharge conduit 81.
Because the secondary coolant inlet ports 85 in the shroud 84 are positioned close to the tube sheet 77 that is adjacent to the reactor core 94, the secondary coolant enjoys a flow path that is essentially parallel with the flow of the pressurized water within the tubes in the bank 83. Upon passing through the tubes in the bank 83, the now colder pressurized water enters the bulbous portion 63 where the impeller 73 pumps this pressurized water from the bulbous portion through the larger diameter tubes 76 in the annular array for recirculation by way of the downcomer 93.
Illustratively, the smaller diameter tubes in the central bank 83 could have an outside diameter of 1/2 inch. The larger diameter tubes 76, on the other hand, might have an outside diameter of 31/2 inches. The larger diameter tubes 76, permit the pressurized water to recirculate with a minimum pressure loss. If a larger number of smaller tubes are used to conduct the same volume of pressurized water with the same mass flow per tube from the impeller discharge the pressure drop in the flowing water would be quite significant, and tend to decrease the overall system efficiency. Special note should be made in this respect that the flow of the pressurized water within the larger diameter tubes 76 and the flow of the secondary coolant that is admitted through the feedwater inlet tube 80 are oriented in the same longitudinal directions or parallel flow. In this circumstance, however, some of the discharged feedwater in contact with the tubes 76 rises into steam and flows toward the discharge conduit 81 in a direction that is opposite to the direction on which the pressurized water is flowing in the tubes 76.
As mentioned above, service inspection, core refueling and the like is significantly easier. For example, the end closure 67 is unbolted and removed, withdrawing the control rod drive linkages from the pressure vessel as a single unit. The impeller 73 and associated shaft and pump motor, however, need not be disconnected while the heat exchanger is undergoing inspection. To refuel the reactor core, the heat exchanger enclosure 56 is disconnected from the reactor core enclosure 57 and removed as a unit with the aid of a suitable tackle in order to expose the reactor core 94 for refueling, inspection and the like. Thus, in accordance with the principles of the invention, shipment of the pressure vessel in smaller, more manageable sections for on-site assembly is eased and simplified, as well as a number of other significant operational problems. | A typical embodiment of an integral pressurized water nuclear reactor and straight-tube steam generator combination in accordance with the invention includes a generally cylindrical pressure vessel that is assembled from three segments which are bolted together at transverse joints to form a fluid and pressure tight unit that encloses the steam generator and the reactor. This novel construction permits primary to secondary coolant heat exchange and improved control rod drive mechanisms which can be exposed for full service access during reactor core refueling, maintenance and inspection. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/193,623, filed Aug. 1, 2005, which is a continuation of U.S. patent application Ser. No. 10/635,679, filed Aug. 7, 2003, which claims priority benefit of U.S. Provisional Patent Application No. 60/401,781, filed Aug. 8, 2002. Each of the above-referenced applications is incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The invention relates to composite screen or perforated surface and filtering membranes.
[0004] 2. Related Art
[0005] Various gutter anti-clogging devices are known in the art and some are described in issued patents.
[0006] In my patent U.S. Pat. No. 6,598,352, incorporated herein by reference, I disclose a filter configuration comprised of a debris repelling membrane, overlying a skeletal structure of ellipsoid rods spaced and resting on vertical planes that serve to break the forward flow of water and to channel water onto and through its integral perforated horizontal plane. Included herein is product literature for LEAFFILTER™, a gutter guard patterned after designs disclosed in U.S. Pat. No. 6,598,352. To date, LEAFFILTER™ has been noted to remain free enough of debris clogs and/or coatings of scum, oil, and pollutants so as to disallow gutter clogs in every known instance of it's installation onto rain gutter systems attached to at least eight thousand residential homes. The LEAFFILTER™ system, however, is costly to manufacture in comparison to other gutter guard systems.
[0007] U.S. Pat. No. 6,463,700 to Davis teaches a composite gutter guard, marketed as Sheer Flo®, comprising a polymer coated fiberglass mesh filter cloth overlying and sonic welded to an underlying perforated plane, disclosed in claims 1 and 4. Davis specifically teaches employment of a medium filter opening fiberglass mesh rather than a fine metal or polymer mesh cloth, disclosed in Column 1 lines 19-35. Such fiberglass mesh of medium openings can be shown to allow the lodging of pine needle tips and to be subject to water-proofing due to oil leaching from roofing shingles. This may cause permanent accumulation of debris upon the composite gutter guard and water-proofing may allow forward, rather than downward flow of water to occur. In instances of high ambient temperatures sonic welded fiberglass has been shown to break free of the underlying polymer plane and the composite gutter guard has been shown to warp and wave due to heat deformation. Davis teaches a mostly single planar composite gutter guard that allows much forward underflow of water to occur on the underside of the disclosed invention and such underflow acts to oppose downward flow of water through perforations.
[0008] U.S. Pat. No. 6,164,020 to Nitch teaches a gutter screen for preventing the accumulation of debris within a gutter. Nitch teaches a gutter screen that has a plurality of v-shaped bars positioned to run above and generally parallel to the gutter. Nitch teaches that the unique shape of the bars minimize the surface area of the underside of the screen decreases water tension on the underside of the screen and postulates that this decreases the ability of water to accumulate on the underside of the screen which promotes the pulling of water into the gutter, disclosed in Col. 2 lines 45 through 50. Such a device can be shown to eventually allow debris to accumulate within the spaces between v-shaped bars. Such a device can additionally be shown to allow the forward channeling of water to occur as an underflow from tip to tip of the downward most portion of the v-shaped bars due to their close spacing and lack of a length of downward extension that would provide a greater directed downward flow of water into the underlying gutter. This and other prior art do not recognize that water adhesion surfaces extending downward from a planar surface into a rain gutter in a height staggered manner or that are separated by a minimum of one inch provide greater siphoning action and are less likely to be overcome by a forward channeling of under flowing water on the underside of surfaces that receive water through perforations or open channels than is reliance on a lesser amount of water adhesion on the underside of perforated surfaces or screens with bottom most water dispersing areas that are closely spaced and follow mostly horizontally linear or follow a linear path that angles downward from the rear most portion of a gutter guard to the front lip of a rain gutter. Allowing for greater spacing of rods or fins or water channeling paths or staggering and/or extending the height of rods or fins so that they extend to a depth that the volume of water they channel downward overcomes by sheer weight and gravity an opposing underflow and continues a downward flow into an underlying gutter has not been found to be a simple matter of anticipation, or design choice by those skilled in the arts. Rather, it has proved to be unclaimed in disclosed prior art and untested in the field with the exception of the LEAFFILTER™ gutter guard which has proved to be very efficient at channeling water downward into a rain gutter while disallowing either the rain gutter or the gutter guard to clog or exhibit an overflow of water. Nitch teaches that fine screens allow for water run-off and are less capable of receiving water than other structural components such as bars or ribs, disclosed in Col. I lines 33-35. This and other prior art such as U.S. Pat. No. 6,463,700 to Davis do not recognize that fine screens can be shown to exhibit great water permeability and downward water channeling properties when contacting ovaled or angled edged surfaces resting on downward extending legs as is disclosed in U.S. Pat. No. 6,598,352 to Higginbotham, Col. 18 lines 26-67, Col. 19 lines 1-54.
[0009] U.S. Pat. No. 5,755,061 to Chen teaches a rain cover that includes pairs of adjacent fins separated by a uniform traverse gap that significantly increases the return of water to the gutter by surface tension with the fin walls, disclosed in the ABSTRACT. As occurs with U.S. Pat. No. 6,164,020, copious amounts of roof runoff may negate the intended effect of water returning to the gutter allowing for forward flow of water past the gutter. The bottom terminal points of the fin walls Chen teaches exist in the same linear plane as do the bottom terminal points of the rods Nitch teaches in U.S. Pat. No. 6,164,020. This allows a forward underflow (beneath the topmost surface of a perforated or open channeled plane) of water to occur. In my U.S. Pat. No. 6,598,352 it is disclosed that such forward rather than downward flow of water has been shown to cease if downward extending planes or rods of varying heights, disallowing a linear channeling path for water to follow, and sufficiently spaced are employed beneath the top most surface of water receiving areas but the disclosed preferred embodiment has been shown costly to manufacture.
[0010] U.S. Pat. No. 5,557,891 to Albracht teaches a gutter protection system for preventing entrance of debris into a rain gutter. Albracht teaches a gutter protection system to include a single continuous two sided well with angled sides and perforated bottom shelf 9 into which rainwater will flow and empty into the rain gutter below. The well is of a depth, which is capable of receiving a filter mesh material. However, attempts to insert or cover such open channels of “reverse-curve” devices with filter meshes or cloths is known to prevent rainwater from entering the water receiving channels. This occurrence exists because of the tendency of such membranes, (unsupported by a proper skeletal structure), to channel water, by means of water adhesion along the interconnected paths existing in the filter membranes (and in the enclosures they may be contained by or in), past the intended water-receiving channel and to the ground. This occurrence also exists because of the tendency of filter mediums of any present known design or structure to quickly waterproof or clog when inserted into such channels creating even greater channeling of rainwater forward into a spill past an underlying rain gutter. Filtering of such open, recessed, channels existing in Albracht's invention as well as in U.S. Pat. No. 5,010,696, to Knittel, U.S. Pat. No. 2,672,832 to Goetz, U.S. Pat. Nos. 5,459,965 & 5,181,350 to Meckstroth, U.S. Pat. No. 5,491,998 to Hansen, U.S. Pat No. 4,757,649 to Vahldieck and in similar “reverse-curved” inventions that rely on “reverse-curved” surfaces channeling water into an open channel have been known to disallow entrance of rainwater into the water-receiving channels. Albracht's as well as previous and succeeding similar inventions have therefore notably avoided the utilization of filter insertions. What may appear as a logical anticipation by such inventions at first glance, (inserting of a filter mesh or material into the channel), has been shown to be undesirable and ineffective across a broad spectrum of filtering materials: Employing insertable filters into such inventions has not been found to be a simple matter of anticipation, or design choice of filter medium by those skilled in the arts. Rather, it has proved to be an ineffective option, with any known filter medium, when attempted in the field. Such attempts, in the field, have demonstrated that the filter mediums will eventually require manual cleaning.
[0011] German Patent 5,905,961 teaches a gutter protection system for preventing the entrance of debris into a rain gutter. The German patent teaches a gutter protection system to include a single continuous two sided well 7 with angled sides and perforated bottom shelf which rainwater will flow and empty into the rain gutter below. The well is recessed beneath and between two solid lateral same plane shelves close to the front of the system for water passage near and nearly level with the front top lip of the gutter. The well is of a depth, which is capable of receiving a filter mesh material. However, for the reasons described in the preceding paragraphs, an ability to attach a medium to an invention, not specifically designed to utilize such a medium, may not result in an effective anticipation by an invention. Rather, the result may be a diminishing of the invention and its improvements as is the case in Albracht's patent 5,557,891, the German Patent, and similar inventions employing recessed wells or channels between adjoining planes or curvatures.
[0012] U.S. Pat. No. 5,595,027 to Vail teaches a continuous opening 24A between the two top shelves. Vail teaches a gutter protection system having a single continuous well 25, the well having a depth allowing insertion and retention of filter mesh material 26 (a top portion of the filler mesh material capable of being fully exposed at the holes). Vail does teach a gutter protection system designed to incorporate an insertable filter material into a recessed well. However, Vail notably names and intends the filter medium to be a tangled mesh fiberglass five times the thickness of the invention body. This type of filtration medium, also claimed in U.S. Pat. No. 4,841,686 to Rees, and in prior art currently marketed as FLO-FREE™ is known to trap and hold debris within itself which, by design, most filter mediums are intended to do, i.e.: trap and hold debris. Vail's invention does initially prevent some debris from entering an underlying rain gutter but gradually becomes ineffective at channeling water into a rain gutter due to the propensity of their claimed filter mediums to clog with debris. Though Vail's invention embodies an insertable filter, such filter is not readily accessible for cleaning when such cleaning is necessitated. The gutter cover must be removed and uplifted for cleaning and, the filter medium is not easily and readily inserted replaced into its longitudinal containing channel extending three or more feet. It is often noted, in the field, that these and similar inventions hold fast pine needles in great numbers which presents an unsightly appearance as well as create debris dams behind the upwardly extended and trapped pine needles. Such filter meshes and non-woven lofty fiber mesh materials, even when composed of finer micro-porous materials, additionally tend to clog and fill with oak tassels and other smaller organic debris because they are not resting, by design, on a skeletal structure that encourages greater water flow through its overlying filter membrane than exists when such filter meshes or membranes contact planar continuously-connected surfaces. Known filter mediums of larger openings tend to trap and hold debris. Known filter mediums smaller openings clog or “heal over” with pollen and dirt that becomes embedded and remains in the finer micro-porous filter mediums. There had not been found, as a matter of common knowledge or anticipation, an effective water-permeable, non-clogging “medium-of-choice” that can be chosen, in lieu of claimed or illustrated filter mediums in prior art, that is able to overcome the inherent tendencies of any known filter mediums to clog when applied to or inserted within the types of water receiving wells and channels noted in prior art until such a medium of inter connected centered threads was disclosed in my U.S. Pat. No. 6,598,352 Col. 22 lines 47-50. The present invention will employ such medium and utilize such in an embodiment less costly to manufacture while remaining effective.
[0013] Vail also discloses that filter mesh material 26 is recessed beneath a planar surface that utilizes perforations in the plane to direct water to the filter medium beneath. Such perforated planar surfaces as utilized by Vail, by Sweers U.S. Pat. No. 5,555,680, by Morin U.S. Pat. No. 5,842,311 and by similar prior art are known to only be partially effective at channeling water downward through the open apertures rather than forward across the body of the invention and to the ground. This occurs because of the principal of water adhesion: rainwater tends to flow around perforations as much as downward through them, and miss the rain gutter entirely. Also, in observing perforated planes such as utilized by Vail and similar inventions (where rainwater experiences its first contact with a perforated plane) it is apparent that they present much surface area impervious to downward water flow disallowing such inventions from receiving much of the rainwater contacting them.
[0014] A simple design choice or anticipation of multiplying the perforations can result in a weakened body subject to deformity when exposed to the weight of snow and/or debris or when, in the case of polymer bodies, exposed to summer temperatures and sunlight.
[0015] U.S. Pat. No. 5,406,754 to Cosby teaches a gutter guard comprising a fine screen supported by a structural stiffening matrix support that prevents the penetration of even fine debris from entering a gutter. When lesser amounts of water flow are present such a device will allow water flow through its combination of screens downward into the gutter. However, during heavy rainfall, roof runoff is known to simply travel over the top most surface of such a device past an underlying gutter rather that downward into the gutter. As with other devices aforementioned in preceding paragraphs, this may occur due to a forward moving underflow of water that can occur beneath the top most surface of nearly planar gutter guards that do not incorporate downward extending planes that break forward flow of water.
[0016] U.S. Pat. No. 4,841,686 to Rees teaches an improvement for rain gutters comprising a filter attachment, which is constructed to fit over the open end of a gutter. The filter attachment comprised an elongated screen to the underside of which is clamped a fibrous material such as fiberglass. Rees teaches in the Background of The Invention that many devices, such as slotted or perforated metal sheets, or screens of wire or other material, or plastic foam, have been used in prior art to cover the open tops of gutters to filter out foreign material. He states that success with such devices has been limited because small debris and pine needles still may enter through them into a rain gutter and clog its downspout opening and or lodge in and clog the devices themselves. Rees teaches that his use of a finer opening tangled fiberglass filter sandwiched between two lateral screens will eliminate such clogging of the device by smaller debris. However, in practice it is known that such devices as is disclosed by Rees are only partially effective at shedding debris while channeling rainwater into an underlying gutter. Shingle oil leaching off of certain roof coverings, pollen, dust, dirt, and other fine debris are known to “heal over” such devices clogging and/or effectively “water-proofing” them and necessitate the manual cleaning they seek to eliminate. (If not because of the larger debris, because of the fine debris and pollutants). Additionally, again as with other prior art that seeks to employ filter medium screening of debris; the filter medium utilized by Rees rests on an inter-connected planar surface which provides non-broken continuous paths over and under which water will flow, by means of water adhesion, to the front of a gutter and spill to the ground rather than drop downward into an underlying rain gutter. Whether filter medium is “sandwiched” between perforated planes or screens as in Rees' invention, or such filter medium exists below perforated planes or screens and is contained in a well or channel, water will tend to flow forward along continuous paths through cur as well as downward into an underlying rain gutter achieving less than desirable water-channeling into a rain gutter.
[0017] U.S. Pat. No. 5,956,904 to Gentry teaches a first fine screen having mesh openings affixed to an underlying screen of larger openings. Both screens are elastically deformable to permit a user to compress the invention for insertion into a rain gutter. Gentry, as Rees, recognizes the inability of prior art to prevent entrance of finer debris into a rain gutter, and Gentry, as Rees, relies on a much finer screen mesh than is employed by prior art to achieve prevention of finer debris entrance into a rain gutter. In both the Gentry and Rees prior art, and their improvements over less effective filter mediums of previous prior art, it becomes apparent that anticipation of improved filter medium or configurations is not viewed as a matter of simple anticipation of prior art which has, or could, employ filter medium. It becomes apparent that improved filtering methods may be viewed as patentable unique inventions in and of themselves and not necessarily an anticipation or matter of design choice of a better filter medium or method being applied to or substituted within prior art that does or could employ filter medium. However, though Rees and Gentry did achieve finer filtration over filter medium utilized in prior art, their inventions also exhibit a tendency to channel water past an underlying gutter and/or to heal over with finer dirt, pollen, and other pollutants and clog thereby requiring manual cleaning. Additionally, when filter medium is applied to or rested upon planar perforated or screen meshed surfaces, there is a notable tendency for the underlying perforated plane or screen to channel water past the gutter where it will then spill to the ground. It has also been noted that prior art listed herein exhibits a tendency to allow filter cloth mediums to sag into the opening of their underlying supporting structures. To compensate for forward channeling of water, prior art embodies open apertures spaced too distantly, or allows the apertures themselves to encompass too large an area, thereby allowing the sagging of overlying filter membranes and cloths. Such sagging creates pockets wherein debris tends to settle and enmesh.
[0018] U.S. Pat. No. 3,855,132 to Dugan teaches a porous solid material which is installed in the gutter to form an upper barrier surface (against debris entrance into a rain gutter). Though Dugan anticipates that any debris gathered on the upper barrier surface will dry and blow away, that is not always the case with this or similar devices. In practice, such devices are known to “heal over” with pollen, oil, and other pollutants and effectively waterproof or clog the device rendering it ineffective in that they prevent both debris and water from entering a rain gutter. Pollen may actually cement debris to the top surface of such devices and fail to allow wash-off even after repeated rains. U.S. Pat. No. 4,949,514 to Weller sought to present more water receiving top surface of a similar solid porous device by undulating the top surface but, in fact, effectively created debris “traps” with the peak and valley undulation. As with other prior art, such devices may work effectively for a period of time but tend to eventually channel water past a rain gutter, due to eventual clogging of the device itself.
[0019] There are several commercial filtering products designed to prevent foreign matter buildup in gutters. For example the FLO-FREE™ gutter protection system sold by DCI of Clifton Heights, Pa. comprises a 0.75-inch thick nylon mesh material designed to fit within 5-inch K-type gutters to seal the gutters and downspout systems from debris and snow buildup. The FLO-FREE™ device fits over the hanging brackets of the gutters and one side extends to the bottom of the gutter to prevent the collapse into the gutter. However, as in other filtering attempts, shingle material and pine needles can become trapped in the coarse nylon mesh and must be periodically cleaned.
[0020] U.S. Pat. No. 6,134,843 to Tregear teaches a gutter device that has an elongated matting having a plurality of open cones arranged in transverse and longitudinal rows, the base of the cones defining a lower first plane and the apexes of the cones defining an upper second plane Col. 5 lines 16-25. Although the Tregear device overcomes the eventual trapping of larger debris within a filtering mesh composed of fabric sufficiently smooth to prevent the trapping of debris he notes in prior art, the Tregear device tends to eventually allow pollen, oil which may leach from asphalt shingles, oak tassels, and finer seeds and debris to coat and heal over a top-most matting screen it employs to disallow larger debris from becoming entangled in the larger aperatured filtering medium it covers. Filtering mediums (exhibiting tightly woven, knitted, or tangled mesh threads to achieve density or “smoothness”) disclosed in Tregear and other prior art have been unable to achieve imperviousness to waterproofing and clogging effects caused by a healing or pasting over of such surfaces by pollen, fine dirt, scum, oils, and air and water pollutants. Tregear indicates that filtered configurations such as a commercially available attic ventilation system known as Roll Vent® manufactured by Benjamin Obdyke, Inc. Warminster, Pa. is suitable, with modifications that accommodate its fitting into a rain gutter. However, such a device has been noted, even in its original intended application, to require cleaning (as do most attic screens and filters) to remove dust, dirt, and pollen that combine with moisture to form adhesive coatings that can scum or heal over such attic filters. Additionally, referring again to Tregear's device, a lower first plane tends to channel water toward the front lip of a rain gutter, rather than allowing it's free passage downward, and allow the feeding and spilling of water up and over the front lip of a rain gutter by means of water-adhesion channels created in the lower first plane.
[0021] Prior art has employed filter cloths over underlying mesh, screens, cones, longitudinal rods, however such prior art has eventually been realized as unable to prevent an eventual clogging of their finer filtering membranes by pollen, dirt, oak tassels, and finer debris. Such prior art has been noted to succumb to eventual clogging by the healing over of debris which adheres itself to surfaces when intermingled with organic oils, oily pollen, and shingle oil that act as an adhesive. The hoped for cleaning of leaves, pine needles, seed pods and other debris by water flow or wind, envisioned by Tregear and other prior art, is often not realized due to their adherence to surfaces by pollen, oils, pollutants, and silica dusts and water mists. The cleaning of adhesive oils, fine dirt, and particularly of the scum and paste formed by pollen and silica dust (common in many soil types) by flowing water or wind is almost never realized in prior art.
[0022] Prior art that has relied on reverse curved surfaces channeling water inside a rain gutter due to surface tension, of varied configurations and pluralities, arranged longitudinally, have been noted to lose their surface tension feature as pollen, oil, scum, eventually adhere to them. Additionally, multi-channeled embodiments of longitudinal reverse curve prior art have been noted to allow their water receiving channels to become packed with pine needles, oak tassels, other debris, and eventually clog disallowing the free passage of water into a rain gutter. Examples of such prior art are seen in various other commercially available products. In one such product, dirt and mildew build up on the bull-nose of the curve preventing water from entering the gutter. Other such products are similarly noted to lose their water-channeling properties due to dirt buildup. These commercial products state such, in literature to homeowners that advises them on the proper method of cleaning and maintaining their products.
[0023] None of theses above-described systems keep all debris out of a gutter system allowing water alone to enter, for an extended length of time. Some allow lodging and embedding of pine needles and other debris within their open water receiving areas causing them to channel water past a rain gutter. Others allow such debris to enter and clog a rain gutter's downspout opening. Still others, particularly those employing filter membranes, succumb to a paste and or scum-like healing over and clogging of their filtration membranes over time rendering them unable to channel water into a rain gutter. Pollen and silica dirt, particularly, are noted to cement even larger debris to the filter, screen, mesh, perforated opening, and/or reverse curved surfaces of prior art, adhering debris to prior art in a manner that was not envisioned.
SUMMARY
[0024] A filter assembly is provided that has a filtering screen and a skeletal structure, the skeletal structure being attached to the filtering screen. At least one of the filtering screen and the skeletal structure form a plurality of downward extending channels. The invention employs a filtering membrane and underlying skeletal support system applicable for disallowing small twigs, leaves, pine needles, pollen, and other debris larger than 100 microns from entering the gutter while directing rain water roof run off into an underlying rain gutter in the presence of such debris. The invention employs downward extending planes underside the filtering membrane and supporting skeletal structure that break the forward flow of water.
[0025] Unlike some prior art gutter guards which have a relatively fine-mesh polymer, fiberglass, or metal layer overlying a perforated panel that exhibits no downward water channeling planes, the gutter guard of the present invention includes a filtering screen integrally joined to a perforated expanded metal panel forming a lateral plane with downward extending water channeling paths. The absence of effective downward extending water channeling paths exhibited in prior art that employs filtering methods often allows for the forward channeling of water past rather than downward into an underlying rain gutter. Unlike prior art that does employ effective downward extending water channeling paths in a polymer body, notably LEAFFILTER™, the present invention has been demonstrated to achieve similar properties through a design more readily accomplished at lower cost of manufacture.
[0026] Accordingly, it is an object of the present invention to provide a gutter shield that permits drainage of water runoff into the gutter trench without debris becoming entrenched or embedded within the surface of the device itself and that employs a filtration membrane configuration that possesses sufficient self-cleaning properties that prevent the buildup of scum, oil, dirt, pollen, and pollutants that necessitate eventual manual cleaning as is almost always the case with prior art.
[0027] Another object of the present invention is to provide a gutter shield that redirects water and self-cleans as effectively as the LEAFFILTER™ gutter shield has been shown to do but do so at a lower cost of manufacture.
[0028] Another object of the present invention is to provide a gutter shield that will accept more water run-off into a five inch K-style rain gutter than such a gutter's downspout opening is able to drain before allowing the rain gutter to overflow (in instances where a single three-inch by five-inch downspout is installed to service 600 square feet of roofing surface).
[0029] Other objects will appear hereinafter.
[0030] It has now been discovered that the above and other objects of the present invention may be accomplished in the following manner. Specifically, the present invention provides a gutter screen for use with gutters having an elongated opening. Normally the gutters are attached to or suspended from a building.
[0031] An important feature of the present invention is to capture and redirect water flow across it's filtering membrane downward through the underlying skeletal support of expanded metal and into an underlying rain gutter as effectively as, and at a lower cost of manufacture, than does the LEAFFILTER™ gutter guard.
[0032] Another important feature of the present invention is to redirect downward flow of water rearward to the rear most portion of a rain gutter by means of angled walls comprising diamond shaped openings present in the underlying skeletal support of expanded metal whereby a forward underflow of water on the bottom surfaces of the gutter screen is greatly diminished.
[0033] The gutter shield device includes a first connecting plane of roll formed metal, a second filtering plane of roll formed metal and metallic or polymer cloth, and a third connecting plane of roll formed metal roll formed into an integral unit. The gutter shield device is adapted for being positioned in a longitudinally extending k-style gutter used for capturing rainwater runoff from roof structures.
[0034] According to another preferred embodiment of the invention, the first plane comprises an angled z-shaped connecting member for securing the gutter shield device to an inwardly extending flange of a k-style gutter to hold the gutter shield in place during use. According to another preferred embodiment of the invention, the first plane is fastened longitudinally along the first edge of the second plane by means of roll formed crimps. According to another preferred embodiment of the invention, the second plane comprises a combined fine filtering membrane with an underlying skeletal support of expanded metal support that may be assembled together as an integral unit.
[0035] According to another preferred embodiment of the invention, the filtering membrane has mesh openings not greater than 80 microns, top and bottom surfaces, first and second opposing edges, two opposing ends and an elongated axis extending between opposing ends. Adjacent the filtering membrane is the expanded metal support having diamond shaped openings, each wall of the opening angled downward at approximately 30 degrees, top and bottom surfaces, first and second opposing edges and two opposing ends.
[0036] According to another preferred embodiment of the invention, the first opposing edge of the expanded metal is fastened and crimped by means of roll forming to the first opposing edge of the filtering membrane to form a fast edge portion.
[0037] According to another preferred embodiment of the invention, the second opposing edge of the expanded metal is fastened and crimped by means of roll forming to the second opposing edge of the filtering membrane to form a second edge portion. The expanded metal support and filtering membrane, so joined as an integral plane, are then roll-formed to create two or more v-shaped downward extending longitudinal channels within the integral plane that transverse the length of the invention parallel to the first and second edge portions for redirecting water flow downward into the gutter.
[0038] According to another preferred embodiment of the invention, the third plane comprises a lateral connecting plane longitudinally fastened to the second edge of the second plane for securing the gutter shield device beneath the shingles of a roof. The first and third connecting planes provide a fastening method for securing the gutter shield device in place over a gutter.
[0039] In another embodiment, the third plane comprises a rear vertical leg fastened to and perpendicular to the second plane for resting on a gutter spike or gutter hangar for securing the gutter shield within the open lateral top of a rain gutter.
OBJECTS AND ADVANTAGES
[0040] Of the above described systems, the LEAFFILTER™ self cleaning gutter guard is known to have demonstrated an ability to, in almost every circumstance and over a period of years, prevent either a rain gutter or the gutter guard itself from clogging, or failing to direct water into a gutters downspout, due to debris lodging, or pollen or scum or oil accumulation. Of the remainder of the above described systems it has been noted that a buildup or coating of debris, pollutants, and oils either cause water adhesion properties to be lost or cause blockage of water receiving openings resulting in rain water roof run-off to flow past, rather than into, an underlying rain gutter.
[0041] An object of the present invention is to provide the above noted advantages, accomplished in the LEAFFILTER™ gutter guard, at a reduced cost to manufacturer and consumer. Additional objects of the present invention are to provide a gutter shield device that employs a fine filtration combination that is not subject to gumming or healing over by pollen, silica dust, oils, and other very fine debris, as well as to provide a filtration configuration and encompassing body that eliminates any forward channeling of rain water on surfaces or undersurfaces as is noted in prior art.
[0042] Another object of the present invention is to provide a filtration configuration that does not allow its filter cloth or membrane to sag and develop debris catching pockets. Another object of the present invention is to provide the noted advantages, accomplished in the LEAFFILTER™ gutter guard, at a reduced cost to manufacturer and consumer. Another object of the present invention is to provide the above advantages in a readily roll-formed gutter guard that may be manufactured on-site, via mobile roll-forming machines, at residential locations allowing for custom fitting of different rain gutters present on residential homes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1 is a top view of a wire screen which is a component of the present invention.
[0044] FIG. 2 is a top view of a filter membrane which is a component of the present invention.
[0045] FIG. 3 is a top view of the filter membrane illustrating 3 applied adhesive strips.
[0046] FIG. 4 is a top view illustrating the filter membrane applied and resting on an underlying support screen of expanded metal, both being components of the present invention.
[0047] FIG. 5 is a top view of components of the present invention generally shown in FIG. 4 , that introduces two fastening sleeve components of the present invention.
[0048] FIG. 6 is a top view of components of the present invention illustrating an alternate embodiment of securing the filter membrane and underlying screen components of the present invention.
[0049] FIG. 7 is a top view of the present invention that illustrates a filter membrane of greater width than an underlying screen.
[0050] FIG. 8 is a top view of two components of the present invention merged by lapping a wider filtering membrane around lateral edges of an underlying screen and crimping both filter membrane and screen together along their respective lateral edges.
[0051] FIG. 9 is an exploded view of lateral edges of components of the present invention.
[0052] FIG. 10 is top view of components of the present invention generally shown in FIG. 4 .
[0053] FIG. 11 is an exploded view of a water directing channel component of the present invention.
[0054] FIG. 12 is an exploded view of a water directing channel component of the present invention exhibiting walls of the channel crimped together.
[0055] FIG. 13 is a top view of the present invention illustrating a rear attaching component.
[0056] FIG. 14 is an exploded view of the rear attaching component generally shown in FIG. 13 .
[0057] FIG. 15 is a top view of the present invention illustrating a rear attaching component unlike the rear attaching component shown in FIG. 13 .
[0058] FIG. 16 is an exploded view of the rear attaching component shown in FIG. 15 .
[0059] FIGS. 17 & 18 are top views of a preferred embodiment of the present invention.
[0060] FIG. 19 is a cross sectional view of an assembling line.
[0061] FIG. 20 is an exploded view of a roller component of the assembling line.
[0062] FIG. 21 is an exploded view of a tensioned roller component of the assembling line.
[0063] FIG. 22 is a cross sectional view of an assembling line generally shown in FIG. 20 .
[0064] FIG. 23 is a general pictorial view, partial in cross section, illustrating a gutter cover according to the present invention and installed above a conventional gutter adjacent to a conventional building.
[0065] FIG. 24 is a general pictorial view of the present invention generally shown in FIG. 23 , illustrating a different rear attaching member than is shown as employed by the present invention in FIG. 23 .
REFERENCE NUMERALS IN DRAWINGS
[0000]
1 Expanded metal screen
1 a width of expanded metal screen
2 downward extending channels
2 a gap between walls of downward extending channels
3 fine mesh membrane
3 a width of fine mesh membrane
4 glue strips
5 sprayed liquid adhesive
6 metal z-shaped sleeve
7 metal u-shaped sleeve 8 crimps
9 rear connecting sleeve
10 width of top plane of rear connecting sleeve
11 recessed channel
12 opening
13 gripping tooth
14 width of recessed channel
15 lower plane of rear connecting sleeve
16 lower plane of rear connecting sleeve
7 lower plane of rear connecting sleeve
18 width of first segment of top plane of rear connecting sleeve
19 width of second segment of top plane of rear connecting sleeve
20 width of third segment of top plane of rear connecting sleeve
21 top horizontal plane of rear connecting member
22 top angled plane of rear connecting member
23 vertical rear leg of rear connecting member
24 height of lower segment of vertical rear leg of rear connecting member
25 a - c decoiling cylinder
26 rolling assembly cylinder
26 a,b,c rolling assembly cylinders
27 , 27 a - e shaping and crimping cylinders
28 roofing shingles
29 rain gutter
30 front lip of k-style gutter
31 subroof
32 preferred embodiments of present invention
33 fascia board
DETAILED DESCRIPTION
[0102] Referring now specifically to the drawings, in FIG. 1 a gutter screen (protector) is illustrated I with downward extending water receiving channels 2 . The preferred gauge of the gutter screen wire is approximately 0.035 to 0.055 inch, which is suitably thick to maintain it's shape and not deform or dip under load bearing weight of snow and ice. The preferred gauge of the gutter screen wire is also of a narrow enough diameter (0.035 to 0.055) to allow the screen 1 sufficient flexibility to be wrapped around a spindle 25 and later unrolled in a manufacturing process as illustrated in FIG. 19 .
[0103] Referring now to FIG. 1 the gutter screen 1 presents a horizontal surface which extrudes downward into channels 2 , which act to inhibit the forward flow of rainwater off a roof structure by means of their open-air areas 2 a , having no greater than ¼ inch width of open air, which interrupt or inhibit some amount of forward water flow. The forward flow of water is further inhibited by being encouraged to flow downward into an underlying gutter due to a downward flowing water path created by the water tension that exists on the wire surfaces of 1 and 2 as they extend downward into any underlying rain gutter. This is an improvement over gutter screens presented in prior art which tend to channel water forward along their single plane or near single plane wire structures, around open air space apertures present in the same plane of the screen, and past, rather than into, a rain gutter. The side walls of channels 2 are crimped closely together contacting each other creating a honey combed wall that has demonstrated an ability to channel greater volumes of water than a solid plane or fin of the same dimensions that would extend downward. Such fins or planes have been utilized in prior art.
[0104] The downward crimped extensions 2 occurring in the horizontal plane of screen 1 also offer an improvement over prior art that employs fine screen or mesh placed over a perforated undulating or wavy support skeleton: Such prior art exhibits lateral weakness, tending to concave, and also provides fewer contact points between fine screen mesh and larger underlying support screen allowing for sagging of the supported mesh to occur. It has also been observed that sequential “waves” or undulations separated by open air space, channel a lesser volume of water downward and allow more to channel forward than does the compressed or crimped channels 2 of the present invention. Prior art that employs waves or undulations as a supporting skeleton for an overlying finer mesh, if constructed of identical material as the present invention, incurs greater cost of manufacture, as more material is required for prior art to cover the same amount of open gutter the present invention would cover.
[0105] Referring now to FIG. 2 : a filtering membrane 3 is illustrated that is comprised of warp-knit or “junctured” (threads not crossing over and under each other but, rather, passing through or adjoining each other) metal or polymer threads that form a fabric or mesh with air space between threads of approximately ≦80 microns. This particular method of fabric or mesh construction prevents the smallest of debris from “catching” and then lodging in the membrane itself as is common with filter methods, cloth, and membranes presented in prior art. Testing has shown that filtering membranes and screens so constructed, and made to contact each other in as many points as possible, as illustrated in FIG. 10 , (with the points of contact being limited to no greater widths than 0.03 inches) exhibit great resistance to clogging or matting due to pollen, oil that leaches from shingles, and other pollutants that commonly coat prior art and eventually lead to the loss of water permeability and water adhesion. A particular test of the invention involved immersing the invention in 30 wt oil: within 10 seconds water permeability of the invention was regained. Prior art so tested: filters, perforated planes, fins, curved surfaces, tangled mesh, louvers, multi-channeled curved surfaces, filtering membranes over planar perforated surfaces, filtering membranes over undulating or wavy surfaces, demonstrated significant loss of water adhesion and siphoning abilities for hours and, in some instances, days.
[0106] As shown in FIG. 1 the screen 1 , can have diamond shaped water receiving openings 51 having angled metal walls 52 . The filtering membrane 3 can contact the top surface of the angled metal walls such that a point of contact forms angles greater than or less than 90 degrees between the bottom surface of the filtering membrane 3 and the top surface of the angled metal walls. The metal walls can be angled approximately 30-40 degrees whereby multi-angled redirection of forward water flow downward into the gutter is realized aiding siphoning and self-cleaning properties of the gutter screen. The metal walls can be angled downward and rearward from the forward longitudinal edge of the gutter screen whereby forward flow of water is further limited and redirected downward. The width of the diamond shaped water receiving openings 51 can be equal to or greater than ⅜ inch whereby water bridging paths across the water receiving openings and resulting forward flow of water is diminished.
[0107] Limiting the space between threads to approximately 80 microns, does allow sufficient water permeability, approximately 75%, to accommodate rainfall run-off if the threads are warp-knit or “junctured”. Tests have shown that when such cloth is tilted at angles greater than 20 degrees, forward flow of water begins and water permeability of the filtering cloth is significantly reduced. When, however, such cloth or membrane 3 is made to contact underlying planes that extend downward, additional surface tension is created at the points of contact and the siphoning ability of the filtering membrane is regained. When such downward extending planes are composed of porous sidewalls that contact each other, the siphoning ability of the filtering membrane is not only regained, but improved and water permeability (or the ability to siphon water downward through the membrane) of filtering membranes will increase and remain as high as 97% even when such membrane is tilted at angles of 50 degrees (referenced to a horizontal plane).
[0108] Referring to FIG. 3 , adhesive strips 4 are applied at each edge and at an approximate center location on the underside of filter membrane 3 . This process may be accomplished at a fabric mill at the time of cloth manufacture and is one method of affixing filtering membrane 3 to underlying screen 1 .
[0109] Referring to FIG. 4 liquefied adhesive paths 5 are sprayed or otherwise applied to the top surface of screen 1 where they then are made to contact the underside of filter membrane 3 as an alternate method (to adhesive strips) of affixing filter membrane 3 to underling screen 1 . The spraying would be accomplished at the site of the roll forming merger of membrane 3 to underlying screen 1 as is illustrated in FIG. 19 : spraying head 41 spraying liquefied adhesive 5 to the top surface of screen 1 .
[0110] Referring to FIG. 22 the filter membrane 3 wound on a spool 25 a , may be unwound and applied and pressed onto the top surface of gutter screen 1 , by tensioning roller bars 26 a , 26 b , and 26 c as is illustrated. The tensioning bars are intended to position the filter membrane 3 in place as the adhesive strips (or narrow paths of adhesive spray) temporarily secure the filter membrane to the gutter screen 1 allowing permanent securing sleeves 6 and 7 (supplied by decoiling cylinders 25 b , 25 c ) to be roll formed and crimped on to sides of filter screen 1 and membrane 3 by tooled dies 27 , 27 a , 27 b , 27 c , 27 d , & 27 e.
[0111] Referring to FIG. 4 it is illustrated that the adhesive strips or spray 5 , which join filter membrane 3 to screen 1 are not positioned over downward extending channels 2 . Doing so may create a “bridging effect” that would encourage forward water flow across the glue paths or strips rather than encourage the downward siphoning effect on water the channels 2 exhibit. The adhesive strips 4 do, however, act to impede the forward flow of water and when positioned away from channels 2 : The adhesive strips or spray paths 5 indirectly allow the downward extensions 2 to more effectively siphon water downward and into the rain gutter beneath by slowing the water flow entering the downward extensions as well as slowing the lesser amounts of water that falls through the remaining non-channeled portions of screen 1 .
[0112] This unique dual use of the adhesive strips or stray paths is an improvement over filtered gutter cover methods presented in prior art that tend to channel water by surface tension along single planed horizontal surfaces past the top opening of a rain gutter. This dual use of the adhesive strips or spray paths also offers an improvement over prior art that employs fine mesh over undulating or wavy support skeletons that may glue filtering mesh to the underlying skeleton along the top of undulations or waves, encouraging forward flow water paths and/or no glue paths whatsoever exist to inhibit forward water flow.
[0113] Referring to FIG. 5 , sleeve 6 is a metal or polymer “z” shaped length, approximately ½″ to 1″ in width, that will be crimped 8 onto the left edge of gutter screen 1 and filter membrane 3 permanently fastening them together as illustrated in FIG. 6 . Sleeve 6 of FIG. 5 provides a means of fastening the left (or forward facing) edge of the invention to the top lip of a K-style rain gutter. Sleeve 7 is a metal or polymer “u” or “v” shaped length approximately ½″ to 1″ in width that will be crimped 8 onto the rear (or right) edge of gutter screen 1 and filter membrane 3 permanently fastening them together.
[0114] The invention offers improvement over prior art in that the junctured or warp-knit construction of both screen 1 and membrane 2 , when joined and achieving as many points of contact as possible exhibits greater water permeability than has been seen in prior art employing fine filtration membrane or cloths whose thread pattern is not so constructed: The invention also offers improvement over prior art that employs filtering screens or cloths, in different embodiments, in that the present invention exposes greater surface area, per rear to forward lateral inch, of water permeable membrane (that is able to effectively direct water flow) to oncoming rain water roof run-off by means of the present invention's downward extensions 2 .
[0115] The invention, FIG. 6 , additionally offers improvement over prior inventions in that it demonstrates great resistance to residual organic buildup which has been demonstrated to clog, and render ineffective, prior art over time. The combination of the particular type of a “warp-knit” or “junctured” filtration cloth or fine mesh over a screen mesh or hardware cloth with diamond shaped openings (that also employs wires junctured together on an equal plane (rather than woven up and under one another) creates a stronger downward siphoning action than is exhibited in prior art that utilizes fine or medium filter membranes or cloth fastened over underlying screens or perforated surface. The strong siphoning action, downward water channeling, and water permeability of the invention is due, in part, to the myriad of “blocks” to forward water flow presented by warp knit or “junctured” mesh or cloth: each thread intersects or abuts another causing water flow to “brake”, then climb up and over a new thread, time and time again at each thread intersection, without being able to follow a more continuous and unobstructed flow path available with other threading methods such as under and over, or knotted thread weaving, or knitting, or non-woven lofty fiber methods. Gravity is then able to exhibit more force on any water, present on the invention, than does the momentum of forward water flow.
[0116] Referring to FIG. 19 , a spray jet 41 spraying a quick drying weak adhesive 5 onto the top surface of gutter screen 1 is shown as an alternative way of temporarily fastening and holding in place the filter cloth membrane 3 until sleeves 6 and 7 are crimped onto the edges of filter cloth membrane 3 and gutter screen 1 achieving a permanent fastening of the filter membrane to the gutter screen.
[0117] Referring to FIG. 7 , there is illustrated a filter membrane 3 slit to a width wider than the underlying skeleton l it will attach to.
[0118] Referring to FIG. 9 , it is illustrated that a metal wire cloth membrane of junctured or warp-knit construction, with thread per inch counts of 100 or more, is wrapped around and under a side edge of a supporting skeleton 1 . The wire cloth is then crimped 8 onto the underlying support screen. This method of securing a screening element to an underlying support structure offers an improvement over prior art in that such a securing method is easily accomplished, economical, and does not require a third additional fastening element or material.
[0119] Referring to FIGS. 10, 11 , & 12 it is illustrated that membrane 3 a is roll formed down into channel 2 , (illustrated in the exploded view of FIG. 11 ). FIG. 12 illustrates that channel 2 is then crimped together so that membrane 3 and screen 1 contact each other within the well of channel 2 . This embodiment of channel 2 is another, less costly, method of achieving “downward extending legs”, disclosed in U.S. Pat. No. 6,598,352, column 13, lines 40-47, that break the forward flow of water and redirect water away from an overlying filtering membrane and also serves to further secure membrane 3 to underlying screen 1 . A downward curve of the combined screen 1 and membrane 3 is created at the top of each “leg” of channel 2 and is another, less costly, method of achieving “oval ellipses”, disclosed in U.S. Pat. No. 6,598,352, column 13, lines 47-51, that redirect water away from an overlying filtering membrane to underlying “downward extending legs”. This embodiment of channel 2 additionally creates a honey-combed porous plane that presents a great number of downward flow paths to water which is traveling the surface of an upper plane the channels 2 are connected to.
[0120] The greater number of flow paths presented by this honey-combed embodiment of channels 2 , over prior art that employs downward extending fins, or open air apertures in a singular plane, or curved surfaces, or singular filters, or filtering membranes over planar surfaces, or filtering membranes over undulating or wavy surfaces, offers improved siphoning ability and water re-direction into an underlying gutter.
[0121] Channel 2 should leave an open air space 2 a of no greater width than ⅛ inch.
[0122] FIGS. 10, 11 , & 12 demonstrate the preferred securing of membrane 3 a to underlying support skeleton 1 . The roll forming of 3 a down into channels 2 illustrates the most effective embodiment of channels 2 of the present invention: this embodiment best redirects water flow into an underlying gutter while presenting only minute areas, 2 a , where debris may tend to gather.
[0123] FIG. 13 and FIG. 15 illustrate two interchangeable rear attachments: 9 and 14 . The attachments have a forward securing configuration 13 , 15 , 16 , and 17 that allow the attachments to interchangeably clip onto main body 1 a . Rear attachment 9 may be utilized in instances where it may be advantageous to install the rear of the gutter cover onto, or sandwiched between, a roof membrane and underlying sub roof as is illustrated in FIG. 24 . Rear attachment 14 may be utilized in instances where it is desirable to allow the gutter cover to rest wholly inside the top open end of a rain gutter and not have any part of the gutter cover extend up onto a roof as is illustrated in FIG. 23 .
[0124] Referring to FIG. 14 it is illustrated that two indented channels 40 lie in plane 10 of rear channel 9 . These channels may serve to act as flex or adjusting points and to enable heating cables to be inserted into them, if desired.
[0125] Referring to FIG. 16 an exploded view of rear attachment 14 is seen. Plane 22 of rear attachment 14 can contact a fascia board and create a rear to forward tension to secure the present invention into the top open end of a rain gutter.
[0126] FIGS. 14 and 17 illustrate a preferred embodiment of the present invention: A cloth filtering membrane 3 , with openings limited to no larger than 80 microns and of junctured or warp knit construction, is roll formed onto the top surface of supporting screen 1 and down into channels 2 and then roll formed around the lateral edges of support screen 1 and subsequently crimped in place near the later edges of supporting screen 1 and filtering membrane 3 , (as illustrated in FIG. 10 ). Channels 2 extend to lengths not less than ¾ inch and are crimped tightly together so that each side wall of the channels physically contact each other creating a micro-porous honey-combed downward extending plane. Testing has indicated that channels 2 begin to forward channel water on the underside of supporting screen 1 when their length is less than ¾ inch. A z-shaped roll-formed strip 6 is then crimped onto the forward lateral edge of the present invention: strip 6 will act to secure membrane 3 to underlying support skeleton 1 as well as serve to secure the gutter screen (the present invention) to the forward top lip of a k-style gutter. A choice of rear attachments 14 and 9 may then act to further secure membrane 3 to screen 1 . Additionally, the attachments allow the present invention 32 to act as a rain gutter screen that may be inserted wholly into the top of a rain gutter, resting on securing spikes or gutter hangars, and held in place by rear to forward tension (when 14 is chosen as the rear attachment) as is illustrated in FIG. 23 , or to serve as a gutter screen that allows for the insertion of it's rear attachment 9 beneath a roofing membrane or shingles to secure the present invention in place as is illustrated in FIG. 24 .
[0127] An improvement if offered over prior art in that the interchangeability of rear attachments 9 and 14 offer a configurable gutter cover that may be adjusted for installation in a wider array of circumstances existing in the field than is offered by prior art, which are known to be limited to the single choice of either “under the shingle” installation or to “wholly inside the gutter” installation.
OPERATION
[0128] Referring to FIGS. 23 and 24 , rain water will flow from a roof structure 28 onto the filtering membrane and screened plane 32 of the invention. The filtering membrane and screen combination 32 will redirect water flow downward into an underlying rain gutter. Testing has shown that 32 , absent channels 2 , is able to redirect approximately 50% of rainfall that contacts 32 when rainfalls of 3 to 5 inches per hour occur over roofs with 32 foot rafter spans and slopes greater than 3/12 pitch. Testing further indicates that, when plane 32 incorporates channels 2 , the invention is able to redirect approximately 97% of rainfall into an underlying rain gutter (when rainfalls of 3-5 inches per hour occur over roofs with 32 foot rafter spans and slopes greater than 3/12 pitch.) Testing of the invention, in it's preferred embodiment, indicate that the invention is capable of redirecting approximately 90% of rain fall into an underlying rain gutter when rainfalls of 8-10 inches per hour occur over roofs with 32 foot rafter spans and slopes greater than 3/12 pitch. Significant water run-off or over shoot has been noted when the invention is installed on rain gutters that service roofs with pitches less than 3/12 and at “inside valleys” of hip valley roofs.
[0129] Debris, that may accompany rainfall runoff or that may, by other means, contact the invention will not lodge within or cling to plane 32 . Prior art commonly allows shingle grit, oak tassels, fir needles, and other small debris to enter a rain gutter or to become within the prior art itself. Testing has indicated the present invention makes this occurrence nearly impossible. Gravity or water adhesion may temporarily cause debris to rest on top of plane 32 , but it has been noted that water from roof run-off will travel beneath such debris and contact plane 32 and be directed into the underlying rain gutter 29 . Debris has been noted to rest or lodge on or within prior art and cause a bridging effect which channels water past the water receiving areas of prior art and onto the ground.
[0130] It has been noted that pollen has the capacity to “cement” debris to prior art, and to the present invention. Testing has shown that pollen may coat 32 but will wash through as soon as water from roof run-off contacts it. Testing has shown this is not the case with prior art: pollen tends to remain on prior art and require physical removal for restoration of water adhesion and/or permeability.
[0131] It is illustrated in FIG. 23 that the present invention may be inserted or snapped into the top open end of a rain gutter and remain in place by a rear to forward tension existing across plane 32 that is created by attachment 14 contacting fascia board 33 and z-shaped roll-formed strip 6 contacting the top upper lip 30 of a k-style gutter. Attachment 14 rests on an underlying hangar or spike and may be notched out to fit over them if necessary to maintain a constant level plane across sections of the invention as it is installed. Many building owners prefer that shingles or roof membranes not be lifted and disturbed due to the possible voiding of shingle warranties, and also prefer a gutter guard to install in a fashion that does not allow it to contact a building's sub roof: much prior art requires such installation.
[0132] Also, many homeowners find the appearance of a gutter guard covering the fast row of shingles on their home to be unattractive. In these instances, an installer in the field may snap attachment 14 onto the rear edge of plane 32 .
[0133] In some instances, a home or building owner may desire a “wholly inside the gutter” installation as is illustrated in FIG. 23 , but certain sections of a rain gutter may have shingles extending down into a gutter, or straps that extend from a subroof down into the gutter or onto it's top front lip, or the gutter may have a cable or other wire directly over it and passing thought the fascia board 33 it is attached to, or a drip edge may extend down into a gutter making the installation of a “wholly inside the gutter” gutter guard difficult or impossible. In these instances, an installer may opt to snap or place attachment 9 onto the rear lateral plane of 32 and continue installation with a matched product.
[0134] The invention will be manufactured in lengths that simply butt together at installation. Either rear attachment allows for quick installation and provides a gutter guard that ensures debris as small as 80 microns, or a grain of shingle grit, will not enter a gutter, and additionally ensures the gutter guard itself will remain water permeable and effective at channeling water into a rain gutter.
[0135] The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the present invention. All examples presented are representative and non-limiting. The above-described embodiments of the invention may be modified or varied, without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the invention may be practiced otherwise than as specifically described. | A filter assembly includes a filtering screen having a top surface and a bottom surface. A skeletal structure is attached to the filtering screen and has a top surface and a bottom surface. The bottom surface of the filtering screen contacts the top surface of the skeletal structure. The skeletal structure forms a plurality of downward extending channels. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is related to a co-pending application entitled "APPARATUS FOR COUPLING A WEAVING MACHINE AND SHED-FORMING MACHINE FOR EFFECTING PICK FINDING AND SLOW SPEED OPERATION", Ser. No. 313 127, filed concurrently herewith.
FIELD OF THE INVENTION
The invention relates to a pick-finding mechanism constructed as a creeping-speed drive for a weaving machine with a shed-forming machine connected thereto and, more particularly, to such a mechanism having a drive motor, a first coupling arrangement for selectively drivingly connecting the drive motor to the shed-forming machine, and a second coupling arrangement for selectively drivingly connecting the weaving machine drive to the shed-forming machine.
BACKGROUND OF THE INVENTION
The term creeping speed means a slow speed of a machine, wherein the functioning of the machine can be observed in slow motion and incorrect sequences can be determined. Also, the creeping speed is used to permit manually stopping the machine as it runs through a critical phase of operation. It is known in smaller machines to simulate the sequence of operations through a manual drive in the creeping speed. In the case of larger or heavier machines, for example weaving machines in which the heddle frames must be lifted, such a manual drive is no longer possible. Instead, the machine is equipped with a special motor for effecting the creeping speed. In weaving machines, a motor-driven creeping speed with forward and backward movement is desired. Thus, the machine can be observed during slow speed operation by a single person over the entire machine width, which is not possible in the case of a manual drive.
It was previously known to equip such a weaving machine with a separate creeping-speed transmission, which usually consists of a small auxiliary motor and a reduction gearing. Operation of the auxiliary motor, for safety reasons, occurs only when the main motor for the weaving machine is switched off. During the weaving process, it is not possible for the transmission and the motor to rotate along freely.
Such a creeping speed transmission could also be used basically for the pick finding in weaving machines. However, it is disadvantageous to have to also drive the entire weaving machine during such a pick finding. Also, not all weaving machines can be driven backwardly. In addition, driving the entire weaving machine in this manner can have disadvantageous effects on threads and fabrics.
A purpose of the invention is therefore to provide a motor-driven mechanism for a weaving machine which makes it possible to permit the weaving machine having a connected shed-forming machine to run without any large extra expenditure at a slow or creeping speed for the purpose of observation and for taking any necessary corrective measures.
SUMMARY OF THE INVENTION
This is achieved with a mechanism of the above-mentioned type, which is characterized inventively by means for moving the two couplings into simultaneous engagement.
This makes it possible for the weaving machine and the shed-forming machine to run with a creeping speed with only small constructive changes of a mechanism which is known in the art of dobby building, like the motor-driven pick finder, which is a great step forward in the weaving technique.
It is possible with the inventive mechanism, without any great extra expenditure and by means of a pick finder with a separate motor which is arranged between a weaving and a shed-forming machine, to rotate both such machines simultaneously, in phase and in two directions.
A preferred embodiment of the pick finder is equipped with a two-stage switch mechanism, whereby with one switching the creeping-speed gearing transmission is simultaneously coupled with the weaving and the shed-forming machine, while with the other switching the gearing is coupled only to the shed-forming machine and simultaneously becomes disengaged from the shed-forming machine of the weaving machine through a coupling which is engaged only in one single position.
A modification consists in the weaving machine being coupled temporarily, while carrying out a pseudo-pick-finding operation, with the shed-forming machine which is equipped with a pick finder, whereby measures are taken so that both machines rotate in phase.
In place of a two-stage switch mechanism a conventional pick finder can be equipped with two couplings which, during pick finding, are both disengaged on the side of the weaving machine and are engaged on the motor side, while during creeping-speed operation the weaving mechanism remains coupled in on the machine side and is coupled in on the motor side.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the inventive pick-finding mechanism are illustrated in the drawings, in which:
FIG. 1 is an elevational side view illustrating a weaving machine with an attached shed-forming machine;
FIG. 2 is a longitudinal sectional side view of a conventional pick-finding mechanism in a "weaving" position;
FIG. 3 is an elevational side view of the pick-finding mechanism of FIG. 2 in a "pick-finding" position;
FIG. 4 is an elevational side view illustrating a pick finder embodying the present invention in a "creeping-speed" position;
FIG. 5 is a longitudinal sectional side view of a pick-finding mechanism embodying the present invention in a "weaving" position; and
FIG. 6 is an elevational side view of the pick-finding mechanism of FIG. 5 in a "creeping-speed" position.
DETAILED DESCRIPTION
FIG. 1 illustrates a weaving machine 2, onto which is mounted a shed-forming machine or dobby 5. The dobby 5 is driven by a sprocket wheel 1 on the drive shaft of the weaving machine, a chain 3 which is indicated in broken lines, and a sprocket wheel 4 which is rotatably supported on a shaft 6 of the dobby. The drive shaft of the weaving machine is driven by a not illustrated drive motor. The sprocket wheel 4 drives the shaft 6 and two bevel gears 7 and 8 of the dobby which are indicated in broken lines through a coupling which is not illustrated in FIG. 1 but is described hereinafter in association with FIGS. 2-6. A heddle frame 9 of the weaving machine is pulled up against the force of release springs 12 in a conventional manner by a member 10 and the actuating cables 11 of the heddle dobby 5.
A conventional pick finder, illustrated in FIGS. 2 and 3, is typically set up on the shaft 6 which is rotatably supported in a conventional manner in the sidewalls or shields 13 of the dobby. It consists of the drive element or sprocket wheel 4, which is driven by the weaving machine as described above and is fixedly secured on a carrier sleeve 14, one side of which has a single tooth or claw 16 which is part of a single-tooth coupling. The sleeve 14 is rotatably supported on the shaft 6 and is secured against movement axially of the shaft 6 by a shoulder 61 on the shaft 6 and the adjusting ring 15 which is secured on the shaft 6.
A tooth 17 on an axially movable sliding sleeve or element 18 supported on the shaft 6 cooperates with the tooth 16, which sliding sleeve 18 is fixed against rotation relative to the shaft by the key 19. The sliding sleeve 18 in turn supports a gear 21, which is operatively connected to the pinion gear 23 of an auxiliary motor 24 which powers the pick finder. The gear 21 is supported freely rotatably on the sleeve 18 and is fixed against axial movement relative thereto by a retaining ring 22 and an axially facing shoulder 18A on the sleeve 18. The gear 21 has on one side a plurality of teeth 30 which are designed to engage the gaps 31 between plural teeth provided on the drive element or bevel gear 7 which is fixedly secured on the shaft 6.
The sliding sleeve 18 can, with the gear 21 which is supported on it, be moved back and forth between end positions of engagement with the carrier sleeve 14 and with the bevel gear 7. The single-tooth coupling 16 and 17 and the multiple-tooth coupling 30 and 31 are each completely engaged or released at the respective end positions. Both of the couplings are engaged in the inbetween position.
The carrier sleeve 18 is moved with the help of a fork-shaped switch lever 27 which is pivotally supported on an axle 28 which is stationarily fixed. The hub of the gear 21 is disposed between the arms of the lever 27. A roller 26 is provided on each of the arms of the fork-shaped part of the switch lever 27 and rolls within an annular groove 25 provided in the gear 21. A relatively strong return spring 29 acts onto the switch lever 27, urging the gear 21 rightwardly in FIG. 1 so that the single-tooth coupling 16 and 17 re-engages within the shortest possible time.
FIG. 2 illustrates the pick finder in the basic "weaving" position, namely during the weaving process of the weaving machine. The single-tooth coupling is engaged and the pick-finding motor 24 is switched off. The dobby 5 is driven by the gear 4 through the carrier sleeve 14, the engaged single-tooth coupling 16 and 17, the sliding sleeve 18, the key 19, the shaft 6, and the bevel gear 7. This position is maintained by the tensioned spring 29.
When the weaving machine is stopped, the switch lever 27 can be pivoted by the machine operator against the force of the return spring 29 from the position according to FIG. 2 into the position according to FIG. 3, by which act the return spring 29 becomes more strongly tensioned. Through this pivoting of the switch lever 27, the sliding sleeve 18 is moved to the position illustrated in FIG. 3. The dobby 5 is released from driving engagement with the weaving machine by the disengagement of the single-tooth coupling 16 and 17. The weaving machine is, as mentioned, stopped. The pick-finding motor 24 can then be switched on. It drives, through the pinion gear 23, the gear 21, the multi-tooth coupling 30 and 31, and the bevel gear 7, the dobby mechanism which is conventional and not illustrated in detail.
Thus, the switch lever 27 is switchable between two positions in the previously known modes of operation, namely, the "weaving" position of FIG. 2 and the "pick-finding" position of FIG. 3. The motor 24 has, in FIG. 3, already driven the gear 21 rotationally for a small distance relative to the sleeve 14.
What is novel here is that, as is illustrated in FIG. 4, the switch lever 27 can be locked by a retaining mechanism in a position intermediate the known end positions, i.e. by pivoting the switch lever 27 from one extreme position at the left hand side--according to Fig. 2--to the extreme position at the right hand side--according to FIG. 3--the roller 40 clicks into the groove 33 on the bottom of the switch lever 27, so that the switch lever is locked in the intermediate position. The roller 40 is supported by the arm 41, which is pivotally mounted on the fixed pin 42. The roller 40 is forced into the groove 33 by the force of the compression spring 43. When the switch lever 27 is in its intermediate position, the sliding sleeve 18 with the gear 21 mounted thereon is also in the intermediate position corresponding the intermediate position in FIG. 4, wherein both the single-tooth coupling 16 and 17 and also the multi-tooth coupling 30 and 31 are engaged. When the weaving machine drive motor is switched off and the brake of the weaving machine is released, it is then possible to switch on the motor 24 of the pick finder. It then drives at a creeping speed, through the pinion gear 23, multi-tooth coupling 30 and 31, and bevel gear 7, the dobby, and through the bevel gear 7 the shaft 6, sleeve 18, single-tooth coupling 16 and 17, carrier sleeve 14, sprocket wheel 4 and chain 3 (FIG. 1), the weaving machine.
By switching the motor 24 of the pick finder on and off, it is possible to observe the weaving machine 2 and the dobby 5 operating at slow speed or to stop it, so long as the switch lever 27 is maintained in the center position.
FIGS. 5 and 6 illustrate an alternative pick-finding mechanism embodying the present invention, in which two pivotally supported switch levers 27 and 32 are provided, each of which can be switched between only two positions. The lever 32 is also supported on a stationary axis. With this, the uncertainty which exists through the possibility of switching between three positions, as in FIG. 4, is avoided.
The pick finder of FIGS. 5 and 6 differs from the already described pick finder in that a gear 210 is axially slidably supported on a cylindrical surface 181 of the sliding sleeve 180. During axial movement of the gear 210 by means of the switch lever 27 which engages the groove 250, the multi-tooth coupling 30 and 31 becomes engaged. The sliding sleeve 180 remains in its normal position and is moved only when the second switch lever 32 which engages the groove 35 of the sliding sleeve 180 is operated. The switch lever 32, which is under the action of a return spring 36, is also fork-shaped, and has a roller 34 on the end of each arm.
When the creeping speed which is effected by the motor 24 is to be switched on, the switch lever 27 is pivoted to the position illustrated in FIG. 6. The switch lever 32 remains unoperated. In this manner, the coupling 30 and 31 is engaged and couples gear 210 and bevel gear 7, and the single-tooth coupling 16 and 17 remains coupled in without change. The motor 24 of the pick finder thus drives both the dobby 5 and also the weaving machine 2. However, a not illustrated safety system which is not part of the present invention takes care that the switch lever 27 can only be operated when the weaving machine is stopped.
Alternatively, the switch lever 32 is pivoted for pick finding. With this, the sliding sleeve 180 moves to the left and, due to an annular shoulder 182 thereon, moves the gear 210 simultaneously to the left. The single-tooth coupling 16 and 17 is thereby released and, at the same time, the gear 210 is moved to the left, so that the multi-tooth coupling becomes engaged. During pick finding, the motor 24 drives only the dobby, and the weaving machine is stopped. The springs 29 and 36, at the end of the pick-finding process, urge the respective switch levers 27 and 32 approximately simultaneously back into the basic position according to FIG. 5. With this, the current to the auxiliary motor 24 is also interrupted.
The embodiment according to FIGS. 5 and 6 has various advantages with respect to the one according to FIG. 4. A clear function separation exists, due to the presence of the two switch levers 27 and 32. A center position of a lever does not need to be maintained. The spring 36 may be substantially weaker than the spring 29, because both act together to provide the relatively large return force at the end of the pick-finding operation which urges the teeth 16 and 17 to again engage one another. The control distances can be adjusted individually in order to suit particular conditions. It is alternatively possible to use friction couplings. The coupling is simpler to handle and is fool-proof.
Although preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | A pick-finding mechanism is arranged between a weaving machine and a shed-forming machine. A sleeve of a gear sits rotatably on a shaft, which gear is driven by the weaving machine. A single-tooth coupling can transmit forces from the gear to a sliding sleeve which is secured by a key to the shaft and can be moved axially of the shaft by a switch lever. The shaft can be driven through a multiple-tooth coupling by a motor and a drive gear. The switch lever serves to couple and uncouple the couplings.
To find the pick, the single-tooth coupling is disengaged and the multi-tooth coupling is engaged. The weaving machine and dobby can be driven together in phase and in both directions by the motor at slow speed, by simultaneously engaging both couplings. This slow or creeping speed permits observation of the functioning and stopping of the machines in any desired position at any time. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national stage application of PCT/US2005/039468, filed Nov. 2, 2005, which claims the benefit of U.S. Provisional Application No. 60/630,008 filed Nov. 22, 2004.
BACKGROUND OF THE INVENTION
This invention relates to a process for removal of methamphetamine from benzphetamine hydrochloride thereby providing highly pure benzphetamine hydrochloride by means of a convenient liquid extraction process employing an organic solvent and water.
The production of benzphetamine has been known for a considerable period of time and was disclosed in U.S. Pat. No. 2,789,138 to Heinzelman et al. The chemical name of the physioacitve material, benzphetamine, is d-N-methyl-N-benzyl-beta-phenylisopropylamine. According to that patent benzyl chloride is reacted with methamphetamine in the presence of a base, typically sodium carbonate. The reaction is typically carried out in a non-reactive organic solvent such as benzene, toluene, xylene or the like. The product is recovered by mixing the reaction mixture with water, extracting with solvent, then converting the benzphetamine to the hydrochloride by addition of hydrochloric acid. The thus produced acid salt is then fractionally distilled under vacuum at temperatures in the range of from about 155° C. to about 165° C. to obtain the amine. Such purification process has several disadvantages including the exposure of the product to high temperatures, and the need for expensive vacuum pumps and a vacuum still to achieve the desired reduced pressure.
The impurity of most concern in the process for preparing benzphetamine hydrochloride is methamphetamine. It is self-evident that any pharmaceutical should be as pure as possible and that such a drug as methamphetamine be eliminated to the extent economically feasible.
Extraction of methamphetamine has been the subject of research in the prior art. An activated methamphetamine is shown in U.S. Pat. No. 5,976,812. The activated methamphetamine is in a class of derivatives of very active materials, typically methamphetamine-p-carboxybutyl-maleinimidoethylamide. In the purification process for this type of compound, the derivative is shaken with sodium hydroxide in water forming oil which is extracted three times with toluene. U.S. Pat. No. 4,056,922 discloses that methamphetamine can be extracted at either pH 2 or pH 9 with concentrating agent selected from silica gel and kieslguhr.
While there are numerous purification schemes available on an analytical basis to remove materials such as methamphetamine, a convenient large-scale production method to provide highly pure benzphetamine hydrochloride substantially free of methamphetamine is not commercially available other than by vacuum distillation. A convenient, large-scale method to provide benzphetamine hydrochloride has not been heretofore available.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with this invention there is provided a novel, efficient and large-scale method for separating methamphetamine from benzphetamine hydrochloride. As noted above, the reaction product of benzyl chloride and methamphetamine is typically acidified to provide benzphetamine hydrochloride. It is inevitable that some amount of methamphetamine is found in the benzphetamine hydrochloride product. There has now been discovered a convenient yet effective liquid extraction method for removing methamphetamine from benzphetamine hydrochloride.
More particularly, it has been discovered that in a narrow pH range of from about 6.0 to about 8.0 there is a high degree of separation of the two amines between an organic phase and an aqueous phase such that the tertiary amine, benzphetamine hydrochloride is converted to the base that partitions into the organic phase while the secondary amine, methamphetamine hydrochloride, is not converted to its base and thus partitions into the aqueous phase. More particularly, in a pH range of from about 6 to about 6.5 there is nearly complete separation of the amines between the organic phase and the aqueous phase. At such pH range, benzphetamine base is conveniently recovered from the organic phase by separating the organic phase from the aqueous phase. The organic phase is then treated with an acid, typically hydrochloric acid, typically providing a pH that converts the benzphetamine base into the acid salt, typically the hydrochloride salt. Such pH to convert the base to the acid salt is typically below about 4 and more preferably about 1. As is well known, the hydrochloride salt is not soluble in the organic phase and can be recovered by any suitable means. As is known in the prior art, the benzphetamine base is typically an oil at room temperature and can be distilled out under vacuum.
DETAILED DESCRIPTION OF THE INVENTION
The present method utilizes the control of the pH of the system so as to take advantage of the difference in the basicity constants, K b , between benzphetamine hydrochloride and methamphetamine. Both amines in the process of this invention are weak bases. Benzphetamine is a tertiary amine, and methamphetamine is a secondary amine. The literature indicates that secondary and tertiary amines differ in K b by a factor of 2. However, it has been discovered that the difference between a benzyl amine (benzphetamine) and a methyl amine (methamphetamine) is quite large. That is, the K b of benzphetamine is about 1/20 th of the K b of methamphetamine. It has further been discovered that concentration of benzphetamine in an organic solvent is approximately 70 to 700 times greater than its solubility in water. Thus a nearly complete separation of benzphetamine can be accomplished by solvent extraction because methamphetamine hydrochloride does not partition in the organic solvent such as toluene.
In accordance with this invention, crude benzphetamine hydrochloride is added to a vessel containing both an organic solvent and water. While stirring vigorously, the pH of the water phase is adjusted to the range of from about 6.0 to about 8.0 by the addition of a suitable acid or base. At such pH range the benzphetamine hydrochloride is converted to a base, and methamphetamine is converted to an acid salt. Vigorous agitation of the mixture assures adequate contact of both phases with the crude benzphetamine base containing methamphetamine contaminant. Upon contact, the benzphetamine partitions into the organic phase and the methamphetamine hydrochloride partitions into the aqueous phase. This operation is performed at ambient temperature and pressure. The only equipment required is a suitable vessel and an adequate stirrer. Optionally, the process of this invention can be carried out in the reactor in which the benzphetamine hydrochloride is produced.
Alternatively, this process works in the opposite direction. A mixture of methamphetamine base and benzphetamine base that is dissolved in an organic solvent may be added to water, and while stirring, the pH may be adjusted to the range of from about 6.0 to about 8.0 with a suitable acid or base. The benzphetamine base remains in the organic phase, while methamphetamine hydrochloride partitions into the aqueous phase.
Any number of organic solvents can be employed in the process of this invention. Such solvent must be non-reactive and have sufficient solubility for benzphetamine hydrochloride. Typical organic solvents include aromatic solvents such as benzene, toluene, xylene, and the like; or aliphatic or cyclic aliphatic solvents such as hexane, heptane, cyclohexane, and the like. A preferred organic solvent for the organic phase in the process of this invention is toluene because it is inert to benzphetamine base and has sufficient solvent ability toward the base.
Typically, the pH of the aqueous phase is adjusted with a base because the hydrochloride salt provides a low pH. Any number of bases can be employed provided such base does not react with the amines in the mixture and should be stronger bases than either of the amines. Such bases include sodium carbonate, alkali metal hydroxides such as sodium hydroxide, potassium hydroxide and the like, alkali metal carbonates and alkali metal bicarbonates such as sodium carbonate or bicarbonate, potassium carbonate or bicarbonate and the like.
Usually, the aqueous phase is rendered acid by the addition of the acid salt, benzphetamine hydrochloride. However, should the pH of the aqueous phase require lowering, any number of acids may be added to lower the pH to the required range. Typically, hydrochloric acid would be added to the aqueous phase to lower the pH as it does not provide any additional elements to the process than is necessarily present. Other acids that could be employed include mineral acids such as sulfuric acid, phosphoric acid, at the like; and organic acids such as acetic acid and the like.
The volume of the organic phase and the aqueous phase is typically equal in the vessel employed in the process of this invention. Equal ratios are not necessary, however, and the organic phase to aqueous phase ratio may be between 1:3 and 3:1; preferable between 1:2 and 2:1, and more preferably 1:1.
After the crude benzphetamine hydrochloride is extracted with the organic solvent and water at a pH in the range of from about 6 to about 8, benzphetamine is in the organic phase, and methamphetamine is in the aqueous phase. The aqueous and organic phases are separated, and benzphetamine hydrochloride may be extracted from the organic phase using, for example, hydrochloric acid. The application of heat to the organic phase may be used to dehydrate the organic phase using distillation, which is more fully described in co-pending U.S. Prov. Appl. entitled “Crystallization Method for Benzphetamine” filed concurrently herewith the same obligations for assignment.
Preferred Embodiments
EXAMPLE 1
To a suitable flask containing 50 ml of deionized water there were added 4 g of crude benzphetamine hydrochloride, having a tan color, and 50 ml of toluene. With vigorous stirring, the pH of the aqueous phase was adjusted to 6.30 with sodium carbonate aqueous solution. The contents of the flask was transferred to a separatory funnel and allowed to settle into two phases. The aqueous layer was decanted. The toluene remaining in the funnel was washed with 25 ml of deionized water and 1.02 equivalents of 37% hydrochloric acid were added. The contents of the funnel were mixed thoroughly by vigorous shaking. The pH of aqueous layer was measured with a paper test strip followed by the addition of a few more drops of hydrochloric acid to bring the pH of the aqueous layer to a range of 0-1. The toluene/acid mixture was transferred to a distillation apparatus consisting of a suitable still, a heating mantle, a magnetic stirrer, a reflux condenser and a Dean Stark trap. After water was collected as a distillate, the apparatus was cooled. The contents of still remained liquid (no solids formed) and a layer of benzphetamine hydrochloride formed. The aqueous layer was drained from the Dean Stark trap and the toluene layer was returned to the still. Upon subsequent heating to the boiling point, the solids dissolved or melted and as distillation continued, sufficient precipitate formed to stop the magnetic stirrer. The toluene/benzphetamine hydrochloride mixture was cooled to room temperature, filtered and washed with additional toluene. There was collected 2.76 g of purified benzphetamine hydrochloride having a white appearance. Analytical analysis, by means of HPLC, of several aspects of the above experiment appear in Table 1 below.
TABLE 1
Benzphetamine
Metham-
Benzphetamine
HCl
phetamine
HCl
Description
Mass (g)
Area %
Area %
Crude Benzphetamine
4.00
6.10
87.17
Aqueous Extract
0.05
67.06
20.63
Aqueous Wash
0.001
18.31
29.28
Toluene Extract
3.307
0.00
94.19
Filtrate
0.260
0.07
76.64
Benzphetamine
2.76
0.00
98.12
Hydrochloride Product
The overall yield of product in the above procedure was 83%, while the yield through the extraction is 97.8%. There was no detectable methamphetamine in the recrystallized product, and only traces of benzphetamine in the aqueous layer. The above described procedure demonstrates the liquid partitioning of benzphetamine hydrochloride from methamphetamine in high yield and improved color.
The partition coefficients for benzphetamine and methamphetamine are presented in Table 2 below. The partition coefficient is defined as the ratio of the equilibrium concentration of the specie in the organic layer to the equilibrium concentration of the specie in the aqueous layer.
TABLE 2
pH
Benzphetamine
Methamphetamine
4
0.600
0.015
6
73.657
0.000
8
∞
0.124
10
∞
3.366
As indicated by the data in Table 2 above, the partition coefficient at pH 6 is highly favorable for maximum separation of the species.
While this invention has been described with respect to various specific examples and embodiments, it is to be understood that the invention is not limited thereto. | The present invention relates to the economical and separation of benzphetamine hydrochloride and methamphetamine by liquid extraction. An extraction process employing a suitable organic solvent and water at a pH in the range of from about 6 to about 8 provides excellent removal of the methamphetamine by dissolution in the water phase while the benzphetamine dissolves in the organic phase. Simple separation of the two phases results in separation of the two amines. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is an instant electrically powered heating system for providing a rapid warm-up to the passenger compartment of a motor vehicle or the like. The heating level may be adjusted and the heating coils are automatically turned off after a manually adjustable time period.
2. Description of the Prior Art
In conventional heaters for motor vehicles, ambient and/or outside air is passed through a heat exchanger and forced into the passenger compartment by a fan through one or more vents generally located in or near the wall separating the passenger compartment from the engine. The heat exchanger also receives fluid from the engine which does not become warm for a significant time after the engine is started, especially in cold weather. Even when the heater begins to pass warmed air, this air does not directly warm the driver, generally because of the location of the heating vents.
Conventional prior art attempts to provide rapid heating to the passenger compartment of the vehicle when the engine is not operating, or prior to warm-up of a cold engine, generally use bulky and often expensive heaters which are also noisy and can drain considerable energy from the vehicle battery, and are thus limited in utility. Furthermore, since heat from the conventional heater is slow in starting, the driver when entering a motor vehicle in cold weather encounters a cold environment, and is uncomfortable until after the engine warms and provides sufficient warm air to the passenger compartment. This situation is unsafe, and could be the cause of accidents. A fast acting heater which is electrically powered, which may be mounted wherever desired and which may be positioned to supply warm air immediately to the driver would be a desirable addition to a motor vehicle.
Some prior art auxiliary electrically powered heaters attempt to overcome the power drain problem by using the three phase AC voltage from the vehicle alternator, but such units are generally complex and expensive. Others attempt to prevent excessive power drain and/or burn-out of the auxiliary heater by using complex or expensive heat or current sensing devices to turn off the auxiliary heater when the vehicle heat supply is sufficient. Representative prior art is shown in U.S. Pat. Nos. 3,313,915; 4,004,126; 4,034,204; 4,188,527; 4,232,211 and 4,562,957.
The present invention avoids the disadvantages of the prior art by providing a small, inexpensive auxiliary electrically powered instant heating system constructed from standard components. The unit may be mounted under the dashboard to supply heat where it is most needed. The heat and power levels are variable, and the electrical power to the heating coils is automatically turned off after a manually adjustable time delay.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved instant heating system for motor vehicles and the like.
A further object of this invention is an improved instant heating system for motor vehicles which is compact and inexpensive, and which may be mounted conveniently under the dashboard so as to provide heat to the desired portion of the vehicle.
Another object of this invention is an improved instant heating system for motor vehicles in which the amount of heat provided, or the power drain of the unit, may be adjusted by a plurality of conveniently positioned manual switches each of which is connected with a separate heating coil or coils and which connect or disconnect the coil or coils from the heating system.
A still further object of this invention is an improved instant heating system for motor vehicles wherein an electronic timer may be set via a manually adjustable dial to provide a preselected time when the heatingcoils are turned off after initiation of the unit.
In accordance with the present invention, there is provided a casing which may be mounted conveniently under the dashboard of the vehicle. The casing contains an airflow passage therein and a fan located in the airflow passage for pulling ambient air into the air flow passage through the casing, passing it over one or more electrically energized heating coils, and back into the vehicle through the casing. Each heating coil or a pair of coils is separately connected to the power source via a manually operable toggle switch, and an electrical circuit automatically turns off all the heating coils after a manually adjustable time delay. A separate switch is provided for energizing the fan without turning on the heating coils. A separate on-off switch initiates the unit, and separate indicator lights are turned on when the blower is energized and when the heating coils are on.
Other objects and advantages of the present invention will become apparent by reference to the following descriptions of the preferred embodiments thereof when read with reference to the accompanying drawings in which like reference characters refer to the like elements throughout the views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic perspective view if the present invention;
FIG. 2 is a diagrammatic side elevational view taken in the direction of arrow 2 in FIG. 1;
FIG. 3 is a diagrammatic rear elevational view taken in the direction of arrow 3 in FIG. 2;
FIG. 4 is a fragmentary diagrammatic view illustrating how the present invention may be mounted under a dashboard of a motor vehicle; and
FIG. 5 is a schematic diagram of the electronic circuitry of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring particularly to FIGS. 1-3, the heater of this invention comprises a casing 10 generally rectangular in shape and constructed preferably from metal and/or high temperature plastic. Top and bottom panels 12 and 14 are solid, while side panels 16 and 18 contain a plurality of apertures 20 at the rearward end of the side panels. Rear wall 22 and front wall 24 also contain apertures 20, but the apertures are only in the bottom portion of front wall 24 for reasons which will be evident. Preferably the top panel 12 and side panels 16 and 18 are constructed in one piece, while bottom panel 14 and front and rear walls 24 and 22 are also in one piece, side panels 16 and 18 having flanges 26 which extend inwardly and overlap the front and rear walls, and bottom panel 14 has a flange 28 on each side thereof which overlaps the bottom most portion of side panels 16 and 18, and which may be secured thereto by screws 30. Rear wall 22 may also contain an inwardly extending flange, not shown, through which additional screws 32 may be secured. Details of construction and assembly of the casing 10 may be modified, and such changes will be apparent to those skilled in the art.
Fixedly attached through the rear wall 22 are two electrical connectors 34 and 36, connector 34 being a two-prong plug receptacle and connector 36 being a three-prong plug receptacle. Two independent connectors are desirable for ease of connection of the heater to electrical extension cords or the like to provide the DC electrical voltage to the heater. Commonly available hardware is used with redundancy. Internally to the heater, like electrical terminals of both connectors 34 and 36 may be electrically connected together to provide a single voltage input regardless of which of the two connectors is used. The reason for having the connectors separate is to connect connector 34 to a control circuit after the car key switch is turned on, if desired, to prevent unintentional operation. Appropriate grounding of the connectors is also necessary.
It is contemplated that the source of DC electrical voltage supplied to the heater will be from a connection to the vehicle battery, but power may be provided from a generator or alternator, or an auxiliary power supply. If filtering or rectification is needed, it may be performed either external to the heater, or a rectifier may be built internal to the heater, although the latter would add unnecessary expense.
Mounted within the casing 10 is an electric fan 38 shown in FIGS. 2 and 3, the fan being fixed within the casing 10 by a bracket or other mounting means, not shown, and electrically connected to the DC voltage source as will be described in conjunction with FIG. 5. The electronics shown in FIG. 5, with the exception of the heating coils, is preferably mounted on a heat resistant circuit board 40, and physically connected within the casing by any convenient support bracket or the like as shown in FIGS. 2 and 3. The electrical wiring inside the casing 10 joining the electrical input connectors, the circuit board 40, the fan 38 and the heating coils to be described subsequently are not shown since such connections are obvious.
An air flow guide 42 shown in phantom in FIGS. 1 and 2, and generally constructed from metal or plastic, is fixedly attached within casing 10 by brackets or other securing means. The purpose of air flow guide 42 is to direct the ambient air, which enters the casing 10 through the apertures 20 in rear wall 22 in side walls 16 and 18 and which thereafter passes through fan 38, through the reduced diameter portion of the chamber shown as 44 in FIGS. 1 and 2. The five heating coils 46a, 46b, 46c, 46d and 46e are also located in chamber portion 44. The fan discharge air is thus heated and then discharged through the apertures 20 in front wall 24 into the passenger compartment. The air flow guide 42 thus directs the air over the heating coils 46, but also reduces the cross sectional area of the airflow passage which increases the air velocity as it exits the heater.
The heater casing 10 is adapted for mounting conveniently inside a motor vehicle, such as under the dashboard of an automobile, as best shown in FIGS. 1 and 4. A pair of upwardly extending mounting brackets 48 are attached to the side panels 16 and 18 by screws and wing nuts 50 which enable the brackets 48 to be vertically rotated. The top of each bracket comprises an expandable circular clamp 52 which is adapted to hold a spring loaded grip-type clamp 54 which may be attached to the lower edge of the vehicle dashboard 56 as best seen in FIG. 4. Other attaching means may also be used.
Located on the front wall 24 near the top thereof and away from the warm air exiting through the bottom of the wall are an on-off switch 60 which controls the fan 38, and a green light 62 which is turned on when the fan 38 is operating. A push button switch 64 provides power to the coils 46 when actuated, and a red light 66 is turned on when power is being supplied to the heating coils 46. A rotary timer control 68, which is preferably a rheostat, adjusts a time delay circuit shown in FIG. 5 to determine the time during which electrical power is supplied to heating coils 46, after which the power to the heating coils is terminated and the coils are automatically turned off. Toggle switches 70a, 70b and 70c each control the supply of power to one of the heating coils, or to a pair of coils, and thus there is a mechanism for determining the heating level of the heater, as well as the amount of electrical power consumed by the heater.
Referring to FIG. 5, the preferred arrangement of electronics controls for the heater is shown. For clarity of circuit description the source of positive voltage is shown at terminals 100 and 102, although it will be evident that the two terminals are not separate. The negative terminal is shown at 104. In most motor vehicles the negative terminal is common, and the positive terminal is at +12 volts. Filtering capacitors 106 and 108 are used to smooth any voltage transients.
Fan 38 is connected to the line voltage via a 5 amp. fuse 188, via switch 60 and via resistor 110. Connected across fan 38 is a capacitor 112 and a pair of series connected Zener diodes 114 and 116 which prevent voltage spikes above 24 volts. A resistor 118 and lamp 62 are connected across fan 38 so that lamp 62, preferably green, will be turned on when the fan 38 is energized.
Also connected across fan 38 is a resistor 120 and a reverse biased Zener diode 122, with the junction between resistor 120 and Zener diode 122 being connected via line 124 to the base junction of NPN transistor 126. The collector junction of the transistor is connected to the positive voltage supply through fuse 128 which is preferably a 10 ampere time delay type thermal fuse, which will disconnect the power from the circuit transistors only after a malfunction occurs, but which will not respond to short transient overloads. Connected between the emitter of transistor 126 and the negative voltage terminal is resistor 130. The junction between transistor 126 and resistor 130 is connected via line 132 to one side of push button switch 64.
Upon the closing of switch 60, fan 38 and lamp 62 are turned on. The voltage at line 124 to the base junction of transistor 126 is maintained at a sufficiently high positive level to cause transistor 126 to conduct and raise the voltage on line 132. However, until switch 64 is actuated or pushed, no current will flow to the heating coils 46, and fan 38 will pass only ambient air. It will also be noted that the fan 38 must be actuated by the closing of switch 60 before switch 64 is actuated or no current will flow through the heating coils 46.
Positive terminal 100 is connected to the heating coils 46 and will produce current flow through the selected coils, i.e., those coils selected by switches 70a, 70b and/or 70c, upon the actuation of switch 64. Heating coil 46a is connected to terminal 100 through switch 70a and 15 amp. fuse 140a. Heating coils 46b and 46c are connected in parallel, and in series with switch 70b and a 25 amp. fuse 140b. Heating coils 46d and 46e are also connected in parallel and in series with switch 70c and a 25 amp. fuse 140c. Connected across coil 46a is lamp 66 and resistor 142, the lamp being turned on when current flows through any of the heating coil 46a, 46b, 46c, 46d and 46e.
All heating coils 46a, 46b, 46c, 46d and 46e are connected to conductor 144 which will be connected to the negative potential on conductor 150 through normally open relay contacts 146 and 148. Contacts 146 and 148 will remain open until switch 64 is actuated, so that no current path is available through any of the heating coils even though any or all of the switches 140a, 140b and 140c are closed. However, upon the actuation of switch 64, the voltage in line 132 is immediately applied to the base junction of transistor 152 causingg it to conduct. The collector of transistor 152 is connected to the positive terminal 102, and the emitter is connected to the base of transistor 154. Connected between the base junction of transistor 152 and negative terminal 104 is an R-C time delay circuit comprising resistor 156 and rheostat 158, the resistance of the rheostat being varied by rotatable switch 68. Capacitor 160 is connected across resistor 156 and rheostat 158, and the values of resistance and capacitance are chosen such that capacitor 160 charges rapidly upon the actuation of switch 64. Since switch 64 is of the push button type, it will be closed for only a brief time. When the switch 64 reopens, capacitor 160 maintains the base-emitter junction of transistor 152 at a current level sufficient to keep the transistor conducting, but gradually the charge on the capacitor is dissipated through the resistors 156 and 158 and the conducting transistor 152, and the current through the base-emitter junction of transistor 152 reduces to the point where transistor 152 no longer conducts. The time constant of the circuit is adjusted by rotatable switch 68 which changes the resistance of the rheostat 158. The values are selected to vary the time constant from between 1 and 5 minutes.
When transistor 152 conducts, it turns on transistor 154, and the current flow from transistor 154 creates a voltage at the junction between resistors 161 and 162 sufficient to turn on transistor 164, connected to negative terminal 104 through resistor 166, and connected to positive terminal 102 through coils 168 and 170 of relays 172 and 174. Upon conduction of transistor 164 current flows through coils 168 and 170, energizing relays 172 and 174 and closing contacts 146 and 148. A current path is thus created from positive terminal 100 through any of the switches 70a, 70b and 70c which are closed, through the heating coils connected to the closed switches 70a, 70b and 70c, through conductor 144, contacts 146 and 148, and conductor 150 back to negative terminal 104. When transistor 152 turns off after the selected time delay, transistor 164 is turned off preventing current flow through coils 168 and 170, contacts 146 and 148 are opened, and current no longer passes through any of the heating coils 46a, 46b, 46c, 46d and 46e. A capacitor 176 is used to prevent arcing at the relay contacts.
Representative values of the circuit components are:
______________________________________Resistors Capacitors______________________________________110 1/2 ohm 106 .1 microfarads118 100 ohms 108 .1 microfarads120 1k ohms 112 4700 microfarads130 1k ohms 160 4700 microfarads142 100 ohms 170 .1 microfarads156 22k ohms158 100k ohms161 1k ohms162 1k ohms166 1/2 ohm______________________________________
It is apparent that changes and modifications may be made to the construction and arrangement of the invention without departing from its scope as hereinafter claimed. | An electrically powered heater for instantly heating the interior of motor vehicles and the like uses DC current to actuate a plurality of heating coils located in an under-dash mounted casing. The casing has an air flow passage therein and a motor driven fan arranged to draw ambient air through apertures in the rear of the casing, over the heated coils and back into the vehicle interior through the front of the casing. Each heating coil is connected either singly or in pairs with a manually operated toggle switch so that each coil may be turned on separately or all coils together to adjust the heat and power consumption levels. The fan is separately switched and may be operated independently of the coils. An electronic control circuit for the heater includes an on-off switch and a manually adjustable time delay network which automatically turns off the heating coils after a preselected time. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates to network counter retrieval.
BACKGROUND
[0002] Typically, in network systems, there are many ways in which network measurements such as usage, delay, variation of delay, packet loss, and the like, can be carried out. In particular, packet-oriented telecommunications network devices typically maintain statistical counters regarding many aspects of network operation. For instance, these statistics are useful for billing, network troubleshooting, network engineering, and trend analysis. Generally, statistics are retrieved from a device to yield relevant data. The retrieval of information typically occurs across the network using a variety of communications protocols, e.g., Simple Network Management Protocol (SNMP) running over the Internet Protocol (IP).
[0003] In some instances, statistics need to be retrieved only under certain circumstances (e.g., statistics used for network troubleshooting). Such statistical information only needs to be retrieved and examined when there are network problems. Other types of statistics need to be retrieved on a regular and continuing basis. For example, statistics pertaining to billing may need to be retrieved frequently and periodically.
SUMMARY
[0004] According to one aspect of the invention, a method and system include collecting information in a network device, determining in the network device when to send a subset of the collected information to a collection system, and determining in the network device which subset of the collected information to send at a given time.
[0005] One or more of the following features may also be included. Information is collected according to a configured periodicity. Information consists of statistical values stored in counters.
[0006] As another feature, the subset is a value of a counter and can also represent values of multiple counters.
[0007] In certain embodiments, determining when to send a subset is user-configurable. In certain embodiments, determining when to send it is done autonomously by a network device. In either case, the determination can include determining a low peak period of a network operation and/or of the network device's own operation, and sending the subset during the low peak period.
[0008] As yet another feature, the method includes associating each unit of the collected information with an identifier. The method also includes the option for using locally significant tags as identifiers for greater efficiency. The method further features associating the locally significant value of the tag with a globally significant identifier value, and expressing that association through a communications channel of a computer network system.
[0009] As another feature, the information of the statistical value that is unchanged is not transmitted from the network device to the collection system.
[0010] The method further includes sending acknowledgements from the collection system to the network device with respect to receipt of the collected information by the collection system. In addition, the collected information is reported at least once within a set time interval.
[0011] According to another aspect of the invention, a system includes a collection system coupled to a network device through a communications channel of a computer network system, and a network device configured to determine when to send a subset of the collected information to a collection system and to determine in the network device which subset of the collected information to send at a given time.
[0012] One or more of the following features may also be included.
[0013] The network device is configured to determine a periodicity for sending all collected information.
[0014] The collected information consists of statistical values stored in counters. The subset is a value of a counter or the values of multiple counters.
[0015] In certain embodiments, the network device being configurable as to when to send a subset of the collected information, and in certain embodiments the network device determining autonomously when to send a subset of the collected information.
[0016] As another feature, the network device determination as to when to send includes the network device determining a low peak period of a network operation, and/or a low peak period of the network device's own operation, and sending the subset during the low peak period.
[0017] Embodiments may have any of the following advantages.
[0018] The collection system receives the needed information without having to poll the network devices, which increases the scalability for periodically retrieving counters when counter instances become large, number of network devices becomes large, or both. It is possible to obtain periodic collection of large numbers of data elements from a large number of network devices, while maintaining a high level of real-time responsiveness characteristic of polled solutions without the drawbacks of a polled approach. Thus, the present methods and systems retain the real-time responsiveness of a polled approach while removing the scalability concerns of polling data from each individual network device.
[0019] The excessive network bandwidth and network device capacity consumed by polling individual counters is eliminated. Such drain on network resources is avoided because the need for requesting, locating and transmitting specific counter instances on demand is eliminated.
[0020] Efficiency is significantly enhanced by providing data aggregation (by the subsets of the collected information sent) and aggregated acknowledgements, as well as by allowing suppression of counters having unchanged values. Furthermore the network device is able to transfer collected information in a sequence convenient to it (such as the sequence in which the information is stored in an internal array) and to schedule the transmission of data at points in time which are convenient and appropriate to the network device.
DESCRIPTION OF DRAWINGS
[0021] [0021]FIG. 1 is a block diagram of a network.
[0022] [0022]FIG. 2 is a flow diagram of a counter retrieval system.
[0023] [0023]FIG. 3 is a diagram of an array.
DETAILED DESCRIPTION
[0024] Referring to FIG. 1, a network counter system 10 includes a group of globally connected computer systems within a computer network 20 such as the Internet, three network devices (e.g., Internet Protocol (IP) service switches 30 a - 30 c ) connected through the network 20 to a collection system 40 such as a billing statistics collection system using communications channels 25 a - 25 d.
[0025] The computer network 20 is a TCP/IP network that carries voice, data, or both. The computer network 20 includes a number of nodes (not shown) interconnected by communications paths and communications channels. The computer network 20 can interconnect with additional networks and include subnetworks. In particular, the IP service switches 30 a - 30 c are linked to the computer network 20 via communications channels 25 a - 25 c , respectively. The collection system 40 is linked to the computer network 20 via the communications channel 25 d.
[0026] In this example, the IP service switches 30 a - 30 c are used to provide access to the computer network 20 , as well as associated Quality of Service (QoS) and security services, for various subscribers (not shown). Each of the IP service switches 30 a - 30 c includes a general central processing unit (CPU) system and other hardware implementing various networking protocol functions, for example, those of the Transport Control Protocol/Internet Protocol (TCP/IP) suite, with associated management and control features. Each of the IP service switches 30 a - 30 c includes statistics agent modules 31 a - 31 c . The statistics agent modules 31 a - 31 c are implemented to report over the computer network 20 statistical information about the IP service switches 30 a - 30 c through their respective communications channels 25 a - 25 c . The statistics agent modules 31 a - 31 c are implemented in hardware, such as with an application-specific integrated circuit (ASIC), or in software, or in a combination of hardware and software.
[0027] For example, each of the IP service switches 30 a - 30 c provides billable IP-based services to a network operator's subscribers. The IP service switches 30 a - 30 c can provide traffic statistics kept on a per-subscriber basis within the IP service switches 30 a - 30 c in support of usage based billing. The IP service switches 30 a - 30 c can support many tens of thousands of subscribers and manage scores of data items (e.g. service usage statistical counters) for each subscriber. The IP service switches 30 a - 30 c are real-time network devices whose primary functions are the processing of data packets, that processing including forwarding and application of IP services to the packets. Although there are other tasks to be accomplished in the IP service switches 30 a - 30 c in support of data packet processing, those tasks have various levels of urgency. The reporting of statistics and related tasks can have lower urgency and therefore lower processing priority relative to most other software or hardware functions.
[0028] Referring to FIG. 2, statistical data 28 is collected across the computer network 20 of FIG. 1 from the IP service switch 30 . The collection system 40 collects statistical data 28 from an IP service switch 30 in a reporting process 50 as time line 22 progresses from a time “0” to a time “t”. The collection system 40 processes the statistical data 28 for such uses as subscriber billing.
[0029] In the reporting process 50 , the IP service switch 30 periodically sends statistical data identified by tag bindings 24 , in any order the IP service switch 30 deems appropriate, to the collection system 40 . In particular, the IP service switch 30 forwards statistical data 28 to the collection system 40 at its convenience during periods of time where the computer network 20 has low network usage, i.e., low levels of data traffic or the IP service switch 30 has low CPU usage. The IP service switch 30 also reports statistical data 28 in an order efficient for the IP service switch 30 , for example, in the order that the data items have been stored in an internal memory or buffer of the IP service switch 30 , thereby avoiding CPU intensive lookups for specific statistical data.
[0030] In operation, at time =0, the IP service switch 30 transmits tag bindings 24 a - 24 c to the collection system 40 . Other tag bindings 24 d may be sent later as they are defined in the IP service switch 30 . The tag bindings 24 announce associations between locally significant tags, and globally significant identifiers of specific data items such as a statistical counter. More specifically, each tag binding, such as tag binding 24 a , associates a tag value (e.g. Tag 1 ) with a globally significant identifier value (e.g., “Identifier 1”). The identifier value can be of any data type that identifies the collected data item of interest. For example, for billing purposes, a company name such as “Acme Corporation,” can serve as the identifying name of an entity for which the billing data is being reported to the collection system 40 . Therefore, identifier values (e.g., “Identifier 1, Identifier 2, Identifier 3, and Identifier 4”), represent globally significant identifiers 32 a - 32 d . Such globally significant identifiers 32 a - 32 d are recognized by the network counter system 10 and can be processed by the collection system 40 , the IP service switch 30 , and any other network node or switch that make up the network counter system 10 . Moreover, the locally significant tags 24 a - 24 d (Tag 1 , Tag 2 , Tag 3 , and Tag 4 ) are bound to and associated with the identifier values 32 a - 32 d. The bound tags 24 a - 24 d are valid for a period of time, and various components of the network counter system 10 can use the bound tags 24 a - 24 d as convenient aliases for the identifiers 32 a - 32 d.
[0031] Using the same communications channels 25 a - 25 d used to transmit tag bindings 24 as described above, at a time=t, where t is greater than 0 , the IP service switch 30 sends statistical data 28 logically associated with the previously transmitted tag bindings 24 . In other words, rather than sending statistical data 28 with the globally significant identifiers 32 a - 32 d , the IP service switch 30 sends statistical data 28 with locally significant identifiers 34 a - 34 d . The locally significant identifiers 34 a - 34 d , with values Tag 1 , Tag 2 , Tag 3 , and Tag 4 , are used by the collection system 40 to identify the accompanying counter or statistical data 28 .
[0032] For example, when the IP service switch 30 sends statistical data 28 a , the IP service switch 30 is transmitting locally significant identifiers 34 a - 34 b with values Tag 1 and Tag 2 , respectively. The collection system 40 , in turn, upon receiving the locally significant identifiers 34 a - 34 b , determines which globally significant identifiers 32 a - 32 b correspond to the data items (counter values) sent in statistical data 28 a . That is, by receiving only the locally significant identifiers Tag 1 and Tag 2 , the collection system 40 is able to computationally resolve that it is the statistical counters for “Identifier 1” and “Identifier 2” that the collection system 40 has received, because the tag bindings 24 a - 24 b have already been received by the collection system 40 earlier in the reporting process 50 .
[0033] The logical association between the locally significant identifiers 34 a - 34 d and the globally significant identifiers 32 a - 32 d is made available to the collection system 40 . This may be done synchronously within the same communications channel 25 that the statistical data 28 are reported through, thus allowing temporal reuse of the locally significant tags 34 a - 34 d without introducing ambiguities as to their current association with globally significant identifiers 32 a - 32 d.
[0034] Rather than tagging the statistical data 28 with the globally significant identifiers 32 a - 32 b , locally significant identifiers are used to identify the statistical data 28 as they are sent to the collection system 40 . This reduces bandwidth consumed at the computer network 20 through the communications channel 25 , since the locally significant identifiers are more compact than the globally meaningful identifiers. Moreover, locally significant identifiers that correspond to array indices can be used, avoiding complex lookups.
[0035] Referring to FIG. 3 the IP service switch 30 stores the statistical counters in a data structure such as an array 70 . Each row 72 of the array 70 contains a counter value 74 for a particular subscriber, for example. FIG. 3 illustrates one statistical counter 74 kept per subscriber, although more are present. The array 70 also stores the subscriber name 76 corresponding to each row 72 of the array 70 , which in this example is the globally significant identifier 32 . Since the IP service switch 30 assigns the values of the locally significant tags 34 , the IP service switch 30 arranges the assignment so that an array index 78 corresponding to a particular subscriber is assigned as the local tag 34 for the statistical data of the subscriber. Since the network counter system 10 allows the IP service switch 30 to transmit collected data subsets in any order, the IP service switch 30 sends the counter values 74 in the order they are stored in the array 70 , tagging each counter value 74 with the associated array index 78 .
[0036] Referring back to FIG. 2, the tag bindings 24 are sent before statistical data 28 using those particular bindings are sent. Thus, before the data identified by a new globally significant identifier code 32 d , namely “Identifier 4,” is sent to the collection system 40 , the new identifier code is first bound to a local tag 24 d (e.g., Tag 4 ). Thereafter, statistical data 28 b tagged with the locally significant tag 34 d is sent to the collection system 40 . Similarly, statistical data 28 c - 28 e tagged with the locally significant tags 34 a - c may be sent to the collection system 40 because the tag bindings 24 a - 24 c have been sent previously to the collection system 40 .
[0037] In the reporting process 50 , the IP service switch 30 transmits statistical data 28 to the collection system 40 in sequence and at specific points in time which are efficient and convenient for the IP service switch 30 (e.g., idle periods for the IP service switch 30 or low peak usage periods for the network 20 or the communication channels 25 ). In particular, the IP service switch 30 reports statistical data 28 during reporting intervals 26 a - 26 b . The IP service switch 30 reports every statistical data 28 at least once per reporting interval 26 . Thus, during a reporting interval 26 a , the IP service switch 30 reports statistical data 28 for locally significant identifiers 34 a - 34 d , and during a reporting interval 26 b , the IP service switch 30 again reports statistical data 28 using the same locally significant identifiers 34 a - 34 d used in the previous reporting interval 26 a . For example, at least once per hour, or once during any predetermined period of time, all statistical data 28 can be reported to the collection system 40 without polling the IP service switch 30 .
[0038] In certain situations, the statistical data 28 may not have advanced or incremented, that is, the statistical data 28 has not been changed since the last reporting. In these cases, the IP service switch 30 refrains from transmitting the statistical data 28 . The collection system 40 can assume the incremental counts are zero unless the IP service switch 30 reports otherwise.
[0039] In the example described above in conjunction with FIGS. 1, 2, and 3 , the reporting process 50 between the IP service switch 30 and the collection system 40 may be preceded by an associated signaling phase where the IP service switch 30 and the collection system 40 authenticate each other, may establish a secure channel of communications, may communicate agreements on general parameters of any further and subsequent transfers of data, and the like.
[0040] The IP service switch 30 may also be used for collecting other types of statistical counters, such as network troubleshooting counters. The reporting process 50 may be applied to the collection of data other than statistical counters, such as event logging records. Moreover, the collection system 40 may transmit acknowledgements (e.g., ACK packets) to the IP service switches 30 a - 30 c to support a reliable network delivery system.
[0041] Other embodiments are within the scope of the following claims. | A method and system include collecting information in a network device, determining in the network device when to send a subset of the collected information to a collection system, and determining in the network device a subset of the collected information to be transmitted at a given time. | 7 |
This application is a continuation in part of U.S. patent application Ser. No. 08/421,167 filed Apr. 13, 1995 which is a division of U.S. patent application Ser. No. 08/245,734 filed on May 18, 1994, now U.S. Pat. No. 5,468,762.
This invention relates to novel azolidines of Formula I below which have demonstrated oral antihyperglycemic activity in diabetic db/db and ob/ob mice, animal models of non-insulin dependent diabetes mellitus (NIDDM or Type II diabetes). The Formula I compounds or pharmaceutical compositions thereof are therefore useful in treating hyperglycemia in mammals having non-insulin dependent diabetes mellitus.
BACKGROUND OF THE INVENTION
Diabetes mellitus is a syndrome characterized by abnormal insulin production, increased urinary output and elevated blood glucose levels. There are two major subclasses of diabetes mellitus. One is the insulin-dependent diabetes mellitus (IDDM or Type I), formerly referred to as juvenile onset diabetes since it was evident early in life, and non-insulin dependent diabetes mellitus (NIDDM or Type II), often referred to as maturity-onset diabetes. Exogenous insulin by injection is used clinically to control diabetes but suffers from several drawbacks. Insulin is a protein and thus cannot be taken orally due to digestion and degradation but must be injected. It is not always possible to attain good control of blood sugar levels by insulin administration. Insulin resistance sometimes occurs requiring much higher doses of insulin than normal. Another shortcoming of insulin is that while it may control hormonal abnormalities, it does not always prevent the occurrence of complications such as neuropathy, retinopathy, glomerulosclerosis, or cardiovascular disorders.
Orally effective antihyperglycemic agents are used to reduce blood glucose levels and to reduce damage to the nervous, retinal, renal or vascular systems through mechanisms affecting glucose metabolism. Such agents act in a variety of different mechanisms including inhibition of fatty acid oxidation, α-glycosidase inhibition, antagonism of α 2 -receptors and inhibition of gluconeogenesis. Two classes of compounds have predominated: the biguanides as represented by phenformin and the sulfonylureas as represented by tolbutamide (Orinase®). A third class of compounds which has shown antihyperglycemic activity are thiazolidinediones of which ciglitazone is the prototype. Ciglitazone suppresses the symptoms of diabetes--hyperglycemia, hypertriglyceridemia and hyperinsulinemia [Diabetes 32, 804-10 (1983)]. ##STR5##
Still another class of antihyperglycemic agents are the N-arylalkyl-N-hydroxy ureas and the 2-(arylalkyl)-[1,2,4]oxadiazolidine-3,5-diones. The published PCT patent application WO 92/03425 discloses compounds of the formula: ##STR6## where R 1 and R 2 are independently H, C 1 -C 9 alkyl, C 3 -C 7 cycloalkyl, phenyl, etc. or R 1 and R 2 together are carbonyl, which have utility as hypoglycemic or hypocholesteremic agents.
The hypoglycemic properties of these compounds in ob/ob mice are discussed by Goldstein et al. J. Med. Chem. 36, 2238-2240 (1993).
SUMMARY OF THE INVENTION
The novel compounds useful in the treatment of hyperglycemia are represented by the following formula: ##STR7## wherein: R 1 is C 1 -C 6 alkyl, C 3 -C 8 cycloalkyl, thienyl, furyl, pyridyl, ##STR8## where R 10 is hydrogen, C 1 -C 6 alkyl, fluorine, chlorine, bromine, iodine, C 1 -C 6 alkyoxy, trifluoroalkyl or trifluoroalkoxy;
R 2 is hydrogen or C 1 -C 6 alkyl;
X is O or S;
n is 1 or 2;
A is ##STR9## where R 3 is hydrogen, C 1 -C 6 alkyl, halogen, C 1 -C 6 alkoxy, trifluoroalkyl or trifluoroalkoxy;
B is ##STR10## where R 4 is hydrogen, C 1 -C 6 alkyl, allyl, C 6 -C 10 aryl, C 6 -C 10 aryl-(CH 2 ) 1-6 --, fluorine, chlorine, bromine, iodine, trimethylsilyl or C 3 -C 8 cycloalkyl;
R 5 is hydrogen, C 1 -C 6 alkyl, C 6 -C 10 aryl, or C 6 -C 10 aryl-(CH 2 ) 1-6 --;
m is 0, 1, or 2;
R 6 is hydrogen or C 1 -C 6 alkyl;
R 7 is hydrogen or C 1 -C 6 alkyl;
R 8 and R 9 are selected independently from hydrogen, C 1 -C 6 alkyl, fluorine, chlorine, bromine, or iodine;
Y is S;
Z is N or CH;
or a pharmaceutically acceptable salt thereof.
The term C 1 -C 6 alkyl means a alkyl group consisting of from one to six carbon atoms which may be a straight or branched chain. The term C 1 -C 6 alkoxy means an O--C 1 -C 6 alkyl group where the C 1 -C 6 group is as defined above. The term C 6 -C 10 aryl means phenyl, 1-naphthyl or 2-naphthyl and may be optionally substituted by one to three substituents as listed above according to commercial availability or synthetic means. The term trifluoroalkyl means a group having the formula CF 3 --(CH 2 ) 0-2 -- and the term trifluoroalkoxy is an O-trifluoroalkyl group where trifluoroalkyl is as defined above.
Compounds of Formula I may be transformed into or isolated as pharmaceutically acceptable salts of alkali metals or alkaline earth metals, such as a sodium, potassium, lithium or calcium salt. It will also be recognized by those skilled in the art that the active compound or salt thereof may be isolated as a solvate or hydrate which is considered to have the pharmacological properties of the active compound.
The preferred compounds are those of Formula Ia below ##STR11## where: R 10 is hydrogen, C 1 -C 6 alkyl, fluorine, chlorine, bromine, iodine, C 1 -C 6 alkoxy, trifluoroalkyl or trifluoroalkoxy;
n is 1 or 2;
A is ##STR12## B is ##STR13## where m is 0, 1 or 2; R 4 , R 5 , R 6 , and R 7 are independently hydrogen or C 1 -C 6 alkyl;
Y is S;
Z is N or CH;
or a pharmaceutically acceptable salt thereof.
The most preferred compounds of this invention are those of Formula Ib ##STR14## wherein: R 10 is hydrogen, CF 3 --, CF 3 O--, CF 3 CH 2 O-- or Cl--;
n is 1 or 2;
A is ##STR15## B is ##STR16## wherein m is 0 or 1; R 4 , R 5 , R 6 , and R 7 are independently hydrogen, methyl or ethyl;
Y is S;
Z is N or CH;
or a pharmaceutically acceptable salt thereof.
The most preferred compounds of the invention are the following:
(E)-2-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione,
(Z)-2-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione,
2-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethyl]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-(3-{3-[5-methyl-2-(4-trifluoromethoxy-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-(3-{3-[5-methyl-2-(4-trifluoro-ethoxy-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-{3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-but-2-enyl}-[1,2,4]oxadiazolidine-3,5-dione,
(Z)-2-{3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy]-phenyl]-but-2-enyl}-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-{3-[3-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione,
2-{3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy]-benzofuran-5-yl]-but-2-enyl}-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-(2-methyl-3-{4-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-(2-ethyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-(1-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-(3-{3-[2-(4-chloro-phenyl)-5-methyl-oxazol-4-ylmethoxy]-phenyl}-1-methyl-allyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-(2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione,
(Z)-2-(2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-(1-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione,
2-[3-(4-{4-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-(2-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-cyclopropylmethyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E)-2-(2-methyl-2-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-cyclopropylmethyl)-[1,2,4]oxadiazolidine-3,5-dione,
(E,E)-2-{5-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy]-phenyl}-hexa-2,4-dienyl)-[1,2,4]oxadiazolidine-3,5-dione,
(Z,E)-2-{5-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy]-phenyl}-hexa-2,4-dienyl)-[1,2,4]oxadiazolidine-3,5-dione,
2-[3-(4-{2-[5-methyl-2-(4-trifluoromethyl-phenyl-oxazol-4-yl]-ethoxy}-phenyl)-propyl-2-ynyl)-[1,2,4]oxadiazolidine-3,5-dione,
2-{1-methyl-3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-propyl-2-ynyl}-[1,2,4]oxadiazolidine-3,5-dione,
(E)-5-{3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethyl]-phenyl]-but-2-enyl}-oxazolidine-2,4-dione,
(E)-5-[3-(3-{5-methyl-2-[4-(2,2,2,-trifluoro-ethoxy)-phenyl]-oxazol-4-ylmethoxy}-phenyl)-but-2-enyl]-oxazolidine-2,4-dione,
(E)-5-(3-{3-[5-methyl-2-(trifluoromethoxy-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-oxazolidine-2,4-dione,
(E)-5-(3-{3-[2-(5-methyl-2-phenyl)-oxazol-4-yl)-ethoxy]-phenyl}-but-2-enyl)-oxazolidine-2,4-dione,(E)-5-{3-[3-(5-methyl-2-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-thiazolidine-2,4-dione,
(E)-5-(3-{3-[5-methyl-2-(4-trifluoromethoxy-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-thiazolidine-2,4-dione, and
(E)-2-(3-{3-[5-methyl-2-(4-trifluoromethoxy-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]thiadiazolidine-3,5-dione.
DETAILED DESCRIPTION OF THE INVENTION
The invention compounds of Formula I may be prepared from intermediates of the formula II below wherein the variables n, R 1 , R 2 , X, A and B are as previously defined. ##STR17## Oxadiazolidinediones of Formula I are prepared from a Formula II intermediate by first convening to a hydroxylamine followed by reaction with N-(chlorocarbonyl)isocyanate or by converting the Formula II alcohol to a N-hydroxyurea which is reacted with methyl chloroformate to give a Formula I oxadiazolidinedione. The Formula I oxazolidinediones and thiazolidinediones are prepared by converting the intermediate of Formula II to the halide of Formula III below followed by reaction with 2,4-oxazolidinedione or 2,4-thiazolidinedione. ##STR18## These synthetic transformations are more fully described in the following reaction schemes I-XII.
Scheme I outlines the synthesis of a Formula II intermediate where A is phenyl and B is an olefinic linking group as shown under Formula I. ##STR19## The terms R 1 -R 5 , X, n, and m are as defined previously.
Scheme II illustrates the synthetic sequence for preparing a Formula I compound from the intermediate VIII. ##STR20## The terms R 1 -R 5 , X, n, and m are as defined previously.
When R 4 is halogen the compounds of the present invention can be prepared according to Scheme III. ##STR21## wherein R 1 , R 2 , R 3 , X, and n are as defined above; R 4 is halogen.
When R 6 is alkyl the compounds of the present invention can be prepared according to Scheme IV ##STR22## wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , X, n and m are as defined above.
Scheme V outlines the synthesis of an intermediate where B is cyclopropylmethyl from an intermediate of Formula VIII where m is 0. ##STR23## wherein R 1 , R 2 , R 3 , X, and n are as defined above; R 4 is hydrogen, alkyl, aryl, aralkyl, cycloalkyl.
Scheme VI outlines the synthesis of a Formula II intermediate where B is propynyl. ##STR24## wherein R 1 , R 2 , R 3 , R 6 , X, and n are as defined above.
Scheme VII outlines the reactions used to prepare Formula I compounds where Z is CH and Y is O or S from an intermediate of Formula VIII. ##STR25## wherein R 1 , R 2 , R 3 , R 5 , R 6 , X, n and m are as defined above; R 4 is hydrogen, alkyl, allyl, aryl, aralkyl, trimethylsilyl, cycloalkyl; Y is O or S.
The Formula I thiadiazolidindiones where Y is S and Z is N are prepared as outlined in Scheme VIIa. ##STR26##
Preparation of a Formula I compound where A is benzofuran-2,5-diyl, Y is O and Z is N is shown in Scheme VIII. ##STR27## wherein R 1 , R 2 , R 5 , x and m are as defined above; R 4 is hydrogen, alkyl, allyl, aryl, aralkyl, trimethylsilyl, cycloalkyl.
The starting heterocyclic intermediates of the formula V can be prepared according to standard literature procedures. For example, 4-(1'-hydroxyethyl)-5-R 2 -2-phenyloxazoles and thiazoles where R 2 is hydrogen or C 1 -C 6 alkyl can be prepared according to Scheme IX (European Patent EP 0177353A2). ##STR28##
The starting heterocyclic intermediates of the formula IV can be prepared by known methods conventional in the art (Heterocyclic Compounds 34, 1979 and Heterocyclic Compounds 45, 1986). The 2-phenyl-4-chloromethyl-5-methyloxazoles can be prepared according to the reaction sequence shown in Scheme X. ##STR29##
The intermediate 4-chloromethyl-2-phenyloxazoles or thiazoles can be prepared according to the reaction shown in Scheme XI. ##STR30##
Intermediate of the formula VII can be prepared either from the commercially available phenols of formula IX or according to the synthetic Scheme XII. ##STR31## The formula I thiadiazolidines are prepared according to the following representative scheme.
The following examples are included for illustrative purposes and are not intended to limit the disclosure of this invention in any way. The reagents, intermediates, or chemicals used herein are either commercially available or can be readily synthesized using standard laboratory procedures known to those skilled in the art.
Example 1
(E)-2-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
Step a) 3-[5-methyl-2-(-4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy)-benzaldehyde
A mixture of 4-chloromethyl-5-methyl-2-(4-trifluoromethyl-phenyl)-oxazole (5.25 g, 19.1 mmol), 3-hydroxylbenzaldehyde (2.33 g, 19.1 mmol), potassium carbonate (3.77 g, 27.3 mmol) and dimethylformamide (50 mL) was stirred at 80° C. for 3 hours. The mixture was then poured into H 2 O, acidified with HCl (2N) and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and crystallization from ethyl ether/hexane, gave a yellow solid (4.47 g, 65% yield, m.p. 104°-105° C.).
Analysis for: C 19 H 14 F 3 NO 3 Calc'd: C, 63.16; H, 3.91; N, 3.88 Found: C, 62.84; H, 3.97; N, 3.87
Step b) l-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-propan-1-one
Ethylmagnesium bromide (11.1 mL, 33.24 mmol) was added dropwise in to a cold (0° C.) solution of 3-[5-methyl-2-(-4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy)-benzaldehyde (12.0 g, 33.24 mmol) and THF (50 mL). After stirring for 30 minutes the reaction mixture was quenched with aqueous NH 4 Cl, poured into water, acidified with HCl (2N) and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation gave a yellowish oil (13.0 g), which was dissolved in acetone (200 mL). The mixture was cooled to 5° C. and freshly prepared Jones' Reagent (40 mL) was added dropwise. After the addition, the mixture was stirred for 30 minutes, poured into water and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and crystallization from ethyl ether/hexane (after cooling to 0° C.), gave a white solid (9.6 g, 74% yield, m.p. 73°-74° C.).
Analysis for: C 38 H 36 N 2 O 9 Calc'd: C, 64.78; H, 4.66; N, 3.60 Found: C, 64.63; H, 4.60; N, 3.91
Step c) (E)-3-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enoic acid ethyl ester
Triethylphosphonoacetate (8.67 ml, 43.1 mmol) was added dropwise in to a cold (0° C.) suspension of sodium hydride (1.24 g, 41.5 mmol) and toluene (200 ml). After the addition, the mixture was stirred for 1 hour, and then 1-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-propan-1-one (8.5 g, 21.85 mmol) in THF (20 ml) was added dropwise. The reaction mixture was stirred at room temperature for 24 hours, poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 8/1) gave the trans-isomer (white solid, 5.5 g, 55% yield, m.p. 85°-86° C.), and the cis-isomer (clear oil, 2.8 g 28% yield).
a) Analysis for: C 25 H 24 F 3 NO 4 (trans-isomer) Calc'd: C, 65.35; H, 5.27; N, 3.05 Found: C, 65.25; H, 5.42; N, 3.01
b) Analysis for: C 25 H 24 F 3 NO 4 (cis-isomer) Calc'd: C, 65.35; H, 5.27; N, 3.05 Found: C, 65.11; H, 5.31; N, 3.00
Step d) (E)-3-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-en-1-ol
Di-isobutyl aluminum hydride (1.0M in THF, 25.05 ml, 25.05 mmol) was added dropwise in to a cold (-50° C.) solution of (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enoic acid ethyl ester (4.6 g, 10 mmol) in THF (100 ml) and ethyl ether (100 mL). The reaction was warmed to 0° C. and stirred for 1 hour. The reaction mixture was quenched with acetone (dropwise addition), methanol, poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 3/1), gave a clear oil (3.8 g, 91% yield).
Analysis for: C 23 H 22 F 3 NO 3 Calc'd: C, 66.18; H, 5.31; N, 3.36 Found: C, 65.88; H, 5.41; N, 3.26
Step e) (E)-N-tert-Butoxycarbonyloxy-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-carbamic acid tert-butyl ester
Diisopropylazodicarboxylate (1.98 ml, 10.07 mmol) in THF (15 ml) was added dropwise n to a cold (-20° C.) solution of (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-en-1-ol (3.5 g, 8.39 mmol) in THF (30 ml), triphenylphosphine (2.64 g, 10.07 mmol) and tert-butyl N-(tert-butoxy-carbonyloxy) carbamate (2.35 g, 10.07 mmol). After the addition, the mixture was stirred for 1 hour, poured into water, and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 7/1) gave a clear oil (5.1 g, 96% yield).
Analysis for: C 33 H 39 F 3 N 2 O 7 ×0.5 H 2 O Calc'd: C, 61.77; H, 6.24; N, 4.37 Found: C, 61.58; H, 6.46; N, 4.60
Step f) (E)-N-(3-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-hydroxylamine
A mixture of (E)-N-tert-butoxycarbonyloxy-3-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pentyl-2-enyl)-carbamic acid tert-butyl ester (5.0 g, 7.9 mmol), CH 2 Cl 2 (100 ml), and trifluoroacetic acid (10 ml) was stirred at room temperature for 8 h. The volatiles were removed in vacuo, and the residue taken in ethylether/water. It was basified to pH=9-10 with NaOH (2N), and the organic layer separated and washed with water and brine. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 1/1, and MeOH/EtOAc 1/10), gave a clear oil (3.0 g, 88% yield).
Analysis for: C 23 H 23 F 3 N 2 O 3 Calc'd: C, 63.88; H, 5.36; N, 6.48 Found: C, 63.63; H, 5.27; N, 6.48
Step g) (E)-2-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
N-(Chlorocarbonyl)isocyanate (0.37 ml, 4.63 mmol) was added dropwise to a cold (-5° C.) mixture of (E)-N-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-hydroxylamine (2.0 g, 4.63 mmol) in THF (20 ml). The mixture was stirred for 30 minutes, then poured into HCl (1N) and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on acid washed (5% H 3 PO 4 /MeOH) silica gel (hexane/EtOAc 3/1) gave a white solid (1.48 g, 64% yield, mp 66°-67° C.).
Analysis for: C 25 H 22 F 3 N 3 O 5 Calc'd: C, 59.88; H, 4.42; N, 8.38 Found: C, 59.83; H, 4.37; N, 8.28
Example 2
(E)-2-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
Step a) (Z)-3-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-en-1-ol
Di-isobutyl aluminum hydride (1.0M in THF, 10.89 ml, 10.89 mmol) was added dropwise in to a cold (-50° C.) solution of (Z)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enoic acid ethyl ester (2.0 g, 4.35 mmol) in THF (30 ml) and ethyl ether (30 mL). The reaction was warmed to 0° C. and stirred for 1 hour. The reaction mixture was quenched with acetone (dropwise addition), methanol, poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 3/1), gave a white solid (1.65 g, 91% yield, m.p. 88°-89° C.).
Analysis for: C 23 H 22 F 3 NO 3 Calc'd: C, 66.18; H, 5.31; N, 3.36 Found: C, 65.85; H, 5.12; N, 3.15
Step b) (Z)-N-(3-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-hydroxylamine
Diisopropylazodicarboxylate (0.68 ml, 3.45 mmol) in THF (10 ml) was added dropwise n to a cold (-20° C.) solution of (Z)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-en-1-ol (1.2 g, 2.87 mmol), THF (20 ml), triphenylphosphine (0.9 g, 3.45 mmol) and tert-butyl N-(tert-butoxy-carbonyloxy) carbamate (0.8 g, 3.45 mmol). After the addition, the mixture was stirred for 1 hour, poured into water, and extracted with EtOAc. Evaporation gave a yellowish oil (1.7 g), which was dissolved in CH 2 Cl 2 (30 mL), and treated with trifluoroacetic acid (3.0 mL). After stirring at room temperature for 8 hours, the volatiles were removed in vacuo, and the residue taken in ethylether/water. It was basified to pH=9-10 with NaOH (2N), and the organic layer separated and washed with water and brine. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 1/1, and MeOH/EtOAc 1/10), gave a white solid (3.0 g, 82% yield, m.p. 72°-73° C.).
Analysis for: C 23 H 23 F 3 N 2 O 3 Calc'd: C, 63.88; H, 5.36; N, 6.48 Found: C, 63.74; H, 5.34; N, 6.26
Step c) (Z)-2-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
N-(Chlorocarbonyl)isocyanate (0.12 ml, 1.5 mmol) was added dropwise to a cold (-5° C.) mixture of (Z)-N-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-2-enyl)-hydroxylamine (0.65 g, 1.5 mmol) in THF (10 ml). The mixture was stirred for 30 minutes, then poured into HCl (1N) and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on acid washed (5% H 3 PO 4 /MeOH) silica gel (hexane/EtOAc 2/1) gave a white solid (0.48 g, 64% yield, mp 126°-127° C.).
Analysis for: C 25 H 22 F 3 N 3 O 5 Calc'd: C, 59.88; H, 4.42; N, 8.38 Found: C, 60.03; H, 4.55; N, 8.03
Example 3
(E)-2-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethyl]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
Step a) 4,5-Dimethyl-2-(4-trifluoromethyl-phenyl)-oxazole N-oxide hydrochloride
HCl gas (21.2 g, 58.1 mmol) was bubbled via syringe into a 0° C. solution of 4-trifluoromethylbenzaldehyde (50 g, 28.7 mmol), 2,3-butanedione monoxime (26.40 g, 26.1 mmol), and EtOAc (105 ml). The reaction was stirred at 5° C. for 3 h. Ice cold ether (575 ml) was then added, and the resultant precipitate was filtered, washed with ether, and dried at 25° C. for 16 h to give the product as a white solid (54.79 g, 71% yield, mp 149°-159° C.).
Analysis for: C 12 H 11 ClF 3 NO 2 Calc'd: C, 49.08; H, 3.77; N, 4.77 Found: C, 49.48; H, 3.81; N, 4.88
Step b) 4-Chloromethyl-5-methyl-2-(4-trifluoromethyl-phenyl)-oxazole
In to a 5° C. solution of 4,5-dimethyl-2-(4-trifluoromethyl-phenyl)-oxazole N-oxide hydrochloride (113.71 g, 387.5 mmol) in CHCl 3 (560 ml), was added phosphorus oxychloride (39.4 ml, 422.4 mmol) in CHCl 3 , dropwise over 15 min. The reaction was refluxed for 2.5 h, then cooled to 5° C., poured into ice water, and basified with NaOH (1N). The organic layer was dried over MgSO 4 . Evaporation and recrystallization from ether/hexane, gave a yellow solid (30.0 g, 28% yield, mp 84°-85° C.).
Analysis for: C 12 H 9 ClF 3 NO Calc'd: C, 52.29; H, 3.29; N, 5.08 Found: C, 52.54; H, 3.20; N, 4.92
Step c) 1-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-ethanone
A mixture of 4-chloromethyl-5-methyl-2-(4-trifluoromethyl-phenyl)-oxazole (24.3 g, 88.2 mmol), 3-hydroxyacetophenone (10.0 g, 73.5 mmol), and potassium carbonate (13.2 g, 95.6 mmol), was stirred at 70° C. for 16 h. The reaction was poured into water, acidified with HCl (1N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 9/1), gave an off-white solid (20.14 g, 60% yield, mp 90°-91° C.).
Analysis for: C 20 H 16 F 3 NO 3 Calc'd: C, 63.99; H, 4.29; N, 3.73 Found: C, 63.86; H, 4.30; N, 3.64
Step d) (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enoic acid ethyl ester
In to a 0° C. mixture of sodium hydride (4.27 g, 142.6 mmol) and toluene (500 ml), was added triethylphosphonoacetate (29.79 ml, 150.1 mmol) via syringe. The reaction was stirred for 1 hour, and then 1-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-ethanone (28.15 g, 75.1 mmol) in THF (150 ml) was added dropwise. The reaction mixture was stirred at room temperature for 16 h, poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 20/1) gave a white solid (24.42 g, 73% yield, mp 91°-92° C.).
Analysis for: C 24 H 23 F 3 NO 4 Calc'd: C, 64.57; H, 5.19; N, 3.14 Found: C, 64.81; H, 5.01; N, 3.13
Step e) (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-en-1-ol
Di-isobutyl aluminum hydride (1.0M in THF) (219.2 ml, 219.2 mmol) was added, by syringe, to a -25° C. solution of 3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enoic acid ethyl ester (24.42 g, 54.8 mmol) in THF (300 ml). The reaction was warmed to 0° C. and stirred for 1.5 h. It was poured into ice water, acidified with HCl (2N), stirred for 45 min, then extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 3/1), gave a light yellow solid (17.68 g, 82% yield, mp 145°-146° C.).
Analysis for: C 22 H 18 F 3 NO 3 Calc'd: C, 65.83; H, 4.52; N, 3.49 Found: C, 65.78; H, 4.53; N, 3.45
Step f) (E)-N-tert-Butoxycarbonyloxy-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-carbamic acid tert-butyl ester
In to a -20° C. solution of 3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-en-1-ol (3.1 g, 7.69 mmol) in THF (50 ml), was added triphenylphosphine (2.42 g, 9.23 mmol) and tert-butyl N-(tert-butoxy-carbonyloxy) carbamate (2.15 g, 9.23 mmol). Diethylazodicarboxylate (1.45 ml, 9.23 mmol) in THF (10 ml) was then added via syringe, and the reaction was stirred for 1 h at 0° C. The reaction was poured into water, and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 6/1) gave a light yellow oil (4.69 g, 98% yield).
Analysis for: C 32 H 37 F 3 N 2 O 7 Calc'd: C, 62.13; H, 6.03; N, 4.53 Found: C, 62.17; H, 6.12; N, 4.67
Step g) (E)-N-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]phenyl}-but-2-enyl)-hydroxylamine
Trifluoroacetic acid (20 ml) was added in to a solution of (E)-N-tert-butoxycarbonyloxy-3-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-carbamic acid tert-butyl ester (4.5 g, 7.28 mmol) and CH 2 Cl 2 (40 ml). The reaction mixture was stirred at room temperature for 8 h. The volatiles were removed in vacuo, and the residue taken in ether/water. It was basified to pH=9-10 with NaOH (2N), and the organic layer separated and washed with water and brine. The organic layer was dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 1/1 and MeOH/EtOAc 1/10), gave a clear oil (2.70 g, 88% yield).
Analysis for: C 22 H 21 F 3 N 2 O 3 Calc'd: C, 63.15; H, 5.06; N, 6.70 Found: C, 63.34; H, 4.79; N, 6.53
Step h) (E)-2-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethyl]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
N-(Chlorocarbonyl)isocyanate (0.548 ml, 6.22 mmol) was added dropwise to a -5° C. mixture of N-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-hydroxylamine (2.6 g, 6.22 mmol) in THF (25 ml). The mixture was stirred for 30 min, then poured into HCl (1N) and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on acid washed (5% H 3 PO 4 /MeOH) silica gel (hexane/EtOAc 3/1), gave a white solid (1.85 g, 61% yield, mp 136°-138° C.).
Analysis for: C 24 H 20 F 3 N 3 O 5 Calc'd: C, 59.14; H, 4.13; N, 8.62 Found: C, 58.95; H, 3.92; N, 8.77
Example 4
(E)-2-(3-{3-[5-methyl-2-(4-trifluoromethoxy-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 3, and was obtained as a white solid, mp 145°-146° C.
Analysis for: C 24 H 20 F 3 N 3 O 6 Calc'd: C, 57.26; H, 4.00; N, 8.35 Found: C, 57.26; H, 3.94; N, 8.22
Example 5
(E)-2-[3-(3-{5-methyl-2-[4-(2,2,2-trifluoro-ethoxy)-phenyl]-oxazol-4-ylmethoxy}-phenyl)-but-2-enyl]-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 3, and was obtained as a white solid, mp 145°-146° C.
Analysis for: C 25 H 22 F 3 N 3 O 6 Calc'd: C, 58.03; H, 4.29; N, 8.12 Found: C, 58.05; H, 3.28; N, 8.30
Example 6
(E)-2-{3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-but-2-enyl}-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 3, and was obtained as a white solid, mp 131°-132° C.
Analysis for: C 23 H 21 N 3 O 5 Calc'd: C, 65.86; H, 5.05; N, 10.02 Found: C, 65.89; H, 5.10; N, 9.87
Example 7
(Z)-2-{3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy]-phenyl]-but-2-enyl}-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 3, and was obtained as a white solid, mp 118°-119° C.
Analysis for: C 23 H 21 N 3 O 5 Calc'd: C, 65.86; H, 5.05; N, 10.02 Found: C, 65.83; H, 5.18; N, 9.97
Example 8
(E)-2-(3-{3-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 2. The required 1-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-ethanone was prepared according to the following procedure. The title compound was obtained as a white solid, m.p. 142°-143° C.
Analysis for: C 24 H 23 N 3 O 5 Calc'd: C, 66.50; H, 5.35; N, 9.69 Found: C, 66.18; H, 5.41; N, 9.48
Preparation of 1-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-ethanone
Diethylazodicarboxylate (20.7 mL, 131.6 mmol) in THF (35 mL) was added dropwise in to a cold (0° C.) solution of 4-(2'-hydroxy-ethyl)-5-methyl-2-phenyloxazole (25.0 g, 123.0 mmol), triphenylphosphine (34.5 g, 131.6 mmol), and 3'-hydroxyacetophenone (18.0 g, 131.6 mmol) and THF (180 mL). The mixture was allowed to come to room temperature and stirred for 48 hours. Then, it was poured into H 2 O, acidified with HCl (2N) and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 5/1) gave a white solid (30.5 g, 77% yield, m.p. 70°-71° C.).
Analysis for: C 20 H 19 NO 3 Calc'd: C, 74.75; H, 5.96; N, 4.36 Found: C, 74.70; H, 6.15; N, 4.28
Example 9
(E)-2-{3-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl]-benzofuran-5-yl]-but-2-enyl}-[1,2,4]oxadiazolidine-3,5-dione
Step a) 1-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-yl]-ethanol
Methyl magnesium choride (4.2 ml, 12.62 mmol) was added in to a cold (0° C.) solution of 2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-carbaldehyde (prepared according to EP 0 428 312 A2, 4.0 g, 12.62 mmol) and THF (20 ml). The reaction was stirred at 0° C. for 20 min, and at room temperature for 30 min, then poured into water, acidified with HCl (2N) and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 2/1) gave a yellow solid (3.75 g, 88% yield, mp 103°-105° C.).
Analysis for: C 21 H 19 NO 3 Calc'd: C, 75.66; H, 5.74; N, 4.20 Found: C, 75.35; H, 5.80; N, 4.11
Step b) 1-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-yl]-ethanone
Freshly prepared Jones' Reagent (6.5 mL, 10.51 mmol) was added dropwise in to a cold (10° C.) solution of 1-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-yl]-ethanol (3.5 g, 10.51 mmol) and acetone (50 mL). After 30 min, the mixture was poured into water, and extracted with ethyl ether/EtOAc: 1/1. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 2/1), gave a yellow solid (3.4 g, 97% yield, mp 108°-109° C.).
Analysis for: C 21 H 17 NO 3 Calc'd: C, 76.12; H, 5.17; N, 4.23 Found: C, 76.38; H, 5.13; N, 4.09
Step c) (E)-3-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-yl]-but-2-enoic acid ethyl ester
The title compound was prepared in substantially the same manner as described in Example 3, step d, and was obtained as a white solid, m.p. 81°-83° C.
Analysis for: C 25 H 23 NO 4 Calc'd: C, 74.80; H, 5.77; N, 3.49 Found: C, 74.68; H, 5.75; N, 3.40
Step d) (E)-3-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-yl]-but-2-en-1-ol
The title compound was prepared in substantially the same manner as described in Example 3, step e, and was obtained as a white solid, m.p. 119°-121° C.
Analysis for: C 23 H 21 NO 3 Calc'd: C, 76.86; H, 5.89; N, 3.90 Found: C, 76.71; H, 5.87; N, 3.77
Step e) (E)-1-hydroxy-1-(3-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-yl]-but-2-enyl)-urea
Diethylazodicarboxylate (2.56 mL, 16.3 mmol) was added dropwise in to a cold (-20° C.) mixture of (E)-3-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-yl]-but-2-en-1-ol (4.5 g, 12.5 mmol), triphenylphosphine (4.27 g, 16.3 mmol), N,O-bis(carbophenoxy)hydroxylamine (4.45 g, 16.3 mmol) and THF (100 mL). After stirring for 30 minutes at -20° C., the mixture was allowed to come to 0° C. and stirred for 2 hours. Then, it was poured into H 2 O and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation gave a yellow oil (6.5), which was placed in a pressure vessel. Anhydrous ammonia (20 mL) was condensed in the vessel. The mixture was stirred at -5° C. to -10° C. for 3 hours and then at room temperature 18 hours. The excess ammonia was allowed to escape in to an acidic solution and the residue was recrystallized from ethyl ether/acetone, to give a white solid (2.5 g, 48% yield, m.p. 111°-113° C.).
Analysis for: C 24 H 23 N 3 O 4 Calc'd: C, 69.05; H, 5.55; N, 10.07 Found: C, 68.66; H, 5.36; N, 9.83
Step f) (E)-1-Methoxycarbonyloxy-1-(3-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-yl]-but-2-enyl)-urea
Sodium hydride (0.3 g, 10.0 mmol) was added portionwise in to a cold (0°) solution of (E)-1-hydroxy-1-(3-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-yl]-but-2-enyl)-urea (1.9 g, 4.55 mmol) and THF (20 mL). After stirring for 1 hour, methyl chloroformate (1.6 mL, 18.2 mmol) was added dropwise. The reaction mixture was stirred for 1 hour, poured in to dioxane (50 mL)/MaOH (2N, 5 mL) solution and after 10 minutes acidified with HCl (2N) and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 2/1), gave a yellow solid (1.72 g, 79% yield, m.p. 65°-67° C.).
Analysis for: C 26 H 25 N 3 O 6 Calc'd: C, 65.68; H, 5.30; N, 8.84 Found: C, 65.94; H, 5.06; N, 8.83
Step g) (E)-2-{3-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl]-benzofuran-5-yl]-but-2-enyl}-[1,2,4]oxadiazolidine-3,5-dione
Sodium hydride (76 mg, 2.52 mmol) was added portionwise in to a cold (0°) solution of E)-N-carbamoyl-N-methoxycarbonyloxy-3-[2-(5-methyl-2-phenyl-oxazol-4-ylmethyl)-benzofuran-5-yl]-but-2-enyl-amine (1.2 g, 2.52 mmol) and DMF (10 mL). The reaction mixture was stirred for 30 minutes and then poured into water (10 mL), acidified with HCl (2N) and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and crystallization from ethyl ether, gave a yellow solid (0.72 g, 65% yield, m.p. 163°-165).
Analysis for: C 25 H 21 N 3 O 5 Calc'd: C, 67.71; H, 4.77; N, 9.47 Found: C, 67.79; H, 4.56; N, 9.39
Example 10
(E)-2-(2-methyl-3-{4-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione
Step a) (E)-2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-acrylic acid ethyl ester
Triethyl 2-phosphonopropionate (2.64 ml, 11.08 mmol) was added dropwise in to a cold (0° C.) suspension of sodium hydride (0.31 g, 10.52 mmol) and toluene (50 ml). After the addition, the mixture was stirred for 1 hour, and then 3-[5-methyl-2-(-4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy)-benzaldehyde (2.0 g, 5.54 mmol) in THF (10 ml) was added dropwise. The reaction mixture was stirred at room temperature for 24 hours, poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 8/1) gave a clear oil (2.2 g, 89% yield).
Analysis for: C 24 H 22 F 3 NO 4 Calc'd: C, 64.71; H, 4.98; N, 3.14 Found: C, 64.82; H, 4.99; N, 2.93
Step b) (E)-2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-prop-2-en-1-ol
The title compound was prepared in substantially the same manner as described in Example 3, step e, and was obtained as a white solid, m.p. 90°-91° C.
Analysis for: C 22 H 20 F 3 NO 3 Calc'd: C, 65.50; H, 4.99; N, 3.47 Found: C, 65.40; H, 5.12; N, 3.33
Step c) (E)-2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-allyl)-hydroxylamine
The title compound was prepared in substantially the same manner as described in Example 2, step b, and was obtained as a yellow oil.
Analysis for: C 22 H 21 F 3 N 2 O 3 Calc'd: C, 63.15; H, 5.06; N, 6.69 Found.: C, 62.82; H, 4.99; N, 6.64
Step d) (E)-2-(2-methyl-3-{4-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 1, step h, and was obtained as a white solid, mp 144°-146° C.
Analysis for: C 24 H 20 F 3 N 3 O 5 Calc'd: C, 59.14; H, 4.13; N, 8.62 Found: C, 59.20; H, 3.95; N, 8.57
Example 11
(E)-2-(2-ethyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 10, and was obtained as a white solid, mp 124°-125° C.
Analysis for: C 25 H 22 F 3 N 3 O 5 Calc'd: C, 59.88; H, 4.42; N, 8.38 Found: C, 59.94; H, 4.40; N, 8.34
Example 12
2-(1-Methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione
Step a) 3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-benzaldehyde
The title compound was prepared in substantially the same manner as described in example 1, step a, and was obtained as a yellow solid, mp 104°-105° C.
Analysis for: C 19 H 14 F 3 NO 3 Calc'd: C, 63.16; H, 3.91; N, 3.88 Found: C, 62.84; H, 3.97; N, 3.87
Step b) (E)-4-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-3-en-2-one
A solution of sodium hydroxide (1.13 g, 28.25 mmol) in water (15 mL), was added to a mixture of 3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-benzaldehyde (6.0 g, 16.62 mmol) and acetone (100 mL). The reaction was stirred for 1 hour, and the excess acetone was removed in vacuo. The residue was acidified with HCl (1N), stirred for 10 min, then extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (EtOAc 4/1) gave a white solid (4.6 g, 69% yield, mp 84°-84° C.).
Analysis for: C 22 H 18 F 3 NO 3 Calc'd: C, 65.83; H, 4.52; N, 3.49 Found: C, 65.74; H, 4.41; N, 3.52
Step c) (E)-4-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-3-en-2-ol
Sodium borohydride (0.389 g, 10.22 mmol) was added to a -20° C. solution of (E)-4-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-3-en-2-one (4.1 g, 10.22 mmol), cerium trichloride (3.81 g, 10.22 mmol), methanol (150 mL), and THF (30 mL). The reaction was stirred for 30 min, then poured into water, acidified with HCl (2N), an extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 2/1), gave a white solid (3.7 g, 89% yield, mp 48°-50° C.).
Analysis for: C 22 H 20 F 3 NO 3 Calc'd: C, 65.50; H, 4.99; N, 3.47 Found: C, 65.78; H, 5.07; N, 3.58
Step d) (E)-N-(1-Methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-hydroxylamine
The title compound was prepared in substantially the same manner as described in Example 1, step b, and was obtained as a white solid, m.p. 118°-120° C.
Analysis for: C 22 H 21 F 3 N 2 O 3 Calc'd: C, 63.15; H, 5.06; N, 6.69 Found: C, 62.72; H, 5.04; N, 6.59
Step e) 2-(1-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 2, step c, and was obtained as a white solid, mp 119°-121° C.
Analysis for: C 24 H 20 F 3 N 3 O 5 Calc'd: C, 59.14; H, 4.13; N, 8.62 Found: C, 59.00; H, 3.96; N, 8.82
Example 13
(E)-2-(3-{3-[2-(4-chloro-phenyl)-5-methyl-oxazol-4-ylmethoxy]-phenyl}-1-methyl-allyl)-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 12, and was obtained as a white solid, mp 172°-174° C.
Analysis for: C 23 H 20 ClN 3 O 5 Calc'd: C, 60.86; H, 4.44; N, 9.26 Found: C, 60.92; H, 4.39; N, 9.17
Example 14
(E)-2-(2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
Step a) (E)-2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enoic acid ethyl ester,
(Z)-2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enoic acid ethyl ester
The title compounds was prepared in substantially the same manner as described in Example 1, step c, and were obtained as white solids.
(trans-) Analysis for: C 25 H 24 F 3 NO 4 Calc'd: C, 65.35; H, 5.26; N, 2.3.05 Found: C, 66.74; H, 5.39; N, 2.84
(cis-) Analysis for: C 25 H 24 F 3 NO 4 Calc'd: C, 65.45; H, 5.26; N, 3.05 Found: C, 65.45; H, 5.29; N, 2.80
Step b) (E)-2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-en-1-ol
The title compound was prepared in substantially the same manner as described in Example 2, step a, and was obtained as a white solid, m.p. 115°-116° C.
Analysis for: C 23 H 22 F 3 NO 3 Calc'd: C, 66.18; H, 5.31; N, 3.56 Found: C, 66.04; H, 5.32; N, 3.49
Step c) (E)-N-(2-Methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-hydroxylamine
The title compound was prepared in substantially the same manner as described in Example 2, step b, and was obtained as a white solid, m.p. 115°-116° C.
Analysis for: C 23 H 23 F 3 N 2 O 3 ×1 H 2 O Calc'd: C, 61.33; H, 5.55; N, 6.22 Found: C, 61.34; H, 5.57; N, 5.84
Step d) (E)-2-(2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 2, step c, and was obtained as a white solid, m.p. 152°-153° C.
Analysis for: C 25 H 22 F 3 N 3 O 5 Calc'd: C, 59.88; H, 4.42; N, 8.38 Found: C, 59.79; H, 4.33; N, 8.16
Example 15
(Z)-2-(2-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 13, and was obtained as a white solid, m.p. 144°-145° C.
Analysis for: C 25 H 22 F 3 N 3 O 5 Calc'd: C, 59.88; H, 4.42; N, 8.38 Found: C, 59.69; H, 4.45; N, 8.37
Example 16
(E)-2-(1-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl}-[1,2,4]oxadiazolidine-3,5-dione
Step a) (E)-3-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enal
In to a solution of (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-en-1-ol (21.48 g, 53.3 mmol) in CH 2 Cl 2 (500 ml), was added manganese dioxide (27.8 g, 319.8 mmol), and the reaction was stirred at room temperature for 60 h. The mixture was filtered through solka floc. Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 7/1), gave a light yellow solid (17.68 g, 82% yield, m.p. 145°-146° C.).
Analysis for: C 22 H 18 F 3 NO 3 Calc'd: C, 65.83; H, 4.52; N, 3.49 Found: C, 65.78; H, 4.53; N, 3.45
Step b) (E)-4-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-pent-3-en-2-ol
Methyl magnesium bromide (3.0M in ether) (13.9 ml, 41.4 mmol) was added to a 0° C. mixture of (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enal (16.68 g, 41.6 mmol) in THF (200 ml). The reaction was stirred at 0°-5° C. for 25 min, then poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 4/1), gave a yellow solid (5.85 g, 33% yield, m.p. 45°-47° C.).
Analysis for: C 23 H 22 F 3 NO 3 Calc'd: C, 66.18; H, 5.31; N, 3.36 Found: C, 65.97; H, 5.24; N, 3.34
Step c) (E)-N-(1-Methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2--enyl)-hydroxylamine
The title compound was prepared in substantially the same manner as described in Example 2, step b, and was obtained as a clear oil.
Analysis for: C 23 H 23 F 3 N 2 O 3 Calc'd: C, 63.88; H, 5.36; N, 6.48 Found: C, 63.48; H, 5.33; N, 5.08
Step d) (E)-2-(1-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl}-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 2, step c, and was obtained as a white solid (0.31 g, 27% yield, mp 55°-56° C.).
Analysis for: C 25 H 22 F 3 N 3 O 5 Calc'd: C, 59.88; H, 4.42; N, 8.38 Found: C, 60.14; H, 4.49; N, 8.32
Example 17
(E)-2-(3-{4-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione
Step a) (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-acrylic ethyl ester
Triethylphosphonoacetate (4.38 ml, 22.06 mmol) was added dropwise in to a cold (0° C.) suspension of sodium hydride (0.59 g, 19.74 mmol) and toluene (100 mL). After the addition, the mixture was stirred for 1 hour, and then 3-[5-methyl-2-(-4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy)-benzaldehyde (5.7 g, 15.79 mmol) in THF (20 ml) was added dropwise. The reaction mixture was stirred at room temperature for 1 hour, poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 5/1), gave a white solid (6.3 g, 93% yield, m.p. 79°-80° C.).
Analysis for: C 23 H 18 F 3 N 3 O 5 Calc'd: C, 64.03; H, 4.67; N, 3.25 Found: C, 64.25; H, 4.63; N, 3.16
Step b) (E)-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-prop-2-en-1-ol
The title compound was prepared in substantially the same manner as described in Example 1, step d, and was obtained as a white solid, m.p. 117°-118° C.
Analysis for: C 21 H 18 F 3 NO 3 Calc'd: C, 64.78; H, 4.66; N, 3.59 Found: C, 64.60; H, 4.54; N, 3.65
Step c) (E)-N-(3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]phenyl}-allyl)-hydroxylamine
The title compound was prepared in substantially the same manner as described in Example 2, step b, and was obtained as a white solid, m.p. 128°-130° C.
Analysis for: C 21 H 19 F 3 N 2 O 3 Calc'd: C, 62.37; H, 4.73; N, 6.93 Found: C, 62.17; H, 4.71; N, 6.79
Step d) (E)-2-(3-{4-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-allyl)-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 1, step g, and was obtained as a white solid, m.p. 179°-181° C.
Analysis for: C 23 H 18 F 3 N 3 O 5 Calc'd: C, 58.35; H, 3.83; N, 8.88 Found: C, 58.47; H, 3.70; N, 8.86
Example 18
(E)-2-(2-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-cyclopropylmethyl)-1,2,4]oxadiazolidine-3,5-dione
(E)-2-(2-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-cyclopropylmethyl)-[1,2,4]oxadiazolidine-3,5-dione
Step a) (E)-2-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-cyclopropyl)-methanol
Chloroiodomethane (3.37 mL, 46.28 mmol) was added dropwise in to a cold (0° C.) solution of diethyzinc (23.14 mL, 23.14 mmol) and dichloroethane (40 mL). After stirring for 10 minutes (E)-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-prop-2-en-1-ol (4.5 g, 11.57 mmol) in dichloromethane (10 mL) was added dropwise. The reaction mixture was stirred for 1 hour, quenched with aqueous NH 4 Cl and allowed to come to room temperature. After 15 minutes it was poured into water and extracted with ethyl ether. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 3/2), gave a clear oil (2.8 g, 80% yield).
Analysis for: C 22 H 20 F 3 NO 3 Calc'd: C, 65.50; H, 5.00; N, 3.47 Found: C, 65.36; H, 5.12; N, 3.43
Step b) (E)-N-(2-{3-[5-methyl-2-(trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-cyclopropylmethyl)-hydroxylamine
The title compound was prepared in substantially the same manner as described in Example 2, step b, and was obtained as a clear oil.
Analysis for: C 22 H 21 F 3 N 2 O 3 Calc'd: C, 63.15; H, 5.06; N, 6.69 Found: C, 62.90; H, 5.07; N, 6.66
Step c) (E)-2-(2-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-cyclopropylmethyl)-[1,2,4}oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 1, step g, and was obtained as a white solid, m.p. 126°-128° C.
Analysis for: C 24 H 20 F 3 N 3 O 5 Calc'd: C, 59.14; H, 4.14; N, 8.62 Found: C, 59.27; H, 3.99; N, 8.78
Example 19
(E)-2-(2-methyl-2-{3-[5-methyl-2-(4-trifluoromethoxy-phenyl)-oxazol-4-ylmethoxy]-phenyl}-cyclopropylmethyl)-[1,2,4}oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 17, and was obtained as a white solid, m.p. 42°-43° C.
Analysis for: C 25 H 22 F 3 N 3 O 6 Calc'd: C, 58.03; H, 4.28; N, 8.12 Found: C, 57.69; H, 4.32; N, 8.09
Example 20
(E,E)-2-{5-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-hexa-2,4-dienyl}-[1,2,4]oxadiazolidine-3,5-dione
Step a) (E,E)-5-(3-[5-Methyl-2--phenyl-oxazol-4-ylmethoxy]-phenyl)-hexa-2,4-dienoic acid ethyl ester
Lithium bis(trimethylsilyl)amide (45.12 mL, 45.12 mmol) was added dropwise in to a cold solution of triethyl 4-phosphonocrotonate (10.0 ml, 45.12 mmol) in THF (200 mL). After stirring for 1 hour, 1-(3-[5-methyl-2-phenyl-oxazol-4-ylmethoxy]-phenyl)-ethanone (12.0 g, 39.1 mmol) in THF (50 mL) was added dropwise. The reaction mixture was allowed to come to room temperature and stirred for 24 hours. Then, it was quenched with aqueous NH 4 Cl, poured into water, acidified with HCL (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 8/1), gave a yellow oil (9.6 g, inseparable mixture of cis- and trans-isomers).
Analysis for: C 25 H 25 NO 4 ×0.25 H 2 O Calc'd: C, 73.62; H, 6.26; N, 3.43 Found: C, 73.69; H, 5.86; N, 3.44
Step b) (E,E)-5-[3-(5-Methyl-2--phenyl-oxazol-4-ylmethoxy]-phenyl)-hexa-2,4-dien-1-ol
Di-isobutyl aluminum hydride (1.0M in THF, 55.83 ml, 55.83 mmol) was added dropwise in to a cold (-50° C.) solution of (E,E)-5-(3-[5-methyl-2--phenyl-oxazol-4-ylmethoxy]-phenyl)-hexa-2,4-dienoic acid ethyl ester (7.5 g, 18.61 mmol, mixture of cis- and trans-isomers), THF (100 ml) and ethyl ether (100 mL). The reaction was warmed to 0° C. and stirred for 1 hour. The reaction mixture was quenched with acetone (dropwise addition), methanol, poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 4/1), gave the trans- (4.9 g), and the cis- (1.7 g) isomers as yellow oils.
(trans-) Analysis for: C 23 H 23 NO 3 Calc'd: C, 76.43; H, 6.41; N, 3.88 Found: C, 76.25; H, 6.36; N, 4.03
(cis-) Analysis for: C 23 H 23 NO 3 Calc'd: C, 76.43; H, 6.41; N, 3.88 Found: C, 75.98; H, 6.21; N, 3.69
Step c) (E,E)-N-(5-[3-(5-Methyl-2--phenyl-oxazol-4-ylmethoxy]-phenyl)-hexa-2,4-dienyl)-hydroxylamine
The title compound was prepared in substantially the same manner as described in Example 2, step b, and was obtained as a light yellow oil.
Analysis for: C 23 H 24 N 2 O 3 Calc'd: C, 73.38; H, 6.43; N, 7.44 Found: C, 73.41; H, 6.45; N, 7.20
Step d) (E,E)-2-{5-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-hexa-2,4-dienyl}-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 2, step c, and was obtained as a white solid, m.p. 151°-152° C.
Analysis for: C 25 H 23 N 3 O 5 Calc'd: C, 67.40; H, 5.20; N, 9.43 Found: C, 67.70; H, 5.28; N, 9.35
Example 21
(Z,E)-2-{5-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-hexa-2,4-dienyl}-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 20, and was obtained as a white solid, m.p. 117°-118° C.
Analysis for: C 25 H 23 N 3 O 5 Calc'd: C, 67.40; H, 5.20; N, 9.43 Found: C, 67.32; H, 5.21; N, 9.32
Example 22
2-(1-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-prop-2-ynyl)-[1,2,4]oxadiazolidine-3,5-dione
Step a) 4-(3-Ethynyl-phenoxymethyl)-5-methyl-2-(4-trifluoromethyl-phenyl)-oxazole
(Bromomethyl)triphenylphosphonium bromide (21.2 g, 48.61 mmol) was added portionwise to a -78° C. mixture of potassium-tert-butoxide (10.9 g, 97.23 mmol) in THF (200 mL). The mixture was stirred for 2 h, then 3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-benzaldehyde (11.7 g, 32.41 mmol) in THF (50 mL) was added dropwise. The mixture was stirred for 1 hour at -78° C., then at room temperature for 2 days. The reaction mixture was quenched with aqueous NH 4 Cl, poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 8/1) gave a white solid (7.5 g, 67% yield, mp 62°-64° C.).
Analysis for: C 20 H 14 F 3 NO 2 ×0.25 H 2 O Calc'd: C, 66.39; H, 4.01; N, 3.87 Found: C, 66.67; H, 3.75; N, 4.15
Step b) 4-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-3-yn-2-ol
Lithium bis(trimethylsilyl)amide (10.5 mL, 10.5 mmol) was added to a cold (0° C.) solution of 4-(3-ethynyl-phenoxymethyl)-5-methyl-2-(4-trifluoromethyl-phenyl)-oxazole (3.0 g, 8.77 mmol) in THF (100 mL). After 1 h at 0° C., acetaldehyde (0.59 mL, 10.5 mmol) was added dropwise. The mixture was stirred for 30 min, then quenched with aqueous NH 4 Cl, poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel(hexane/EtOAc 4/1) gave a yellow solid (2.1 g, 59% yield, m.p. 86°-87° C.).
Analysis for: C 22 H 18 F 3 NO 3 Calc'd: C, 65.83; H, 4.52; N, 3.49 Found: C, 65.89; H, 4.38; N, 3.36
step c) N-(1-Methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-prop-2-ynyl)-hydroxylamine
The title compound was prepared in substantially the same manner as described in Example 2, step b, and was obtained as a light yellow solid, m.p. 110°-112° C.
Analysis for: C 22 H 19 F 3 N 2 O 3 Calc'd: C, 63.46; H, 4.60; N, 6.73 Found: C, 66.71; H, 4.56; N, 6.69
Step d) 2-(1-methyl-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-prop-2-ynyl)-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 1, step g, and was obtained as a white solid, m.p. 84°-86° C.
Analysis for: C 24 H 18 F 3 N 3 O 5 Calc'd: C, 59.38; H, 3.74; N, 8.66 Found: C, 59.38; H, 3.50; N, 8.56
Example 23
2-{1-methyl-3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-prop-2-ynyl}-[1,2,4]oxadiazolidine-3,5-dione
The title compound was prepared in substantially the same manner as described in Example 21, and was obtained as a white solid, m.p. 55°-57° C.
Analysis for: C 23 H 19 N 3 O 5 ×0.25 H 2 O Calc'd: C, 65.40; H, 4.01; N, 9.95 Found: C, 65.20; H, 4.36; N, 10.23
Example 24
(E)-5-{3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethyl]-phenyl]-but-2-enyl}-oxazolidine-2,4-dione
Step a) (E)-4-[3-(3-Chloro-1-methyl-propenyl)-phenoxymethyl]-5-methyl-2-phenyl-oxazole
3-[3-(5-Methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-but-2-en-1-ol (10.0 g, 29.85 mmol) in ether (50 mL) was added to a cold (0° C.) suspension of phosphorus oxychloride (9.31 g, 44.77 mmol), calcium carbonate (4.47 g, 44.77 mmol), and ether (300 mL). After 30 minutes, the reaction mixture was poured into water. The organic layer was separated, washed with water and brine. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 5/1) gave a clear oil (9.1 g, 86% yield).
Analysis for: C 21 H 20 ClNO 2 Calc'd: C, 71.28; H, 5.70; N, 3.96 Found: C, 71.42; H, 5.71; N, 3.88
Step b) (E)-5-{3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethyl]-phenyl]-but-2-enyl}-oxazolidine-2,4-dione
Tert-butyl lithium (17.5 mL, 29.7 mmol) was added dropwise in to a rapidly stirred cold (-78° C.) solution of lithium chloride (3.6 g, 84.84 mmol) and oxazolidine-2,4-dione (1.43 g, 14.14 mmol) in THF (90 mL). The mixture was stirred at -78° C. for 30 minutes, then gradually warmed to 0° C. After recooling to -78° C., (E)-4-[3-(3-chloro-1-methyl-propenyl)-phenoxymethyl]-5-methyl-2-phenyl-oxazole (5.0 g, 14.14 mmol) in THF (5 mL) was added all at once. After stirring for 10 minutes at -78° C., the mixture was gradually warmed to room temperature, and allowed to stir for 5 hours. Then, the reaction mixture was quenched with aqueous NH 4 Cl, poured into water, acidified with HCl, and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 3/1), gave a white solid (3.5 g, 59% yield, m.p. 138°-139° C.).
Analysis for: C 24 H 22 N 2 O 5 Calc'd: C, 68.89; H, 5.30; N, 6.69 Found: C, 68.49; H, 5.29; N, 6.71
Example 25
(E)-5-[3-(3-{5-methyl-2-[4-(2,2,2-trifluoro-ethoxy)-phenyl]-oxazol-4-ylmethoxy}-phenyl)-but-2-enyl]-oxazolidine-2,4-dione
The title compound was obtained in substantially the same manner as described in Example 24, and was obtained as a white solid, m.p. 120°-121° C.
Analysis for: C 26 H 23 F 3 N 2 O 6 Calc'd: C, 60.46; H, 4.49; N, 5.42 Found: C, 60.62; H, 4.47; N, 5.18
Example 26
(E)-5-(3-{3-[5-methyl-2-(4-trifluoromethoxy-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-oxazolidine-2,4-dione
The title compound was obtained in substantially the same manner as described in Example 24, and was obtained as a white solid, m.p. 105°-106° C.
Analysis for: C 25 H 21 F 3 N 2 O 6 Calc'd: C, 59.76; H, 4.21; N, 5.58 Found: C, 59.92; H, 4.12; N, 5.54
Example 27
(E)-5-(3-{3-[2-(5-methyl-2--phenyl-oxazol-4-yl)-ethoxy]-phenyl}-but-2-enyl)-oxazolidine-2,4-dione
The title compound was obtained in substantially the same manner as described in Example 24, and was obtained as a white solid, m.p. 100°-101° C.
Analysis for: C 25 H 24 N 2 O 5 Calc'd: C, 69.43; H, 5.59; N, 6.48 Found: C, 69.59; H, 5.89; N, 6.16
Example 28
(E)-5-{3-[3-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-but-2-enyl}-thiazolidine-2,4-dione
Butyl lithium (16.6 mL, 41.58 mmol) was added dropwise in to a cold (-78° C.) solution of thiazolidine-2,4-dione (2.31 g, 19.8 mmol) and THF (80 mL). The mixture was stirred at -78° C. for 15 minutes, then gradually warmed to 0° C., and stirred for 30 minutes to complete the dianion formation. After recooling to -78° C., 4-[3-(3-chloro-1-methyl-propenyl)-phenoxymethyl]-5-methyl-2-phenyl-oxazole (7.0 g, 19.8 mmol) in THF (15 mL) was added all at once. After stirring for 30 minutes at -78° C., the mixture was gradually warmed to room temperature, and allowed to stir for 2 hours. Then, the reaction mixture was quenched with aqueous NH 4 Cl, poured into water, acidified with HCl, and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on acid washed (5% H 3 PO 4 /MeOH) silica gel (hexane/EtOAc 3/1), gave a white solid (2.9 g, 33% yield, m.p. 48°-49° C.).
Analysis for: C 24 H 22 N 2 O 4 S×0.25 H 2 O Calc'd: C, 65.68; H, 5.13; N, 6.38 Found: C, 65.72; H, 5.19; N, 6.45
Example 29
(E)-5-(3-{3-[5-methyl-2-(4-trifluoromethoxy-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-thiazolidine-2,4-dione
The title compound was obtained in substantially the same manner as described in Example 27, and was obtained as a light yellow solid, m.p. 50°-51° C.
Analysis for: C 25 H 21 F 3 N 2 O 5 S Calc'd: C, 57.91; H, 4.08; N, 5.40 Found: C, 57.57; H, 4.16; N, 5.30
Example 30
(E)-2-(3-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]-thiadiazolidine-3,5-dione
Step a) 4,5-Dimethyl-2-(4-trifluoromethyl-phenyl)-oxazole N-oxide hydrochloride
HCl gas (21.2 g, 58.1 mmol) was bubbled via syringe into a 0° C. solution of 4-trifluoromethylbenzaldehyde (50 g, 28.7 mmol), 2,3-butanedione monoxime (26.40 g, 26.1 mmol), and EtOAc (105 ml). The reaction was stirred at 5° C. for 3 h. Ice cold ether (575 ml) was then added, and the resultant precipitate was filtered, washed with ether, and dried at 25° C. for 16 h to give the product as a white solid (54.79 g, 71% yield, mp 149°-159° C.).
Analysis for: C 12 H 11 ClF 3 NO 2 Calc'd: C, 49.08; H, 3.77; N, 4.77 Found: C, 49.48; H, 3.81; N, 4.88
Step b) 4-Chloromethyl-5-methyl-2-(4-trifluoromethyl-phenyl)-oxazole
In to a 5° C. solution of 4,5-dimethyl-2-(4-trifluoromethyl-phenyl)-oxazole N-oxide hydrochloride (113.71 g, 387.5 mmol) in CHCl 3 (560 ml), was added phosphorus oxychloride (39.4 ml, 422.4 mmol) in CHCl 3 , dropwise over 15 min. The reaction was refluxed for 2.5 h, then cooled to 5° C., poured into ice water, and basified with NaOH (1N). The organic layer was dried over MgSO 4 . Evaporation and recrystallization from ether/hexane, gave a yellow solid (30.0 g, 28% yield, mp 84°-85° C.).
Analysis for: C 12 H 9 ClF 3 NO Calc'd: C, 52.29; H, 3.29; N, 5.08 Found: C, 52.54; H, 3.20; N, 4.92
Step c) 1-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-ethanone
A mixture of 4-chloromethyl-5-methyl-2-(4-trifluoromethyl-phenyl)-oxazole (24.3 g, 88.2 mmol), 3-hydroxyacetophenone (10.0 g, 73.5 mmol), and potassium carbonate (13.2 g, 95.6 mmol), was stirred at 70° C. for 16 h. The reaction was poured into water, acidified with HCl (1N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 9/1), gave an off-white solid (20.14 g, 60% yield, mp 90°-91° C.).
Analysis for: C 20 H 16 F 3 NO 3 Calc'd: C, 63.99; H, 4.29; N, 3.73 Found: C, 63.86; H, 4.30; N, 3.64
Step d) (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enoic acid ethyl ester
In to a 0° C. mixture of sodium hydride (4.27 g, 142.6 mmol) and toluene (500 ml), was added triethylphosphonoacetate (29.79 ml, 150.1 mmol) via syringe. The reaction was stirred for 1 hour, and then 1-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-ethanone (28.15 g, 75.1 mmol) in THF (150 ml) was added dropwise. The reaction mixture was stirred at room temperature for 16 h, poured into water, acidified with HCl (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 20/1) gave a white solid (24.42 g, 73% yield, mp 91°-92° C.).
Analysis for: C 24 H 23 F 3 NO 4 Calc'd: C, 64.57; H, 5.19; N, 3.14 Found: C, 64.81; H, 5.01; N, 3.13
Step e) (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-en-1-ol
Di-isobutyl aluminum hydride (1.0M in THF) (219.2 ml, 219.2 mmol) was added, by syringe, to a -25° C. solution of 3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enoic acid ethyl ester (24.42 g, 54.8 mmol) in THF (300 ml). The reaction was warmed to 0° C. and stirred for 1.5 h. It was poured into ice water, acidified with HCl (2N), stirred for 45 min, then extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 3/1), gave a light yellow solid (17.68 g, 82% yield, mp 145°-146° C.).
Analysis for: C 22 H 18 F 3 NO 3 Calc'd: C, 65.83; H, 4.52; N, 3.49 Found: C, 65.78; H, 4.53; N, 3.45
Step f) (E)-4-[3-(3-Chloro-1-methyl-propenyl)-phenoxymethyl]-5-methyl-2-(4-trifluoromethyl-phenyl)-oxazole
(E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-en-1-ol (6.0 g, 14.9 mmol) in ether (50 mL) was added to a cold (0° C.) suspension of phosphorus oxychloride (4.4 g, 20.84 mmol), calcium carbonate (1.5 g, 14.9 mmol), and ether (50 mL). After 30 minutes, the reaction mixture was poured into water. The organic layer was separated, washed with water and brine. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (hexane/EtOAc 20/1) gave a clear oil (2.1 g, 35% yield).
Step g) (E)-3-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-ylmethoxy]phenyl}-but 2-enylamine
A mixture of (E)-4-[3-(3-Chloro-1-methyl-propenyl)-phenoxymethyl]-5-methyl-2-(4-trifluoromethyl-phenyl)-oxazole (5.0 g, 11.86 mmol), sodium azide (2.31 g, 35.6 mmol) and DMF (100 mL) was stirred at 80° C. for 18 hours. The reaction mixture was poured into water (200 mL), acidified to pH=3 with HCL (2N), and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation gave a brown oil (4.3 g), which was dissolved in THF (100 mL) and cooled to 0° C. Lithium aluminum hydride (5.5 mL, 1.0M, 5.5 mmol) was added dropwise over a 20 minutes period. The reaction mixture was quenched with EtOAc (20 mL) and NaOH (100 mL, 2.5N), and extracted with ethyl ether. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (eluting solvent EtOAc:MeOH 1:1) gave a yellow oil (2.0 g, 42% yield). MS (m/e): 402 (M+).
Step h) (E)-3-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-ylmethoxy]-phenyl}-but-2-enyl)-urea
Trimethylsilylisocyanate (1.35 mL. 9.95 mmol) was added dropwise to a solution of (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-ylmethoxy]-phenyl}-but-2-enylamine (2.0 g, 4.97 mmol) in dioxane (75 mL). The reaction mixture was stirred for 18 hours, and poured into mixture of water (100 mL) and saturated ammonium chloride (100 mL). The aqueous layer was extracted with EtOAc, and the organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on silica gel (eluting solvent EtOAc:EtOH 1:1) gave a white solid (1.2 g, 55% yield). MS (m/e): 445 (M+).
Analysis for: C 23 H 22 F 3 N 3 O 3 Calc'd: C, 62.02; H, 4.98; N, 9.43 Found: C, 61.25; H, 4.63; N, 9.28
Step i) (E)-2-(3-{3-[5-Methyl-2-(4-trifluoromethyl-phenyl)-oxazol-4-ylmethoxy]-phenyl}-but-2-enyl)-[1,2,4]-thiadiazolidine-3,5-dione
Chlorocarbonylsulfenyl chloride (0.54 mL, 6.4 mmol) was added dropwise into a mixture of (E)-3-{3-[5-methyl-2-(4-trifluoromethyl-phenyl)-oxazol-ylmethoxy]-phenyl}-but-2-enyl)-urea (2.2 g, 4.94 mmol) and toluene (40 mL). The reaction mixture was heated to 60° C. for 4 hours, poured into water, acidified with HCl (2N) and extracted with EtOAc. The organic extracts were dried over MgSO 4 . Evaporation and purification by flash chromatography on acidic silica gel (MeOH/H 3 PO 4 , eluting solvent EtOAc:hexane 1:3) gave an off-white solid (0.63 g, 25 5 yield; m.p. 60°-61° C.).
Analysis for: C 24 H 20 F 3 N 3 O 4 S Calc'd: C, 57.25; H, 4.00; N, 8.35 Found: C, 56.94; H, 3.97; N, 8.21
Pharmacology
Determination of Blood Glucose Lowering in db/db Mice
On the morning of Day 1, 35 mice [male diabetic db/db (C57BL/KsJ) mice (Jackson Laboratories), 2-7 months of age and 50-70 g] were fasted for 4 hours, weighed and a baseline blood sample (15-30 μl) was collected from the tail-tip of each mouse without anesthesia, and placed directly into a fluoride-containing tube, mixed and maintained on ice. Food was then returned to the mice. The plasma was separated and levels of glucose in plasma determined by the Abbott VP Analyzer. Because of the variable plasma glucose levels of the db/db mice, 5 mice having the most extreme (i.e., highest or lowest) plasma glucose levels were excluded and the remaining 30 mice were randomly assigned into 7 groups of equivalent mean plasma glucose levels (N=6 for vehicle and N=4 for each drug group). On the afternoon of Days 1, 2 and 3, the vehicle, control or test drugs were administered (p.o.) to the ad libitum fed mice. On the morning of Day 4, the mice were weighed and food removed, but water was available ad libitum. Three hours later, a blood sample was collected and then the mice were given the fourth administration of drug or vehicle. Blood samples were collected again from the unanesthetized mice at 2 and 4 hrs after drug administration. The plasma was separated and levels of glucose in plasma was determined by the Abbott VP Analyzer.
For each mouse, the percent change of its plasma glucose level on Day 4 (mean of the 2 and 4 hr samples) from respective level before drug administration (Day 1 baseline sample) is determined as follows: ##EQU1##
Analysis of variance followed by Dunnett's multiple comparison (one-sided) will be used to estimate the degree of statistical significance of the difference between the vehicle control group and the individual drug-treated groups. A drug will be considered active, at the specific dosage administered, if the difference of the plasma glucose level has a p<0.05. The actual difference between the mean percent change of the vehicle and drug-treated groups is shown in Table 1.
The positive control, ciglitazone produces a 18 to 34% decrease in plasma glucose levels at 100 mg/kg/day×4 days, p.o.
TABLE 1______________________________________ db/db dataCompound of Dose % ChangeExample No. mg/kg, p.o. glucose______________________________________1 100 -762 100 -783 100 -714 100 -455 100 -476 100 -337 100 -509 100 -4710 100 -4711 100 -3012 100 -5016 100 -2018 100 -3821 50 -3224 100 -2325 100 -49______________________________________ References: 1. Coleman, D. L. (1982) Diabetesobesity syndromes in mice. Diabetes 31 (Suppl. 1); 1-6. 2. Tutwiler, G. F., T. Kirsch, and G. Bridi (1978). A pharmacologic profile of McN3495 [N(1-methyl-2-pyrrolidinylidene)-Nphenyl-1-pyrrolidine-carboximidamide], new, orally effective hypoglycemic agent. Diabetes 27: 856-857. 3. Lee, S. M., G. Tutwiler, R. Bressler, and C. H. Kircher (1982). Metabolic control and prevention of nephropathy by 2tetradecylglycidate i the diabetic mouse (db/db). Diabetes 31: 12-18. 4. Chang, A. Y., B. W. Wyse, B. J. Gilchrist, T. Peterson, and R. Diani (1983) Ciglitazone, a new hypoglycemic agent. 1. Studies in ob/ob and db/db mice, diabetic Chinese hamsters, and normal and streptozocindiabeti rats. Diabetes 32: 830-838. 5. Hosokawa, T., K. Ando, and G. Tamura (1985). An ascochlorin derivative AS6, reduces insulin resistance in the genetically obese diabetic mouse, db/db. Diabetes 34: 267-274.
Determination of Blood Glucose Lowering Effect in ob/ob mice
The non-insulin-dependent diabetic syndrome can be typically characterized by obesity, hyperglycemia, abnormal insulin secretion, hyperinsulinemia and insulin resistance. The genetically obese-hyperglycemic ob/ob mouse exhibits many of these metabolic abnormalities and is thought to be a useful media to search for hypoglycemic agents to treat NIDDM (Coleman, 1978)
Male or female ob/ob mice (C57B1/6J), ages 2 to 5 months (10 to 65 g), of a similar age are randomized according to plasma glucose into 4 groups of 10 mice. The mice are housed 5 per cage and are maintained on normal rodent chow with water ad libitum. The mice receive test compound daily. The test compound is suspended in 0.5 mL of 0.5% methyl cellulose and is administered by gavage (dissolved in drinking water) or admixed in the diet. The dose of compound given ranges from 2.5 to 200 mg/kg/day. Body weight of fed animals is measured at the beginning of each week and doses for the entire week are calculated using this weight and are expressed in terms of the active moiety of the compound. Control mice receive vehicle only.
On the morning of Days 4, 7 or 14 two drops of blood (approximately 50 μl) are collected into sodium fluoride containing tubes either from the tail vein or after decapitation. For those studies in which the compound is administered daily by gavage, the blood samples are collected four hour after compound administration. The plasma is isolated by centrifugation and the concentration of glucose is measured enzymatically on an Abbott V. P. Analyzer and the plasma concentration of insulin is determined by radioimmunoassay (Heding, 1972). For each mouse, the percentage change in plasma glucose on Day 4, 7 or 14 is calculated relative to the mean plasma glucose of the vehicle treated mice. Analysis of variance followed by Dunnett's Comparison Test (one tailed) is used to estimate the significant difference between the plasma glucose values from the control group and the individual compound treated groups. The results are presented in Table II.
The diabetic db/db (C57BL/KsJ) mouse exhibits many metabolic abnormalities that are associated with non-insulin dependent diabetes mellitus (Type II) in humans. The animals are obese, glucose intolerant and have fasting hyperglycemia which is sometimes accompanied by a paradoxical hyperinsulinemia (1). Furthermore, the db/db mouse will eventually develop some of the long-term complications that have been associated with diabetes mellitus (1). In spite of these commonalities, the acute administration of sulfonylureas (even at extremely high doses) will not reduce the hyperglycemia of the db/db mouse (2). The ability of a few other hypoglycemic agents to be effective in this species suggest that the other agents have mechanism of action which are different from that of the sulfonylureas (2,3,4,5). Such compounds, therefore, are more likely to be efficacious in the population of type II diabetic patients that do not respond to sulfonylurea therapy.
TABLE II______________________________________ ob/ob dataCompound of Dose % Change % ChangeExample No. mg/kg, p.o. glucose insulin______________________________________4 100 -39 -826 100 -39 -767 100 -30 -7510 100 -36 -2822 100 -32 -9130 100 -29 -26______________________________________ References: 1. Brichard, S., Bailey, C. and Henquin, J.: Marked improvement of glucos homeostasis in diabetic ob/ob mice given oral vanadate. Diabetes 39: 1326-1332, 1990. 2. Chang, A., Wyse, B., Gilchrist, B., Peterson, T. and Diani, A.: Ciglitazone, a new hypoglycemic agent. I. Studies in ob/ob and db/db mice diabetic Chinese hamsters, and normal and streptozoticininduced diabetic rats. Diabetes 32: 830-838, 1983. 3. Coleman, D.: Obese and diabetes: Two mutant genes causing diabetesobesity syndromes in mice. Diabetologia 14: 141-148, 1978. 4. Heding, L. G.: Determination of total serum insulin (IRI) in insulintreated diabetic patients. Diabetologia 8: 260-266, 1972.
Pharmaceutical Composition
Based on the results of the pharmacological assay, the compounds of this invention are useful in the treatment of hyperglycemia in diabetes mellitus.
The compounds may be administered neat or with a pharmaceutical carrier to a mammal in need thereof. The pharmaceutical carrier may be solid or liquid and the active compound shall be a therapeutically effective amount.
A solid carrier can include one or more substances which may also act as flavoring agents, lubricants, solubilizers, suspending agents, fillers, glidants, compression aids, binders or tablet-disintegrating agents; it can also be an encapsulating material. In powders, the carrier is a finely divided solid which is in admixture with the finely divided active ingredient. In tablets, the active ingredient is mixed with a carrier having the necessary compression properties in suitable proportions and compacted in the shape and size desired. The powders and tablets preferably contain up to 99% of the active ingredient. Suitable solid carriers include, for example, calcium phosphate, magnesium stearate, talc, sugars, lactose, dextrin, starch, gelatin, cellulose, methyl cellulose, sodium carboxymethyl cellulose, polyvinylpyrrolidine, low melting waxes and ion exchange resins.
Liquid carriers are used in preparing solutions, suspensions, emulsions, syrups, elixirs and pressurized compositions. The active ingredient can be dissolved or suspended in a pharmaceutically acceptable liquid carrier such as water, an organic solvent, a mixture of both or pharmaceutically acceptable oils or fats. The liquid carrier can contain other suitable pharmaceutical additives such as solubilizers, emulsifiers, buffers, preservatives, sweeteners, flavoring agents, suspending agents, thickening agents, colors, viscosity regulators, stabilizers or osmo-regulators. Suitable examples of liquid carriers for oral and parenteral administration include water (partially containing additives as above, e.g. cellulose derivatives, preferably sodium carboxymethyl cellulose solution), alcohols (including monohydric alcohols and polyhydric alcohols, e.g. glycols) and their derivatives, and oils (e.g. fractionated coconut oil and arachis oil). For parenteral administration, the carrier can also be an oily ester such as ethyl oleate and isopropyl myristate. Sterile liquid carriers are useful in sterile liquid form compositions for parenteral administration. The liquid carrier for pressurized compositions can be halogenated hydrocarbon or other pharmaceutically acceptable propellent.
Liquid pharmaceutical compositions which are sterile solutions or suspensions can be utilized by, for example, intramuscular, intraperitoneal or subcutaneous injection. Sterile solutions can also be administered intravenously. The compound can also be administered orally either in liquid or solid composition form.
Preferably, the pharmaceutical composition is in unit dosage form, e.g. as tablets or capsules. In such form, the composition is sub-divided in unit dose containing appropriate quantities of the active ingredient; the unit dosage forms can be packaged compositions, for example, packeted powders, vials, ampoules, prefilled syringes or sachets containing liquids. The unit dosage form can be, for example, a capsule or tablet itself, or it can be the appropriate number of any such compositions in package form. A dosage range of from 0.1 to 200 mg/kg/day is contemplated, with a preferred dosage of from 0.1 to 100 mg/kg/day. Due to uncertainty in relating laboratory mouse study data to other mammals, the degree of hyperglycemia, and the compound selected, the dosages used in the treatment of non-insulin dependent diabetes mellitus must be subjectively determined by a physician or veterinarian according to standard medical or veterinary practice. | This invention relates to novel compounds which have demonstrated oral antihyperglycemic activity in diabetic ob/ob and db/db mice, animal models on non-insulin dependent diabetes mellitus (NIDDM ot Type II diabetes). These compounds have the formula: ##STR1## wherein: R 1 is C 1 -C 6 alkyl, C 3 -C 8 cycloalkyl, thienyl, furyl, pyridyl, ##STR2## where R 10 is hydrogen, C 1 -C 6 alkyl, fluorine, chlorine, bromine, iodine, C 1 -C 6 alkyoxy, trifluoroalkyl or trifluoroalkoxy;
R 2 is hydrogen or C 1 -C 6 alkyl;
X is O or S;
n is 0, 1, or 2;
A is ##STR3## where R 3 is hydrogen, C 1 -C 6 alkyl, halogen, C 1 -C 6 alkoxy, trifluoroalkyl or trifluoroalkoxy;
B is ##STR4## where R 4 is hydrogen, C 1 -C 6 alkyl, allyl, C 6 -C 10 aryl, C 6 -C 10 aryl-(CH 2 ) 1-6 --, fluorine, chlorine, bromine, iodine, trimethylsilyl or C 3 -C 8 cycloalkyl;
R 5 is hydrogen, C 1 -C 6 alkyl, C 6 -C 10 aryl, or C 6 -C 10 aryl-(CH 2 ) 1-6 --;
m is 0, 1, or 2;
R 6 is hydrogen or C 1 -C 6 alkyl;
R 7 is hydrogen or C 1 -C 6 alkyl;
R 8 and R 9 are selected independently from hydrogen, C 1 -C 6 alkyl, fluorine, chlorine, bromine, or iodine;
Y is S;
Z is N or CH;
or a pharmaceutically acceptable salt thereof. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of electrical contactors for motor starters and similar devices, and in particular to an electronic interlock that senses the open or closed condition of the contactor by monitoring the inductance of the contactor coil, the inductance changing as a function of the air gap between the armature and the magnet.
2. Prior Art
Electromagnetic contactors having one or more sets of contacts which are opened and closed by voltage applied to a coil are useful for various switching and control functions. A contactor usually has a magnetic circuit which includes a fixed magnet and a movable magnet or armature, with an air gap between them when the contactor is opened. An electromagnetic coil is controllable upon command to interact with a source of voltage which can be coupled across the main contacts of the contactor for electromagnetically accelerating the armature towards the fixed magnet, thus reducing the air gap.
The armature carries a set of bridging contacts, operable to electrically connect fixed contacts, mounted in the contactor case, as the magnetic circuit is energized and the armature is moved. The load and the voltage source are usually connected to the fixed contacts and become interconnected with one another as the bridging contacts make with the fixed contacts.
As the armature is accelerated towards the magnet, it is opposed by two spring forces. The first spring force is due to a kickout spring which is subsequently used to disengage the contacts by moving the armature in the opposite direction when the power applied to the coil has been removed. This occurs as the contacts are opened. The other spring force is due to a contact spring which begins to compress as the bridging contacts abut the fixed contacts, but while the armature is still moving towards the fixed magnet as the air gap is reduced to zero.
Unlike a simple circuit breaker, which opens contacts in overcurrent conditions and must be manually reset, a contactor may be arranged to open and close contacts in various ways, sometimes repeatedly, for example to start, stop, coast or reverse a motor. Contactors can be combined with various overload protection means, in which case the contactor is typically called a motor controller. Single phase and multiphase contactor switching arrangements can be used, and high current switching capability can be provided.
There are numerous possibilities for specific applications of contactors. With a bidirectional motor, for example, two contactors may be coupled to the motor circuit, one for establishing contacts for forward rotation and the other for reverse. Other possibilities include varying the connections to a motor for starting or stopping in sequential steps, connecting the motor as an autotransformer, switching between wye and delta connections, etc. In order to control or coordinate operation of one or more contactors coupled to a control apparatus, or to a manually operated switching means, it is often desirable to provide a signal which indicates the present status of the contactor, i.e., whether the contacts are open or closed. This signal can be used by the control circuits for switching between respective control states. It would be possible to use, the switched voltage to provide such a status indication. However, this is not desirable for a number of reasons. The voltage is very noisy due to the current variations caused by contact bounce and by the typically inductive nature of the load. The state of the contacts may need to be determined before a voltage is available at the contacts, e.g., before operating a switching means more proximally coupled to the power mains. On the other hand, coupling the contact voltage to an external sensing device requires additional parts. For all these reasons, it would be desirable to provide a different form of interlock.
Apart from signals which may be coupled to external control circuits to govern operation of a system including an electromagnetic contactor, internal control circuits for contactors are known and used for various purposes. U.S. Pat. No. 4,893,102--Bauer teaches a contactor apparatus including a microprocessor controller operable to vary the power applied to the contactor coil during a closing stroke, to accelerate the armature at high power during an initial phase of closing, then to coast and finally to maintain contact, at reduced power. This arrangement reduces mechanical shock, contact bounce and other adverse effects of accelerating the armature at equal power over the stroke. The power applied to the coil is varied by a timing technique wherein a triac is triggered at progressively later times during the alternating current half cycles so as to apply progressively less current to the coil.
An objective according to Bauer is to control the velocity of the armature by reducing the coil drive current to a hold level after applying only sufficient acceleration for the armature to complete the stroke. The velocity of the armature thus slows to zero just as the air gap reaches zero and the remaining coil drive current holds the contacts closed. However, it is difficult to set this relationship exactly, or once the relationship is set to assume that it will not change over time. It would be desirable in a controller according to Bauer to sense when the air gap has reached zero. This would save power by providing feedback to the controller as to the particular amount of acceleration which is needed to just overcome the kickout spring and the contact spring.
U.S. Pat. No. 4,819,118--Mueller et al also teaches a microprocessor controller for a contactor system. Two contactors each have their own controllers, and are arranged to apply power to a reversing motor for rotation in opposite directions. The two controllers are coupled in communication and either can cause both contactors to trip in the event of thermal overloading of the motor. Current supplied to the load from each of the two contactors is monitored using analog to digital converters. The respective controller's microprocessor samples the output of the analog to digital converter and develops an estimation of the heat accumulated by the motor in its reversing operation. In this manner the current applied through both contactors is used to determine heating in the load, rather than only the current applied through the contactor which happens to be active.
It is an object of the present invention to sense the open/closed status of- an electromagnetic contactor by monitoring for the change in inductance of the coil circuit which occurs as a function of the air gap, or lack of an air gap, between the armature and the coil of the magnetic circuit.
It is another object of the invention to apply the current and voltage level sensing apparatus of a microprocessor controlled electromagnetic contactors to collect sufficient information to detect the change in the inductance of the magnetic circuit.
It is a further object of the invention to improve the operation of a microprocessor controller which switches current to a contactor coil in timed partial half cycles by sensing the change in the phase angle of switching which occurs between the open and closed states of the contactor.
These and other objects are accomplished in an electrical contactor having first and second contacts movably mounted to engage for achieving continuity in an electrical circuit, via an electromagnet and armature defining a magnetic circuit with an air gap that is closed in a first position of the contactor, normally when the contacts are made, and open in a second position of the contactor. A controller switches an alternating current voltage to the coil of the electromagnet during a timed portion of each AC half cycle, and senses the current level in the coil in a feedback loop. The controller adjusts the voltage-on time to achieve a predetermined average current as needed for accelerating the armature or coasting during a closing operation, for holding the armature in place when closed, etc. In order to sense whether the contactor is presently open or closed, the controller monitors and stores the phase angle between the previous voltage zero crossing and the time of voltage turn-on. When the inductance of the magnetic circuit including the electromagnet and armature changes rapidly due to opening or closing of the air gap between them, the controller detects a corresponding variation in the phase angle. The controller is preferably a microprocessor, programmed to normalize the phase angle over a range of coil drive voltages. The microprocessors of a number of such contactors can communicate in order to effect coordinated operations.
The microprocessor can test the inductance of the magnetic circuit including the coil and armature during a known status of the contactor. For example, after initiating a closing operation by applying wide voltage pulses to the coil, the microprocessor can output a train of shorter test pulses, e.g., of sufficient width to hold the armature once the contacts are closed, monitoring and storing the phase angle of the time at which the voltage must be switched on to maintain a holding current level. As the air gap closes, the inductance and the phase angle change, whereupon the microprocessor outputs an appropriate signal indicating a closed status or otherwise branches in its control routine in view of the change in status.
Similarly, during an opening operation the microprocessor ceases switching voltage to the electromagnet for sufficient time to allow the kickout spring and contact spring to exert a force which will accelerate the armature open, then outputs a series of pulses, again maintaining a given current level in the electromagnet and monitoring for the change in voltage switching phase angle that indicates opening of the air gap and a drop in inductance of the magnetic circuit. The same operation can also detect sudden opening (i.e., opening due to mechanical shock or the like) during an ongoing close-and-hold operation.
The invention facilitates coordinated operation of a number of contactors, each having a local control microprocessor operable to detect the status of the local contactor unit, and each being coupled in data communication with one or more others. An example is a coordinated motor reversing operation in a contactor arrangement having a first contactor for operating the motor in a forward mode and a second contactor for reverse. The invention is readily applicable to a contactor of the type having a microprocessor or similar controller to vary the current level in the electromagnetic coil to effect soft-close operations in which the level of energy applied to pull in the armature is minimized to the amount needed to overcome the kickout spring and contact spring force.
BRIEF DESCRIPTION OF THE DRAWINGS
An understanding of these and other objects and aspects of the invention can be obtained from the following description of certain preferred embodiments when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a functional block diagram showing an electrical contactor and control system according to the invention.
FIG. 2 is a schematic circuit diagram showing a coil driver circuit for energizing the contactor.
FIG. 3 is a graph of contactor coil voltage vs. time, showing the change in voltage conditions between contactor-closed (solid line) and contactor-open (broken line) conditions under control of the microprocessor controller.
FIG. 4 is a graph of contactor coil current, corresponding to FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention comprises an all-electronic interlock that senses the closed or open position of a contactor using the change in inductance of the coil circuit. The interlock functionally replaces an external electrical interlock to provide feedback information as to whether the contactor is closed or open. However, additional hardware is not required because the change in coil circuit inductance is detected by a change in timing (i.e., phase angle) which occurs in the switching of a feedback-operated current controlling circuit.
The conditions addressed by the interlock include verification of closing, verification of opening, sudden opening and status verification for operation of sequential and reversing contactor controls, This information can be made available from the contactor to a contactor or motor starter control system encompassing a number of contactor units, for example over data communication links from or between the microprocessors of individual contactor controllers such as the microwire or IMPACC communication links which are available in some contactor control circuits. The status report thus can become a parameter which facilitates sequential starter control functions such as autotransformer, wye-delta and other switching functions.
In FIG. 1, a modular electrical contactor control system is shown in block form, for example to be used to control application of power to a motor from a three-phase power line. FIG. 2 illustrates a preferred embodiment of the driver and coil current sensing circuits of the contactor control system. A forward contactor and a reverse contactor may be provided and coupled in data communications for coordinating operation. Only one phase and only one contactor are shown in the drawings.
The contactor 20 has an electromagnet 22 including a coil 23 operable when energized with a driving current to apply a magnetic force to an armature 24, which typically includes a permanent magnet. A first electrical contact 25 is fixed in the contactor casing, and a second electrical contact 26 is movable by displacement of the armature 24, into engagement with the fixed contact 25. A contactor controller 30 switches power to the coil 23 to effect making or breaking of continuity between contacts 25, 26, typically to switch AC power to a load circuit 32. A kickout spring 33 is provided to urge the armature 24 into an open position, i.e., to resist the magnetic force on the armature which is exerted by the coil 23 when energized. Accordingly, when current to coil 23 is switched off, the contacts 25, 26 disengage, and when current is switched on, the contacts engage. In addition to the kickout spring 33, at least one of the contacts 25, 26 is mounted resiliently on a contact spring intended to press the contacts together when the armature 24 is fully retracted toward the coil 23, and the air gap 34 in the magnetic circuit which includes the coil 23 and armature 24 is zero.
The contactor can switch AC power to a motor 42 from a power line 44, and can be operated in conjunction with additional circuitry to effect a sequence of contact making and breaking operations as needed for starting or stopping the motor 42, coasting, reversing, etc. Load current sensing current transformer 46 can be coupled along the conductor 32 leading to the load, for effecting an overload protection function via analog to digital converter 67, coupled to processor 62 of controller 30, as shown in FIG. 1.
Power for operating the contactor 20 and the controller 30 can be separate from the switched power line or obtained from two of the phases of the power line 44 on the source side of the contactor. A DC power source is needed to operate the coil 23 and the controller 30, and a transformer 52, rectifier 54 are provided to obtain DC power. The controller 30 for the contactor preferably comprises a microprocessor 62, for example as disclosed in U.S. Pat. Nos. 4,893,102--Bauer and/or 4,819,118--Mueller et al, which are hereby incorporated. In addition to simple logical functions, the microprocessor 62 and the memory 63 enable more complex control of the contactor, such as time averaging of current loading, indirect estimation of temperature conditions, communication over external data inputs and outputs 64, 65 between plural contactors operating in conjunction, and other functions.
Current, voltage and timing information are provided to the microprocessor 62. An analog to digital converter 66 is coupled to a coil current sensing resistor 167 for sampling instantaneous coil current level. A voltage zero crossing detector 72 provides a pulse to the microprocessor 62 at voltage zero crossings 80 on the AC power supply to the coil driving circuit (See FIG. 3), for timing reference to the beginning of an AC cycle or half cycle. Pulses from a clock oscillator 92 providing the microprocessor clock signal can be applied to a counter 94 having outputs coupled to the microprocessor 62 for obtaining elapsed time information, or the microprocessor can determine timing information by a programmed function such as by counting the number of cycles through a programmed status checking loop.
In a conventional mode of operation, the microprocessor 62 adjusts the time during each voltage half cycle that the contactor coil 23 is energized, to thereby control the contactor coil current as needed for the particular operation. When initiating a closing operation, the microprocessor 62 triggers the application of current to the coil 23 relatively earlier in each voltage cycle, for example using a triac or similar switching element 124. The earlier application of current during the successive cycles is such that a relatively larger proportion of the total energy which would be available from each full half cycle is applied to accelerate the armature 24 toward the closed position as the current is integrated over the remainder of each half cycle. The armature 23 is accelerated sufficiently early in the closing operation to bring the armature to a predetermined velocity that will be sufficient to overcome the resistance of the kickout spring 33 and the contact spring 128 when the armature 23 engages these springs later in the closing operation.
While switching the voltage to the coil 23 over a portion of each half cycle, the microprocessor 62 repetitively reads the current level in the coil a coil current sensing resistor 167, coupled to analog to digital converter 66. Preferably, the coil current is read at one predetermined point during each half cycle, however it would also be possible to sample the current at a plurality of points. The microprocessor increases or decreases the delay between a zero crossing 80 and the switch-on point 140, to increase or decrease the level of current in coil 23 in a feedback control loop. The particular levels of current which are needed for the respective operations can be stored in memory 63, or calculated based on other sensed parameters.
After accelerating the armature 23 to the required velocity during a closing operation, the current level is reduced by switching the current to the coil on at a later point in each half cycle. During this intermediate part of the closing operation the coil 23 substantially maintains the velocity of the armature (i.e., the armature coasts). Although it would be possible to reduce coil current to zero, according to the invention the current is reduced only to a test level which enables the microprocessor 62 to record the phase angle of the voltage switch-on point, for later comparison.
As the contactor closes, the microprocessor switches only sufficient current to hold the contactor closed. The energy applied is a function of coil current, being controlled by operation of the microprocessor to maintain this sufficient holding energy. Inasmuch as the closing of the contacts reduces the air gap between the armature and the coil magnet to zero, the inductance of the coil circuit increases upon closing, and more electromagnetic energy is stored in the coil circuit. As a result, a shorter on-time will maintain the same current level at the time the current is sampled.
The-amount of energy required for holding the armature against the force of the springs 33, 128 does not change. The energy applied is a function of current and the coil circuit inductance. When the inductance increases due to closure of the air gap, the microprocessor (which is still maintaining the predetermined current level) responds by moving the switch-on point to a later time, or greater phase angle, in the voltage half cycle.
This operation is shown graphically in FIGS. 3 and 4, which compare the timing of current switching when the contactor 20 is closed (solid lines) and open (broken lines). The microprocessor or other control circuit is arranged to monitor for the change in phase angle upon switching, and to output a signal representing the closed status of the contactor when the phase angle of the current switching (i.e., delay from previous voltage zero crossing) increases.
The change in inductance can also be used for verification of opening. During standard opening functions (i.e., controlled opening) as well as fast opening and closing (inadvertent or uncontrolled), the change in inductance identifies opening of the air gap and imminent or completed loss of electrical continuity between contacts 25, 26.
During controlled opening, the holding current is removed from the coil 23. A short interval elapses after the holding current until the air gap 34 opens due to the action of the contact spring 128 and kickout spring 33 lifting the armature 24 from the coil magnet and breaking the contacts 25, 26. The microprocessor 62 can determine the point at which the contactor opens by maintaining a minimal test current in the coil, and monitoring for the change in phase angle (now a reduction in the delay from zero crossing) which occurs when the air gap 34 opens and the coil circuit inductance drops.
Fast opening is detected by a change of phase angle which occurs while the microprocessor 62 continues to apply holding current to the coil. The holding current level is normally only sufficient to hold the armature when the air gap is zero, and it is desirable to apply only as much energy as necessary. In the event of a mechanical shock or the like which jars the armature 24 and opens the air gap 34, the holding current may not be sufficient to recover the closed position of the contactor. However, according to the invention the microprocessor 62 can readily detect fast opening and increase the coil driving current to re-seat the armature, or otherwise react to the condition (e.g., by signalling a larger control system or another contactor).
The particular inductance and the magnitude of inductance change due to opening/closing of the air gap will depend on the particular structure of the contactor coil circuit. By way of example, the Westinghouse Electric Corporation Model F34 contactor has a magnet/armature open inductance of 50 mH and a magnet/armature closed inductance of 80 mH. It will be apparent that this change in inductance produces a readily discernable difference in switching phase angle when controlling for a predetermined coil current level in the feedback control. The phase angle thus can be used to determine the position of the armature in a dependable manner.
FIG. 2 shows a contactor coil driver circuit 150, of the type used to control Westinghouse contactor-99 devices. The microprocessor 62 (U1) outputs a high level via resistor 152 (R26) that turns on FET switching transistor 154 (Q4) via a switching circuit including an optical isolator 156 (U2), which is biased by resistor R15 and zener diode CR5. The output of the optical isolator 154 is coupled to the FET switch through NPN switching transistor 158 (Q3). The emitter of transistor 158 is coupled to the gate input of FET 154, and biased by resistors 164 (R14, R16, R18). In this manner current is switched on to flow through the contactor coil 23 via diodes CR10-CR13. The circuit forms a full wave rectifier wherein the voltage is switched on at the time of the signal from microprocessor 62.
The coil current level is sampled and fed back to the microprocessor 62 via resistor 167 (R7). To obtain coil current regulation, the microprocessor 62 samples the coil current, as represented by the voltage on resistor 167, via the A to D converter 66 as in FIG. 1. The microprocessor samples the current level at the same phase angle or time 170 in each half cycle relative to the previous voltage zero crossing 80, in a "point on wave" current sampling method. As shown in FIGS. 3 and 4, the point 170 of sampling can correspond to a zero crossing 80 in the voltage supply. The exact shape and magnitude of the coil current before and after the instantaneous point of measurement need not be sampled by the microprocessor, however the shape and magnitude are affected by inductance and it is conceivable to sample the current at various phase angles and to use the shape of the current wave as an indicator of the change in inductance occurring upon opening or closure of the air gap 34.
FIG. 3 shows switched voltage over time. The leftmost half cycle shows the available supply voltage in dot-dash lines. When accelerating the armature, the microprocessor switches on the voltage early in the half cycle, e.g., before the voltage peak. The voltage remains on until the next zero crossing 80, as represented by hatching under the waveform. For holding the armature, or to test the inductance of the magnetic circuit, the microprocessor turns the voltage on nearer to the zero crossing 80, as shown by additional (cross) hatching. The remainder of FIG. 3, as well as FIG. 4, demonstrate the effect of the change in inductance of the magnetic circuit between the contactor-closed situation (solid lines) and the contactor-open situation (broken lines) as the microprocessor controls the coil current by regulating the turn-on point to maintain a constant current level at time 170, when the current is sampled.
When the contactor is open the microprocessor 62 must maintain a longer voltage on-time in order to maintain a given current at the time of instantaneous measurement, than when the contactor is closed. The increased on-time is needed because with less inductance in the open condition, less energy is stored in the coil circuit. The microprocessor increases the on-time by using a shorter timed delay t open than the delay t closed when the contactor is closed.
Closing verification is performed by periodically applying holding pulses when the contactor is open, which can be, for example, a tenth of the required closing current, in order to test the phase angle delay of the coil circuit when open. The phase angle delay can be represented by counting clock pulses from the previous zero crossing 80, using a binary counter 94 as shown in FIG. 1, or via a programmed operation of the microprocessor, e.g., responsive to an interrupt. The result of at least one such measurement of the open condition phase angle at holding current conditions is stored, or preferably the results of a number of measurements are averaged.
When a closing operation is commenced, the armature 24 is accelerated for a period as discussed above. Then holding level currents are again applied to the coil 23, and the phase angle delay is compared to the data obtained when the contactor 20 was open. The phase angle differs substantially from the stored data when the contactor closes, providing an indication that closing has been completed.
The phase angle delay maintained by the microprocessor 62 must differ as a function of voltage as well, since the object is to maintain the predetermined level of current. Should a voltage shift occur in the AC voltage applied to the coil driving circuit, e.g., due to loading by a motor coupled through the contactor to the same AC mains, the phase angle delay can be related to the voltage as sensed by the microprocessor 62, using a linear approximation. As shown by exemplary binary (hexadecimal) counts in TABLE I, the difference in phase angle delay between the open and closed contactor conditions are readily apparent.
TABLE I______________________________________Phase Angle Delays: Closing VerificationVOLTAGE CLOSED OPEN______________________________________130 251 219120 248 1F2110 226 1E9100 211 1C290 1EC 19880 1C0 16F75 1A2 150______________________________________
A similar operation can be used for opening verification. The voltage and phase angle delay are recorded while the contactor is closed and the holding current is applied (i.e., before commencing an opening operation). Upon commencing opening, the coil current is switched off entirely, and the microprocessor can sample the coil current to ensure that it is zero before proceeding. Alternatively, the coil driving current can be reduced to a level insufficient to overcome the spring pressure. As the pressure of the contactor spring and kickout spring come into play, a series of test pulses are again applied, e.g., at the holding level, and the voltage and phase angle are compared to the data recorded while holding (that is, before the opening force of the springs was applied without opposition to the armature). When the air gap 34 opens due to the springs 33, 128 forcing the armature 24 open, the phase angle delays shorten, and the appropriate status signal is generated by the microprocessor. TABLE II shows exemplary phase angles which occur during opening verification.
TABLE II______________________________________Phase Angle Delays: Opening VerificationVOLTAGE CLOSED OPEN______________________________________130 251 21A120 246 1F5110 221 1E8100 211 1C190 1E8 19480 1BA 16270 18B 13260 137 F450 108 AA______________________________________
This technique also identifies instances of sudden opening. Although infrequent, sudden opening may occur in the event of a large mechanical shock or a large fault current. In such a case it is appropriate to obtain a status indication of the open/closed condition of the contactor in order to enable the control system as a whole to respond appropriately, whereas lack of such information may result in the contactor circuits assuming anomalous states. Sudden opening is detected by keeping a running record of the phase angle delay and the voltage, and comparing the phase angle and voltage during each half cycle to the recorded data. A sudden opening results in a sudden decrease in phase angle which is not accompanied by a corresponding dip in voltage, and can be identified by the microprocessor, which then outputs a suitable status signal. It may be appropriate to require sudden opening detection over two or several half cycles before outputting the status signal, to reduce the possibility of erroneous operation as a result of line noise.
The invention does not require the addition of hardware to a contactor circuit because the information needed to verify closing and opening is available from the voltage and current sensing means, and the timing capability of the contactor circuit and the microprocessor included therein. The controller nevertheless responds very directly to the physical status of the contactor as provided by the existence or non-existence of an air gap between the armature and coil magnet. A complete interlock is provided, allowing for closing verification, opening verification, and detection of a sudden opening. No external electrical interlocks are required for providing status indications whereby contactors can be operated, coordinated, and included in larger control systems which rely on the status verification signals.
Exemplary embodiments of the invention having been disclosed, variations in keeping with the invention will also be apparent to persons skilled in the art. Whereas the invention is not limited to the foregoing examples, reference should be made to the appended claims to assess the scope of the invention in which exclusive rights are claimed. | An electrical contactor has first and second contacts movably mounted to engage for achieving continuity in an electrical circuit, via an electromagnet and armature defining a magnetic circuit with an air gap that closes in a first position of the contactor and opens in a second position of the contactor. A controller switches an alternating current voltage to the coil of the electromagnet during a timed portion of each AC half cycle, and senses the current level in the coil in a feedback loop. The controller adjusts the voltage-on time to achieve a predetermined average current as needed for accelerating the armature or coasting during a closing operation, for holding the armature in place when closed, etc. In order to sense whether the contactor is presently open or closed, the controller monitors and stores the phase angle between the previous voltage zero crossing and the time of voltage turn-on. When the inductance of the magnetic circuit including the electromagnet and armature changes rapidly due to opening or closing of the air gap between them, the controller detects a corresponding variation in the phase angle. The controller is preferably a microprocessor, programmed to normalize the phase angle over a range of coil drive voltages. The microprocessors of a number of such contactors can communicate in order to effect coordinated operations. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a digital multifrequency signaling receiving system using discrete Fourier transform and more specifically to a digital multifrequency signaling receiving system with reduced number of operations.
Presently, multifrequency signaling (hereinafter referred to as MF signaling) is used for transmission of inter-office register signaling as standardized signaling between crossbar exchanges. For the exchanges themselves, stored-program controlled exchanges and time division multiplexed exchanges have come to be used, and for the signaling system, there is a movement to swtich over to the common channel signaling system. These stored-program controlled exchanges, however, must employ the MF signaling for the crossbar exchanges, so that it is important to improve receiving systems for such MF signaling.
In such MF signaling receiving systems, the input frequency has conventionally been detected by the digital filter (DF) method. This DF method detects the frequency of the input signal through filter banks. For technical literature, reference is made to "An All Digital Telephony Signalling Module" (IEEE Proc. circuit and system theory, 1975), by P. Kaul and H. Lieberman.
According to the DF method, however, filters for an analogue receiver are directly replaced by the digital filters, so that the order of the filters becomes large and the size of hardware used or number of operations will be increased.
As another conventional method, there is the discrete Fourier transform (DFT) method. In this method, the input signal is Fourier-transformed, and the input frequency is detected by obtaining the coefficients of the Fourier series of the input signal. For technical literature concerning this method, reference is made to "Digital MF Receiver using Discrete Fourier Transform" (IEEE Trans. on Communications vol. COM-21, No. 12).
However, as may be seen from the above literature, software in a universal computer cannot process the input signal in real time in the DFT MF reception system, so that the receiver need be composed of dedicated hardware. Although such receiver may effectively be used as a receiver for large-office service, it is defective in economical efficiency, extension cost, etc. for small-office use.
SUMMARY OF THE INVENTION
The object of this invention is to provide a digital multifrequency signaling receiving system eliminating the above defects, reducing the number of operations in the operation processes for MF signals, and providing high economical efficiency and extensibility even for small-office use.
In order to attain the above object, the digital multifrequency signaling receiving system of this invention comprises a first operation means for executing an operation to multiply multifrequency (MF) signals as input signals composed of N samples by a window function to obtain products, the window function including coefficients required for fast Fourier transformation of the products; a second operation means for fast Fourier transforming of the products as sample signals, the second operation means including a delay means for delaying the products to halve the number of the products and a subtractor for delivering difference signals or N/2 sample signals representing the difference between the delayed products and the current products, and a logic circuit for executing a logical operation on the difference signals or N/2 sample signals, taking advantage of the fact that some outputs of a Fourier transform are represented as the conjugate complex of the other outputs of Fourier transformation in the process of Fourier transform for the N/2 sample signals delivered from the subtractor; a third operation means for executing discrete Fourier transform for the MF signal samples delivered from the logic circuit; and a fourth operation means for providing an output to detect the input frequencies of the discrete-Fourier-transformed MF signals.
With the above-mentioned construction, the digital multifrequency signaling receiving system of this invention performs fast Fourier transformation of the sample signals immediately before discrete Fourier transformation at the second operation means. The number of multiplications in the detection of the input MF signals can be reduced be using fast Fourier transform and by taking advantage of the fact that some outputs of the fast Fourier transform may be represented by the conjugate complex of the other outputs in the fast Fourier transform process. Accordingly, there may be provided an economical digital multifrequency signaling receiving system using a general microprocessor in which a calculation program in accordance with a flow chart is performed, and which is efficient for a small-office use receiving system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram for illustrating the operation processes for MF signals according to this invention;
FIG. 2 is a chart showing the operation sequences of fast Fourier transform (FFT) parts shown in FIG. 1;
FIG. 3 is a chart indicating that the operation sequences of FIG. 2 can be simplified;
FIG. 4 is a block diagram showing the specific arrangements of sections for executing the operations in the operation processes as shown in FIG. 3;
FIG. 5 is a circuit diagram showing an example of an input part as shown in FIG. 4;
FIG. 6 is a circuit diagram showing another example of the input part as shown in FIG. 4;
FIG. 7 is a specific circuit diagram of a logic circuit in an FFT operation part as shown in FIG. 4;
FIG. 8 is a more specific block diagram based on the block diagram of FIG. 4;
FIG. 9 is a specific connection diagram of a logic circuit constituting the FFT operation part as shown in FIG. 8;
FIG. 10 is a specific connection diagram of another logic circuit as shown in FIG. 8;
FIG. 11 is a specific connection diagram of still another logic circuit as shown in FIG. 8;
FIG. 12 is a specific connection diagram of a logic circuit constituting the discrete Fourier transform (DFT) operation part as shown in FIG. 8;
FIG. 13 is a block diagram showing an example in which part of the hardware of FIG. 4 is included in a processor;
FIG. 14 is a block diagram showing an example in which part of the hardware of FIG. 13 is included in a processor;
FIG. 15 shows another example of a subtractor at section B1 as shown in FIG. 4;
FIG. 16 is a time chart for illustrating the operation of the example of FIG. 15;
FIG. 17 is a block diagram showing circuit arrangements according to another embodiment of this invention; and
FIG. 18 is a block diagram showing still another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In general, MF signaling is formed by combining two out of six frequencies--700 Hz, 900 Hz, 1,100 Hz, 1,300 Hz, 1,500 Hz and 1,700 Hz. The common period of the six frequencies is 10 msec. MF signaling sampled with a sampling period of 125 μsec, 80 samples of the MF signal are obtained. That is, the frequency of the MF signaling may be detected by making an analysis for each 80 samples. The discrete Fourier transform F k of an MF signaling f n =f(nT) (n=0, 1, . . . N-1) at K×100 Hz (k=7, 9, 11, 13, 15, 17) is calculated as follows: ##EQU1## where T is sampling period (125 μsec), N is number of samples (80), Ω is detection frequency space of discrete Fourier transform (Ω=2π/NT=2π×100), and j=√-1.
The existence of signals for each of the MF signaling frequencies may be detected by comparing the square of the absolute value of F k , that is,
P(kΩ)=|F(kΩ)|.sup.2 (k=7, 9, 11, 13, 15, 17)
(2)
with a fixed threshold value. Here h n is a window function for improving the frequency selectivity of P(kΩ), such as humming window given by ##EQU2##
In equation (1), ##EQU3## W is a unit vector obtained by dividing into 80 equal parts a unit circle of a Gaussian plane with real and imaginary numbers respectively on the axes of the abscissa and ordinate, shifted -2π/80 radian from the real axis. For example, W 0 =1, W 40 =-1, W 20 =-j, W 60 =j, ##EQU4##
80-point DFT system or DFT 80 directly calculates equation (1). Suffix n of DFT n represents the number of points of the discrete Fourier transform. The DFT 80 system requires 80 multiplications of the window function, 8×6 multiplications of a sine wave of W and 80×6 multiplications of a cosine wave of W. Thus, 1,040 (=80+80×6×2) multiplications must be carried out in 10 msec in a DFT 80 system. Here the operation of a vector sum and comparator is not included, because this part can be realized only by ROMs as will be described later.
FIG. 1 indicates that the operation processes for the MF signals of this invention are executed by an input part or means 1, a window function multiplication part or means 2, an FFT operation part or means 3, a DFT 5 operation part or means 4 for 5-point discrete Fourier transform, a vector sum and comparator part or means 5, and an output part or means 6. The window function multiplication part 2 consists of 5 portions W 0 to W 4 , and the FFT operation part 4 consists of 5 portions FFT 0 to FFT 4 . The DFT 5 operation part 4 consists of 6 DFT 5 's corresponding to 6 frequencies of the MF signaling.
The input part 1 classifies the MF signals into 80 samples f 0 to f 79 , applying f n to W 0 where
n=5l+20j(l=0, 1, 2, 3; j=0, 1, 2, 3), (4)
to W 1 where
n=5l+2j+1(l=0, 1, 2, 3; j=0, 1, 2, 3), (5)
to W 2 where
n=5l+20j+2(l=0, 1, 2, 3; j=0, 1, 2, 3), (6)
to W 3 where
n=5l+20j+3(l=0, 1, 2, 3; j=0, 1, 2, 3), (7)
and to W 4 where
n=5l+20j+4(l=0, 1, 2, 3; j=0, 1, 2, 3). (8)
In the window function multiplication part 2, the 80 samples of input MF signals f 0 to f 79 are multiplied by g n obtained by multiplying the window function h n by A=cos π/8 and or 1/√2 as constants required for fast Fourier transform as will be mentioned later. Thus, g n can be given by ##EQU5## where i=0, 1, 2, 3, 4 and j=0, 1, 2, 3. If n=11, for example, i=1 and j=0, and so f 11 is multiplied by g 11 =(1/√2)h 11 .
FIG. 3 shows the FFT operation part 3 in detail. In order to give a detailed explanation of the drawing of FIG. 3, it is necessary first to describe the operation sequences, with reference to FIG. 2. FIG. 2 illustrates a W 0 -FFT 0 part of FIG. 1 in detail, in which the FFT operation part 3 is formed of B1, B2, B3 and B4. In FIG. 2, "An algorithm for the Machine Calculation of Complex Fourier Series" (Mathematics of Computation, Vol. 19, No. 90, 1965) by Cooley, J. W. and Tukey, L. W. is applied to the 80 samples of the MF signaling.
The input and output samples of the FFT operation part 3 in FIG. 2 are selected from those for W 0 and FFT 0 , for example; the description here may cover also other W i and FFT i (i=1, 2, 3, 4). In FIG. 2, an input MF signal f n (n=0, 1, . . . 79) is multiplied by h n (n=0, 1, . . . 79) at the window function multiplication part 2. That is
x.sub.n =h.sub.n f.sub.n (10)
Then, x n (n=0, 1, . . . 79) is applied to the input of the FFT operation part 3.
In the FFT operation part 3, the output F k of DFT 80 is obtained as follows: ##EQU6## In equation (11), the sum covering n=0 to 79 may be divided into two portions; n=0 to 39 and n=40 to 79. Thus, F k can be obtained as follows: ##EQU7## Here the second term may be changed into ##EQU8##
W.sup.(n+40)k by replacing n with n+40. Then we obtain ##EQU9## That is, it will be required only that a n =x n +x n+40 W 40k be calculated for the input signal x n , and that 40-point DFT (DFT 40 ) be calculated for a n , assuming, ##EQU10## Considering that W 40 is -1 as mentioned before and k is an odd number in an MF receiver, a n is
a.sub.n =x.sub.n -x.sub.n+40 (15)
These operations are performed at B1 of FIG. 2.
Thus, F k may be calculated according to equation (14) from a n which can be obtained from x n . Hereupon, equation (14) may be divided into two portions; n=0 to 19 and n=20 to 39. That is, we obtain ##EQU11## Then, after b n =a n +a n+20 W 20k is calculated, F k can obtained from 20-point DFT (DFT 20 ) given by ##EQU12## Since W 20 is -j as mentioned before, W 20k =j for k=7, 11, 15 and W 20k is 31j for k=9, 13, 17. Namely, b n =a n +ja n+20 is calculated for 700 Hz, 1,100 Hz and 1,500 Hz, and b n =a n -ja n+20 is calculated for 900 Hz, 1,300 Hz and 1,700 Hz. These operations are performed at B2 of FIG. 2.
Thus, F k may be calculated according to equation (17), obtaining a n from x n and b n from a n . Equation (17) may be divided into two portions: n=0 to 9 and n=10 to 19. That is, we obtain ##EQU13## Then, after c n =b n +b n+10 W 10k is calculated, F k can be obtained from 10-point DFT (DFT 10 ) given by ##EQU14## Since W 10 is (1/√2)(1-j) as mentioned before, we obtain ##EQU15## That is, ##EQU16## are calculated. These operations are performed at B3 of FIG. 2.
Thus, F k may be calculated according to equation (19), obtaining a n from x n , b n from a n , and c n from b n . Equation (19) may be divided into two portions; n=0 to 4 and n=5 to 9. That is, we obtain ##EQU17## Then, after d n =c n +c n+5 W 5k is calculated, F k can be obtained from 5-point DFT (DFT 5 ) given by ##EQU18## Since ##EQU19## as mentioned before, d n is ##EQU20## Accordingly, d n can be calculated from c n according to equation (23).
These operations are performed at B4 of FIG. 2.
Thus, the input signal f n is multiplied by the window function h n to provide x n , from which a n is obtained. Then, b n , c n and d n are obtained from a n , b n and c n respectively, and finally F k can be obtained from d n according to equation (23). Further, the frequency of the input signal may be detected by obtaining P(kΩ) (k=7, 9, 11, 13, 15, 17) from F k according to equation (2) and comparing it with the fixed threshold value. These processes are shown in the flow charts of FIGS. 1 and 2.
The input part makes rearrangements in accordance with equations (4) to (8), and then the window function multiplication part calculates x n =h n f n . Moreover, sections B1, B2, B3 and B4 perform operations of a n =x n -x n+40 , b n =a n +a n+20 W 20k , c n =b n +b n+10 W 10k , and d n +c n +c n+5 W 5k respectively, the DFT 4 operation part operates ##EQU21## and the vector sum and comparator part operates P(kΩ)=|F k | 2 (k=7, 9, . . . 17).
Now there will be described features and advantages of this invention.
FIG. 2, in which the FFT is applied to an MF receiver, can be simplified as shown in FIG. 3, and the number of operations can be reduced. The first facility for such simplification is the relations ##EQU22## in FIG. 2. Here c n k is c n for k. The second facility is that the number of multiplications at the FFT operation part can be reduced by previously multiplying the window function h n by the coefficient 1/√2 of equation (20) and coefficient A of equation (24). Namely, the input MF signal is multiplied by g n given by equation (9) as follows:
y.sub.n =f.sub.n g.sub.n (26)
These two points are the features of this invention.
Meanwhile, it can be understood that equation (25) holds as follows. That is, in the equation d n 9 =d n 7 , the real part of d n 9 equals the real part of d n 7 , and the imaginary part of d n 9 equals the imaginary part of d n 7 , provided its sign is inverted; d n 9 and d n 7 are conjugate complex numbers.
With respect to d n 9 =d n 7 , for example, d n 9 is ##EQU23## according to equation (24). From equation (20), c n 9 is ##EQU24## In equation (28), b n 9 becomes ##EQU25## Further, a n 9 is ##EQU26## Here x n -x n+40 =a n 7 , so that equation (29), (28) and (27) can be respectively rewritten as follows: ##EQU27## Accordingly, d n 9 =d n 7 holds.
Likewise, d n 17 =d n 15 of equation (25) holds because we can obtain ##EQU28##
Moreover, d n 13 =c n 13 +(B=Aj)c n+5 13 of equation (24) also holds because we can obtain ##EQU29##
From this first point of view, the outputs of d n 9 , d n 13 and d n 17 need not be calculated, but may be obtained from the outputs of d n 7 , d n 11 and d n 15 respectively.
Further, from a second point of view, the operations for the sections B3 and B4 may be simplified by incorporating the multiplications for the sections B3 and B4 into the window function. g n (n=0, 1, . . . 79) is the product of the window function and the constants for the sections B3 and B4, and y n is the products of the input f n and g n .
As may be seen from the above description, the operation processes of FIG. 2 can be simplified as shown in FIG. 3. A section B5 of the FFT operation part is a section for obtaining d n 9 , d n 13 and d n 17 respectively from d n 7 , d n 11 and d n 15 , omitting the operations for d n 9 , d n 13 and d n 17 at the sections B2, B3 and B4.
According to the operation of FIG. 3, for the reception of MF signaling, 16×5 multiplications of the window function and the constant g n , 4×5 multiplications of c at a section B 4-1 and 4×4×6 the multiplications at the DFT 5 operation part are required. Thus, the number of multiplications is 16×5+4×5+4×4×6=196 in 10 msec.
FIG. 4 shows the specific hardware arrangements of sections for actually executing the operations in the operation processes as shown in FIG. 3. The input part 1 to which the MF signal is applied is provided with an analogue-digital converter 11 when the MF signal is an analogue signal. When the MF signal is a digital signal, there is provided a digital interface circuit 12, as shown in FIG. 5. Moreover, if the digital signal is compressed in a nonlinear code, there will be added a digital expander 13 for converting the nonlinear code into a linear code, as shown in FIG. 6. The digital expander 13 may be composed of ROMs (read-only memory), for example. The MF signal f n from the input part 1 is applied to a multiplier 21 of the window function multiplication part 2. The constant g n given by equation (9) is stored in the ROM 22, which delivers g n corresponding to f n to multiply the MF signal f n by g n at the multiplier 21.
Outputs from the window function multiplication part 2 are applied to the section B1 of the FFT operation part 3. The section B1 is composed of a delay circuit 31 for delaying the input signal 40 samples, for example, the delay circuit 31 including a shift register or RAM (random access memory), and a subtractor 32 providing the difference between the current input signal and the delayed output from the delay circuit 31.
The outputs from the subtractor 32 are applied to the sections B2 and B3. The sections B2 and B3, which are composed of a register section 33 including four parallel-connected registers 0, 1, 2, 3, a first logic circuit 34 and a register 35, perform operations for processors B 21 and B '-1 as shown in FIG. 3, as well as time-divided operations for processes B 2-2 and B 3-2 and processes B 2-1 , B 3-1 , B 2-2 and B 3-2 of another FFT i (i=1, 2, 3, 4).
The four registers 0, 1, 2 and 3 are supplied respectively with
a 0 , a 1 , a 2 , a 3 , a 4 , a 5 , a 6 , a 7 , a 8 and a 9 (for register 0),
a 20 , a 21 , a 22 , a 23 , a 24 , a 25 , a 26 , a 27 , a 28 and a 29 (for register 1),
a 10 , a 11 , a 12 , a 13 , a 14 , a 15 , a 16 , a 17 , a 18 and a 19 (for register 2) and
a 30 , a 31 , a 32 , a 33 , a 34 , a 35 , a 36 , a 37 , a 38 and a 39 (for register 3).
First, prescribed operations are executed for a 0 , a 20 , a 10 and a 30 at the first logic circuit 34, and the results are transferred to a register 35 and then applied to a buffer memory 36.
FIG. 7 shows a specific arrangement of the first logic circuit 34, where prescribed operations are performed for the processes B 2-1 and B 3-1 of FIG. 3. In FIG. 7, adders 1 to 6 calculate, respectively, a i+10 +a i+30 , a i+10 -a i+30 , the sum of the output of the adder 1 and a i+20 , the difference between a i-20 and the output of the adder 1, the sum of a i and the output of the adder 2, and the difference between a i and the output of the adder 2, and there appear ##EQU30## outputs 7 to 10 respectively. Here i varies from 0 to 9. These outputs are applied to a logic circuit 41 through the register 35 and the buffer memory 36 logic circuit.
For example, a processor is used as the logic circuit 41
In the logic circuit 41, ##EQU31## are calculated with i=5, 6, 7, 8, 9 for the outputs U i , X i , Y i and Z i . These outputs are the outputs of B 4-1 as shown in FIG. 3.
Then, ##EQU32## are calculated with i=0, 1, 2, 3, 4. These outputs are the outputs of B4 of FIG. 3, which correspond to the real and imaginary parts of d i 7 , d i 11 , d i 15 and d i 13 respectively.
Subsequently, to calculate d i 9 , d i 17 and d i 13 , ##EQU33## are calculated respectively for the imaginary parts of d i 9 , d i 17 and d i 13 . Thus, the operations for the section B5 of FIG. 3 are completed.
Then, operations corresponding to the DFT 5 operation part 4 of FIG. 1 are performed. First, d n k is multiplied by W nk with k=7 and n=0, 1, 2, 3, 4, and ##EQU34## is calculated. Likewise ##EQU35## for k=9, 11, 13, 15, 17 is calculated.
In the vector sum and comparator 5, the sum of the square of the real part of F k and the square of the imaginary part of F k is calculated for k=7, 9, 11, 13, 15, 17, and is compared with a predetermined fixed threshold value. The output of the logic circuit 41, logical value "1" (when the sum is larger than the fixed threshold value) or logical value "0" (when the sum is smaller than the threshold value) is delivered to a central processor of an exchange via the interface of the output part 6.
Referring now to FIGS. 8 to 12, there will be described further specific arrangements of the FFT operation part 3 and the DFT 5 operation part 4 as shown in FIG. 4.
In FIG. 8, the same reference numerals are employed to designate parts as elements corresponding to those shown in FIG. 1.
The register 0 to 7 (33 1 and 33 2 ) at the sections B2 and B3 of the FFT operation part 3 are supplied with a i as shown in FIG. 3 or given by equation (15). That is,
a 0 , a 1 , a 2 , a 3 , and a 4 (for register 0),
a 20 , a 21 , a 22 , a 23 and a 24 (for register 1),
a 10 , a 11 , a 12 , a 13 and a 14 (for register 2),
a 30 , a 31 , a 32 , a 33 and a 34 (for register 3),
a 5 , a 6 , a 7 , a 8 and a 9 (for register 4),
a 25 , a 26 , a 27 , a 28 and a 29 (for register 5),
a 15 , a 16 , a 17 , a 18 and a 19 (for register 6), and
a 35 , a 36 , a 37 , a 38 and a 39 (for register 7)
are applied to the registers 0 to 7 respectively.
Subsequently, (a i , a i+20 , a i+10 and a i+30 ) and (a i+5 , a i+25 , a i+15 and a i+35 ) (i=0, 1, 2, 3, 4) are applied to two logic circuits 34 1 and 34 2 respectively. For these logic circuits 34 1 and 34 2 , the circuit arrangement of FIG. 7 may be used.
Outputs U i , X i , Y i and Z i of the logic circuit 34 1 are applied to delay circuits 35 0 , 1, 2, 3 respectively. These delay circuits 35, composed of shift registers or RAM's, for example, provide a delay equivalent to the delay of a logic circuit 37.
Outputs U i+5 , X i+5 , Y i+5 and Z i+5 of the logic circuit 34 2 are applied to the logic circuit 37.
The logic circuit 37, which is so constructed as shown in FIG. 9, performs operations corresponding to equation (34). As shown in FIG. 9, the logic circuit 37 is composed of four multipliers 90, 91, 92 and 93, adder-subtractors 94, 95, 96 and 97, and complementary circuits 98 and 99.
In the logic circuit 37, inputs U i+5 , X i+5 , Y i+5 and Z i+5 are severally multiplied by a constant C(=B/A=tan(π/8)), X i+5 is added to the output of the multiplier 90 by the adder 94, and the sign of the resultant figure is inverted by the complementary circuit 98 to provide an output Q i+5 .
The output of the multiplier 91 is subtracted from U i+5 by the subtractor 95 to provide an output P i+5 .
Z i+5 is added to the output of the multiplier 92 by the adder 96, and an output R i+5 is obtained by inverting the sign of the output by means of the complementary circuit 99.
The output of the multiplier 93 is subtracted from Y i+5 by the subtractor 97 to provide an output S i+5 . Here i varies from 0 to 4. These outputs are applied to a logic circuit 38.
The logic circuit 38, which is supplied with outputs U i , X i , Y i and Z i of the delay circuits 35 0 , 1, 2, 3, and outputs P i+5 , Q i+5 , R i+5 and S i+5 of the logic circuit 37, performs operations for B 4-2 of FIG. 3 corresponding to equation (34). The logic circuit 38, as shown in FIG. 10, is composed of adders 1 to 4 and subtractors 5 to 8. U i and P i+5 are added by the adder 1 to provide an output Re(d i 7 ). X i and Q i+5 are added by the adder 2 to provide an output Im(d i 7 ). Y i and P i+5 are added by the adder 3 to provide an output Re(d i 11 ). Z i and S i+5 are added by the adder 4 to provide an output Im(d i 11 ). P i+5 is subtracted from U i by the subtractor 5 to provide an output Re(d i 15 ). Q i+5 is subtracted from X i by the subtractor 6 to provide an output Im(d i 15 ). R i+5 is subtracted from Y i by the subtractor 7 to provide an output Re(d i 13 ). S i+5 is subtracted from Z i by the subtractor 8 to provide an output -Im(d i 13 ). Here i varies from 0 to 4. These outputs are applied to a logic circuit 39.
The logic circuit 39, which includes complementary circuit 39 1 , 39 2 and 39 3 as shown in FIG. 11, receives outputs from the logic circuit 38 and performs operations for the section B5 of the FFT operation part as shown in FIG. 3 or operations corresponding to equation (36). Outputs Im(d i 9 ), Im(d i 15 ) and Im(d i 17 ) are obtained by inverting the signs of inputs Im(d i 7 ), Im(d i 13 ) and -Im(d i 17 ) respectively. Here i varies from 0 to 4, and these outputs are applied to a logic circuit 42 as shown in FIG. 8.
The logic circuit 42, as shown in FIG. 12, is composed of, for example, twelve registers 0 to 11, two selectors 120 and 121 for suitably selecting sample outputs from these registers 0 to 11, first and second multipliers 122 and 123 provided for the outputs from the selector 120, third and fourth multipliers 124 and 125 provided for the outputs from the selector 121, a first adder 126 connected to the first and third multipliers 122 and 124 and a second adder 127 following the first adder 126, a third adder 128 connected to the multipliers 123 and 125 and a fourth adder 129 following the third adder 128, and shift registers 130 and 131 provided correspondingly to the adders 127 and 129. The logic circuit 42 has its registers 0 to 11 supplied with outputs Re(d i k ) and Im(d i k ) (i=0, 1, 2, 3, 4; k=7, 9, 11, 13, 15, 17) from the logic circuit 39, as illustrated. For example, 5 samples for i=0, 1, 2, 3, 4 are supplied to each of the registers 0 to 11, and zeroth samples of th registers 0 , 1 are selected by the selectors 120 and 121 and multiplied by Re(W i7 ) at the first and fourth multipliers 122 and 125. The samples are multiplied by Im(W i7 ) at the second and third multipliers 123 and 124, and the results of multiplication are subjected to addition or subtraction at the first and third adders 126 and 128, the outputs of which are added respectively to the outputs of the shift registers 130 and 131 by the second and fourth adders 127 and 129. Then, first, second, third and fourth samples are selected by the selectors 120 and 121, operated as aforesaid, and added to the zeroth, first, second and third operation results stored in the shift registers. Re(W i9 ) and Im(W i9 ) are applied for the zeroth samples of the registers 2 , 3, while Re(W i11 ) and Im(W i11 ) are supplied for the zeroth samples of the registers 4 and 5. Re(d i k ) and Im(d i k ) applied successively to the registers are subjected to prescribed operations, and then final outputs F k (k=7, 9, 11, 13, 15, 17) are obtained as Re(F k ) and Im(F k ). Namely, as mentioned before, the logic circuit 42 performs operations for the DFT 5 operation part 4 as shown in FIG. 1 or operations corresponding to equation (23).
The outputs obtained from the logic circuit 42 are applied to a logic circuit 51 formed of the vector sum and comparator part 5 as shown in FIG. 1 or ROM.
The vector sum and comparator part 5, as shown in FIG. 17, is composed of multipliers 178 and 179 to which outputs Re(F k ) and Im(F k ) from the DFT operation part are applied respectively, an adder 180 for adding outputs from the multipliers 178 and 179 or making a calculation (Re(F k )) 2 +(Im(F k )) 2 , and a comparator 181 for comparing an output from a threshold value generator 182 with an output from the adder 180. If a ROM is used for the vector sum and comparator part, address bits necessary for the ROM is at most the sum of the bits to express the absolute value of Re(F k ) and the bits to express the absolute value of Im(F k ). The contents of ROM is 1 for the addresses that (Re(F k )) 2 +(Im(F k )) 2 is larger than the threshold value, and 0 for the addresses that the threshold value is larger. With such ROM, a result of comparison with the threshold value may be obtained at the output of ROM by applying the absolute values of Re(F K ) and Im(F k ) to the address port of ROM.
Although this invention may be formed of the hardware as shown in FIG. 4 or 8, as described hereinbefore, the outputs from the section B1 composed of the delay circuit 31 and subtractor 32 forming part of the FFT operation part 3 may alternatively be applied directly to the register 35 1 , as shown in FIG. 13, to perform the operations for the registers 33 and logic circuit 34 of the FFT operation part 3 as shown in FIG. 4 in the processor 41 through a buffer memory 36 1 .
Referring to FIG. 14, the outputs of the window function multiplication part 2 are directly applied to the register 35 2 , whereby the operations for the difference operation part B1, registers 33 and the logic circuit 34 of the FFT operation part 3 as shown in FIG. 4 may be performed in the logic circuit 41 through a buffer memory 36 2 .
FIG. 15 shows another example of the section B1 of the FFT operation part 3 for delaying and difference operation, in which two sets of delay circuits 31a, 31b and subtractors 32a, 32b are connected in parallel with each other. As may be seen from the description of the section B1 with reference to FIG. 3, this is an example which enables processing of input signals with a double number of circuits, in consideration of the fact that 80-point discrete Fourier transform DFT 80 may be reduced to 40-point DFT 40 or halved in the number of operations. FIG. 16 is a time chart for such processing. Referring to FIG. 16(a), a first MF signaling expressed by Z, A, B, each consisting of 40 samples, is applied to the subtractor 32a. The first MF signaling (Z, A, B) is delayed 40 samples by the delay circuit 31a (FIG. 16(b)). A second MF signaling (C, D, E) (FIG. 16(c)) is applied to the subtractor 32b, and at the same time delayed 40 samples by the delay circuit 31b (FIG. 16(d)). Subtractor 32a produces the difference signals (Z-A) and (A-B) (FIG. 16(e)). The subtractor 32b produces difference signals (C-D) and (D-E) (FIG. 16(f) after subtraction. FIG. 16(g) shows a control signal supplied to a selector 150. At its low level the control signal causes the selector 150 to select an output f from the subtractor 32b, while at the high level it induces the selector 150 to select an output e from the subtractor 32a. With an output thus obtained from the selector 150, the first MF signaling (A, B) with the samples of 10 msec is reduced to a signal (A-B) (FIG. 16(h)) with samples of 5 msec, and the second MF signal (C, D) is also reduced to a signal (C-D) (FIG. 16(h)) with samples of 5 msec. For each of these signals (A-B) and (C-D), 40-sample discrete Fourier transform DFT 40 is performed. Accordingly, a double number of circuits may be processed by using the conventional DFT 80 .
The operation for the output of the selector 150 can be achieved by the DFT 40 and vector sum and comparator 5 according to the prior art, as shown in FIG. 15. When performing the operation in the processor 41, as shown in FIG. 13, instead of using the DFT 40 , however, the function g n may be stored in the ROM of the window function multiplication part 2 for reducing the number of operations.
FIG. 17 is a specific circuit diagram showing the DFT 40 and vector sum and comparator of FIG. 15. The DFT 40 is composed of a register 171, multipliers 172 and 173 for multiplying an output from the register 171 respectively by sine and cosine components, and adders 174 and 175 and shift registers 176 and 177 provided for the respective products from the multipliers 127 and 173. In this case, the shift registers 176 and 177 have double memory capacity so that input signals for the double number of circuits may be processed in response to the use of the two sets of delay circuits and subtractors in the difference operation part B1.
FIG. 18 shows an embodiment capable of processing signals for the same number of circuits with the conventional DFT, but reduced hardware for the DFT 40 . The DFT 40 is composed of a register 181, a multiplier 182 for multiplying an output from the register 181 by sine and cosine components, and an adder 183 and a shift register 184 provided for the products from the multiplier 182. In this embodiment, the 80-sample MF signal is reduced to a 40-sample MF signal by the difference operation part B1, so that the number of operations are reduced to the half of the conventional case. In this case, a multiplier 182 serially performs the multiplications by the sine and cosine components, making the most of the surplus processing time for 40 samples. The shift register 184 has a memory capacity capable of storing the sum of the multiplication values from the sine and cosine components. In the vector sum and comparator part 5 of this embodiment, the products of the output obtained from the DFT 40 and the sine and cosine components are squared by a multiplier 185 and delayed by a shift register 187, the subsequently obtained sine or cosine component is added to the cosine or sine component by an adder 186, and the output of the adder 186 is compared with an output from a threshold value generator 182. As a result, a logical level "1" is delivered if the output is larger than the threshold value, whereas a logical level "0" is delivered if the output is smaller than the threshold value.
The multipliers and adder-subtractors used in the above embodiment may be selected among those which appear in "An Approach to the Implementation of Digital Filters" (IEEE, Trans. Audio Electroacoustics, vol. AU-16 pp. 413 to 421, September, 1968) by Leland B. Jackson, James F. Kaiser and Henry S. McDonald. For the processor may be used a microcomputer, such as 8080 manufactured by Intel Corporation and M 6800 manufactured by Motorola Semiconductor Products Inc., etc. | Disclosed is a digital multifrequency signaling receiving system in which a first operation device executes an operation to multiply multifrequency signals composed of N samples as input signals by a window function including coefficients required for fast Fourier transform. An output produced at the first operation device, as a sample signal, is subjected to fast Fourier transformation at a second operation device which includes a subtractor and a logic circuit. In the subtractor, the sample signals are delayed N/2 samples to halve the number of sample signals. The logic circuit executes an operation for the sample signals, taking advantage of the fact that some frequencies of the outputs of the Fourier transform are represented as the conjugate complex of the other outputs of the Fourier transform. The sample signals fast-Fourier-transformed and produced at the second operation device are subjected discrete Fourier transformation in a processor, where an output for detecting the multifrequency signals is obtained. | 7 |
[0001] Continuation application of U.S. Ser. No. 09/942,602 filed on Aug. 31, 2001
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electronic book or “e-book” being a device that presents text and/or graphics, for example the text of a book or magazine and associated pictures, upon an electronic screen. Such devices typically comprise a display screen, for example an LCD screen under control of a programmed microprocessor. The microprocessor reads data from a data storage medium such as a Micro-CD-ROM or memory card such as a PCMIA card and converts the data into text and/or graphics that are displayed on the LCD screen.
[0004] 2. Description of Related Art
[0005] One commercially available electronic book is the REB1100 available from RCA. That device has a monochrome LCD touch screen and a built in 33.6 kbps v.34 capable modem that allows digital book data to be downloaded from a remote database into an onboard 8 MB memory.
[0006] In U.S. Pat. No. 6,229,502 there is described an electronic book which is configured to read digital book data from a ROM such as a PCMIA card.
[0007] In U.S. Pat. No. 6,037,954 to McMahon there is described an electronic book which includes a Micro-CD-ROM drive for reading digital book data encoded onto a Micro-CD-ROM.
[0008] One problem with these devices is that they rely on data storage or distribution systems which are relatively expensive and complex to implement.
BRIEF SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide an electronic text and/or graphics presentation device that is capable of reading book data encoded on a low cost, high capacity medium that may be conveniently carried.
[0010] According to the present invention there is provided an electronic text and/or graphics presentation device including:
[0011] scanning means arranged to scan a pattern encoding text and/or graphics;
[0012] a user input control means;
[0013] processing means coupled to the scanning means and responsive to the user input control means and operatively programmed to generate a data signal corresponding to the text and/or graphics; and
[0014] a display means controlled by the processing means and arranged to display the text and/or graphics in response to the processing means.
[0015] The device preferably includes a foldable housing comprising first and second housing portions pivotal relative to each other.
[0016] According to the preferred embodiment the first and second housing portions are each pivotally connected to a common spine.
[0017] Batteries for powering the unit may be conveniently located in a battery compartment formed in the spine.
[0018] It is desirable that the pattern be formed on a card and said device includes a roller mechanism arranged to retract the card into said device.
[0019] In the preferred embodiment the roller mechanism is incorporated into the first housing portion.
[0020] In order for a user of the device to readily determine if the device is loaded with a card the first portion may include a window for observing cards retracted into the first portion.
[0021] Preferably the device includes a card storage magazine. Preferably this is located in the second portion.
[0022] The display means may comprise a flexible LCD screen that is located across inner surfaces of the first and second housing portions.
[0023] In order to reduce power consumption it is advantageous that the flexible LCD screen be of a bi-stable type.
[0024] Preferably the housing includes a recess, for example formed in the spine, for receiving a loop of the LCD screen upon pivoting the first and second housing portions to a closed position in order that creasing of the LCD screen is avoided.
[0025] It is preferred that first and second printed circuit boards are located in the first and second housing portions respectively.
[0026] The flexible LCD screen may include conductive traces coupling the first and second printed circuit boards to each other.
[0027] In the preferred embodiment the user interface comprises a joystick assembly.
[0028] According to a fourth aspect of the present invention there is provided an electronic text and/or graphics presentation device including:
[0029] a scan head arranged to scan a pattern corresponding to text and/or graphics;
[0030] a processor coupled to the scanner and configured to generate data corresponding to the text and/or graphics;
[0031] a display screen responsive to the processor and arranged to display the text and/or graphics.
[0032] According to a final aspect of the present invention, there is provided a method for distributing text and/or graphics comprising the steps of:
[0033] encoding the text and/or graphics as a printed pattern on a plurality of cards;
[0034] distributing the cards to a plurality of users;
[0035] providing each of the users with an electronic text presentation device including means arranged to scan one of said cards and convert said pattern into readable text.
[0036] According to a fifth aspect of the invention, there is provided an electronic text and/or graphics presentation device including:
[0037] a foldable housing comprising first and second housing portions pivotal relative to each other, and
[0038] a display comprising a flexible screen located across inner surfaces of the first and second housing portions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] [0039]FIG. 1 is a first perspective view of an apparatus according to a preferred embodiment of the present invention.
[0040] [0040]FIG. 2 is a second perspective view of the apparatus.
[0041] [0041]FIG. 3 is a third perspective view of the apparatus.
[0042] [0042]FIG. 4 is a perspective view of the apparatus shown open for use.
[0043] [0043]FIG. 5 is an exploded perspective view of the apparatus.
[0044] [0044]FIG. 6 is a system block diagram of the apparatus.
[0045] [0045]FIG. 7 is a cross sectional view of the apparatus open and through line B-B′ of FIG. 4.
[0046] [0046]FIG. 8 is a cross sectional view of the apparatus closed and through line B-B′ of FIG. 4.
[0047] [0047]FIG. 9 is a cross sectional view of the apparatus through line A-A′ of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0048] The drawings illustrate an electronic book that is configured to read data encoded as a pattern printed on a sheet of card.
[0049] With reference to FIGS. 1 and 2, there is depicted a view of the front of an electronic book or “e-book” 2 according to a preferred embodiment of the invention. The e-book has a foldable housing including first and second housing portions in the form of front door 6 and a rear door 8 each pivotally connected to a spine 16 . A clasp 14 holds the two doors closed when the e-book is not being used. The outside of the front door 6 features a clear window 10 through which a data card 18 is visible. The data card is inserted under the window through a card slot 24 and is engaged by a roller and fed into an internal cartridge 38 (FIG. 5). On one side of the data card there is printed information for a user to read such as the title and author of a book. Accordingly a user of the e-book is able to determine at a glance the content that the e-book is loaded with. The text of the book is encoded as a pattern on the reverse side of the data card.
[0050] At the top of the outside of front door 6 there is located an eject button 12 . Upon operation of the eject button, card 18 is ejected from the e-book by the internal roller mechanism.
[0051] At the base of spine 16 there is located a battery cover 4 that covers a battery compartment for accommodating two AAA size batteries that power the e-book.
[0052] The outside of rear door 8 is visible in FIG. 3. Storage magazine 20 is hinged to swing out from rear door 8 to a position, as shown, where data cards 22 may be stored or selected for removal and insertion into card slot 24 .
[0053] [0053]FIG. 4 shows the e-book with the front and rear doors swung about spine 16 to an open position. In that position a flexible LCD screen 24 is visible. It is preferred that a VGA resolution monochrome screen be used being a passive bistable reflective polymer doped liquid crystal (PDLC) display fabricated on a flexible polymer substrate. By using a bi-stable screen power consumption is reduced as the screen draws zero current while presenting a static image.
[0054] The LCD screen operatively displays the text of the book encoded on card 24 . A user of the e-book is able to control which page of text is presented by means of joystick 26 .
[0055] The internal arrangement of the e-book may be comprehended by referring to FIG. 5 which is an exploded view. It will be noted that on the underside of LCD 24 there are located two PCBs 26 and 28 . PCB 28 has mounted directly upon it a scanner head 30 . The PCBs 26 and 28 are loaded with various electronic components including a microprocessor, RAM and ROM memory chips and power supply conditioning circuitry. It is envisaged that a VLIW microprocessor and accompanying circuitry, as described in U.S. patent application Ser. No. 09/113,053 and hereby incorporated by reference in its entirety, be used. PCBs 26 and 28 communicate by means of conductive traces on the back of flexible LCD 24 . The conductive traces terminate in peripheral contact regions 58 and 60 of the LCD screen which are folded over the edges of the PCB's to form connections with contact pads on the PCBs.
[0056] Adjacent scan head 30 there is located a motor 32 which drives roller 34 via reduction gearing. A switch 36 is provided to detect depression of eject button 12 . FIG. 6 provides a further exploded view internal cartridge 38 and window 10 .
[0057] Power for the electric motor and various circuit modules is conveyed from a battery compartment in the spine of the e-book to PCB 28 by means of cable 29 .
[0058] A block diagram of various electronic components of the e-book is shown in FIG. 6. Power from batteries 40 is conditioned and distributed by power supply circuit 42 to the various circuit modules located on the PCBs. To extend battery life, the processor circuitry is powered down whenever the screen display is constant. Near zero power consumption allows the e-book to appear to always be “on” in the manner of a conventional paper based book.
[0059] Processing module 44 includes a central processing unit 46 , which communicates with BIOS memory chip 48 and RAM 50 in the conventional manner. The CPU operates according to a program stored in program memory chip 52 . The processing module receives data and control signals from eject sensor 36 , joystick 26 and scanner 30 . In a further, more complex implementation, LCD screen 24 may be touch sensitive in which case the processing module would also be responsive to command signals generated by a user touching the LCD screen.
[0060] In operation a book data card is inserted through card slot 24 . In response card insertion sensor 48 generates a signal alerting processing module 44 to activate electric motor 32 thereby causing roller 34 to draw the card into internal cartridge 38 . As the card is drawn in scan head 30 converts a pattern on the card into corresponding data signals which are decoded by CPU 46 according to an algorithm implemented in the software stored in program memory chip 52 . The resulting decoded text file is stored in RAM 50 .
[0061] The decoded signals are displayed as readable text on LCD 24 under control of display controller 44 . Of course, as referred to previously, in magazines and some books, such as childrens' books, technical volumes and manuals, illustrations or graphics may feature prominently. Accordingly, the software stored in program memory chip 52 may also include instructions to decode figures encoded on the book data card.
[0062] The processing module 44 is responsive to signals generated by joystick 26 and is programmed to allow a user to move forward or backwards through the displayed text. In particular, processing module 44 retrieves different data segments from RAM 50 in response to movement of the joystick.
[0063] Several systems for encoding the data cards are appropriate and have been described in the prior art. For example, in U.S. Pat. No. 6,176,427 there is described a method for coding digital data, such as a text file, into a pattern printable on an A4 or Letter size piece of paper. In the system that is described it is possible to encode slightly more than 1 MB of data on to one side of a printed letter size page of paper using a high resolution printer and a 600 dpi scanner. In the presently described preferred embodiment the scanner head 30 is implemented by means of the scan head technology described in the previously incorporated U.S. patent application Ser. No. 09/113,053. Such a scanner has an output resolution of 4800 dpi.
[0064] It is further envisaged that the data card be produced using the very high resolution print heads described in the previously referred to U.S. patent application Ser. No. 09/113,053. Accordingly the amount of data that may be stored on a data card of dimensions 8.5 cm×5 cm (3.5″×2″) is approximately 1 Mb. Encoding of the text on to the data card may be performed as described in U.S. patent application Ser. No. 09/112,781 which is hereby incorporated by reference in its entirety.
[0065] Accordingly an entire novel may be stored on a single credit card sized plastic card by means of a pattern formed as an array of 16 million printed ink dots. The manufacturing cost per card is less than 1 cent, or about one fiftieth the cost of manufacturing a floppy disk. While it is envisaged that the card be made of plastic it would also be possible to use other substrates such as paper.
[0066] While it is primarily envisaged that the data stored on the data card will correspond to the text of a book or magazine, it is also possible to encode an executable program file. Accordingly updates to the software program stored in program memory 43 may be conveniently distributed in the form of encoded data cards.
[0067] The mechanical arrangement of the e-book will now be described further with reference to FIG. 7 where it will be noted that front door 6 and rear door 8 are independently pivoted about hinges 50 and 52 . Power cable 29 is deliberately left slack to accommodate movement of the front door 6 during closure of the book. It will be noted that the spine 16 and outer surfaces of the front and rear doors are configured so that upon fully opening the e-book the flexible LCD screen is drawn taught and flat for convenient viewing.
[0068] A further cross sectional view of the e-book, with doors 6 and 8 brought to a closed position appears in FIG. 8. It will be noted that in the closed position a mid portion 54 of the flexible LCD screen 24 is able to loop into the spine by virtue of a recess formed in the spine for and front and rear doors for receiving the screen. Consequently creasing and damage of the LCD screen is avoided.
[0069] Also visible in FIG. 8 are screen-to-PCB contact areas 58 , 60 which respectively connect the underside of the PCB to the outer edges of each of PCBs 26 and 28 . As previously explained, conductive traces on the underside of the PCB provide a path for the PCBs to exchange power and data signals.
[0070] A further cross-sectional view is provided in FIG. 9 through the long axis of spine 16 showing two AAA batteries located in a battery compartment formed in the spine. As will be realized by those skilled in the art, embodiments of the invention other than the preferred embodiment described in detail herein are possible. Accordingly the following claims are not to be read as limited by the preferred embodiment. | An electronic book for presenting text and/or graphics includes a scanner for scanning data cards bearing a pattern encoding the text and/or graphics. The electronic book further includes a programmed processor for decoding the text and/or graphics and a screen for displaying same. In a preferred embodiment the electronic book is provided in a compact foldable housing with an appearance similar to a conventional book including a flexible and foldable screen. The housing includes a spine having a recess to allow the folded screen to loop without damage occurring due to creasing. | 8 |
BACKGROUND OF THE INVENTION
[0001] (A) Field of the Invention
[0002] The present invention relates to a structure and manufacturing method of an over-current protection device. More specifically, the present invention relates to a resettable chip-like over-current protection device utilizing a polymeric positive temperature coefficient (PPTC) material as a substrate thereof.
[0003] (B) Description of Related Art
[0004] PPTC devices have been widely used in circuits of electronic devices today. The conductive composite material used in the PPTC devices is mostly composed of polyethylene and electrically conductive particles (mostly carbon black). Under normal operating temperatures, polyethylene confines the conductive particles tightly in a crystalline structure thereby to form a low resistance conductive network. When an abnormally high current is present, the heat generated on the device will reform the polyethylene from crystalline to amorphous. In such a situation, confined conductive particles will be separated due to quick expansion of the polyethylene, which breaks original conductive network. As a result, the resistance rises quickly so that the abnormal current passing through the device will be limited. After termination of the abnormal current, the temperature of the device will drop to room temperature and the conductive composite material will return to the original structure, which means that the polyethylene again confines the conductive particles in the crystalline structure, forming a low resistance conductive network, whereby the purpose of automatic resetting is obtained.
[0005] Currently, PPTC devices are mostly used for the purpose of over-current protection. In additional to radial-leaded type devices similar to conventional fuses, the PPTC devices are applied to surface-mount type devices used in a printed circuit board (PCB), which is composed of an at least 5-layer structure of a PPTC substrate, two main electrode conductive metal foil on top and bottom surfaces of the substrate, and two surface connecting electrode layers. For instance, U.S. Pat. No. 6,292,088 (entitled “PTC Electrical Devices for Installation on Printed Circuit Boards”) shown in FIG. 1A ˜ FIG. 1F discloses that on a PPTC substrate 10 , two main electrode conductive metal foils 11 a and 11 b are applied on two surfaces of the PPTC substrate firstly, as shown in FIG. 1A and FIG. 1B so as to form a sandwich structure as shown in FIG. 1C and FIG. 1D , then a via 12 necessary for connecting top and bottom electrode conductive layers is formed, as shown in FIG. 1E and FIG. 1F . Subsequently, a connecting electrode layer 13 is formed on the via 12 , as shown in FIG. 1G and FIG. 1H . Then electrode isolation areas 14 required in installation of terminal electrodes of the chip-like resettable over-current protection device are formed, as shown in FIG. 1I and FIG. 1J . Finally, a finished substrate is separated into individual devices according to predetermined cutting lines 15 as shown in FIG. 1K and FIG. 1L , and then the chip-like resettable over-current protection device with two terminal electrodes 16 and 17 is finished. The said terminal electrodes 16 and 17 are isolated from each other but connected to themselves located on top and bottom surfaces.
[0006] After analyzing this prior art, it is understood that the prior art has the following drawbacks:
1. The structure of 5-layer “surface connecting electrode conductive layer-main electrode conductive metal foil-PPTC substrate-main electrode conductive metal foil-surface connecting electrode conductive layer” and the manufacturing method thereof are too complex. 2. In preparing the electrode isolation areas, parts of electrode conductive metal foils 11 a and 11 b on device need to be removed and this process consumes much power and produces pollution.
SUMMARY OF THE INVENTION
[0009] The present invention is a solution for eliminating the drawbacks mentioned in the prior art. According to the present invention, the purposes of reducing process steps, saving resources and mitigating pollution concern can be achieved.
[0010] The present invention mainly relates to a method of manufacturing a chip-like resettable over-current protection device, comprising the step of:
[0011] forming a plurality of vias on predetermined locations on a substrate of a PPTC material.
[0012] Subsequently any one of the following two processes can be performed:
[0013] Process 1
At least one metal interface layer is deposited on both surfaces of the substrate and walls of the vias by sputtering, electroless electroplating (such as chemical plating), or other chemical or physical processes (such as printing, projecting, and evaporation.) Then, a layer of conductive metal is formed on the metal interface layer for a thickness of at least 10 μm. Subsequently, at least one layer of conductive metal at predetermined locations on both surfaces of the substrate is removed so as to expose the substrate on locations of electrode isolation areas.
[0015] Process 2
A plurality of electrically isolated protective layers are deposited on predetermined locations of both surfaces of the substrate. The protective layers are covered by a mask of the same size in area. At least one metal interface layer is applied on both faces of the substrate and walls of the vias by sputtering, electro-less plating (such as chemical plating), or other chemical or physical processes (such as printing, spraying, evaporation, etc.). Then, a layer of conductive metal is deposited on the metal interface layer for a thickness of at least 10 μm. Subsequently, all the masks are removed.
[0017] Finally, the substrate is cut through a plurality of predetermined cutting lines so as to obtain a plurality of devices, wherein the cutting lines pass through the vias and make the inner walls of the vias become a part of side walls of each of the devices. The conductive inner walls are at locations of electrodes of the devices.
[0018] The manufacturing process is completed so far. The completed chip-like over-current protection device comprises a three-layer structure of electrode conductive layer-PPTC substrate-electrode conductive layer, which is simpler than the conventional five-layer structure. Besides, the present invention comprises the following advantages:
1. The prior art metal foil is not required. 2. The prior art sandwich structure manufacturing process is not required, so that time and energy is saved.
[0021] Because protective layers are applied on electrode isolation areas in advance, the process can be simplified by selectively processing areas in manufacturing the electrode conductive layer so as to simplify process, reduce resource consumption and mitigate pollution. Moreover, the protective layers are of the same thickness as electrode conductive layers, and the surface of the device will be flatter than conventional ones.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1A , FIG. 1C , FIG. 1E , FIG. 1G , FIG. 11 and FIG. 1K show structures obtained in manufacturing steps of a prior art device.
[0023] FIG. 1B , FIG. 1D , FIG. 1F , FIG. 1H , FIG. 1J and FIG. 1L are cross-section view of FIG. 1A , FIG. 1C , FIG. 1E , FIG. 1G , FIG. 11 and FIG. 1K taken at line A-A′, respectively.
[0024] FIG. 2A , FIG. 2C , FIG. 2E , FIG. 2G and FIG. 21 are top view of structures obtained in manufacturing steps of the first embodiment of the present invention.
[0025] FIG. 2B , FIG. 2D , FIG. 2F , FIG. 2H and FIG. 2J are cross-section view of FIG. 2A , FIG. 2C , FIG. 2E , FIG. 2G and FIG. 2I at line A-A′, respectively.
[0026] FIG. 3A , FIG. 3C , FIG. 3E , FIG. 3G and FIG. 31 are top view of manufacturing steps of second embodiment of the present invention FIG. 3B , FIG. 3D , FIG. 3F , FIG. 3H and FIG. 3J are cross-section view of FIG. 3A , FIG. 3C , FIG. 3E , FIG. 3G and FIG. 3I at line A-A′, respectively.
[0027] FIG. 4A , FIG. 4C , FIG. 4E , FIG. 4G , FIG. 4I and FIG. 4K are top view of manufacturing steps of third embodiment of the present invention, wherein FIG. 4E and FIG. 4G are opposite faces of the same device at the same manufacturing step.
[0028] FIG. 4L is the opposite face of the same device of FIG. 4K .
[0029] FIG. 4B , FIG. 4D , FIG. 4F , FIG. 4H , FIG. 4J and FIG. 4M are cross-section view of FIG. 4A , FIG. 4C , FIG. 4E , FIG. 4G , FIG. 4I and FIG. 4K at line A-A′, respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Please refer to FIGS. 2 A˜ FIG. 2J , FIG. 3A . FIG. 3J and FIG. 4A ˜ FIG. 4M for procedure of implementation and structure of embodiments. The embodiments only illustrate possible methods for embodying the present invention so as to make the present invention easier to understand but not used to limit ways to embody the present invention. Persons skilled in the art can modify ways of embodying the present invention without departing from the scope and spirit of the present invention.
[0031] Please refer to FIGS. 2 A˜ FIG. 2J for the first embodiment of the present invention. Vias 12 are made at predetermined locations on a parallelepiped PPTC substrate 10 which has a top surface 1 , a bottom surface 2 , a left surface 3 and a right surface 4 , as shown in FIG. 2A and FIG. 2B . Surface treatment of the whole PPTC substrate 10 and vias are done as preparation for subsequent plating process, as shown in FIG. 2C and FIG. 2D . Subsequently, at least one metal interface layer is formed by sputtering, electroless plating (such as chemical plating). Then, an upper electrode conductive layer 21 a , a lower electrode conductive layer 21 b , and a connecting electrode conductive layer 13 for a thickness of at least 10 μm are formed by plating, as shown in FIG. 2E and FIG. 2F . The upper and lower electrode conductive layers are not required to use conductive metal foil. Then, as what is done in the prior art, electrode isolation areas required for terminal electrodes 16 and 17 of the chip-like resettable over-current protection device are formed, as shown in FIG. 2G and FIG. 2H . Finally, the completed conductive substrate is cut through cutting lines 15 into individual devices, as shown in FIG. 21 and FIG. 2J . Thus, the chip-like over-current protective device has separate terminal electrodes 16 and 17 , and each of the terminal electrodes 16 and 17 is of a single piece.
[0032] Please refer to FIG. 3A ˜ FIG. 3J for the second embodiment of the present invention. Vias 12 are made at predetermined locations on a parallelepiped PPTC substrate 10 which has top surface 1 , a bottom surface 2 , a left surface 3 and a right surface 4 , as shown in FIGS. 3A and 3B . Surface treatment of surfaces of the whole PPTC substrate 10 and vias are done as preparation for subsequent plating process, as shown in FIG. 3C and FIG. 3D . Next, an electrically isolated, protective layer 31 is applied on predetermined locations of electrode isolation areas, as shown in FIG. 3E and FIG. 3F . Subsequently, a mask on protective layer 31 is applied. At least one metal interface layer is deposited by sputtering, electroless plating (such as chemical plating). An upper electrode conductive layer 21 a , lower electrode conductive layer 21 b , and connecting electrode conductive layer 13 are deposited by electroplating technique for a thickness of at least 10 μm, as shown in FIG. 2E and FIG. 2F . After the mask is removed, the result is shown in FIG. 3G and FIG. 3H . The upper and lower electrode conductive layers 21 a and 21 b do not need the conventional conductive metal foil. Meanwhile, the upper and lower electrode conductive layers 21 a and 21 b cannot cover the protective layer 31 . More preferably, the upper and lower electrode conductive layers 21 a and 21 b are substantially at the same level with the protective layer 31 . Electrode isolation areas required by terminal electrodes 16 and 17 of the chip-like resettable over-current protective device are directly formed by the protective layer 31 . Finally, the completed substrate is cut through cutting lines 15 into individual devices, as shown in FIG. 3I and FIG. 3J . Thus, the chip-like over-current protective device has separate terminal electrodes 16 and 17 . Each of the electrodes 16 and 17 is of a single piece.
[0033] Please refer to FIG. 4A ˜ FIG. 4M for the second embodiment of the present invention. Vias 12 are formed at predetermined locations on a parallelepiped PPTC substrate 10 which has a top surface 1 , a bottom surface 2 , a left surface 3 and a right surface 4 , as shown in FIG. 4A and FIG. 4B . Surface treatment of surfaces of the whole PPTC substrate 10 and vias are done as preparation for subsequent plating process, as shown in FIG. 4C and FIG. 4D . Next, an electrically isolated protective layer 31 is applied on predetermined locations of electrode isolation areas, as shown in FIG. 4E and FIG. 4G . Subsequently, a mask is applied on the protective layer 31 . Then at least one metal interface layer is deposited by sputtering electro-less electroplating (such as chemical plating). The upper electrode conductive layer 21 a , lower electrode conductive layer 21 b , and connecting electrode conductive layer 13 are deposited for a thickness of at least 10 μm, as shown in FIG. 41 and FIG. 4J . The mask covering the protective layer 31 is removed, the result is shown in FIG. 4I and FIG. 4J . The upper and lower electrode conductive layer do not need the conventional conductive metal foil. The upper and lower electrode conductive layers cannot cover said protective layer 31 . More preferably, the upper and lower electrode conductive layers 21 a and 21 b are substantially at the same level with the protective layer 31 . Electrode isolation areas required by terminal electrodes 16 and 17 of the chip-like resettable over-current protective device are directly formed by the protective layer 31 . Finally, the completed conductive substrate is cut through cutting lines 15 into individual devices, as shown in FIG. 4K , FIG. 4L and FIG. 4M . The chip-like over-current protective device has separate terminal electrodes 16 and 17 . Each of the terminal electrodes 16 and 17 is of a single piece. | The invention relates to resettable chip-type over-current protection devices and methods of making the same, characterized by directly forming upper and lower electrode conductor and connection electrode conductor on a PPTC substrate so as to constitute a simplified three-layer structure of “electrode conductor-PPTC substrate-electrode conductor.” | 7 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention generally relates to fuel injection systems for internal combustion engines. More particularly, the invention relates to improved methods and devices for supplying high-pressure diesel fuel for injection into an internal combustion engine. Accordingly, the general objects of the present invention are to provide novel and improved methods and devices of such character.
(2) Description of the Related Art
Fuel-supply systems for internal combustion engines are well known in the art. Recent developments in the fuel injection art have focused on supplying fuel to fuel injectors from a common fuel-supply rail which can reach very high-pressure levels. For example, pressure levels in such systems can vary from 2,000 psi up to about 29,000 psi (i.e., about 138 bars to about 2,000 bars). A fuel injection system of this type is described in co-pending U.S. patent application 09/065,895, filed on Apr. 23, 1998, the contents of which are hereby incorporated by reference. One characteristic of fuel-supply systems of the type shown and described in the incorporated reference is that optimal performance requires that the fuel-pressure from the common rail be varied with engine performance conditions. Thus, while the fuel-pressure in the common rail is generally maintained within a predetermined range, the fuel-pressure will optimally deviate with rapid changes in the engine operating conditions. Fuel-pressure rates of change on the order of 300 bars over a 0.2 second time interval are typically desired during engine operation. Accordingly, an optimal common rail fuel-supply system should be capable of both increasing and decreasing fuel-pressure at least fast enough to meet this pressure change criterion.
While a number of fuel-supply systems currently in use can meet the above-noted pressure change criterion, they all suffer from one deficiency or another. One such fuel system uses a constant displacement high-pressure fuel pump and regulates common rail fuel-pressure by utilizing an electronically controlled actuator to spill excess fuel as necessary. In this system, an electronically controlled spill valve becomes more restrictive when increased fuel-pressure is needed in the common rail. Under the influence of the electronic control unit, the system dumps excess fuel when reduced fuel-pressure in the common rail is desired. Significantly, the system suffers from high parasitic losses at light and mid loads.
In other fuel systems of the type noted above, a variable displacement pump is utilized in conjunction with an electronically controlled spill valve to improve fuel-supply efficiency. However, these systems rely upon expensive electronically controlled dump valves which are used to reduce fuel-pressure in the common rail. Moreover, two levels of electronic control, one for the pump and one for the spill valve, are necessary to efficiently operate the system.
Yet another fuel-supply system of the type noted above utilizes a variable displacement pump and leakage from at least one fuel injector to reduce fuel-pressure in the common rail as necessary. In such a system it is only necessary to provide electronic control over the variable displacement pump. However, the pump of this system is typically unable to obtain fuel-pressure decreases on the order of 300 bars over a 0.2 second time interval at light loads.
Accordingly, there is a need in the art for an inexpensive fuel-pressure-reduction device which permits fuel systems of the nature discussed above to achieve the desired fuel-pressure-reduction rates with a minimum of electronic control and without any complex components. Such a fuel-pressure-reduction device should be both inexpensive and permit efficient engine operation at low, medium and high loads.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the present invention to provide an inexpensive hydro-mechanical device which improves fuel-pressure-reduction rates in common rail fuel-supply systems and which does not rely on auxiliary electronic actuators for operation.
It is a further objection of the present invention to provide methods of improving fuel-pressure-reduction rates in a fuel-supply system of the general type noted above, such methods relying on high pressure fuel pump delivery volumes to regulate fuel-pressure within the system.
It is still another object of the present invention to provide a fuel-supply system of the type noted above which can achieve an optimal combination of simplicity, reliability, efficiency and economy.
These and other objects and advantages of the present invention are provided in one embodiment by a hydro-mechanical device for receiving fuel from a high-pressure fuel pump of a fuel-supply system and delivering the fuel to a common rail of the fuel-supply system. The device passively regulates the fuel-pressure in the fuel-supply system, at least in part, by initiating spill of over pressure fuel based on the variable output of the high-pressure fuel pump.
The device is a pressure-reduction-valve assembly which includes a housing, a movable shuttle valve and biasing means for resiliently and constantly biasing the shuttle valve within the housing. The housing includes an interior cavity having first and second opposing ends and a spill port for returning spilled fuel to an excess fuel receptacle. In one preferred embodiment, the housing is affixed to the fuel pump such that the first end of the cavity is capable of receiving pressurized fuel directly from the output end of the fuel pump. The housing, in use, is also affixed to the common rail such that the second end of the cavity is in fluid communication with the common rail. A first valve, which is preferably a check valve, can be disposed within the housing cavity for limiting fuel-flow between the fuel pump and the cavity. The shuttle valve is preferably sealingly disposed within the housing cavity intermediate the first and second ends thereof and regulates fuel-flow through the pressure-reduction valve assembly. This shuttle valve is capable of movement between a fuel-transfer position, wherein the common rail is capable of receiving fuel from the fuel pump, and a fuel-spill position, wherein the common rail is capable of delivering fuel to the spill port. The biasing means resiliently and constantly biases the shuttle valve toward the fuel-spill position.
When used in its intended fashion, the inventive fuel-pressure-reduction valve assembly passively regulates the fuel within the fuel-supply system at least in part based upon the output of the variable displacement high-pressure fuel pump with which it is utilized. If this fuel pump is an intermittent pump, it intermittently supplies pressurized charges of fuel to the pressure-reduction valve assembly for delivery to the common rail as desired. In particular, the pump alternately (1) transfers fuel from the pump to the pressure-reduction valve assembly for an unpredetermined period of time, and (2) ceases the transfer of fuel from the pump into the pressure-reduction valve assembly for an unpredetermined period of time. The net result of this activity is to create a variable bias-pressure within the pressure-reduction valve assembly which counteracts the constant bias force provided by the biasing means and, sometimes, by the fuel-pressure in the common rail. It should be noted, however, that the inventive pressure-reduction valve assembly can also be utilized with a constant flow variable displacement pump, in which case the first valve would be unnecessary and fuel flow would be continuous.
In a preferred embodiment of the present invention, a small portion of the fuel transferred from the pump into the pressure-reduction valve assembly is selectively spilled therefrom to gradually reduce the bias-pressure within the pressure-reduction valve assembly. The pressure-reduction valve assembly transfers fuel to the common rail when the variable bias-pressure force within the pressure-reduction valve assembly exceeds the combined force of the biasing means and the fuel-pressure within the common rail. Conversely, fuel is transferred from the common rail into the pressure-reduction valve assembly when the combined force of the biasing means and the fuel-pressure within the common rail exceeds the variable bias-pressure force within the pressure-reduction valve assembly. Once this occurs, the fuel entering the pressure-reduction valve assembly from the common rail is spilled into an excess fuel receptacle thereby reducing the fuel pressure in the common rail. When the desired fuel pressure in the common rail is reached, fuel is delivered from the pump to the fuel-pressure reduction valve which reestablishes the bias pressure and terminates spillage from the common rail. The process noted above repeats as necessary to regulate the fuel-pressure within the common rail to achieve optimal engine performance and efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the present invention will be described below with reference to the accompanying drawings wherein like numerals represent like structures and wherein:
FIG. 1 is a cross-sectional view of the inventive pressure-reduction valve assembly in combination with a fuel pump and a fuel utilization device, the inventive valve assembly being shown in a fuel-spill position; and
FIG. 2 is a cross-sectional view of the inventive pressure-reduction valve assembly in combination with a fuel pump and a fuel utilization device, the inventive valve assembly being shown in a fuel-transfer position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, an inventive pressure-reduction valve assembly 5 is preferably installed in a variable displacement high-pressure pump 4 using a first threaded fitting 9. Additionally, a fuel utilization device, in this case the common rail 10 of the common rail fuel-supply system, is affixed to valve assembly 5 using a second threaded fitting 12. Valve assembly 5 includes a housing 6 which is connected to fuel pump 4 and common rail 10 such that an interior cavity 8 thereof is, at least, capable of being in fluid communication with fuel pump 4 and common rail 10. As shown, housing 6 defines an interior cavity 8 with opposing first and second ends 8' and 8", respectively. Housing 6 further defines a spill port 7 laterally extending from cavity 8. Shuttle valve 20 is disposed within cavity 8 intermediate first and second ends 8' and 8". As shown, shuttle body 21 is preferably generally cylindrical and is disposed for linear reciprocal movement within cavity 8 along a longitudinal axis A.
A first valve 14, is preferably disposed within cavity 8 in alignment with longitudinal axis A. The valve 14 is preferably a check valve which permits charges of pressurized fuel to flow from fuel pump 4 to first end 8' of cavity 8. Naturally, valve 14 prevents the flow of fuel from cavity 8 back into fuel pump 4.
Fuel pump 4 is preferably a variable displacement high-pressure pump. When fuel is transferred into first end 8' of cavity 8 and the fuel-pressure builds to a sufficiently high level, the fuel-pressure urges various internal elements, described hereafter, of shuttle valve 20 rightwardly until a resilient compression spring 18 is compressed (See FIG. 2).
Shuttle valve 20 is preferably comprised of a shuttle body 21, a first fuel passage 22 with an associated annular portion 23, a second fuel passage 24 with an associated annular portion 25 at one end thereof and a shuttle-response passage 26 extending between first and second fuel passages 22 and 24, respectively. Finally, bore 27 extends through shuttle body 21 to enhance fluid communication between second fuel passage 24 and cavity 8.
As shown in FIG. 1, shuttle 20 is in a fuel-spill position wherein shuttle body 21 has been urged leftwardly by compression spring 18. In this fuel-spill position, second fuel passage 24 is in fluid communication with all of spill port 7, second end 8" of cavity 8, shuttle-response passage 26 and common rail 10. Thus, in this fuel-spill condition, excess fuel from common rail 10 is permitted to flow from common rail 10 through cavity 8, spill port 7, a second valve 19 and into an excess fuel receptacle (not shown) fluidly connected to second valve 19. This fuel-spill condition is the "default" condition in that biasing member 18 urges shuttle body 21 into this fuel-spill position in the absence of any other substantial influences on shuttle body.
It will be appreciated that the condition shown in FIG. 1 occurs when the output of fuel pump 4 drops after having previously urged shuttle body 21 rightwardly to the position shown in FIG. 2. During a first portion of the shuttle body's traversal from the FIG. 2 position to the FIG. 1 position, the bias-pressure of the fuel from first end 8' of cavity 8 is in equilibrium with that of the fuel from the common rail, because the common rail and first end 8' are in fluid communication with one another via annular portion 23. Under these conditions, shuttle body 21 is urged leftwardly solely by spring, or biasing member, 18. Once annular portion 23 is no longer in fluid communication with the common rail, however, the fuel from first end 8' of cavity 8 leaks through shuttle-response passage 26 at a rate which permits shuttle body 21 to move toward its leftward most position (FIG. 1) in about 0.1 seconds. Thus, at normal speeds, shuttle body 21 is effectively pinned in its rightward position by the repeated transfer of fuel charges into cavity 8. Fuel is, therefore, permitted free passage all the way from fuel pump 4 to common rail 10 under such conditions.
At low cranking speeds, the transfer of fuel charges into cavity 8 occurs at intervals greater than the 0.1 seconds which it takes for shuttle body 21 to move leftwardly and the above-described fuel-spill can occur. A minimum fuel-pressure is maintained in the common rail by placing second valve 19 downstream of spill port 7. Second valve 19 is preferably a check valve which is pre-biased by a bias mechanism 19' to maintain a minimum fuel-pressure within the fuel-supply system of a predetermined level, preferably 200 to 600 bar. Those of ordinary skill will, thus, appreciate that a number of well known styles of regulating valves can be used as valve 19.
Shuttle-response passage 26 is disposed between first and second passages 22 and 24 and its size and orientation controls the rate at which shuttle body 21 returns to its leftward most position. Preferably, the rate of fuel-flow through shuttle-response passage 26 is substantially lower than that of the fuel flowing through either of first or second fuel passages 22 and 24, respectively. It is also contemplated that shuttle-response passage 26 could be eliminated by designing and/or machining the various components of assembly 5 to permit limited leakage between first and second passages 22 and 24 and/or between shuttle body 21 and housing 6. It should be appreciated that passage 26 and/or the above-described leakage serves the purpose of preventing the fuel-pressure in first end 8' of the cavity from permanently trapping shuttle body 21 in its rightward most position due to creation of a hydraulic lock within first end 8' in the absence of passage 26.
As described above, the inventive pressure-reduction valve assembly operates on a hydro-mechanical principal and, therefore, obviates the need to rely on expensive electronic control systems in order to achieve the same or similar results. This design can, thus, achieve results comparable to much more expensive systems at a much lower cost. The inventive pressure-reduction valve assembly described herein is, therefore, advantageous relative to systems of the related art described above. Finally, those of ordinary skill will appreciate that the device of the present invention can be implemented as a device which is disposed in the fuel line downstream of the fuel pump rather than as an additional component of the fuel pump.
While the present 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 limited to the disclosed embodiment, but is intended to cover the various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A hydro-mechanical device and methods therefor, for receiving fuel from a variable displacement fuel pump of a fuel-supply system and delivering the fuel to a common rail of the fuel-supply system, regulates the fuel-pressure in the fuel-supply system, at least in part, based on the output of the fuel pump such that optimal engine performance can be maintained under varying operating conditions. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of copending application bearing U.S. Ser. No. 848,596 filed on Apr. 7, 1986.
DESCRIPTION OF THE INVENTION
It has been found that insecticidal and acaricidal activity is possessed by compounds of the formula ##STR2## wherein X is oxygen or sulfur;
R is alkyl or alkenyl of up to twenty carbon atoms, phenyl, or phenalkyl of up to ten carbon atoms;
R 1 is alkyl, or alkenyl of up to six carbon atoms, or phenalkyl of up to ten carbon atoms;
R 2 is alkyl, alkenyl, alkynyl, haloalkyl or alkylthioalkyl of up to ten carbon atoms; napthyl, pyridyl, or thienyl; phenyl, or phenalkyl or phenalkenyl of up to ten carbon atoms, which may be substituted on the ring by from one to three substitutents selected from halogen, methyl, methoxy, nitro, amino, mono- and dialkylamino, and mono- and dialkylaminocarbonyl wherein each alkyl moiety contains from one to four carbon atoms;
R 3 is
(a) one of the moieties represented by R 2 or is ##STR3## wherein R 4 is alkyl of one to four carbon atoms, phenyl, or phenalkyl of up to ten carbon atoms, R 5 is hydrogen or one of the moieties represented by R 4 , or R 4 and R 5 together with the interjacent nitrogen atom represent 1-piperidino, 2-(ethoxycarbonyl)-1-piperidino, or 4-morpholino.
In these compounds, each alkyl, alkenyl, alkylene and alkenylene (as in phenalkyl and phenalkenyl) moiety may be straight-chain or branched-chain.
Compounds of Formula I can be prepared by treating a phosphonothioic or phosphonodithioic chloride of the formula: ##STR4## with an alkali metal salt of a sulfonamide of the formula ##STR5##
The treatment of the chloride (II) with a salt of the sulfonamide (III) is effected by adding the chloride at a controlled rate to a solution of the salt in an inert solvent, at a low temperature--for example, 0° C.-5° C.--moisture being excluded, then warming the mixture to room temperature, or somewhat above. Preferably, the chloride is added as a solution in the same solvent in which the salt is dissolved. Suitable as the solvent are organic materials such as ether and tetrahydrofuran, or acetonitrile. The product is isolated and purified by conventional procedures, as shown in the examples, hereinafter.
As is shown in U.S. Pat. No. 4,390,929, and in U.S. Pat. No. 4,190,652, the phosphonodithioic chloride precursor (II, X is sulfur) can be prepared by treating a phosphonothioic dichloride of the formula ##STR6## with an appropriate thiol, R 1 -SH, in the presence of a solvent and an amine base, as hydrogen halide acceptor. Aromatic hydrocarbons, such as toluene, are suitable as the solvent. Any tertiary amine base is suitable, but the trialkylamines appear to be most suitable. Water should be excluded from the reaction mixture--as by using anhydrous reagents and conducting the treatment under nitrogen. Isolation of the product is effected by conventional techniques.
The phosphonothioic chloride precursor (II, X is oxygen) can be prepared by a method analogous to that described in U.S. Pat. No. 4,190,652 for preparing the corresponding phosphonodithioic chloride--i.e., by treating a phosphonic dichloride of the formula ##STR7## with an appropriate thiol, R 1 -SH, in the presence of an inert solvent and an amine base as hydrogen chloride acceptor. Aromatic hydrocarbons, such as toluene, are suitable as the solvent. Any tertiary amine base is suitable, but the trialkylamines appear to be most suitable. Water should be excluded from the reaction mixture--as by using anhydrous reagents and conducting the treatment under nitrogen. Isolation of the product is effected by conventional techniques.
The phosphonothioic chloride (II, X is oxygen) also can be prepared by the method described by A. A. Neimysheva, et al., Journal of General Chemistry, U.S.S.R. (English), 1966, volume 36, pages 520-525--i.e., by slowly adding an appropriate sulfenyl chloride
R.sup.1 --S--Cl (VI)
to a stirred solution of the appropriate phosphonous dichloride of the formula ##STR8## in sulfur dioxide at a low temperature--e.g., -15° C. to -60° C.--then warming the resulting mixture to room temperature, stripping it of volatiles and vacuum distilling the residue to give the product.
Those phosphonothioic chlorides (II, X is oxygen) wherein R 1 is alkyl also can be prepared by treating a S,S--di--R 1 R-phosphonodithioate of the formula ##STR9## wherein both of R 1 are the same, with a chlorinating agent selected from sulfuryl chloride and chlorine. Suitably, the treatment is conducted by adding the chlorinating agent to a stirred solution of the dithioate in an inert solvent, at a temperature of about 0°-10° C. Suitable solvents are the haloalkanes, such as methylene dichloride and carbon tetrachloride. Water should be excluded from the reaction mixture--as by using anhydrous reagents and conducting the treatment under nitrogen--i.e., in a nitrogen atmosphere. Preferably a slight stoichiometric excess--up to about 10% excess--of the chlorinating agent is used, relative to the dithioate. Isolation and purification of the product is accomplished by conventional techniques. In many cases, the by-product R 1 -sulfenyl chloride is a low-boiling material that is easily removed by evaporation techniques.
The dithioate precursors (formula VIII) can be prepared by known methods. Conveniently, they can be prepared by treating the appropriate alkylphosphonous dichloride (VII) in an inert solvent, with two equivalents of the appropriate thiol, R 1 -SH, either in the form of its alkyl metal salt, or in the presence of two equivalents of a hydrogen chloride acceptor.
The sulfonamide precursors (III) as a class are known compounds, and the alkali metal salts thereof are prepared by conventional methods and techniques, as is demonstrated in the Examples, hereinafter. Those of the class that are novel are readily prepared by conventional methods, as by treating the appropriate sulfonyl halide, R 3 --SO 2 --halogen, with the appropriate amine, R 2 NH 2 . Compounds of Formula III wherein R 3 =-NR 4 R 5 are prepared; a method for their preparation is described by G. Weisz and G. Schulze, Annalen Der Chemic, volume 729, pages 40-51 (1969).
The preparation and isolation of particular individual species of the genus of Formula I are described in the Examples, hereinafter. Other typical individual species are the following, each identified in terms of the symbols in Formula I, in all cases X being oxygen:
______________________________________Species R R.sup.1 R.sup.2 R.sup.3______________________________________A methyl propyl methyl 1-piperidinoB ethyl 1-methyl- methyl 1-piperidino propylC ethyl propyl methyl 4-morpholinoD methyl 1-methyl- methyl 4-morpholino propylE methyl propyl methyl di-(n-butyl)aminoF ethyl 1-methyl- methyl di-(n-butyl)amino propylG ethyl propyl methyl (methyl)(phenyl)aminoH methyl 1-methyl- methyl (methyl)(phenyl)amino propylI ethyl propyl propargyl methylJ methyl 1-methyl- propargyl methyl propylK methyl propyl propargyl dimethylaminoL ethyl 1-methyl- propargyl dimethylamino propylM methyl propyl methyl 2-(ethoxycarbonyl)-1- piperidinoN ethyl 1-methyl- methyl 2-(ethoxycarbonyl)-1- propyl piperidino______________________________________
The preparation, isolation and testing of individual species of the genus of Formula I, in particular instances, are described in the following examples. In each case, the identity of each of the products, and each of the precursors, was confirmed as necessary by appropriate chemical and spectral analyses.
EXAMPLE 1
S-(1-methylpropyl) P-ethyl N-methyl-N-(methylsulfonyl)-phosphonamidothioate (1)
Under nitrogen, 30.7 ml of triethylamine was added over 10 minutes to a stirred mixture of 14.7 g of ethylphosphonic dichloride, 23.9 ml of 2-butanethiol and 125 ml of dry toluene at 5°-10° C. The resulting mixture was stirred at 5° C. for 2 hours, then at room temperature for 15 hours, diluted with ether and filtered. The filtrate was washed with water, dried (Na 2 SO 4 ) and stripped of solvent. Hexane was added to the residue, and the mixture was washed with dilute aqueous bicarbonate solution, then with water, dried (Na 2 SO 4 ) and stripped of solvent. The residue was distilled in a Kugelrohr apparatus to give S,S-bis(1-methylpropyl)ethylphosphonodithioate (1A).
Under nitrogen, a solution of 1.64 ml of sulfuryl chloride in 10 ml of carbon tetrachloride was added drop-by-drop over 36 minutes to a stirred solution of 5.09 g of 1A in 40 ml of carbon tetrachloride at 0° C. The resulting mixture was stirred at 0° C. for 7 minutes, for 1.5 hours at 5° C., then stripped of solvent under very low pressure, and the residue was distilled in a Kugelrohr apparatus to give S-(1-methylpropyl)ethylphosphonochloridothioate (1B), as a colorless liquid, b.p.: 70° C., 0.005 Torr.
7.55 g of methylamine was added over one hour to a stirred mixture of 11.4 g of methanesulfonyl chloride and 50 ml of ether at 5° C. The resulting mixture was stirred at 5° C. for one hour, for 15 hours at room temperature, then filtered. The filtrate was dried (MgSO 4 ) and stripped of solvent, to give N-methyl methanesulfonamide (1C), as a yellow liquid.
0.12 g of sodium hydride was added to a stirred mixture of 0.54 g of 1C and 10 ml of ether, at 5° C. under nitrogen. The resulting mixture was stirred at room temperature for one hour, cooled to 5° C. and a solution of 1 g of 1B in 3 ml of ether was added drop-by-drop, at 5°-10° C. The mixture was stirred for 2.5 hours at 5° C., at room temperature for 24 hours, then 3 ml of tetrahydrofuran was added and the mixture was stirred for 16 hours. Then the mixture was diluted with methylene chloride, and washed with water, and the organic phase was dried (Na 2 SO 4 ) and the solvent was evaporated. The residue was vacuum-chromatographed over silica gel, using ether as eluent, to give 1, as an amber liquid.
EXAMPLE 2
S-propyl P-ethyl N-(ethylsulfonyl)-N-methylphosphonamidothioate (2)
41.0 g of sulfuryl chloride was added drop-by-drop to 25.5 ml of 1-propanethiol, with stirring, at 0° C., under nitrogen. After 15 minutes, the mixture was added drop-by-drop (over 45 minutes) to 40.62 g of ethylphosphonous dichloride and 60 ml of sulfur dioxide at -70° C. under nitrogen. After 20 minutes the mixture was allowed to warm to room temperature and the solvent was evaporated. The residue was distilled in a Kugelrohr apparatus to give S-propyl ethylphosphonochloridothioate (2A) as a colorless liquid, b.p.: 95° C., 0.30 Torr.
2 was prepared as a yellow liquid, by treating 2A with N-methyl ethanesulfonamide (prepared from ethylsulfonyl chloride and methylamine, according to the procedure described for preparing 1C from methylsulfonyl chloride and methylamine), according to the procedure described in Example 1 for preparing 1 from 1B and 1C.
EXAMPLES 3 TO 138
The following additional individual species of the genus of Formula I, each identified in terms of the symbols used in Formula I, in all cases X being oxygen, were prepared from the appropriate reagents by the procedures described in Examples 1 and 2.
TABLE I__________________________________________________________________________ExampleCompoundNo. No. R R.sup.1 R.sup.2 R.sup.3 Physical State__________________________________________________________________________3 3 ethyl propyl methyl methyl Amber liquid4 4 ethyl 1-methylpropyl methyl phenyl Yellow liquid5 5 ethyl propyl methyl phenyl Yellow liquid6 6 ethyl 1-methylpropyl methyl 4-methylphenyl Amber liquid7 7 ethyl propyl methyl 4-methylphenyl Amber liquid8 8 ethyl 1-methylpropyl methyl phenyl Amber liquid9 9 ethyl 1-methylpropyl methyl 4-chlorophenyl Amber liquid10 10 ethyl 1-methylpropyl 1-methyl- phenyl Amber liquid ethyl11 11 ethyl 1-methylpropyl benzyl phenyl Yellow liquid12 12 ethyl 1-methylpropyl methyl styryl Yellow liquid13 13 ethyl 1-methylpropyl methyl 2,4,6-trimethyl- Amber liquid phenyl14 14 ethyl 1-methylpropyl methyl 2,5-dichloro- White solid, m.p.: phenyl 90-96° C.15 15 ethyl 1-methylpropyl methyl 4-bromophenyl Yellow liquid16 16 ethyl 1-methylpropyl methyl 2-nitrophenyl Amber liquid17 17 ethyl 1-methylpropyl methyl 1-methylethyl Pale yellow liquid18 18 ethyl propyl methyl chloromethyl Yellow liquid19 19 ethyl propyl methyl butyl Pale yellow liquid20 20 ethyl propyl methyl 3-chloropropyl Yellow liquid21 21 ethyl propyl methyl 1-methylethyl Yellow liquid22 22 ethyl 1-methylpropyl phenyl phenyl Yellow liquid23 23 ethyl 1-methylpropyl methyl 1-naphthyl Yellow liquid24 24 ethyl 1-methylpropyl methyl 2,4,5-tri- Amber liquid chlorophenyl25 25 ethyl 1-methylpropyl methyl 4-nitrophenyl Amber liquid26 26 ethyl 1-methylpropyl methyl 4-methoxyphenyl Yellow liquid27 27 ethyl propyl methyl 2-naphthyl Yellow liquid28 28 ethyl propyl methyl 2,4,6-trimethyl- Yellow liquid phenyl29 29 ethyl propyl methyl 1-naphthyl Yellow liquid30 30 ethyl propyl methyl 2,4,5-tri- Yellow liquid chlorophenyl31 31 ethyl propyl methyl 2,5-dichloro White solid phenyl m.p.: 81.5-85.532 32 ethyl propyl methyl 2-nitrophenyl Yellow liquid33 33 ethyl propyl methyl 4-bromophenyl Yellow liquid34 34 ethyl propyl methyl 4-nitrophenyl Yellow liquid35 35 ethyl propyl methyl 4-methoxyphenyl Yellow liquid36 36 ethyl 1-methylpropyl methyl chloromethyl Yellow liquid37 37 ethyl 1-methylpropyl methyl 3-chloropropyl Yellow liquid38 38 ethyl 1-methylpropyl methyl butyl Pale yellow liquid49 39 ethyl 1-methylpropyl methyl ethyl Yellow liquid40 40 ethyl 1-methylpropyl methyl 4-chlorophenyl Yellow liquid41 41 ethyl propyl methyl benzyl Yellow liquid42 42 ethyl propyl methyl styryl Yellow liquid43 43 ethyl butyl methyl 1-methylethyl Colorless liquid44 44 methyl propyl methyl 1-methylethyl Yellow liquid45 45 methyl 1-methylpropyl methyl 2-naphthyl Yellow liquid46 46 ethyl propyl methyl phenyl Yellow liquid47 47 ethyl 2-methylpropyl methyl 1-methylethyl Pale yellow liquid48 48 ethyl 2-methylpropyl methyl 3-chlorophenyl Pale yellow liquid49 49 ethyl 2-methylpropyl methyl ethyl Pale yellow liquid50 50 ethyl hexyl methyl 1-methylethyl Colorless liquid51 51 ethyl 2-methylpropyl methyl butyl Pale yellow liquid52 52 ethyl 2-methylpropyl methyl 2-chlorophenyl Colorless liquid53 53 ethyl 1,1-dimethylethyl methyl ethyl Pale yellow liquid54 54 ethyl 1,1-dimethylethyl methyl 3-chloropropyl Pale yellow liquid55 55 ethyl 1,1-dimethylethyl methyl 1-methylethyl Yellow liquid56 56 ethyl 1,1-dimethylethyl methyl chloromethyl Colorless liquid57 57 ethyl propyl methyl dichloromethyl Yellow liquid58 58 ethyl 1-methylpropyl methyl dichloromethyl Yellow liquid59 59 ethyl propyl methyl propyl Pale yellow liquid60 60 ethyl propyl 1-methylethyl phenyl Yellow liquid61 61 ethyl propyl methyl phenyl Yellow liquid62 62 ethyl 1-methylpropyl methyl 4-fluorophenyl Amber liquid63 63 ethyl 1-methylpropyl methyl 4-iodophenyl Amber liquid64 64 ethyl 1-methylpropyl methyl 3-nitrophenyl Amber liquid65 65 ethyl 1-methylpropyl methyl 2-aminophenyl Amber liquid66 66 ethyl 1,1-dimethylpropyl methyl methyl Pale yellow liquid67 67 ethyl 1,1-dimethylpropyl methyl 1-methylethyl Pale yellow liquid68 68 ethyl propyl methyl octyl Pale yellow liquid69 69 methyl propyl methyl ethyl Pale yellow liquid70 70 methyl 1-methylpropyl methyl ethyl Pale yellow liquid71 71 ethyl 1-methylpropyl methyl 2-thienyl Amber liquid72 72 methyl propyl methyl propyl Pale yellow liquid73 73 methyl propyl methyl octyl Pale yellow liquid74 74 methyl 1-methylpropyl methyl octyl Pale yellow liquid75 75 methyl propyl methyl chloromethyl Pale yellow liquid76 76 methyl 1-methylpropyl methyl propyl Yellow liquid77 77 methyl propyl methyl 3-chloropropyl Pale yellow liquid78 78 methyl 1-methylpropyl methyl 3-chloropropyl Yellow liquid79 79 methyl 1-methylpropyl methyl chloromethyl Pale yellow liquid80 80 ethyl 1-methylpropyl methyl 2,4-dinitrophenyl Amber liquid81 81 ethyl 1-methylpropyl methyl 4-(methylamino) Yellow liquid 3-nitrophenyl82 82 ethyl 1-methylpropyl methyl 2,4,6-trimethyl Yellow liquid phenyl83 83 ethyl 1-methylpropyl methyl 3-(methylamino- Yellow gel carbonyl)phenyl84 84 ethyl propyl methyl 4-iodophenyl Yellow liquid85 85 ethyl propyl methyl 4-fluorophenyl Yellow liquid86 86 methyl propyl methyl butyl Yellow liquid87 87 methyl 1-methylpropyl methyl butyl Pale yellow liquid88 88 methyl 1-methylpropyl methyl 1-methylethyl Yellow liquid89 89 methyl propyl methyl methyl Pale yellow liquid90 90 methyl 1-methylpropyl methyl methyl Pale yellow liquid91 91 ethyl 1-methylpropyl methyl propyl Pale yellow liquid92 92 ethyl 1,1-dimethylethyl methyl methyl Pale yellow liquid93 93 ethyl propyl methyl 2,4-dinitro- Yellow liquid phenyl94 94 ethyl propyl methyl 4-(methylamino)-2- Yellow liquid nitrophenyl95 95 ethyl propyl methyl 2-aminophenyl Amber liquid96 96 ethyl propyl methyl 2-thienyl Yellow liquid97 97 ethyl 1,1-dimethylethyl methyl propyl Pale yellow liquid98 98 ethyl 1-methylpropyl methyl propyl Pale yellow liquid99 99 ethyl propyl methyl 4-fluorophenyl Yellow liquid100 100 ethyl propyl methyl 2,4,6-trimethyl- Yellow liquid phenyl101 101 ethyl 2-methylpropyl methyl methyl Very pale yellow liquid102 102 ethyl 2-methylpropyl methyl octyl Pale yellow liquid103 103 methyl propyl methyl 2-methyl-2- Very pale yellow propenyl liquid104 104 methyl 1-methylpropyl methyl 2-methyl-2- Very pale yellow propenyl liquid105 105 ethyl 1-methylpropyl methyl 2-methyl-2- Pale yellow liquid propenyl106 106 ethyl propyl methyl 3-(methylamino- Colorless liquid carbonyl)phenyl107 107 ethyl 1-methylpropyl methyl 3-pyridyl Amber liquid108 108 ethyl propyl methyl 3-pyridyl Amber liquid109 109 methyl propyl methyl phenyl Amber liquid110 110 methyl 1-methylpropyl methyl phenyl Yellow liquid111 111 methyl propyl methyl 4-bromophenyl Yellow liquid112 112 methyl 1-methylpropyl methyl 4-bromophenyl Yellow liquid113 113 methyl propyl ethyl methyl Pale yellow liquid114 114 methyl 1-methylpropyl ethyl ethyl Yellow liquid115 115 methyl propyl ethyl ethyl Very pale yellow liquid116 116 methyl 1-methylpropyl ethyl methyl Pale yellow liquid117 117 methyl 1-methylpropyl methyl methyl Pale yellow liquid118 118 methyl 1,1-dimethylethyl methyl 3-chloropropyl Pale yellow liquid119 119 methyl 1,1-dimethylethyl methyl methyl Yellow liquid120 120 methyl 1,1-dimethylethyl methyl propyl Pale yellow liquid121 121 methyl 1-methylpropyl ethyl 1-methylethyl Yellow liquid122 122 methyl 1-methylpropyl propyl 1-methylethyl Yellow liquid123 123 methyl 1-methylpropyl propyl ethyl Pale yellow liquid124 124 ethyl propyl methyl 2-methyl-2- Pale yellow liquid propenyl125 125 methyl 1,1-dimethylpropyl methyl 1-methylethyl Yellow liquid126 126 methyl propyl propyl methyl Yellow liquid127 127 methyl propyl propyl ethyl Yellow liquid128 128 methyl 2-methylpropyl methyl methyl Yellow liquid129 129 methyl 2-methylpropyl methyl propyl Yellow liquid130 130 ethyl 1,1-dimethylethyl methyl butyl Pale yellow liquid131 131 methyl propyl ethyl 1-methylethyl Yellow liquid132 132 methyl 2-methylpropyl methyl 1-methylethyl Yellow liquid133 133 methyl 1-methylpropyl methyl octyl Pale yellow liquid134 134 methyl propyl methyl 3-(ethylthio)- Yellow liquid propyl135 135 methyl 1-methylpropyl methyl 3-(ethylthio) Pale yellow liquid propyl136 136 methyl 1-methylpropyl ethyl 3-chloropropyl Yellow liquid137 137 ethyl propyl methyl 3-(ethylthio) Yellow liquid propyl138 138 ethyl 1-methylpropyl methyl 3-(ethylthio) Yellow liquid propyl__________________________________________________________________________
EXAMPLE 139
S-1,1-dimethylpropyl N,P-dimethyl-N-((1-methylethyl)sulfonyl)phosphonamidodithioate (139)
At about 0° C., 17.05 g of 40% methylamine in water was added drop-by-drop to a solution of 14.25 g of 1-methylethanesulfonyl chloride in 30 ml of methylene chloride. Then the mixture was allowed to warm to room temperature, held for 2 hours, and diluted with water. The organic phase was separated, dried (Na 2 SO 4 ) and stripped of solvent to give N,1-dimethylethanesulfonamide (139A), as an amber liquid.
26.85 g of methylphosphonothioic dichloride and 18.5 ml of 1,1-dimethylpropanethiol were mixed with 25 ml of dry toluene under nitrogen. Then 15.15 g of triethylamine was added drop-by-drop to the mixture over 45 minutes, the temperature of the mixture being allowed to rise to 38° C. The mixture was filtered, and the solvent was stripped from the filtrate. The residue was slurried in ether, the slurry was filtered, and the filtrate was stripped of solvent. The residue was distilled under reduced pressure in a Kugelrohr apparatus to give 1,1-dimethylpropyl methylphosphonochloridodithioate (139B), b.p.: 70° C. at 0.03 Torr.
A solution of 0.95 g of 139A in 1 ml of dry THF was added drop-by-drop to a suspension of 0.37 g of sodium hydride in 4 ml of dry THF, under nitrogen, at 0° C. The mixture was allowed to warm to room temperature, then after 30 minutes was cooled to 0° C. and a solution of 1.5 g of 139B in 2 ml of dry THF was added drop-by-drop. The mixture was allowed to warm to room temperature and after 3 hours and 40 minutes was filtered. The solvent was stripped from the filtrate. The residue was flash chromatographed over silica gel using a 1.5:8.5 v:v mixture of ethyl acetate and a hexane as eluent, to give 139, as a yellow liquid.
EXAMPLE 140
S-1-methylpropyl P-ethyl-N-methyl-N-(phenylsulfonyl)phosphonamidodithioate (140)
With stirring at 5° C., 6.8 g of 40% methylamine in water was added over 45 minutes to 17.7 g of a mixture of benzenesulfonyl chloride and 50 ml of dry THF. Then the mixture was stirred at room temperature for 5.5 hours, diluted with methylene chloride and filtered. The filtrate was washed with water, dried (Na 2 SO 4 ) and stripped of solvent. The residue was dissolved in methylene chloride, the solution was washed with water, dried and stripped of solvent to give N-methyl-benzenesulfonamide (140A), as a yellow liquid.
At 5° C., under nitrogen, 34.8 ml of triethylamine was added drop-by-drop over 10 minutes to a stirred mixture of 40.75 g of ethylphosphonothioic dichloride and 22.5 g of 2-butanethiol. The resulting mixture was stirred at room temperature for 21 hours, diluted with ether, filtered, and the solvent was stripped from the filtrate. The residue was distilled in a Kugelrohr apparatus to give 1-methylpropyl ethylphosphonochloridodithioate (140B), as a yellow liquid, b.p.: 90° C., 0.003 Torr.
At 5° C., under nitrogen, 1.2 g of potassium tertiary-butoxide was added to a stirred solution of 1.7 g of 140A in 30 ml of acetonitrile. The mixture was stirred at room temperature for one hour, a solution of 2.25 g of 140B in 6 ml of acetonitrile was added drop-by-drop, the mixture was stirred for 3 hours and then refluxed for 4 days. The mixture was diluted with methylene chloride, washed with water, dried (Na 2 SO 4 ) was stripped of solvent. The residue was vacuum-chromatographed on silica gel, using a 9:1 v:v mixture of methylene chloride and ether as eluent. The entire product was rechromatographed over silica gel using a 1:1 v:v mixture of methylene chloride and hexane, to give 140, as a yellow liquid.
EXAMPLES 141 TO 144
The following additional individual species of the genus of Formula I, each identified in terms of the symbols used in Formula I, X being sulfur in all cases, were prepared from the appropriate reagents by the procedures described in Examples 139 and 140.
TABLE II______________________________________Ex-am- Com-ple pound PhysicalNo. No. R R.sup.1 R.sup.2 R.sup.3 State______________________________________141 141 methyl 1-methyl- methyl 1-methyl- colorless propyl ethyl liquid142 142 ethyl 1-methyl- methyl 1-methyl- colorless propyl ethyl liquid143 143 ethyl propyl methyl 1-methyl- colorless ethyl liquid______________________________________
EXAMPLE 144
S-(1-methylpropyl) P-ethyl-N-(dimethylaminosulfonyl)-N-methylphosphonamidothioate (144)
At 5° C., 6.8 g of a 40% solution of methylamine in water was added over 12 minutes to a stirred mixture of 14.3 g of dimethylsulfamoyl chloride and 50 ml of methylene chloride, and the mixture was stirred at room temperature for 24 hours. The organic phase was separated, washed with water, dried (MgSO 4 ) and stripped of solvent, to give trimethylsulfamide (144A), as a colorless liquid.
At 5° C., under nitrogen, 0.24 g of sodium hydride was added to a stirred solution of 0.69 g of 144A in 15 ml of THF, then a solution of 1.1 g of 1B in 3 ml of THF was added drop-by-drop over 2 minutes. The mixture was stirred a room temperature for 5 days, diluted with methylene chloride, washed with water, dried (Na 2 SO 4 ) and stripped of solvent. The residue was vacuum chromatographed over silica gel, using a 9:1 v:v mixture of methylene chloride and ether as eluent, to give 144, as a yellow liquid.
EXAMPLES 145-147
The following additional individual species of the genus of Formula I, each identified in terms of the symbols used in Formula I, X being oxygen and R 3 being dimethylamino, in all cases, were prepared from the appropriate reagents by the procedures described in Example 141.
TABLE III______________________________________Example Compound PhysicalNo. No. R R.sup.1 R.sup.2 State______________________________________145 145 ethyl propyl methyl yellow liquid146 146 methyl propyl methyl amber liquid147 147 methyl 1-methyl- methyl amber propyl liquid______________________________________
Compounds of the invention have been found to be toxic with respect to invertebrate pests, by which is meant insects of the class Insecta and related classes of arthropods, such as the acarids (e.g., mites), ticks, spiders, wood lice and the like. In particular, they have been found to be highly toxic to mites. Further, it has been found that compounds of the invention act systemically--that is, when applied to the plant, a compound of the invention penetrates into the cells and vascular system of the plant and is translocated therein and thereby disseminated throughout the plant without injury to the plant, yet effectively kills insects that chew upon tissues of the plant or suck juices from the plant. Some of the compounds act upon the insects very rapidly--i.e., they are "quick-knockdown agents", even though they may not be very toxic to the insects.
For application, a compound of the invention ordinarily is applied most effectively by formulating it with a suitable inert carrier or surface-active agent, or both. The invention, therefore, also includes compositions suitable for combatting pests, such compositions comprising an inert carrier or surface-active agent, or both, and as active ingredient at least one compound of the invention. The invention also provides a method of combatting pests at a locus, which comprises applying to that locus a compound of the invention or a pesticidal composition according to the invention.
The term "carrier" as used herein means an inert solid or liquid material, which may be inorganic or organic and of synthetic or natural origin, with which the active compound is mixed or formulated to facilitate its application to the plant, seed, soil or other object to be treated, or its storage, transport and/or handling. Any of the materials customarily employed in formulating pesticides--i.e., horticulturally acceptable adjuvants--are suitable.
Suitable solid carriers are natural and synthetic clays and silicates, for example, natural silicas such as diatomaceous earths; magnesium silicates, for example, talcs; magnesium aluminum silicates, for example, attapulgites are vermiculites; aluminum silicates, for example, kaolinites, montmorillonites and micas; calcium carbonate; calcium sulfate; synthetic hydrated silicon oxides and synthetic calcium or aluminum silicates; elements such as, for example, carbon and sulfur; natural and synthetic resins such as, for example, coumarone resins, polyvinyl chloride and styrene polymers and copolymers; bitumen; waxes such as, for example, beeswax, paraffin wax, and chlorinated mineral waxes; solid fertilizers, for example, superphosphates; and ground, naturally-occurring, fibrous materials, such as ground corncobs.
Examples of suitable liquid carriers are water, alcohols such as isopropyl alcohol and glycols; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone; ethers such as cellosolves; aromatic hydrocarbons such as benzene, toluene and xylene; petroleum fractions such as kerosene, light mineral oils; chlorinated hydrocarbons such as carbon tetrachloride, perchloroethylene and trichloromethane. Also suitable are liquefied, normally vaporous and gaseous compounds. Mixtures of different liquids are often suitable.
The surface-active agent may be an emulsifying agent or a dispersing agent or a wetting agent; it may be nonionic or ionic. Any of the surface-active agents usually applied in formulating herbicides or insecticides may be used. Examples of suitable surface-active agents are the sodium and calcium salts of polyacrylic acids and lignin sulfonic acids; the condensation products of fatty acids or aliphatic amines or amides containing at least 12 carbon atoms in the molecule with ethylene oxide and/or propylene oxide; fatty acid esters of glycerol, sorbitan, sucrose or pentaerythritol; condensates of these with ethylene oxide and/or propylene oxide; condensation products of fatty alcohols or alkyl phenols, for example, p-octylphenol or p-octylcresol, with ethylene oxide and/or propylene oxide; sulfates or sulfonates of these condensation products, alkali or alkaline earth metal salts, preferably sodium salts, of sulfuric or sulfonic acid esters containing at least 10 carbon atoms in the molecule, for example, sodium lauryl sulfate, sodium secondary alkyl sulfates, sodium salts of sulfonated castor oil, and sodium alkylaryl sulfonates such as sodium dodecylbenzene sulfonate; and polymers of ethylene oxide and copolymers of ethylene oxide and propylene oxides.
The compositions of the invention may be prepared as wettable powders, dusts, granules, solutions, emulsifiable concentrates, emulsions, suspension concentrates and aerosols. Wettable powders are usually compounded to contain 25-75% by weight of active compound and usually contain, in addition to the solid carrier, 3-10% by weight of a dispersing agent, 2-15% of a surface-active agent and, where necessary, 0-10% by weight of stabilizer(s) and/or other additives such as penetrants or stickers. Dusts are usually formulated as a dust concentrate having a similar composition to that of a wettable powder but without a dispersant or surface-active agent, and are diluted in the field with further solid carrier to give a composition usually containing 0.5-10% by weight of the active compound. Granules are usually prepared to have a size between 10 and 100 BS mesh (1.676-0.152 mm), and may be manufactured by agglomeration or impregnation techniques. Generally, granules will contain 0.5-25% by weight of the active compound, 0-1% by weight of additives such as stabilizers, slow release modifiers and binding agents. Emulsifiable concentrates usually contain, in addition to the solvent and, when necessary, cosolvent, 10-50% weight per volume of the active compound, 2-20% weight per volume emulsifiers and 0-20% weight per volume of appropriate additives such as stabilizers, penetrants and corrosion inhibitors. Suspension concentrates are compounded so as to obtain a stable, non-sedimenting, flowable product and usually contain 10-75% weight of the active compound, 0.5-5% weight of dispersing agents, 1-5% of surface-active agent, 0.1-10% weight of suspending agents, such as defoamers, corrosion inhibitors, stabilizers, penetrants and stickers, and as carrier, water or an organic liquid in which the active compound is substantially insoluble; certain organic solids or inorganic salts may be dissolved in the carrier to assist in preventing sedimentation or as antifreeze agents for water.
Of particular interest in current practice are the water-dispersible granular formulations. These are in the form of dry, hard granules that are essentially dust-free, and are resistant to attrition on handling, thus minimizing the formation of dust. On contact with water, the granules readily disintegrate to form stable suspensions of the particles of active material. Such formulations contain 90% or more by weight of finely divided active material, 3-7% by weight of a blend of surfactants, which act as wetting, dispersing, suspending and binding agents, and 1-3% by weight of a finely divided carrier, which acts as a resuspending agent.
Aqueous dispersions and emulsions, for example, compositions obtained by diluting a wettable powder or a concentrate according to the invention with water, also lie within the scope of the present invention. The said emulsions may be of the water-in-oil or of the oil-in-water type, and may have thick, mayonnaise-like consistency.
It is evident from the foregoing that this invention contemplates compositions containing as little as about 0.0001% by weight to as much as about 95% by weight of a compound of the invention as the active ingredient.
The compositions of the invention may also contain other ingredients, for example, other compounds possessing pesticidal, especially insecticidal, acaricidal or fungicidal properties, as are appropriate to the intended purpose.
The method of applying a compound of the invention to control pests comprises applying the compound, ordinarily in a composition of one of the aforementioned types, to a locus or area to be protected from the insects, such as the foliage and/or the fruit of plants. The compound, of course, is applied in an amount sufficient to effect the desired action. This dosage is dependent upon many factors, including the carrier employed, the method and conditions of the application, whether the formulation is present at the locus in the form of an aerosol, or as a film, or as discrete particles, the thickness of film or size of particles, and the like. Proper consideration and resolution of these factors to provide the necessary dosage of the active compound at the locus to be protected are within the skill of those versed in the art. In general, however, the effective dosage of the compound of the invention at the locus to be protected--i.e., the dosage which the insect contacts--is of the order of 0.001 to 0.5% based on the total weight of the formulation, though under some circumstances the effective concentration will be as little as 0.0001% or as much as 2%, on the same basis.
Activity of compounds of the invention with respect to insect and acarine pests was determined by using standardized test methods to measure the toxicity of the compounds as follows:
I. Houseflies (Musca domestica (Linne)) were tested by placing 50 4- to 5-day old adult houseflies into a spray cage and spraying with 0.6 ml of a solution of test compound. After spraying, the flies were observed to ascertain any knockdown effect, and then were anesthetized with CO 2 and transferred to a recovery cage containing a milk pad for food. The cages were held for 18-20 hours after which mortality counts were made. Both dead and moribund flies were counted. The tests were conducted employing several different dosage rates for each test compound.
II. Pea aphids (Acyrthosiphon pisum (Harris)) were tested by placing about 100 adult aphids on broad bean plants. The plants were sprayed with dilutions of an acetone solution of the test compound in water containing an emulsifier and held under laboratory conditions for 18 to 20 hours, at which time the living aphids on the plants were counted. The tests were conducted employing several different dosage rates for each test compound.
III. Adult female two-spotted spider mites (Tetranychus urticae (Koch)) were tested by placing 50-75 mites on the bottom side of leaves of pinto bean plants. The leaves were sprayed with dilutions of an acetone solution of the test compound in water containing an emulsifier and kept under laboratory conditions for about 20 hours, at which time mortality counts were made. The tests were conducted employing several different dosage rates for each compound.
IV. Third instar corn earworm larvae (Heliothis zea (Boddie)) were tested by spraying broad bean plants with dilutions of an acetone solution of the test compound in water containing an emulsifier. Immediately after spraying, 5 larvae were transferred to the plant and held for 44-46 hours, at which time the dead and moribund larvae were counted. The tests were conducted employing several different dosage rates for each test compound.
In each set of tests, identical tests were conducted using parathion as a standard for comparison.
In each instance, the toxicity of the test compound was compared to that of a standard pesticide, parathion, the relative toxicity of the test compound then being expressed in terms of the relationship between the amount of the test compound and the amount of the standard pesticide required to produce the same percentage (50%) of mortality in the test insects. By assigning the standard pesticide an arbitrary rating of 100, the toxicity of the test compound was expressed in terms of the Toxicity Index, which compares the toxicity of the test compound of the invention with that of the standard pesticide. That is to say, a test compound having a Toxicity Index of 50 would be half as active, while one having a Toxicity Index of 200 would be twice as active, as the standard pesticide. The results are set forth in Table IV.
TABLE IV______________________________________ Toxicity IndexCompound Pea Corn SpiderNumber Housefly Aphid Earworm Mite______________________________________1 30K.sup.(a) 30K 30.sup. 21002 25K.sup. 20K 60.sup. 23003 40K.sup. 10K 35.sup. 24004 30K.sup. 25K 10.sup. 120005 10K.sup. 10.sup. 55.sup. 32006 10 .sup. 20K 0.sup. 5207 0 .sup. 10K 0.sup. 3708 30K.sup. 100.sup. 15.sup. 38009 30K.sup. 70.sup. 45.sup. 260010 25K.sup. 30K 20.sup. 150011 30K.sup. 150K 10.sup. 85012 15K.sup. 50K 20.sup. 100013 10K.sup. 35K 10.sup. 47014 15K.sup. 25K 10.sup. 230015 15K.sup. 25K 10.sup. 1750016 30K.sup. 25K 10.sup. 65017 25K.sup. 30.sup. 40.sup. 140018 30K.sup. 25K 15.sup. 350019 20K.sup. 10K 5.sup. 410020 20K.sup. 15.sup. 10.sup. 500021 15K.sup. 10.sup. 15.sup. 700022 10K.sup. 15K 10.sup. 100023 <5K.sup. 15K 5.sup. 110024 <5K.sup. 15K 10.sup. 50025 5K.sup. 5K 5.sup. 75026 10K.sup. 35K 0.sup. 75027 0 .sup. 5.sup. 0.sup. 44028 0 .sup. 5.sup. 0.sup. 5029 0 .sup. 5.sup. 0.sup. 46030 <5 .sup. 5.sup. 0.sup. 80031 <5K.sup. 5.sup. 0.sup. 510032 10K.sup. <5K 0.sup. 54033 <5 .sup. 5K 10.sup. 240034 < 5 .sup. <5.sup. 0.sup. 65535 <5 .sup. 5.sup. 0.sup. 42536 20K.sup. 15K 5.sup. 220037 15K.sup. 25K 5.sup. 220038 20K.sup. 60.sup. 5.sup. 320039 20K.sup. 60.sup. 10.sup. 220040 15K.sup. 20K 5.sup. 290041 10K.sup. 20.sup. 15.sup. 290042 5K.sup. 10K 5.sup. 120043 0 .sup. 5K 0.sup. 34044 10K.sup. 10K 280.sup. 420045 <5K.sup. 10K 10.sup. 90046 <5K.sup. 5K 5.sup. 85047 5K.sup. 10K 0.sup. 90048 5 .sup. 120K 0.sup. 100049 5K.sup. 60K 30.sup. 43050 0 .sup. <5.sup. 0.sup. 4551 5K.sup. 30K 0.sup. 100052 15K.sup. 30K 5.sup. 490053 15K.sup. 45K 95.sup. 80054 5K.sup. 30K 15.sup. 250055 10K.sup. 45K 35.sup. 100056 15K.sup. 40K 35.sup. 300057 5K.sup. 10.sup. 5.sup. 320058 15K.sup. 20.sup. 0.sup. 460059 10K.sup. 15.sup. 65.sup. 510060 0 .sup. 5.sup. 0.sup. 150061 <5 .sup. 5.sup. 10.sup. 35062 15K.sup. 40.sup. 10.sup. 480063 5K.sup. 30.sup. 20.sup. 280064 10K.sup. 10.sup. 15.sup. 510065 10K.sup. 10.sup. 0.sup. 29066 30K.sup. 90.sup. 15K 120067 25K.sup. 120.sup. 15.sup. 170068 0 .sup. 0.sup. 0.sup. 510069 10K.sup. 20.sup. 160.sup. 450070 15K.sup. 10.sup. 160K 230071 10K.sup. 50.sup. 0.sup. 240072 10K.sup. 35.sup. 115K 240073 0 .sup. <5.sup. 0.sup. 50074 <5K.sup. 45.sup. 30.sup. 65075 10K.sup. 25.sup. 35K 240076 20K.sup. 85.sup. 35.sup. 380077 10K.sup. 10.sup. 20.sup. 550078 10K.sup. 35.sup. 70.sup. 550079 20K.sup. 130K 20.sup. 180080 <5 .sup. 0.sup. 0.sup. 26081 <5 .sup. <5.sup. <5.sup. 65082 <5 .sup. <5.sup. 0.sup. 65083 <5 .sup. 5.sup. 0.sup. 45084 <5K.sup. 5.sup. 10.sup. 170085 <5K.sup. 0.sup. 10.sup. 130086 <5K.sup. 5.sup. 30.sup. 160087 10K.sup. 20K 20.sup. 430088 15K.sup. 20K 40.sup. 830089 15K.sup. 15K 110.sup. 120090 20K.sup. 20K 130.sup. 230091 5K.sup. 15K 0.sup. 280092 15K.sup. 30K 75.sup. 160093 <5 .sup. 0.sup. 0.sup. 8594 0 .sup. 0.sup. 5.sup. 46095 0 .sup. 0.sup. 0.sup. 6096 5 .sup. 10.sup. 0.sup. 530097 5K.sup. 10.sup. 25.sup. 480098 10K.sup. 20.sup. 15.sup. 790099 <5 .sup. 5.sup. 30.sup. 4800100 0 .sup. 5.sup. 0.sup. 2300101 10K.sup. 25.sup. 0.sup. 3200102 < 5K.sup. 10.sup. 0.sup. 2700103 <5K.sup. 5.sup. 10.sup. 2000104 5K.sup. 20.sup. 10.sup. 1700105 10K.sup. 40.sup. 0.sup. 4100106 <5K.sup. <5.sup. 0.sup. 475107 5K.sup. 20.sup. 0.sup. 3000108 5K.sup. 10.sup. 10.sup. 2000109 5K.sup. 30.sup. 55.sup. 3300110 5 .sup. 75.sup. 25.sup. 4300111 75 .sup. 5.sup. 20.sup. 1100112 5 .sup. 20.sup. 20.sup. 1800113 10 .sup. 20.sup. 120.sup. 1700114 10 .sup. 30.sup. 70.sup. 1800115 5 .sup. 15.sup. 90.sup. 2400116 10 .sup. 120.sup. 35.sup. 750117 10 .sup. 25.sup. 20.sup. 1000118 5 .sup. 60.sup. 15.sup. 1600119 10 .sup. 30.sup. 20.sup. 600120 15 .sup. 120.sup. 10.sup. 100121 10 .sup. 40.sup. 30.sup. 750122 20K.sup. 85K 30K 2600123 20K.sup. 65K 20K 5300124 10K.sup. 25K <5.sup. 3300125 20K.sup. 95K 30.sup. 3500126 20K.sup. 25.sup. 35.sup. 1900127 20K.sup. 40K 35K 6200128 25K.sup. 70K 100K 3500129 20K.sup. 70K 70K 2400130 5K.sup. 30.sup. 5K 800131 10K.sup. 45.sup. 25K 1100132 20K.sup. 50.sup. 35.sup. 500133 5K.sup. 25.sup. 0.sup. 1700134 5K.sup. 30.sup. 25.sup. 800135 20K.sup. 60.sup. 40.sup. 1100139 10K.sup. 30K 20.sup. 240140 <5 .sup. 10.sup. 0.sup. 280141 10K.sup. 15K 30.sup. 240142 5K.sup. 60K 5.sup. 45143 5 .sup. 15.sup. 10.sup. 430144 20K.sup. 100.sup. 20.sup. 2800145 5K.sup. 20.sup. 25.sup. 1200146 15 .sup. 60.sup. 20.sup. 1100147 15 .sup. 40.sup. 80.sup. 1900______________________________________ .sup.(a) K indicates "rapid knockdown
Additional compounds of this invention are those of Formula I wherein R, R 1 , R 2 and R 3 are as defined in Table V.
TABLE V______________________________________Com- Phys-pound ical*No. R R.sup.1 R.sup.2 R.sup.3 State______________________________________148 CH.sub.3 n-C.sub.3 H.sub.7 C.sub.2 H.sub.5 CH.sub.3 P Y L149 CH.sub.3 sec-C.sub.4 H.sub.9 C.sub.2 H.sub.5 C.sub.2 H.sub.5 Y L150 CH.sub.3 n-C.sub.3 H.sub.7 C.sub.2 H.sub.5 C.sub.2 H.sub.5 P Y L151 CH.sub.3 sec-C.sub.4 H.sub.9 C.sub.2 H.sub.5 CH.sub.3 P Y L152 CH.sub.3 sec-C.sub.4 H.sub.9 n-C.sub.3 H.sub.7 CH.sub.3 P Y L153 CH.sub.3 tert-C.sub.5 H.sub.11 CH.sub.3 3-chloro-propyl Y L154 CH.sub.3 tert-C.sub.5 H.sub.11 CH.sub.3 CH.sub.3 Y L155 CH.sub.3 tert-C.sub.5 H.sub.11 CH.sub.3 n-C.sub.3 H.sub.7 P Y L156 CH.sub.3 sec-C.sub.4 H.sub.9 C.sub.2 H.sub.5 iso-C.sub.3 H.sub.7 Y L157 CH.sub.3 sec-C.sub.4 H.sub.9 n-C.sub.3 H.sub.7 iso-C.sub.3 H.sub.7 Y L158 CH.sub.3 sec-C.sub.4 H.sub.9 n-C.sub.3 H.sub.7 C.sub.2 H.sub.5 P Y L159 C.sub.2 H.sub.5 n-C.sub.3 H.sub.7 CH.sub.3 2-methyl-1- P Y L propene160 CH.sub.3 tert-C.sub.5 H.sub.11 CH.sub.3 iso-C.sub.3 H.sub.7 Y L161 CH.sub.3 C.sub.3 H.sub.7 n-C.sub.3 H.sub.7 CH.sub.3 Y L162 CH.sub.3 C.sub.3 H.sub.7 n-C.sub.3 H.sub.7 C.sub.2 H.sub.5 Y L163 CH.sub.3 iso-C.sub.4 H.sub.9 CH.sub.3 CH.sub.3 Y L164 CH.sub.3 iso-C.sub.4 H.sub.9 CH.sub.3 C.sub.3 H.sub.7 Y L165 C.sub.2 H.sub.5 tert-C.sub.4 H.sub.9 CH.sub.3 n-C.sub.4 H.sub.9 P Y L166 CH.sub.3 n-C.sub.3 H.sub.7 C.sub.2 H.sub.5 iso-C.sub.3 H.sub.7 Y L167 CH.sub.3 iso-C.sub.4 H.sub.9 CH.sub.3 iso-C.sub.3 H.sub.7 Y L168 C.sub.2 H.sub.5 sec-C.sub.4 H.sub.9 CH.sub.3 n-C.sub.8 H.sub.17 P Y L169 CH.sub.3 n-C.sub.3 H.sub.7 CH.sub.3 3-ethylthio-propyl Y L170 CH.sub.3 sec-C.sub.4 H.sub.9 CH.sub.3 3-ethylthio-propyl P Y L171 C.sub.2 H.sub.5 tert-C.sub.4 H.sub.9 CH.sub.3 phenyl Y L172 CH.sub.3 tert-C.sub.4 H.sub.9 CH.sub.3 phenyl Solid mp 95° to 101° C.173 CH.sub.3 sec-C.sub.4 H.sub.9 CH.sub.3 3-chloropropyl Y L174 C.sub.2 H.sub.5 n-C.sub.3 H.sub.7 CH.sub.3 3-ethylthiopropyl Y L175 C.sub.2 H.sub.5 sec-C.sub.4 H.sub.9 CH.sub.3 3-ethylthiopropyl Y L176 C.sub.2 H.sub.5 iso-C.sub.4 H.sub.9 CH.sub.3 dimethylamino Y L177 CH.sub.3 tert-C.sub.4 H.sub.9 CH.sub.3 dimethylamino Y L178 CH.sub.3 iso-C.sub.4 H.sub.9 CH.sub.3 dimethylamino Y L179 C.sub.2 H.sub.5 tert-C.sub.4 H.sub.9 CH.sub.3 dimethylamino Y L180 C.sub.2 H.sub.5 n-C.sub.3 H.sub.7 C.sub.2 H.sub.5 dimethylamino Y L181 C.sub.2 H.sub.5 tert-C.sub.4 H.sub.9 C.sub.2 H.sub.5 dimethylamino Y L182 C.sub.2 H.sub.5 sec-C.sub.4 H.sub.9 C.sub.2 H.sub.5 dimethylamino Y L183 C.sub.2 H.sub.5 sec-C.sub.4 H.sub.9 CH.sub.3 4-morpholino B L184 C.sub.2 H.sub.5 sec-C.sub.4 H.sub.9 CH.sub.3 piperidino B L185 CH.sub.3 tert-C.sub.4 H.sub.9 C.sub.2 H.sub.5 dimethylamino Y L186 CH.sub.3 n-C.sub.3 H.sub.7 C.sub.2 H.sub.5 dimethylamino Y L187 C.sub.2 H.sub.5 tert-C.sub.4 H.sub.9 CH.sub.3 4-morpholino Y L188 CH.sub.3 tert-C.sub.4 H.sub.9 CH.sub.3 4-morpholino Y L189 CH.sub.3 iso-C.sub.4 H.sub.9 CH.sub.3 4-morpholino Y L190 CH.sub.3 tert-C.sub.4 H.sub.9 CH.sub.3 piperidino Y L191 CH.sub.3 iso-C.sub.4 H.sub.9 CH.sub.3 piperidino Y L192 CH.sub.3 tert-C.sub.5 H.sub.11 CH.sub.3 4-morpholino Y L193 CH.sub.3 tert-C.sub.5 H.sub.11 CH.sub.3 piperidino Y L194 CH.sub.3 tert-C.sub.5 H.sub.11 CH.sub.3 dimethylamino Y L195 C.sub.2 H.sub.5 tert-C.sub.5 H.sub.11 C.sub.2 H.sub.5 dimethylamino Y L196 C.sub.2 H.sub.5 tert-C.sub.5 H.sub.11 CH.sub.3 dimethylamino Y L______________________________________ *P Y L = Pale Yellow Liquid Y L = Yellow Liquid B L = Brown Liquid
Systemic Activity Tests
Systemic activity of compounds of Formula I was determined as follows:
Mite Tests
The roots of pinto bean plants (Phaseolus vulgaris) in the primary leaf stage were placed in a flask containing water plus the test chemical. The stem of the plant was wrapped with non-absorbent cotton fitted snugly into the neck of the flask, to prevent possible fumigant action by the test chemical. Then the plant was infested with 50-100 adult female two-spotted spider mites, held for 48 hours at 85° F., and 50% relative humidity when mortality in the mites was determined visually. A series of different dosages of the test compound in the water were used, and the LC 50 dosage (the dosage in parts per million by weight of the test chemical in the water required to effect fifty percent kill of the mites) was determined.
Compounds Nos. 1, 2, 3, 5, 17, 18, 19, 21, 26, 36, 37, 39, 44, 48, 51-59, 62, 64, 66, 67, 69-72, 75-79, 86-92, 96-99, 101, 103-105, 107-110, 120, 122-129, 131, 135 and 144-147 were found to have significant activity.
Aphid Tests
Broad bean plants in the 6 to 8 leaf stage were removed from pots and their roots were washed free of soil. Each was placed in a flask containing 100 ml of a water solution of the test compound. The plant stems were wrapped with non-absorbent cotton fitted snugly into the neck of the flask to prevent possible fumigant action by the test compound. The flask was positioned under a wooden stage with the stem of the plant extending up through a slot in the stage. A 6"×6" square of paper was placed flat on the stage around the stem of the plant. A plastic ring 5 inches in diameter and 2 inches high, coated on the inside with petroleum jelly, was placed around the plant to prevent the aphids from escaping. 50 to 100 aphids were placed within each ring. Then the plant was held for 48 hours at 85° F., and 50% relative humidity when mortality in the mites was determined visually. A series of different dosages of the test compound in the water were used, and the LC 50 dosage (the dosage in parts per million by weight of the test chemical in the water required to effect fifty percent kill of the aphids) was determined.
Compounds Nos. 1, 3, 17, 18, 21, 39, 44, 48, 52, 55, 56, 59, 66, 69, 71, 72, 75-79, 86-92, 97, 98, 101, 105, 107, 110, 114, 116, 122-129, 131, 133-135, 144 and 147 were found to have significant activity. | Compounds of the formula ##STR1## wherein the symbols have assigned meanings, and their use as insecticides and/or miticides. | 2 |
TECHNICAL FIELD
This invention relates generally to voice over Internet protocol (VOIP) and more specifically to providing information about the location of a VOIP telephone user associated with a 911 request for emergency services.
BACKGROUND
Advances in technology continue to provide alternatives for consumers in the telecommunication field. Telephony services provided by VOIP are now relatively commonplace. However, new implementations and capabilities, such as VOIP telephone service as compared with traditional wireline switch based services, also present challenges in providing comparable features and abilities provided by the existing technology. Sometimes the advantages of the new technology may give rise to challenges not faced by the existing technology.
For example, consider a VOIP/IP system that provides telephony services for users in a large office building or in a campus of related buildings. The use of VOIP telephones in such a system provides substantial flexibility in that a telephone can be easily moved to a new location or office within the system just by plugging the telephone in a different VOIP port. This minimizes the administrative and technical support and costs associated with relocating a person or a group from one location within the complex to another location.
However, this gives rise to an increased challenge with regard to providing effective emergency services in response to a 911 call origination. In a traditional wireline telephone system, each telephone was associated with a specific telephone line that was located in a predetermined location. The location of the telephone line/telephone, which did not change without a request being made to the telecommunication provider, could be stored in a database by the telecommunications provider and utilized in conjunction with providing emergency personnel with location information upon the user making a 911 emergency request. Because VOIP telephones are easily transportable at least within the designed system, determining the location of a VOIP telephone user initiating a 911 emergency request call is not as straightforward as it was with wireline telephones. Thus, a need exists for an improved and reliable way of maintaining the specific location of a VOIP telephone, especially one located within a multiple story building, that can be utilized to provide location information for 911 services.
SUMMARY
It is an object of the present invention to address this need.
An exemplary method automatically identifies the location of a voice over Internet protocol (VOIP) telephone relative to the structure of a building upon the VOIP telephone making a 911 call. The identity of the VOIP telephone is transmitted to a database accessible by the VOIP system upon a 911 call origination. Records have been previously created and stored in the database that link each VOIP telephone located in or associated with a building to one of a plurality of text based descriptions of areas of the building. A node instructs the database to find the stored record associated with the VOIP telephone. The identity of the VOIP telephone and the text based location information of the location of the VOIP telephone relative to the structure of the building are transmitted to the 911 call center. This enables a 911 call center operator to immediately discern the location of the 911 caller relative to the structure of the building.
Further implementations of the invention encompass a VOIP system for practicing the method and a node in the VOIP system that is instrumental in obtaining the location information from the database and transmitting it to the 911 call center upon a 911 call origination. Additionally, personnel such as security, fire or medical located in or near the building can be automatically sent a message notifying them upon a 911 call origination.
DESCRIPTION OF THE DRAWINGS
Features of exemplary implementations of the invention will become apparent from the description, the claims, and the accompanying drawings in which:
FIG. 1 is a block diagram of the exemplary VOIP telecommunication system in accordance with the present invention.
FIG. 2 is a block diagram of an exemplary VOIP telephone in accordance with the present invention.
FIG. 3 is a flow diagram of an exemplary method in accordance with the present invention where locations of significant areas within a building are determined and stored.
FIG. 4 is a flow diagram of an exemplary method in accordance with the present invention where locations of VOIP telephones within the building are determined and associated with the location of an area in the building.
FIG. 5 is a flow diagram of an exemplary method in accordance with the present invention illustrating the communication of location information about a VOIP telephone from which a 911 call request is initiated.
DETAILED DESCRIPTION
Referring to FIG. 1 , an exemplary VOIP telephony system 10 is utilized to provide telephone services to a plurality of users in a multiple story office building 12 . In this example it is assumed that a single business enterprise occupies all of building 12 and hence controls an integrated VOIP telephony system utilized to provide services to all of its employees within the building. Illustrative offices within the multiple stories of the building may contain a desk 14 and a VOIP telephone 16 that preferably includes a data input jack suited for receiving and transmitting data such as with a user's laptop computer 18 . Each VOIP telephone is connected by a cable that is ultimately served by a VOIP router 22 that handles the routing of packets received from the VOIP telephones and routing of packets to the destination VOIP telephone. The router 22 is connected to an IP server 24 and to the public switched telephone network (PSTN) 26 that is connected to a plurality of telecommunication devices including a 911 service center 30 . The service center 30 is typically a telecommunications center with one or more operators supported by a community for handling requests for emergency services such as directed to police, fire, or medical service units. Typically each operator of a service center is provided with a voice line for communicating with a user making an emergency request and also a data line associated with the voice line for receiving information such as location information that may be displayed on a monitor or a visual location on a map. The server 24 is also connected to an E-911 database 28 that stores a record for each VOIP telephone 16 with the record containing location information or an index to the current location on the VOIP telephone. The determination on the location of each VOIP telephone will be discussed in more detail below.
FIG. 2 is a block diagram of an exemplary VOIP telephone 50 in accordance with an embodiment of the present invention. A central processing unit (CPU) 52 is supported by read-only memory (ROM) 54 and random access memory (RAM) 56 . The CPU operates under program instructions initially stored in the ROM. The RAM provides run-time control instructions for the CPU as well as providing for the storage of data an input and output signals. A global positioning satellite system (GPS) module 58 is coupled to the CPU and provides location information consisting of latitude, longitude and altitude. The GPS module needs to receive satellite signals in order to provide the location information. The signals can be acquired by an antenna 60 coupled to the GPS module or from a remote antenna connected to signal input jack 62 coupled to the GPS module. An input/output (I/O) module 64 is coupled to the CPU and facilitates the coupling of external signals to the CPU and transferring of signals from the CPU to other devices or transmission lines. In the illustrative example, a microphone 66 couples a user's voice information to the CPU and a speaker 68 couples output audio information to the user. A transmission line 70 is supported by I/O module 64 and carries packet data between the VOIP telephone 50 and an external node such as VOIP router 22 . Also supported by the I/O module 64 is a transmission line 72 that carries data and control information between the VOIP telephone 50 and an external node such as laptop computer 18 . Any convenient communication protocol, e.g. Ethernet, could be utilized to convey the information between the VOIP telephone 50 and the computer 18 .
A general understanding of the exemplary method by which current location information associated with a VOIP telephone is made available in conjunction with emergency 911 call requests from the VOIP telephone will be helpful in understanding the detailed description explained with regard to FIG. 3 . The kind of location information normally desired by a 911 service center is a location of the calling party (the calling party's telephone) in terms of street address and if the user is in a multiple story office building, the specific area or office number of the user. The location of the user within a multiple story office building is especially important because the operator at the 911 service center may be required to dispatch different equipment and/or emergency service personnel depending upon the location of the user. For example, the operator may dispatch a conventional fire truck unit if the user is located on the first or second floor of an office building. However, if the user is known to be located on the fifth floor of an office building, the operator may dispatch a special long reach hook and latter fire truck unit in the event of a fire emergency. Thus, having such current location information available is important in order to dispatch in the first instance proper personnel and equipment.
The E-911 database 28 may contain location information about each office or significant area within building 12 as well as the street address of the office building. This location information may be collected by performing a manual walk-through of the building utilizing a laptop computer in association with a GPS receiver. A series of records may be created in which each record identifies the office or significant area of the building along with a corresponding GPS three-dimensional location. This information which is essentially an internal map of the building is stored in the database.
Periodically each VOIP telephone is required to transmit its GPS location to database 28 . This could occur at scheduled intervals or be automatically triggered for transmission upon a 911 call being initiated. The GPS location of the VOIP telephone is utilized as an index to scan the database for the closest appropriate GPS location stored in a record that corresponds to a designated office or area of the building. The subject VOIP telephone is then associated with the corresponding record having the same or nearest location. This association can be maintained in a variety of ways. For example, the telephone number associated with the VOIP telephone can be stored in the same record associated with the office/area location, or a new record can be created containing the VOIP telephone number and the corresponding office location and information, e.g. “office on third floor, northwest corner” or “office 312 ”.
FIG. 3 is an exemplary flow diagram explaining how a multiple story building is mapped so that a location is stored for each significant area associated with the building. In the illustrative example, the location of each area is stored as a corresponding latitude, longitude and altitude such as available from a GPS receiver. In step 100 the GPS location (LB) of each significant area in the multiple story building is determined. In step 102 a text description (TD) is generated for each of the significant areas. The GPS locations may be manually determined by a walk-through of the building while utilizing a portable GPS receiver. The text description may also be manually generated by entering an alphanumeric description of the area into a record of a database. The text description can take any form that would be of use to 911 emergency personnel in determining the location of the area in the building. For example, a text description could be: “third-floor office, northwest corner” or “conference room 502 ” or “southeast corner of interior courtyard”. In step 104 a record is created in a database (DB) that is accessible to the VOIP network where the record contains the TD and LB. A determination is made in step 106 of whether all of the significant areas of the building have had a corresponding location determined. A YES determination results in termination of the process at END step 108 . A NO determination results in the process continuing by returning to step 100 where locations of additional areas will be determined.
FIG. 4 is a flow diagram illustrating an exemplary method by which the location of each VOIP telephone associated with the building is identified with a corresponding building location LB. In step 140 the GPS location (LT) of each VOIP telephone associated with the multiple story building is periodically determined. If each VOIP telephone preferably includes a GPS module 58 as shown in FIG. 2 , each telephone can be configured to periodically transmit its GPS location LT to the database DB. This may for example be programmed to occur during a time interval when loading of the VOIP network is light such as at 2 a.m. each day. Alternatively, an administrator using a laptop computer and a GPS receiver (which may be built-in to the laptop computer) can physically couple the computer to each VOIP telephone, determine a GPS location, and cause the VOIP telephone to transmit the data to the database DB. This manual collection by the administrator could be accomplished at any periodic interval, e.g. during each Saturday. In step 142 the identification of the VOIP telephone together with the location LT is transmitted to the database DB. In step 144 the database or processing node associated with the database compares the location LT of each VOIP telephone to the stored locations LB in the database. A determination is made on the appropriate location LB closest to the location LT of the VOIP telephone. In step 146 the identification of the VOIP telephone is stored in a record so that it is associated with the corresponding identified location LB. In step 148 a determination is made of whether it is time for a check of the location LT of the VOIP telephones. A NO determination results in the process returning to the beginning of step 148 creating essentially a wait state. A YES determination results in the process returning to the beginning of step 140 .
FIG. 5 is a flow diagram of an illustrated embodiment demonstrating how information about the location of a specific VOIP telephone is automatically transmitted to a 911 call center upon a 911 call being initiated from the VOIP telephone. In step 170 a 911 call request is initiated from a VOIP telephone in the multiple story building. In step 172 identification of the VOIP telephone is automatically transmitted to the database DB. The identification of the VOIP telephone may for example consist of its assigned telephone number or other identification code. In step 174 the database or a processing node associated with the database locates the record in the database associated with the identity of the VOIP telephone. In step 176 information from the located record is transmitted to the 911 call center. The information will preferably contain at least the identity of the VOIP telephone and the location LB associated with it. It is preferred that the location LB that is transmitted consist of the text description of the location of the VOIP telephone together with additional information such as the complete street address of the building. Of course, the specific GPS location LB of the VOIP telephone could be transmitted in addition to, or in place of, the text information depending upon the needs of the switching and location equipment used by the 911 call center. The transmission of this location information may be associated with, i.e. linked to, the corresponding voice call being simultaneously generated by the initiation of the 911 call from the VOIP telephone.
The steps or operations described herein are just exemplary. There may be many variations to these steps or operations without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted, or modified.
Although exemplary implementations of the invention have been depicted and described in detail herein, it will be apparent to those skilled in the relevant art that various modifications, additions, substitutions, and the like can be made. For example, the VOIP router 22 or server 24 could function as the node by which the building locations are initially mapped and stored within the database. This node can also serve as the intelligent query element that retrieves the corresponding text based description of the location of the VOIP telephone upon a 911 call origination. It is of course possible for the intelligence associated with this node to be embedded in various network elements. Even the 911 service center could function as such a node and generate queries upon the receipt of a 911 call based on the identification of the VOIP telephone.
Similarly, the database itself could be integrated within another network element. Although the identity of a VOIP telephone must be linked to the text based location information stored in the database, this can be accomplished in different ways. For example, the identity of a VOIP telephone can be stored in the record that contains the text based location information or a pointer or list index could be utilized to establish the correspondence between the VOIP telephone identity and the text based location information.
In selecting the closest “appropriate” location of an area mapped within the building with which to associate the location of a particular VOIP telephone, it will be beneficial to consider factors that will be useful to emergency personnel. For example, the appropriate closest location should be selected to be on the same level or floor of the building as the VOIP telephone even if a physically closer area exists on a different floor. Although GPS location information is envisioned, other ways of identifying a three-dimensional location could be used. Personnel such as security, fire or medical located in or near the building can be automatically notified upon a 911 call origination. The identity of such personnel can be stored in the database and can be sent a message based on which personnel are closest to the VOIP telephone making the 911 call origination. This action is in addition to the normal routing of the call to 911. Further such personnel can be conferenced in a full duplex mode or listen only mode to the 911 call itself either at the VOIP router or PSTN switch serving the 911 call center.
The scope of the invention is defined by the following claims. | An exemplary method automatically identifies the location of a voice over Internet protocol (VOIP) telephone relative to the structure of a building upon the VOIP telephone making a 911 call. The identity of the VOIP telephone is transmitted to a database accessible by the VOIP system upon a 911 call origination. Records have been previously created and stored in the database that link each VOIP telephone located in or associated with a building to a text based description of an area of the building. A node instructs the database to find the stored record associated with the VOIP telephone. The identity of the VOIP telephone and the text based location information of the location of the VOIP telephone relative to the structure of the building are transmitted to the 911 call center. This enables a 911 call center operator to immediately discern the location of the 911 caller relative to the structure of the building. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a garment steamer. More particularly, the present invention relates to a transportable garment steamer providing improved efficiency, effectiveness and convenience in use.
[0003] 2. Description of the Prior Art
[0004] Garment steamers for use in the home are well known. For example, U.S. Pat. No. 5,609,047, U.S. Pat. No. 5,123,266, U.S. Pat. No. 4,426,857 and EP 0 079 866 each disclose a different variation on such a device.
[0005] None of the above, provide for a garment steamer that cooperates with a variety of different attachments to create a variety of different steam or vapor emitting effects, generates/emits a concentration of ions and/or ozone, and has a variety of other advantageous features. Such features include a collapsible/telescopic hanger/rod assembly, a separable fluid container, a separable insulated hose, as well as various safety features for improving safety in use. Thus, there is a need for a portable home garment steamer having the aforementioned features to provide greater flexibility, convenience, and efficiency in use. Also, preferably the steamer has a body that is sleek, compact, lightweight, and easily transportable.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a garment steamer for use in a home.
[0007] It is another object of the present invention to provide such a garment steamer that is sleek, compact and lightweight.
[0008] It is still another object of the present invention to provide such a garment steamer that improves flexibility and efficiency in use.
[0009] It is yet another object of the present invention to provide such a garment steamer that cooperates with a variety of different attachments for producing a variety of different steam or vapor emitting effects.
[0010] It is a further object of the present invention to provide such a garment steamer that has a selectively adjustable and collapsible telescopic hanger/rod assembly.
[0011] It is still a further object of the present invention to provide such a garment steamer that has an ion and/or ozone generating/emitting feature.
[0012] These and other objects and advantages of the present invention are achieved by a garment steamer having a housing or base, a separable fluid container in separable fluid communication with a fluid heating assembly, a fluid heating assembly, a separable hose in separable fluid communication with the fluid heating assembly as well as with a variety of attachments, an adjustable and collapsible telescopic hanger/rod assembly, and at least one ion/ozone generator/emitter assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention is more fully understood by reference to the following detailed description of an illustrative embodiment in combination with the drawings identified below.
[0014] [0014]FIG. 1 is a side view of the garment steamer in accordance with an illustrative embodiment of the present invention;
[0015] [0015]FIG. 2 is a side partially sectional view of the garment steamer of FIG. 1;
[0016] [0016]FIG. 3 is a side view of the garment steamer of FIG. 1, showing the fluid container separated from the base;
[0017] [0017]FIG. 4 is a side section view of an illustrative adapter-hose connection;
[0018] [0018]FIG. 5 is a first view of a collapsible hanger for cooperating with the garment steamer of FIG. 1, showing the hanger in an extended or open position;
[0019] [0019]FIG. 6 is a second view of the collapsible hanger of FIG. 5, showing the hanger in a collapsed or closed position;
[0020] [0020]FIG. 7 is a side view of a straightening attachment for cooperating with the garment steamer of FIG. 1;
[0021] [0021]FIG. 8 is a top view of the straightening attachment of FIG. 7;
[0022] [0022]FIG. 9 is an end view of the straightening attachment of FIG. 7;
[0023] [0023]FIG. 10 is a side view of a concentrating attachment for cooperating with the garment steamer of FIG. 1;
[0024] [0024]FIG. 11 is a top view of the concentrating attachment of FIG. 10;
[0025] [0025]FIG. 12 is an end view of the concentrating attachment of FIG. 10;
[0026] [0026]FIG. 13 is a side view of a wand attachment for cooperating with the garment steamer of FIG. 1;
[0027] [0027]FIG. 14 is a side view of a nozzle attachment for cooperating with the garment steamer of FIG. 1;
[0028] [0028]FIG. 15 is a top view of the nozzle attachment of FIG. 14;
[0029] [0029]FIG. 16 is an end view of the nozzle attachment of FIG. 14;
[0030] [0030]FIG. 17 is a side view of a brush accessory for cooperating with the nozzle attachment of FIG. 14;
[0031] [0031]FIG. 18 is a top view of the brush accessory of FIG. 17;
[0032] [0032]FIG. 19 is an end view of the brush accessory of FIG. 17;
[0033] [0033]FIG. 20 is a side view of a fluff accessory for cooperating with the nozzle attachment of FIG. 14; and
[0034] [0034]FIG. 21 is an end view of the fluff accessory of FIG. 20.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Referring to the drawings and in particular, FIGS. 1 and 2, there is shown a garment steamer in accordance with an illustrative embodiment of the present invention generally represented by reference numeral 1 . Garment steamer 1 has a housing or base 10 , a fluid container 20 , a fluid heating assembly 30 , a hose 40 , a hanger/rod assembly 50 , and at least one ion/ozone generator/emitter assembly 70 . Preferably, garment steamer 1 cooperates with a variety of different attachments 80 to provide a variety of different steaming or vaporizing effects.
[0036] Preferably, base 10 has a wide relatively flat lower portion 12 and a tall relatively cylindrical upper portion 14 configured to distribute the weight of steamer 1 such that the center of gravity thereof is lowered closer to the ground thereby improving the overall stability of the device. Also preferably, lower portion 12 and upper portion 14 each enclose a portion of fluid heating assembly 30 .
[0037] Lower portion 12 preferably has a number of transport structures 16 mounted to a bottom surface thereof. Preferably, transport structures 16 have at least four lightweight wheels made preferably of a durable plastic material. However, transport structures 16 can be of any type known to facilitate easy transport of steamer 1 . Lower portion 12 preferably also has a cord reel (not shown) for selectively retaining or storing a power chord (not shown). Alternatively, lower portion 12 can have a cord wrap 18 that allows a user to wrap and store a power cord (also not shown). In addition, lower portion 12 preferably has a control 19 disposed thereon for controlling one or more operative functions, including powering the device. Control 19 can be of any type known and sufficient to provide the user with effective access and easy use.
[0038] Upper portion 14 preferably is centrally disposed above lower portion 12 . Upper portion 14 preferably has a recess 11 with a first connector 13 for receiving fluid container 20 and connecting fluid container 20 to fluid heating assembly 30 , a second connector 15 for connecting fluid heating assembly 30 to hose 40 , and a third connector 17 for connecting hanger/rod assembly 50 .
[0039] Referring to FIGS. 2 and 3, fluid container 20 preferably can be removed or separated from recess 11 . Fluid container 20 preferably has a handle 22 and a cap 24 . Handle 22 preferably enables the user to easily manage or cope with fluid container 20 as he/she selectively connects and/or separates the fluid container to and from recess 11 . In the illustrative embodiment shown in FIG. 3, cap 24 preferably is removable to allow the user to add fluid into fluid container 20 when the container is separated from recess 11 . Cap 24 preferably also has a spring valve 26 and an air vent 28 . Spring valve 26 can release when fluid container 20 has a volume of fluid therein and is placed into recess 11 such that cap 24 is in fluid communication with fluid heating assembly 30 via first connector 13 . The release of spring valve 26 allows gravity to force the fluid in fluid container 20 into fluid heating assembly 30 . Air vent 28 preferably prevents a vacuum from being created to ensure that the fluid can flow until an equilibrium point is reached with respect to the fluid position between fluid container 20 and fluid heating assembly 30 . Once the equilibrium point is reached, the fluid stops flowing.
[0040] Referring to FIG. 2, fluid heating assembly 30 preferably is centrally disposed in base 10 and has a fluid inlet 32 located in lower portion 12 of base 10 , a boiler 34 , and a fluid outlet 36 located in upper portion 14 of base 10 . Fluid inlet 32 preferably has a first tube 33 connecting boiler 34 and first connector 13 so that the first connector is in separable or releasable fluid communication with fluid container 20 . Boiler 34 preferably is die-cast and produces steam or vapor within a relatively short period of time (i.e. about 1 to about 2 minutes). Fluid outlet 36 preferably has a second tube 37 connecting boiler 34 to second connector 15 so that the second connector is in separable or releasable fluid communication with hose 40 .
[0041] Referring to FIG. 4, hose 40 is preferably an insulated hose that can be removably or separably connected to second connector 15 shown in FIG. 1. Preferably hose 40 is flexible and has at least an inner tube 42 and an outer tube 44 surrounding inner tube 42 . Inner tube 42 preferably facilitates thermal retention as well as fluid flow. Inner tube 42 can also preferably be formed of any suitable material for conducting heated steam or vapor. Outer tube 44 preferably provides a layer of insulation that improves thermal efficiency and increases safety in user handling. Preferably, hose 40 has an adapter 45 at each end thereof for selectively cooperating with second connector 15 and/or the variety of different attachments 80 . Preferably, adapter 45 has a tubular hollow shaft 46 with a number of annular ribs or barbs 47 and an abutment 48 disposed thereon. Barbs 47 and abutment 48 cooperate with the ends of hose 40 and a fastener 49 to frictionally connect adapter 45 , inner tube 42 , and outer tube 44 . It is noted that various other known connector assemblies may also be employed to accomplish the purpose of securely sealing and connecting hose 40 with the variety of different attachments 80 and second connector 15 , thereby providing fluid communication between heating assembly 30 and the variety of attachments. Thus, preferably when fluid container 20 is filled with fluid and placed in recess 11 such that cap 24 engages first connector 13 , fluid can flow through fluid inlet 32 and into boiler 34 to be rapidly heated or vaporized, which vapor is conveyed through fluid outlet 36 into hose 40 and out one of the variety of attachments 80 . Accordingly, the user is able to direct, manipulate or control the intensity and/or emission of the vapor to provide a variety of different steaming or vaporizing effects.
[0042] Referring to FIGS. 5 and 6, in one embodiment of the present invention, garment steamer 1 preferably cooperates with hanger/rod assembly 50 to support or hold garments during the steaming process. Hanger/rod assembly 50 is preferably selectively telescopically adjustable and collapsible. Preferably, assembly 50 has a rod 51 telescopically connected to base 10 and a hanger 52 , connected, preferably integrally to rod 51 to collapsibly cooperate therewith. Preferably, rod 51 is telescopically received and retained in base 10 and can have a number of locks 53 to allow the rod 51 to be securely fixed at a variety of different vertical positions. Also, rod 51 can cooperate with a hose retaining mechanism 41 for storing hose 40 when not in use. Further, rod 51 can be separably connected to base 10 and can have a selectively collapsible tripod or stand (not shown) connected or integral therewith. The collapsible stand preferably cooperates with rod 51 to allow the rod to both stand alone, separate from base 10 , and to be selectively received, supported and/or retained by the base. Thus, base 10 can serve as a holder and/or as a storage container for rod 51 when not in use.
[0043] Preferably, hanger 52 has an upper support or hub 54 , shown clearly in FIGS. 5 and 6, having one or more hanging supports 55 . Hanger 52 also preferably has at least two arms 56 pivotally connected to hub 54 . Each arm 56 has at least one hinge 57 pivotally connecting at least two beams 58 . Further, hanger 52 preferably has a lock/release button 59 for selectively positioning and securing arms 56 in a number of different positions to accommodate different types of garments. Still further, hanger 52 has at least two ribs 60 for cooperating with a slider 61 , which is slidable along rod 51 , to facilitate accomplishing the selective positioning of arms 56 . Also, hanger 52 , in addition to being connected, and preferably integral with rod 51 , can be selectively separable therefrom. This creates a greater flexibility in use, enabling the user to separably hang or support a garment on a wall or door. Also preferably, hanger 52 can be slidable along rod 51 such that the hanger can be selectively and securely positioned at any point along the rod.
[0044] Referring to FIG. 2, in another embodiment of the present invention, garment steamer 1 preferably cooperates with an ion and/or ozone assembly 70 to infuse a garment with odor-neutralizing ions and/or ozone. Preferably, assembly 70 has one or more ion and/or ozone generator(s) 71 and one or more ion and/or ozone emitter(s) 72 operatively connected with the one ion and/or ozone generator(s). However, it is noted that ion and/or ozone assembly 70 can be any device or system capable of generating and/or emitting ions and/or ozone, such as for example, an ultraviolet (UV) light source (not shown). Preferably, the ion and/or ozone generator 71 and the ion and/or ozone emitter 72 can be positioned at any location in relation to garment steamer 1 , suitable to optimize the effective operation thereof. The ion and/or ozone generator 71 can be any device suitable for adjustably generating voltage outputs of varying intensity and/or polarity as well as different combinations thereof. The ion and/or ozone emitter 72 can have any configuration suitable to conform to the arrangement and operation of garment steamer 1 . For example, the ion and/or ozone emitter 72 can be a conductive needle, a conductive plate or any other like structure. Further, the ion and/or ozone emitter 72 can be formed of any material suitable to effectively emit ions and/or ozone as well as to conform to the constraints associated the arrangement and/or operation of the garment steamer 1 . Examples of materials that might be used include, for example, conductive metal, conductive polymer, carbon material, or silicon based material. It is noted that the ion and/or ozone generator 71 and the ion and/or ozone emitter 72 are preferably configured for safety, as well as protection from damage caused by extensive and prolonged use.
[0045] It is noted that the variety of different attachments 80 , which cooperate with garment steamer 1 , to provide a variety of different steaming or vaporizing effects, can preferably be of any type suitable for effective use with heated vapor. For example, these attachments 80 may be a straightening attachment, as shown in FIGS. 7 through 9, a concentrator attachment, as shown in FIGS. 10 through 12, a wand attachment, as shown in FIG. 13, and a nozzle attachment, as shown in FIGS. 14 through 16. It is further noted that each of the variety of different attachments 80 can be configured to selectively cooperate with a variety of different accessory parts. For example, a brush accessory, as shown in FIGS. 17 through 19, or a fluff accessory, as shown in FIGS. 20 and 21. Thus, the accessory parts provide greater flexibility and efficiency in use.
[0046] Having identified and described the preferred embodiments of the present invention, it is appreciated that details may be modified in a variety of ways and that alternative embodiments are also within the scope of the present invention. For example, it is possible to provide at least one of the variety of different attachments 80 , shown in FIGS. 7 through 16 and/or accessory parts shown in FIGS. 17 through 21, with an ion and/or ozone generator and a corresponding ion and/or ozone emitter (not shown), having at least each of the attributes previously preferably described with respect to each. In this alternative embodiment, the ion and/or ozone emitter is preferably situated to effectively infuse or introduce ions and/or ozone into a garment. This introduction of ions and/or ozone into a garment has an odor-neutralizing effect and thus facilitates in the removal of lingering odors from various garments and fabrics. It is noted that the ion and/or ozone emitter can preferably be located in a selectively removable protective casing (not shown) thus preserving the integrity of the ion and/or ozone emitter and allowing selective access thereto, for cleaning and/or replacement thereof.
[0047] In another example, it is preferably possible to situate an ion and/or ozone generator and a corresponding ion and/or ozone emitter (not shown), having at least the attributes previously preferably described with respect to each, in base 10 proximate fluid outlet 36 . In this embodiment, the ion and/or ozone emitter is preferably situated to effectively infuse or introduce ions and/or ozone into the vaporized fluid exiting fluid outlet 36 . It is noted that infusing the vaporized fluid with ions and/or ozone can have a beneficial cleansing effect thereon to reduce the build up of dust and other debris, thereby improving efficiency and effectiveness of garment steamer 1 as well as extending the useful life thereof.
[0048] The present invention having been thus described with particular reference to the illustrated embodiments thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit of the present invention as defined herein. | There is provided a garment steamer for domestic use that cooperates with a variety of different attachments to provide a variety of different steam or vapor emitting effects. The garment steamer also has an ionic and/or ozone generating/emitting feature to facilitate neutralizing odor and removing undesirable particulate from a garment. The garment steamer may also have a hanger and rod assembly in which a collapsible hanger selectively cooperates with a telescopic rod, which is connected to a base, such that the hanger can be selectively positioned at any location along the height of the rod and/or disengaged from the rod. The garment steamer also includes a fluid heating assembly enclosed in the base, a separable fluid container in separable fluid communication with the fluid heating assembly, and a separable hose in separable fluid communication with the fluid heating assembly, as well as with the variety of different attachments. | 3 |
BACKGROUND
Numerous processes are within the purview of those skilled in the art for forming toners. Emulsion aggregation (EA) is one such method. EA toners are generally formed by aggregating a colorant with a latex polymer formed by emulsion polymerization. For example, U.S. Pat. No. 5,853,943, the disclosure of which is hereby incorporated by reference in its entirety, is directed to a semi-continuous emulsion polymerization process for preparing a latex emulsion by first forming a seed polymer. Other methods of emulsion/aggregation/coalescing for preparing toners are illustrated in U.S. Pat. Nos. 3,644,263; 3,879,327; 4,243,566; 5,403,693; 5,418,108; 5,364,729; 5,346,797; 5,527,658; 5,585,215; 5,650,255; 5,650,256; 5,501,935; 7,683,142; 7,977,024; 8,124,309; 8,163,459; and 8,168,699, the disclosures of which are hereby incorporated by reference in their entirety
Polyester toners have been prepared utilizing amorphous and crystalline polyester resins. The incorporation of these polyester resins into toner requires that the resins first be formulated into emulsions prepared by solvent containing batch processes, for example solvent-based phase inversion emulsification (PIE). PIE is currently the main process of forming emulsified polyester resin latex for use in polyester emulsion aggregation toners. Ammonium hydroxide (NH 4 OH) is commonly used as a “basic neutralization agent” in the polyester emulsification process. The ammonium hydroxide inverts the resin dissolved oil phase (resin/solvent solution) in water to form a stable aqueous emulsion.
In the PIE process, the type of base or neutralizing agent and ratio of neutralizing agent to resin or solvent plays a very critical role. There are many input process parameters such as resin composition, resin molecular weight and acid value that can vary which make it difficult to emulsify high molecular weight branched amorphous polyester resins to produce the desired particle size range (e.g., 100-250 nm) and a narrow particle size distribution. Lot-to-lot variations of resin acid value, viscosity, and resin softening point requires adjustments in the PIE process parameters such as neutralization ratio and solvent ratio to achieve the desired toner particle size. Determining such adjustments is time-consuming and requires much trial and error to identify the exact conditions that will allow a resin lot to be successfully emulsified. Moreover, even with these modifications some polyester resins are not successfully emulsified with failed batches.
It would thus be advantageous to identify a new process which can consistently provide the desired particle size without batch-to-batch variations.
SUMMARY
According to embodiments illustrated herein, there is provided a process for making a latex emulsion comprising: mixing at least one resin with an organic solvent to form a resin composition; generating neutralization agent vapors; combining the neutralization agent vapors with steam; and exposing the resin composition to the combination of the neutralization agent vapors and steam to initiate emulsification of the resin composition to form a latex emulsion.
In particular, the present embodiments provide a process for making a toner comprising: mixing at least one polyester resin with a solvent to form a resin composition; generating neutralization agent vapors; combining the neutralization agent vapors with steam; exposing the resin composition to the combination of the neutralization agent vapors and steam to initiate emulsification of the resin composition to form a latex emulsion; forming a pre-toner mixture by mixing the latex emulsion with an optional colorant, and an optional wax; aggregating particles from the pre-toner mixture; and coalescing the aggregated particles to form toner particles.
In further embodiments, there is provided an apparatus for preparing a latex or emulsion, comprising: a reaction vessel for initiating emulsification, a steam generator connected to the reaction vessel for providing steam to the reaction vessel; and a source of neutralization agent liquid connected to the reaction vessel for providing neutralization agent vapors to the reaction vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present embodiments, reference may be had to the accompanying figures.
FIG. 1A is an illustration of an apparatus for preparing a latex or emulsion according to the present embodiments;
FIG. 1B is an illustration of an alternative apparatus for preparing a latex or emulsion according to the present embodiments;
FIG. 10 is an illustration of yet another alternative apparatus for preparing a latex or emulsion according to the present embodiments;
FIG. 2 is a graph illustrating the particle size distribution achieved with the PIE process; and
FIG. 3 is a graph illustrating the particle size distribution achieved with the process according to the present embodiments.
DETAILED DESCRIPTION
In the following description, it is understood that other embodiments may be utilized and structural and operational changes may be made without departure from the scope of the present embodiments disclosed herein.
Processing
The main process of forming emulsified polyester resin latex for use in polyester emulsion aggregation toners is a solvent-based phase inversion emulsification (PIE) process. In this process, the neutralization agent is often used to invert the resin dissolved oil phase (resin/solvent solution) in water to form a stable aqueous emulsion. As stated above, in the PIE process, the type of base or neutralizing agent and ratio of neutralizing agent to resin or solvent plays a very critical role. The conventional PIE process took a series of trial-and-error to determine a correct ratio for preparing small size particle.
The present embodiments provide a new process for preparing latex emulsions with small particle size, through the simultaneous and direct injection of steam and neutralization agent vapors. In embodiments, the neutralizing agent is selected from the group consisting of ammonium hydroxide, sodium carbonate, potassium hydroxide, sodium hydroxide, sodium bicarbonate, lithium hydroxide, potassium carbonate, triethyl amine, triethanolamine, pyridine, pyridine derivatives, diphenylamine, diphenylamine derivatives, poly(ethylene amine), poly(ethylene amine) derivatives, amine bases and pieprazine, and mixtures thereof. In a specific embodiment, the neutralization agent is ammonium hydroxide.
In the present embodiments, steam and neutralization agent vapors are used to contact a resin composition, such as a polyester resin composition, rather than mixing the neutralization agent in liquid form as in the conventional PIE process. The resin composition is obtained by mixing at least one resin with an organic solvent to form a resin composition. In embodiments, the resin is selected from the group consisting of polyester, polyacrylate, polyolefin, polystyrene, polycarbonate, polyamide, polyimide, and mixtures thereof. In further embodiments, the polyester resin is selected from the group consisting of amorphous resins, crystalline resins, and mixtures thereof. In one embodiment, the water and neutralization agent in liquid form are separately heated to form steam and neutralization vapors. The steam and vapors are mixed before being introduced into the system to contact the polyester resin composition. In another embodiment, the neutralization agent is added to water and the two are heated together to gas phase. The resulting steam and vaporized neutralization agent are then brought in contact with the polyester resin composition. In another embodiment, the water is first heated to form steam and the steam is brought to heat the neutralization agent to form vapors. The resulting steam and vaporized neutralization agent are then brought in contact with the polyester resin composition.
As shown in FIG. 1 , the present process starts a local emulsification as prompted by gas phases and quickly expands the same scale emulsification globally. The expanded emulsification is driven by a dominant diffusion process enhanced locally by gas-phase and globally by heat/vapor pressure. Steam is generated and mixed with the neutralization agent vapors. In embodiments, a neutralization ratio of the neutralization agent in the latex emulsion is from 25% to 500%. In embodiments, the steam and neutralization agent vapors are mixed at a weight ratio of from about 1:100 to about 10:1, or of from about 1:50 to about 1:1, or of from about 1:25 to about 1:10. In embodiments, the temperature of the steam is from about 80° C. to about 150° C., or from about 80° C. to about 120° C., or from about 95° C. to about 100° C. In embodiments, then a pressure of the steam introduced to the resin composition is from 0.04 bar to about 4.76 bar. The introduction temperature range of the steam may fall outside of the above ranges, however, in cases where the introduction pressure range is modified, for example, increased to higher than or decreased to lower than the stated pressure ranges above. The mixture of steam and neutralization agent vapors is then brought in contact with the resin composition to prepare latex emulsion.
In the present embodiments, the prepared latex emulsion has a small average particle size of from about 5 nm to about 1000 nm, or from about 50 nm to about 700 nm, or from about 80 nm to about 300 nm.
The present embodiments can be carried out with an apparatus for preparing a latex or emulsion as shown in FIGS. 1A-1C . FIGS. 1A-1C show alternative embodiments of the apparatus 5 . In FIG. 1A , the apparatus 5 comprises a steam generator 10 to provide steam and a reaction vessel 15 connected to the steam generator 10 . The reaction vessel 15 is used to prepare the emulsion. The reaction vessel 15 may have an injection nozzle 20 which provides entry for the steam and neutralization agent vapors into the reaction vessel 15 . The reaction vessel 15 may also include an optional jacket 25 . A container 30 of neutralization agent liquid is connected to the reaction vessel 15 through a pump 35 that pumps the neutralization agent liquid to the reaction vessel 15 . The neutralization agent liquid forms vapors when it contacts the steam provided by the steam generator 10 en route to the reaction vessel 15 . In embodiments, a mechanical agitator 40 can be used to mix the contents of the reaction vessel 15 and initiate the emulsification.
In FIG. 1B , an alternative configuration of the apparatus 5 is provided. In this configuration, both water and neutralization agent are loaded in the same boiler 45 , wherein both water and neutralization agent are vaporized together in the boiler 45 . The reaction vessel 15 may have an injection nozzle 20 which provides entry for both of the steam and the neutralization agent vapor.
In FIG. 1C , an alternative configuration of the apparatus 5 is provided. In this configuration, the apparatus 5 comprises a steam generator 10 connected to a reaction vessel 15 to provide steam. The reaction vessel 15 also includes an optional jacket 25 . A neutralization agent vapor generator 50 is connected to the reaction vessel 15 which provides neutralization agent vapors to the reaction vessel 15 for the emulsification. The reaction vessel 15 may have an injection nozzle 20 which provides entry for the steam and neutralization agent vapors into the reaction vessel 15 . A mechanical agitator 40 can be used to mix the contents of the reaction vessel 15 and initiate the emulsification.
Resin
The resin composition may comprise one or more resins, such as two or more resins. The total amount of resin in the resin composition can be from about 1% to 99%, such as from about 10% to about 95%, or from about 20% to 90% by weight of the resin composition.
A resin used in the method disclosed herein may be any latex resin utilized in forming Emulsion Aggregation (EA) toners. Such resins, in turn, may be made of any suitable monomer. Any monomer employed may be selected depending upon the particular polymer to be used. Two main types of EA methods for making toners are known. First is an EA process that forms acrylate based, e.g., styrene acrylate, toner particles. See, for example, U.S. Pat. No. 6,120,967, incorporated herein by reference in its entirety, as one example of such a process. Second is an EA process that forms polyester, e.g., sodio sulfonated polyester. See, for example, U.S. Pat. No. 5,916,725, incorporated herein by reference in its entirety, as one example of such a process.
Illustrative examples of latex resins or polymers selected for the non-crosslinked resin and crosslinked resin or gel include, but are not limited to, styrene acrylates, styrene methacrylates, butadienes, isoprene, acrylonitrile, acrylic acid, methacrylic acid, beta-carboxy ethyl arylate, polyesters, known polymers such as poly(styrene-butadiene), poly(methyl styrene-butadiene), poly(methyl methacrylate-butadiene), poly(ethyl methacrylate-butadiene), poly(propyl methacrylate-butadiene), poly(butyl methacrylate-butadiene), poly(methyl acrylate-butadiene), poly(ethyl acrylate-butadiene), poly(propyl acrylate-butadiene), poly(butyl acrylate-butadiene), poly(styrene-isoprene), poly(methyl styrene-isoprene), poly(methyl methacrylate-isoprene), poly(ethyl methacrylate-isoprene), poly(propyl methacrylate-isoprene), poly(butyl methacrylate-isoprene), poly(methyl acrylate-isoprene), poly(ethyl acrylate-isoprene), poly(propyl acrylate-isoprene), poly(butyl acrylate-isoprene); poly(styrene-propyl acrylate), poly(styrene-butyl acrylate), poly(styrene-butadiene-acrylic acid), poly(styrene-butadiene-methacrylic acid), poly(styrene-butyl acrylate-acrylic acid), poly(styrene-butyl acrylate-methacrylic acid), poly(styrene-butyl acrylate-acrylonitrile), poly(styrene-butyl acrylate-acrylonitrile-acrylic acid), and the like, and mixtures thereof. The resin or polymer can be a styrene/butyl acrylate/carboxylic acid terpolymer. At least one of the resin substantially free of crosslinking and the cross linked resin can comprise carboxylic acid in an amount of from about 0.05 to about 10 weight percent based upon the total weight of the resin substantially free of cross linking or cross linked resin.
The monomers used in making the selected polymer are not limited, and the monomers utilized may include any one or more of, for example, styrene, acrylates such as methacrylates, butylacrylates, β-carboxy ethyl acrylate (β-CEA), etc., butadiene, isoprene, acrylic acid, methacrylic acid, itaconic acid, acrylonitrile, benzenes such as divinylbenzene, etc., and the like. Known chain transfer agents, for example dodecanethiol or carbon tetrabromide, can be utilized to control the molecular weight properties of the polymer. Any suitable method for forming the latex polymer from the monomers may be used without restriction.
The resin that is substantially free of cross linking (also referred to herein as a non-crosslinked resin) can comprise a resin having less than about 0.1 percent cross linking. For example, the non-crosslinked latex can comprise styrene, butylacrylate, and beta-carboxy ethyl acrylate (beta-CEA) monomers, although not limited to these monomers, termed herein as monomers A, B, and C, prepared, for example, by emulsion polymerization in the presence of an initiator, a chain transfer agent (CTA), and surfactant.
The resin substantially free of cross linking can comprise styrene:butylacrylate:beta-carboxy ethyl acrylate wherein, for example, the non-cross linked resin monomers can be present in an amount of about 70 percent to about 90 percent styrene, about 10 percent to about 30 percent butylacrylate, and about 0.05 parts per hundred to about 10 parts per hundred beta-CEA, or about 3 parts per hundred beta-CEA, by weight based upon the total weight of the monomers, although not limited. For example, the carboxylic acid can be selected, for example, from the group comprised of, but not limited to, acrylic acid, methacrylic acid, itaconic acid, beta carboxy ethyl acrylate (beta CEA), fumaric acid, maleic acid, and cinnamic acid.
In a feature herein, the non-crosslinked resin can comprise about 73 percent to about 85 percent styrene, about 27 percent to about 15 percent butylacrylate, and about 1.0 part per hundred to about 5 parts per hundred beta-CEA, by weight based upon the total weight of the monomers although the compositions and processes are not limited to these particular types of monomers or ranges. In another feature, the non-crosslinked resin can comprise about 81.7 percent styrene, about 18.3 percent butylacrylate and about 3.0 parts per hundred beta-CEA by weight based upon the total weight of the monomers.
The initiator can be, for example, but is not limited to, sodium, potassium or ammonium persulfate and can be present in the range of, for example, about 0.5 to about 3.0 percent based upon the weight of the monomers, although not limited. The CTA can be present in an amount of from about 0.5 to about 5.0 percent by weight based upon the combined weight of the monomers A and B, although not limited. The surfactant can be an anionic surfactant present in the range of from about 07 to about 5.0 percent by weight based upon the weight of the aqueous phase, although not limited to this type or range.
The resin can be a polyester resin such as an amorphous polyester resin, a crystalline polyester resin, and/or a combination thereof. The polymer used to form the resin can be a polyester resin described in U.S. Pat. Nos. 6,593,049 and 6,756,176, the disclosures of each of which are hereby incorporated by reference in their entirety. Suitable resins also include a mixture of an amorphous polyester resin and a crystalline polyester resin as described in U.S. Pat. No. 6,830,860, the disclosure of which is hereby incorporated by reference in its entirety.
The resin can be a polyester resin formed by reacting a diol with a diacid in the presence of an optional catalyst. For forming a crystalline polyester, suitable organic diols include aliphatic diols with from about 2 to about 36 carbon atoms, such as 1,2-ethanediol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, 1,12-dodecanediol and the like; alkali sulfo-aliphatic diols such as sodio 2-sulfo-1,2-ethanediol, lithio 2-sulfo-1,2-ethanediol, potassio 2-sulfo-1,2-ethanediol, sodio 2-sulfo-1,3-propanediol, lithio 2-sulfo-1,3-propanediol, potassio 2-sulfo-1,3-propanediol, mixture thereof, and the like. The aliphatic diol may be, for example, selected in an amount of from about 40 to about 60 mole percent, such as from about 42 to about 55 mole percent, or from about 45 to about 53 mole percent (although amounts outside of these ranges can be used), and the alkali sulfo-aliphatic diol can be selected in an amount of from about 0 to about 10 mole percent, such as from about 1 to about 4 mole percent of the resin (although amounts outside of these ranges can be used).
Examples of organic diacids or diesters including vinyl diacids or vinyl diesters selected for the preparation of the crystalline resins include oxalic acid, succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, fumaric acid, dimethyl fumarate, dimethyl itaconate, cis, 1,4-diacetoxy-2-butene, diethyl fumarate, diethyl maleate, phthalic acid, isophthalic acid, terephthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, cyclohexane dicarboxylic acid, malonic acid and mesaconic acid, a diester or anhydride thereof; and an alkali sulfo-organic diacid such as the sodio, lithio or potassio salt of dimethyl-5-sulfo-isophthalate, dialkyl-5-sulfo-isophthalate-4-sulfo-1,8-naphthalic anhydride, 4-sulfo-phthalic acid, dimethyl-4-sulfo-phthalate, dialkyl-4-sulfo-phthalate, 4-sulfophenyl-3,5-dicarbomethoxybenzene, 6-sulfo-2-naphthyl-3,5-dicarbomethoxybenzene, sulfo-terephthalic acid, dimethyl-sulfo-terephthalate, 5-sulfo-isophthalic acid, dialkyl-sulfo-terephthalate, sulfoethanediol, 2-sulfopropanediol, 2-sulfobutanediol, 3-sulfopentanediol, 2-sulfohexanediol, 3-sulfo-2-methylpentanediol, 2-sulfo-3,3-dimethylpentanediol, sulfo-p-hydroxybenzoic acid, N,N-bis(2-hydroxyethyl)-2-amino ethane sulfonate, or mixtures thereof. The organic diacid may be selected in an amount of, for example, from about 40 to about 60 mole percent, in embodiments from about 42 to about 52 mole percent, such as from about 45 to about 50 mole percent (although amounts outside of these ranges can be used), and the alkali sulfo-aliphatic diacid can be selected in an amount of from about 1 to about 10 mole percent of the resin (although amounts outside of these ranges can be used).
Examples of crystalline resins include polyesters, polyamides, polyimides, polyolefins, polyethylene, polybutylene, polyisobutyrate, ethylene-propylene copolymers, ethylene-vinyl acetate copolymers, polypropylene, mixtures thereof, and the like. Specific crystalline resins may be polyester based, such as poly(ethylene-adipate), poly(propylene-adipate), poly(butylene-adipate), poly(pentylene-adipate), poly(hexylene-adipate), poly(octylene-adipate), poly(ethylene-succinate), poly(propylene-succinate), poly(butylene-succinate), poly(pentylene-succinate), poly(hexylene-succinate), poly(octylene-succinate), poly(ethylene-sebacate), poly(propylene-sebacate), poly(butylene-sebacate), poly(pentylene-sebacate), poly(hexylene-sebacate), poly(octylene-sebacate), poly(decylene-sebacate), poly(decylene-decanoate), poly(ethylene-decanoate), poly(ethylene dodecanoate), poly(nonylene-sebacate), poly(nonylene-decanoate), copoly(ethylene-fumarate)-copoly(ethylene-sebacate), copoly(ethylene-fumarate)-copoly(ethylene-decanoate), copoly(ethylene-fumarate)-copoly(ethylene-dodecanoate), alkali copoly(5-sulfoisophthaloyl)-copoly(ethylene-adipate), alkali copoly(5-sulfoisophthaloyl)-copoly(propylene-adipate), alkali copoly(5-sulfoisophthaloyl)-copoly(butylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(pentylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(hexylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(octylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(ethylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(propylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(butylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(pentylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(hexylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(octylene-adipate), alkali copoly(5-sulfoisophthaloyl)-copoly(ethylene-succinate), alkali copoly(5-sulfoisophthaloyl)-copoly(propylene-succinate), alkali copoly(5-sulfoisophthaloyl)-copoly(butylenes-succinate), alkali copoly(5-sulfoisophthaloyl)-copoly(pentylene-succinate), alkali copoly(5-sulfoisophthaloyl)-copoly(hexylene-succinate), alkali copoly(5-sulfoisophthaloyl)-copoly(octylene-succinate), alkali copoly(5-sulfo-isophthaloyl)-copoly(ethylene-sebacate), alkali copoly(5-sulfo-isophthaloyl)-copoly(propylene-sebacate), alkali copoly(5-sulfo-isophthaloyl)-copoly(butylene-sebacate), alkali copoly(5-sulfo-isophthaloyl)-copoly(pentylene-sebacate), alkali copoly(5-sulfo-isophthaloyl)-copoly(hexylene-sebacate), alkali copoly(5-sulfo-isophthaloyl)-copoly(octylene-sebacate), alkali copoly(5-sulfo-isophthaloyl)-copoly(ethylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(propylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(butylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(pentylene-adipate), alkali copoly(5-sulfo-isophthaloyl)-copoly(hexylene-adipate), poly(octylene-adipate), wherein alkali is a metal like sodium, lithium or potassium. Examples of polyamides include poly(ethylene-adipamide), poly(propylene-adipamide), poly(butylenes-adipamide), poly(pentylene-adipamide), poly(hexylene-adipamide), poly(octylene-adipamide), poly(ethylene-succinimide), and poly(propylene-sebecamide). Examples of polyimides include poly(ethylene-adipimide), poly(propylene-adipimide), poly(butylene-adipimide), poly(pentylene-adipimide), poly(hexylene-adipimide), poly(octylene-adipimide), poly(ethylene-succinimide), poly(propylene-succinimide), and poly(butylene-succinimide).
The crystalline resin can be present, for example, in an amount of from about 5 to about 50 percent by weight of the toner components, such as from about 10 to about 35 percent by weight of the toner components (although amounts outside of these ranges can be used). The crystalline resin can possess various melting points of, for example, from about 30° C. to about 120° C., in embodiments from about 50° C. to about 90° C. (although melting points outside of these ranges can be obtained). The crystalline resin can have a number average molecular weight (M n ), as measured by gel permeation chromatography (GPC) of, for example, from about 1,000 to about 50,000, such as from about 2,000 to about 25,000 (although number average molecular weights outside of these ranges can be obtained), and a weight average molecular weight (M w ) of, for example, from about 2,000 to about 100,000, such as from about 3,000 to about 80,000 (although weight average molecular weights outside of these ranges can be obtained), as determined by Gel Permeation Chromatography using polystyrene standards. The molecular weight distribution (M w /M n ) of the crystalline resin can be, for example, from about 2 to about 6, in embodiments from about 3 to about 4 (although molecular weight distributions outside of these ranges can be obtained).
Examples of diacids or diesters including vinyl diacids or vinyl diesters used for the preparation of amorphous polyesters include dicarboxylic acids or diesters such as terephthalic acid, phthalic acid, isophthalic acid, fumaric acid, dimethyl fumarate, dimethyl itaconate, cis, 1,4-diacetoxy-2-butene, diethyl fumarate, diethyl maleate, maleic acid, succinic acid, itaconic acid, succinic acid, succinic anhydride, dodecylsuccinic acid, dodecylsuccinic anhydride, glutaric acid, glutaric anhydride, adipic acid, pimelic acid, suberic acid, azelaic acid, dodecane diacid, dimethyl terephthalate, diethyl terephthalate, dimethylisophthalate, diethylisophthalate, dimethylphthalate, phthalic anhydride, diethylphthalate, dimethylsuccinate, dimethylfumarate, dimethylmaleate, dimethylglutarate, dimethyladipate, dimethyl dodecylsuccinate, and combinations thereof. The organic diacid or diester can be present, for example, in an amount from about 40 to about 60 mole percent of the resin, such as from about 42 to about 52 mole percent of the resin, or from about 45 to about 50 mole percent of the resin (although amounts outside of these ranges can be used).
Examples of diols that can be used in generating the amorphous polyester include 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, pentanediol, hexanediol, 2,2-dimethylpropanediol, 2,2,3-trimethylhexanediol, heptanediol, dodecanediol, bis(hydroxyethyl)-bisphenol A, bis(2-hydroxypropyl)-bisphenol A, 1,4-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, xylenedimethanol, cyclohexanediol, diethylene glycol, bis(2-hydroxyethyl)oxide, dipropylene glycol, dibutylene, and combinations thereof. The amount of organic diol selected can vary, and can be present, for example, in an amount from about 40 to about 60 mole percent of the resin, such as from about 42 to about 55 mole percent of the resin, or from about 45 to about 53 mole percent of the resin (although amounts outside of these ranges can be used).
Polycondensation catalysts which may be used in forming either the crystalline or amorphous polyesters include tetraalkyl titanates, dialkyltin oxides such as dibutyltin oxide, tetraalkyltins such as dibutyltin dilaurate, and dialkyltin oxide hydroxides such as butyltin oxide hydroxide, aluminum alkoxides, alkyl zinc, dialkyl zinc, zinc oxide, stannous oxide, or combinations thereof. Such catalysts may be used in amounts of, for example, from about 0.01 mole percent to about 5 mole percent based on the starting diacid or diester used to generate the polyester resin (although amounts outside of this range can be used).
Suitable amorphous resins include polyesters, polyamides, polyimides, polyolefins, polyethylene, polybutylene, polyisobutyrate, ethylene-propylene copolymers, ethylene-vinyl acetate copolymers, polypropylene, combinations thereof, and the like. Examples of amorphous resins which may be used include alkali sulfonated-polyester resins, branched alkali sulfonated-polyester resins, alkali sulfonated-polyimide resins, and branched alkali sulfonated-polyimide resins. Alkali sulfonated polyester resins may be useful in embodiments, such as the metal or alkali salts of copoly(ethylene-terephthalate)-copoly(ethylene-5-sulfo-isophthalate), copoly(propylene-terephthalate)-copoly(propylene-5-sulfo-isophthalate), copoly(diethylene-terephthalate)-copoly(diethylene-5-sulfo-isophthalate), copoly(propylene-diethylene-terephthalate)-copoly(propylene-diethylene-5-sulfoisophthalate), copoly(propylene-butylene-terephthalate)-copoly(propylene-butylene-5-sulfoisophthalate), copoly propoxylated bisphenol-A-fumarate)-copoly(propoxylated bisphenol A-5-sulfo-isophthalate), copoly(ethoxylated bisphenol-A-fumarate)-copoly(ethoxylated bisphenol-A-5-sulfo-isophthalate), and copoly(ethoxylated bisphenol-A-maleate)-copoly(ethoxylated bisphenol-A-5-sulfo-isophthalate), wherein the alkali metal is, for example, a sodium, lithium or potassium ion.
An unsaturated amorphous polyester resin can be used as a latex resin. Examples of such resins include those disclosed in U.S. Pat. No. 6,063,827, the disclosure of which is hereby incorporated by reference in its entirety. Exemplary unsaturated amorphous polyester resins include, but are not limited to, poly(propoxylated bisphenol co-fumarate), poly(ethoxylated bisphenol co-fumarate), poly(butyloxylated bisphenol co-fumarate), poly(co-propoxylated bisphenol co-ethoxylated bisphenol co-fumarate), poly(1,2-propylene fumarate), poly(propoxylated bisphenol co-maleate), poly(ethoxylated bisphenol co-maleate), poly(butyloxylated bisphenol co-maleate), poly(co-propoxylated bisphenol co-ethoxylated bisphenol co-maleate), poly(1,2-propylene maleate), poly(propoxylated bisphenol co-itaconate), poly(ethoxylated bisphenol co-itaconate), poly(butyloxylated bisphenol co-itaconate), poly(co-propoxylated bisphenol co-ethoxylated bisphenol co-itaconate), poly(1,2-propylene itaconate), and combinations thereof. A suitable polyester resin can be a polyalkoxylated bisphenol A-co-terephthalic acid/dodecenylsuccinic acid/trimellitic acid resin, or a polyalkoxylated bisphenol A-co-terephthalic acid/fumaric acid/dodecenylsuccinic acid resin, or a combination thereof.
Such amorphous resins can have a weight average molecular weight (Mw) of from about 10,000 to about 100,000, such as from about 15,000 to about 80,000.
An example of a linear propoxylated bisphenol a fumarate resin that can be used as a latex resin is available under the trade name SPARII from Resana S/A Industrias Quimicas, Sao Paulo Brazil. Other propoxylated bisphenol a fumarate resins that can be used and are commercially available include GTUF and FPESL-2 from Kao Corporation, Japan, and EM181635 from Reichhold, Research Triangle Park, N.C., and the like.
Suitable crystalline resins that can be used, optionally in combination with an amorphous resin as described above, include those disclosed in U.S. Patent Application Publication No. 2006/0222991, the disclosure of which is hereby incorporated by reference in its entirety. In embodiments, a suitable crystalline resin can include a resin formed of dodecanedioic acid and 1,9-nonanediol.
Such crystalline resins can have a weight average molecular weight (Mw) of from about 10,000 to about 100,000, such as from about 14,000 to about 30,000.
For example, a polyalkoxylated bisphenol A-co-terephthalic acid/dodecenylsuccinic acid/trimellitic acid resin, or a polyalkoxylated bisphenol A-co-terephthalic acid/fumaric acid/dodecenylsuccinic acid resin, or a combination thereof, can be combined with a polydodecanedioic acid-co-1,9-nonanediol crystalline polyester resin.
The resins can have a glass transition temperature of from about 30° C. to about 80° C., such as from about 35° C. to about 70° C. The resins can have a melt viscosity of from about 10 to about 1,000,000 Pa*S at about 130° C., such as from about 20 to about 100,000 Pa*S. One, two, or more toner resins may be used. Where two or more toner resins are used, the toner resins can be in any suitable ratio (e.g., weight ratio) such as, for instance, about 10 percent (first resin)/90 percent (second resin) to about 90 percent (first resin)/10 percent (second resin). The resin can be formed by emulsion polymerization methods.
The resin can be formed at elevated temperatures of from about 30° C. to about 200° C., such as from about 50° C. to about 150° C., or from about 70° C. to about 100° C. However, the resin can also be formed at room temperature.
Stirring may be used to enhance formation of the resin. Any suitable stirring device may be used. In embodiments, the stirring speed can be from about 10 revolutions per minute (rpm) to about 5,000 rpm, such as from about 20 rpm to about 2,000 rpm, or from about 50 rpm to about 1,000 rpm. The stirring speed can be constant or the stirring speed can be varied. For example, as the temperature becomes more uniform throughout the mixture, the stirring speed can be increased. However, no mechanical or magnetic agitation is necessary in the method disclosed herein.
Solvent
Any suitable organic solvent can be contacted with the resin in the resin composition to help dissolve the resin in the resin composition. Suitable organic solvents for the methods disclosed herein include alcohols, such as methanol, ethanol, isopropanol, butanol, as well as higher homologs and polyols, such as ethylene glycol, glycerol, sorbitol, and the like; ketones, such as acetone, 2-butanone, 2-pentanone, 3-pentanone, ethyl isopropyl ketone, methyl isobutyl ketone, diisobutyl ketone, and the like; amides, such as dimethylformamide, dimethylacetamide, N-methylpyrrolidone, 1,2-dimethyl-2-imidazolidinone, and the like; nitriles, such as acetonitrile, propionitrile, butyronitrile, isobutyronitrile, valeronitrile, benzonitrile, and the like; ethers, such as ditertbutyl ether, dimethoxyethane, 2-methoxyethyl ether, 1,4-dioxane, tetrahydrohyran, morpholine, and the like; sulfones, such as methylsulfonylmethane, sulfolane, and the like; sulfoxides, such as dimethylsulfoxide; phosphoramides, such as hexamethylphosphoramide; benzene and benzene derivatives; as well as esters, amines and combinations thereof, in an amount of, for example from about 1 wt % to 99 wt %, from about 20 wt % to 80 wt %, or from about 20 wt % to about 50 wt %.
The organic solvent can be immiscible in water and can have a boiling point of from about 30° C. to about 100° C. Any suitable organic solvent can also be used as a phase or solvent inversion agent. The organic solvent can be used in an amount of from about 1% by weight to about 25% by weight of the resin, such as from about 5% by weight to about 20% by weight of the resin, or from about 10% by weight of the resin to about 15% by weight of the resin.
Neutralizing Agent
A neutralizing agent can be contacted with the resin in the resin composition to, for example, neutralize acid groups in the resins. The neutralizing agent can be contacted with the resin as a solid or in an aqueous solution. The neutralizing agent herein can also be referred to as a “basic neutralization agent.” Any suitable basic neutralization reagent can be used in accordance with the present disclosure.
Suitable basic neutralization agents include both inorganic basic agents and organic basic agents. Suitable basic agents include, for example, ammonium hydroxide, potassium hydroxide, sodium hydroxide, sodium carbonate, sodium bicarbonate, lithium hydroxide, potassium carbonate, potassium bicarbonate, combinations thereof, and the like. Suitable basic agents also include monocyclic compounds and polycyclic compounds having at least one nitrogen atom, such as, for example, secondary amines, which include aziridines, azetidines, piperazines, piperidines, pyridines, pyridine derivatives, bipyridines, terpyridines, dihydropyridines, morpholines, N-alkylmorpholines, 1,4-diazabicyclo[2.2.2]octanes, 1,8-diazabicycloundecanes, 1,8-diazabicycloundecenes, dimethylated pentylamines, trimethylated pentylamines, triethyl amines, triethaholamines, diphenyl amines, diphenyl amine derivatives, poly(ethylene amine), poly(ethylene amine derivatives, amine bases, pyrimidines, pyrroles, pyrrolidines, pyrrolidinones, indoles, indolines, indanones, benzindazones, imidazoles, benzimidazoles, imidazolones, imidazolines, oxazoles, isoxazoles, oxazolines, oxadiazoles, thiadiazoles, carbazoles, quinolines, isoquinolines, naphthyridines, triazines, triazoles, tetrazoles, pyrazoles, pyrazolines, and combinations thereof. The monocyclic and polycyclic compounds can be unsubstituted or substituted at any carbon position on the ring.
The basic agent can be used as a solid such as, for example, sodium hydroxide flakes, so that it is present in an amount of from about 0.001% by weight to 50% by weight of the resin, such as from about 0.01% by weight to about 25% by weight of the resin, or from about 0.1% by weight to 5% by weight of the resin.
As noted above, the basic neutralization agent can be added to a resin possessing acid group. The addition of the basic neutralization agent may thus raise the pH of an emulsion including a resin possessing acid group to a pH of from about 5 to about 12, in embodiments, from about 6 to about 11. The neutralization of the acid groups can enhance formation of the emulsion.
The neutralization ratio can be from about 25% to about 500%, such as from about 50% to about 450%, or from about 100% to about 400%.
Surfactant
As discussed above, a surfactant can be contacted with the resin prior to formation of the resin composition used to form the latex emulsion. One, two, or more surfactants can be used. The surfactants can be selected from ionic surfactants and nonionic surfactants. The latex for forming the resin used in forming a toner can be prepared in an aqueous phase containing a surfactant or co-surfactant, optionally under an inert gas such as nitrogen. Surfactants used with the resin to form a latex dispersion can be ionic or nonionic surfactants in an amount of from about 0.01 to about 15 weight percent of the solids, such as from about 0.1 to about 10 weight percent of the solids.
Anionic surfactants that can be used include sulfates and sulfonates, sodium dodecylsulfate (SDS), sodium dodecylbenzene sulfonate, sodium dodecylnaphthalene sulfate, dialkyl benzenealkyl sulfates and sulfonates, acids such as abietic acid available from Aldrich, NEOGEN®, NEOGEN SC™ obtained from Daiichi Kogyo Seiyaku Co., Ltd., combinations thereof, and the like. Other suitable anionic surfactants include, DOWFAX™ 2A1, an alkyldiphenyloxide disulfonate from The Dow Chemical Company, and/or TAYCA POWER BN2060 from Tayca Corporation (Japan), which are branched sodium dodecyl benzene sulfonates. Combinations of these surfactants and any of the foregoing anionic surfactants can be used.
Examples of cationic surfactants include, but are not limited to, ammoniums, for example, alkylbenzyl dimethyl ammonium chloride, dialkyl benzenealkyl ammonium chloride, lauryl trimethyl ammonium chloride, alkylbenzyl methyl ammonium chloride, alkyl benzyl dimethyl ammonium bromide, benzalkonium chloride, C12, C15, C17 trimethyl ammonium bromides, combinations thereof, and the like. Other cationic surfactants include cetyl pyridinium bromide, halide salts of quaternized polyoxyethylalkylamines, dodecylbenzyl triethyl ammonium chloride, MIRAPOL and ALKAQUAT available from Alkaril Chemical Company, SANISOL (benzalkonium chloride), available from Kao Chemicals, combinations thereof, and the like. A suitable cationic surfactant includes SANISOL B-50 available from Kao Corp., which is primarily a benzyl dimethyl alkonium chloride.
Examples of nonionic surfactants include, but are not limited to, alcohols, acids and ethers, for example, polyvinyl alcohol, polyacrylic acid, methalose, methyl cellulose, ethyl cellulose, propyl cellulose, hydroxyl ethyl cellulose, carboxy methyl cellulose, polyoxyethylene cetyl ether, polyoxyethylene lauryl ether, polyoxyethylene octyl ether, polyoxyethylene octylphenyl ether, polyoxyethylene oleyl ether, polyoxyethylene sorbitan monolaurate, polyoxyethylene stearyl ether, polyoxyethylene nonylphenyl ether, dialkylphenoxy poly(ethyleneoxy) ethanol, combinations thereof, and the like. Commercially available surfactants from Rhone-Poulenc such as IGEPAL CA-210™, IGEPAL CA-520™, IGEPAL CA-720™, IGEPAL CO-890™, IGEPAL CO-720™, IGEPAL CO-290™, IGEPAL CA-210™, ANTAROX 890™ and ANTAROX 897™ can be used.
The choice of particular surfactants or combinations thereof, as well as the amounts of each to be used, are within the purview of those skilled in the art.
Preparation of Toner
As discussed above, the latex emulsion produced according to the method disclosed herein can be used to form a toner, such as an EA toner. The latex emulsion can be added to a pre-toner mixture, such as before particle aggregation in the EA coalescence process. The latex or emulsion, as well as a binder resin, a wax such as a wax dispersion, a colorant, and any other desired or required additives such as surfactants, may form the pre-toner mixture.
The pre-toner mixture can be prepared, and the pH of the resulting mixture can be adjusted, by an acid such as, for example, acetic acid, nitric acid or the like. The pH of the mixture can be adjusted to be from about 4 to about 5, although a pH outside this range can be used. Additionally, the mixture can be homogenized. If the mixture is homogenized, homogenization can be accomplished by mixing at a mixing speed of from about 600 to about 4,000 revolutions per minute, although speeds outside this range can be used. Homogenization can be accomplished by any suitable means, including, for example, an IKA ULTRA TURRAX T50 probe homogenizer.
Aggregation
Following the preparation of the above mixture, including the addition or incorporation into the pre-toner mixture of the latex emulsion produced by the methods disclosed herein, an aggregating agent can be added to the mixture. Any suitable aggregating agent can be used to form a toner. Suitable aggregating agents include, for example, aqueous solutions of a divalent cation or a multivalent cation material. The aggregating agent can be, for example, polyaluminum halides such as polyaluminum chloride (PAC), or the corresponding bromide, fluoride, or iodide, polyaluminum silicates such as polyaluminum sulfosilicate (PASS), and water soluble metal salts including aluminum chloride, aluminum nitrite, aluminum sulfate, potassium aluminum sulfate, calcium acetate, calcium chloride, calcium nitrite, calcium oxylate, calcium sulfate, magnesium acetate, magnesium nitrate, magnesium sulfate, zinc acetate, zinc nitrate, zinc sulfate, zinc chloride, zinc bromide, magnesium bromide, copper chloride, copper sulfate, and combinations thereof. The aggregating agent can be added to the mixture at a temperature that is below the glass transition temperature (TG) of the resin.
The aggregating agent can be added to the mixture used to form a toner in an amount of, for example, from about 0.01 percent to about 8 percent by weight, such as from about 0.1 percent to about 1 percent by weight, or from about 0.15 percent to about 0.8 percent by weight, of the resin in the mixture, although amounts outside these ranges can be used. The above can provide a sufficient amount of agent for aggregation.
To control aggregation and subsequent coalescence of the particles, the aggregating agent can be metered into the mixture over time. For example, the agent can be metered into the mixture over a period of from about 5 to about 240 minutes, such as from about 30 to about 200 minutes, although more or less time can be used as desired or required. The addition of the agent can occur while the mixture is maintained under stirred conditions, such as from about 50 revolutions per minute to about 1,000 revolutions per minute, or from about 100 revolutions per minute to about 500 revolutions per minute, although speeds outside these ranges can be used. The addition of the agent can also occur while the mixture is maintained at a temperature that is below the glass transition temperature of the resin discussed above, such as from about 30° C. to about 90° C., or from about 35° C. to about 70° C., although temperatures outside these ranges can be used.
The particles can be permitted to aggregate until a predetermined desired particle size is obtained. A predetermined desired size refers to the desired particle size to be obtained as determined prior to formation, and the particle size being monitored during the growth process until such particle size is reached. Samples can be taken during the growth process and analyzed, for example with a Coulter Counter, for average particle size. The aggregation thus can proceed by maintaining the elevated temperature, or slowly raising the temperature to, for example, from about 30° C. to about 99° C., and holding the mixture at this temperature for a time from about 0.5 hours to about 10 hours, such as from about hour 1 to about 5 hours (although times outside these ranges may be utilized), while maintaining stirring, to provide the aggregated particles. Once the predetermined desired particle size is reached, then the growth process is halted. The predetermined desired particle size can be within the desired size of the final toner particles.
The growth and shaping of the particles following addition of the aggregation agent can be accomplished under any suitable conditions. For example, the growth and shaping can be conducted under conditions in which aggregation occurs separate from coalescence. For separate aggregation and coalescence stages, the aggregation process can be conducted under shearing conditions at an elevated temperature, for example, of from about 40° C. to about 90° C., such as from about 45° C. to about 80° C. (although temperatures outside these ranges may be utilized), which can be below the glass transition temperature of the resin as discussed above.
Once the desired final size of the toner particles is achieved, the pH of the mixture can be adjusted with a base to a value of from about 3 to about 10, such as from about 5 to about 9, although a pH outside these ranges may be used.
The adjustment of the pH can be used to freeze, that is to stop, toner growth. The base utilized to stop toner growth can include any suitable base such as, for example, alkali metal hydroxides such as, for example, sodium hydroxide, potassium hydroxide, ammonium hydroxide, combinations thereof, and the like. In embodiments, ethylene diamine tetraacetic acid (EDTA) may be added to help adjust the pH to the desired values noted above.
Core-Shell Structure
After aggregation, but prior to coalescence, a resin coating can be applied to the aggregated particles to form a shell thereover. Any resin described above as suitable for forming the toner resin can be used as the shell.
Resins that can be used to form a shell include, but are not limited to, crystalline polyesters described above, and/or the amorphous resins described above for use as the core. For example, a polyalkoxylated bisphenol A-co-terephthalic acid/dodecenylsuccinic acid/trimellitic acid resin, a polyalkoxylated bisphenol A-co-terephthalic acid/fumaric acid/dodecenylsuccinic acid resin, or a combination thereof, can be combined with a polydodecanedioic acid-co-1,9-nonanediol crystalline polyester resin to form a shell. Multiple resins can be used in any suitable amounts.
The shell resin can be applied to the aggregated particles by any method within the purview of those skilled in the art. The resins utilized to form the shell can be in an emulsion including any surfactant described above. The emulsion possessing the resins can be combined with the aggregated particles described above so that the shell forms over the aggregated particles. In embodiments, the shell may have a thickness of up to about 5 microns, such as from about 0.1 to about 2 microns, or from about 0.3 to about 0.8 microns, over the formed aggregates, although thicknesses outside of these ranges may be obtained.
The formation of the shell over the aggregated particles can occur while heating to a temperature of from about 30° C. to about 80° C. in embodiments from about 35° C. to about 70° C., although temperatures outside of these ranges can be utilized. The formation of the shell can take place for a period of time of from about 5 minutes to about 10 hours, such as from about 10 minutes to about 5 hours, although times outside these ranges may be used.
For example, the toner process can include forming a toner particle by mixing the polymer latexes, in the presence of a wax dispersion and a colorant with an optional coagulant while blending at high speeds. The resulting mixture having a pH of, for example, of from about 2 to about 3, can be aggregated by heating to a temperature below the polymer resin Tg to provide toner size aggregates. Optionally, additional latex can be added to the formed aggregates providing a shell over the formed aggregates. The pH of the mixture can be changed, for example, by the addition of a sodium hydroxide solution, until a pH of about 7 may be achieved.
Coalescence
Following aggregation to the desired particle size and application of any optional shell, the particles can be coalesced to the desired final shape. The coalescence can be achieved by, for example, heating the mixture to a temperature of from about 45° C. to about 100° C., such as from about 55° C. to about 99° C. (although temperatures outside of these ranges may be used), which can be at or above the glass transition temperature of the resins used to form the toner particles, and/or reducing the stirring, for example, to a stirring speed of from about 100 revolutions per minute to about 1,000 revolutions per minute, such as from about 200 revolutions per minute to about 800 revolutions per minute (although speeds outside of these ranges may be used). The fused particles can be measured for shape factor or circularity, such as with a Sysmex FPIA 2100 analyzer, until the desired shape is achieved.
Higher or lower temperatures can be used, it being understood that the temperature is a function of the resins used for the binder. Coalescence may be accomplished over a period of from about 0.01 hours to about 9 hours, such as from about 0.1 hours to about 4 hours (although times outside of these ranges can be used).
After aggregation and/or coalescence, the mixture can be cooled to room temperature, such as from about 20° C. to about 25° C. The cooling can be rapid or slow, as desired. Suitable cooling methods include introducing cold water to a jacket around the reactor. After cooling, the toner particles can be washed with water, and then dried. Drying can be accomplished by any suitable method for drying including, for example, freeze-drying.
Wax
A wax can be combined with the latex or emulsion, colorant, and the like in forming toner particles. When included, the wax can be present in an amount of, for example, from about 1 weight percent to about 25 weight percent of the toner particles, such as from about 5 weight percent to about 20 weight percent of the toner particles, although amounts outside these ranges can be used.
Suitable waxes include waxes having, for example, a weight average molecular weight of from about 500 to about 20,000, such as from about 1,000 to about 10,000, although molecular weights outside these ranges may be utilized. Suitable waxes include, for example, polyolefins such as polyethylene, polypropylene, and polybutene waxes such as commercially available from Allied Chemical and Petrolite Corporation, for example POLYWAX™ polyethylene waxes from Baker Petrolite, wax emulsions available from Michaelman, Inc. and the Daniels Products Company, EPOLENE N-15™ commercially available from Eastman Chemical Products, Inc., and VISCOL 550-P™, a low weight average molecular weight polypropylene available from Sanyo Kasei K. K.; plant-based waxes, such as carnauba wax, rice wax, candelilla wax, sumacs wax, and jojoba oil; animal-based waxes, such as beeswax; mineral-based waxes and petroleum-based waxes, such as montan wax, ozokerite, ceresin, paraffin wax, microcrystalline wax, and Fischer-Tropsch wax; ester waxes obtained from higher fatty acid and higher alcohol, such as stearyl stearate and behenyl behenate; ester waxes obtained from higher fatty acid and monovalent or multivalent lower alcohol, such as butyl stearate, propyl oleate, glyceride monostearate, glyceride distearate, and pentaerythritol tetra behenate; ester waxes obtained from higher fatty acid and multivalent alcohol multimers, such as diethyleneglycol monostearate, dipropyleneglycol distearate, diglyceryl distearate, and triglyceryl tetrastearate; sorbitan higher fatty acid ester waxes, such as sorbitan monostearate, and cholesterol higher fatty acid ester waxes, such as cholesteryl stearate. Examples of functionalized waxes that can be used include, for example, amines, amides, for example AQUA SUPERSLIP 6550™, SUPERSLIP 6530™ available from Micro Powder Inc., fluorinated waxes, for example POLYFLUO 190™, POLYFLUO 200™, POLYSILK 19™, POLYSILK 14™ available from Micro Powder Inc., mixed fluorinated, amide waxes, for example MICROSPERSION 19™ also available from Micro Powder Inc. imides, esters, quaternary amines, carboxylic acids or acrylic polymer emulsion, for example JONCRYL 74™, 89™, 130™, 537™, and 538™, all available from SC Johnson Wax, and chlorinated polypropylenes and polyethylenes available from Allied Chemical and Petrolite Corporation and SC Johnson wax. Mixtures and combinations of the foregoing waxes can be used. Waxes can be included as, for example, fuser roll release agents.
Colorant
The toner particles described herein can further include colorant. Colorant includes pigments, dyes, mixtures of dyes, mixtures of pigments, mixtures of dyes and pigments, and the like.
When present, the colorant can be added in an effective amount of, for example, from about 1 to about 25 percent by weight of the particle, such as from about 2 to about 12 weight percent. Suitable colorants include, for example, carbon black like REGAL 330® magnetites, such as Mobay magnetites MO8029™, MO8060 ™; Columbian magnetites; MAPICO BLACKS™ and surface treated magnetites; Pfizer magnetites CB4799™, CB5300™, CB5600™, MCX6369™; Bayer magnetites, BAYFERROX 8600™, 8610™; Northern Pigments magnetites, NP-604™, NP-608™; Magnox magnetites TMB-100™, or TMB-104™; and the like. As colored pigments, there may be selected cyan, magenta, yellow, red, green, brown, blue or mixtures thereof. Specific examples of pigments include phthalocyanine HELIOGEN BLUE L6900™, D6840™, D7080™, D7020™, PYLAM OIL BLUE™, PYLAM OIL YELLOW™, PIGMENT BLUE 1™ available from Paul Uhlich & Company, Inc., PIGMENT VIOLET 1™, PIGMENT RED 48™, LEMON CHROME YELLOW DCC 1026™, E.D. TOLUIDINE RED™ and BON RED C™ available from Dominion Color Corporation, Ltd., Toronto, Ontario, NOVAPERM YELLOW FGL™, HOSTAPERM PINK E™ from Hoechst, and CINQUASIA MAGENTA™ available from E.I. DuPont de Nemours & Company, and the like. Generally, colorants that can be selected are black, cyan, magenta, or yellow, and mixtures thereof. Examples of magentas are 2,9-dimethyl-substituted quinacridone and anthraquinone dye identified in the Color Index as CI 60710, CI Dispersed Red 15, diazo dye identified in the Color Index as CI 26050, CI Solvent Red 19, and the like. Illustrative examples of cyans include copper tetra(octadecyl sulfonamido) phthalocyanine, x-copper phthalocyanine pigment listed in the Color Index as CI 74160, CI Pigment Blue, and Anthrathrene Blue, identified in the Color Index as CI 69810, Special Blue X-2137, and the like; while illustrative examples of yellows are diarylide yellow 3,3-dichlorobenzidene acetoacetanilides, a monoazo pigment identified in the Color Index as CI 12700, CI Solvent Yellow 16, a nitrophenyl amine sulfonamide identified in the Color Index as Foron Yellow SE/GLN, CI Dispersed Yellow 33 2,5-dimethoxy-4-sulfonanilide phenylazo-4′-chloro-2,5-dimethoxy acetoacetanilide, and Permanent Yellow FGL. Colored magnetites, such as mixtures of MAPICO BLACK™, and cyan components can also be selected as colorants. Other known colorants may be selected, such as Levanyl Black A-SF (Miles, Bayer) and Sunsperse Carbon Black LHD 9303 (Sun Chemicals), and colored dyes such as Neopen Blue (BASF), Sudan Blue OS (BASF), PV Fast Blue B2G01 (American Hoechst), Sunsperse Blue BHD 6000 (Sun Chemicals), Irgalite Blue BCA (Ciba-Geigy), Paliogen Blue 6470 (BASF), Sudan III (Matheson, Coleman, Bell), Sudan II (Matheson, Coleman, Bell), Sudan IV (Matheson, Coleman, Bell), Sudan Orange G (Aldrich), Sudan Orange 220 (BASF), Paliogen Orange 3040 (BASF), Ortho Orange OR 2673 (Paul Uhlich), Paliogen Yellow 152, 1560 (BASF), Lithol Fast Yellow 0991K (BASF), Paliotol Yellow 1840 (BASF), Neopen Yellow (BASF), Novoperm Yellow FG 1 (Hoechst), Permanent Yellow YE 0305 (Paul Uhlich), Lumogen Yellow D0790 (BASF), Sunsperse Yellow YHD 6001 (Sun Chemicals), Suco-Gelb L1250 (BASF), Suco-Yellow D1355 (BASF), Hostaperm Pink E (American Hoechst), Fanal Pink D4830 (BASF), Cinquasia Magenta (DuPont), Lithol Scarlet D3700 (BASF), Toluidine Red (Aldrich), Scarlet for Thermoplast NSD PS PA (Ugine Kuhlmann of Canada), E.D. Toluidine Red (Aldrich), Lithol Rubine Toner (Paul Uhlich), Lithol Scarlet 4440 (BASF), Bon Red C (Dominion Color Company), Royal Brilliant Red RD-8192 (Paul Uhlich), Oracet Pink RF (Ciba-Geigy), Paliogen Red 3871K (BASF), Paliogen Red 3340 (BASF), and Lithol Fast Scarlet L4300 (BASF).
Other Additives
The toner particles can contain other optional additives, as desired or required. For example, the toner can include positive or negative charge control agents, for example, in an amount of from about 0.1 to about 10 percent by weight of the toner, such as from about 1 to about 3 percent by weight of the toner (although amounts outside of these ranges may be used). Examples of suitable charge control agents include quaternary ammonium compounds inclusive of alkyl pyridinium halides; bisulfates; alkyl pyridinium compounds, including those disclosed in U.S. Pat. No. 4,298,672, the disclosure of which is hereby incorporated by reference in its entirety; organic sulfate and sulfonate compositions, including those disclosed in U.S. Pat. No. 4,338,390, the disclosure of which is hereby incorporated by reference in its entirety; cetyl pyridinium tetrafluoroborates; distearyl dimethyl ammonium methyl sulfate; aluminum salts such as BONTRON E84™ or E88™ (Orient Chemical Industries, Ltd.); combinations thereof, and the like. Such charge control agents can be applied simultaneously with the shell resin described above or after application of the shell resin.
External additive particles can be blended with the toner particles after formation including flow aid additives, which additives can be present on the surface of the toner particles. Examples of these additives include metal oxides such as titanium oxide, silicon oxide, aluminum oxides, cerium oxides, tin oxide, mixtures thereof, and the like; colloidal and amorphous silicas, such as AEROSIL®, metal salts and metal salts of fatty acids inclusive of zinc stearate, calcium stearate, or long chain alcohols such as UNILIN 700, and mixtures thereof.
In general, silica can be applied to the toner surface for toner flow, tribo enhancement, admix control, improved development and transfer stability, and higher toner blocking temperature. TiO2 may be applied for improved relative humidity (RH) stability, tribo control and improved development and transfer stability. Zinc stearate, calcium stearate and/or magnesium stearate can be used as an external additive for providing lubricating properties, developer conductivity, tribo enhancement, enabling higher toner charge and charge stability by increasing the number of contacts between toner and carrier particles. A commercially available zinc stearate known as Zinc Stearate L, obtained from Ferro Corporation, can be used. The external surface additives can be used with or without a coating.
Each of these external additives can be present in an amount of from about 0.1 percent by weight to about 5 percent by weight of the toner, such as from about 0.25 percent by weight to about 3 percent by weight of the toner, although the amount of additives can be outside of these ranges. The toners may include, for example, from about 0.1 weight percent to about 5 weight percent titanium dioxide, such as from about 0.1 weight percent to about 8 weight percent silica, or from about 0.1 weight percent to about 4 weight percent zinc stearate (although amounts outside of these ranges may be used). Suitable additives include those disclosed in U.S. Pat. Nos. 3,590,000, 3,800,588, and 6,214,507, the disclosures of each of which are hereby incorporated by reference in their entirety. Again, these additives can be applied simultaneously with the shell resin described above or after application of the shell resin.
The toner particles can have a weight average molecular weight (Mw) in the range of from about 17,000 to about 80,000 daltons, a number average molecular weight (Mn) of from about 3,000 to about 10,000 daltons, and a MWD (a ratio of the Mw to Mn of the toner particles, a measure of the polydispersity, or width, of the polymer) of from about 2.1 to about 10 (although values outside of these ranges can be obtained).
EXAMPLES
The examples set forth herein below and are illustrative of different compositions and conditions that can be used in practicing the present embodiments. All proportions are by weight unless otherwise indicated. It will be apparent, however, that the present embodiments can be practiced with many types of compositions and can have many different uses in accordance with the disclosure above and as pointed out hereinafter.
Materials Preparation
10 g amorphous resin 1 (Mw=44120, Tg onset=568° C.) was dissolved in 20 g MEK and 2 g IPA solvent mixture with stirring at room temperature.
Comparative Example
Emulsification with Old Process
3.48 g of Sample 1 were transferred into a 10 ml glass vial, followed by the addition of 0.025 g of 10 wt % ammonium hydroxide. The contents of the glass vial were mixed completely and emulsified by adding de-ionized water (DIW) drop wise with agitation. The emulsion obtained had an average particle size of 135.2 nm, as illustrated in FIG. 2 .
TABLE 1
Example
Particle Size
ID
(nm)
Mw
Mn
POI
Process
Example
89.6
43.4
5.8
7.4
New
Comparative
135.2
47.6
5.8
8.2
Old
Example
Example 1
Emulsification with New Process
10% ammonium hydroxide was pre-loaded in a syringe which will be connected to the “neutralization agent injection” inlet 40. Then, 3.24 g resin/solvent solution was transferred to 50 ml Erlenmeyer flask (called “Reaction Vessel” 45). De-ionized water was loaded in “Steam Generator” 50 and boiled to generate steam. During boiling process, about 3 g 10% ammonium hydroxide was injected through the “neutralization agent injection” inlet by request through the monitoring on the emulsification process in the “Reaction Vessel”. In the process, the ammonium hydroxide was immediately vaporized by the steam during boiling and brought into the “Reaction Vessel” through a cooper tube. The emulsification immediately started locally around injection opening and quickly and spontaneously expanded to other virgin areas in the resin composition with continuous injection of mixture of steam and neutralization agent vapor. The whole process to get full emulsification about 10 minutes. The prepared latex was sent for particle size analysis with about 89.6 nm particle size and a particle size distribution as shown in FIG. 3 . The Gel permeation chromatography (GPC) analysis in Table 1 shows that there was no significant molecular weight difference between Example by “new” process and Comparative Example by “old” process. Thus, the method used for Example did not degrade the original resin.
The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others. Unless specifically recited in a claim, steps or components of claims should not be implied or imported from the specification or any other claims as to any particular order, number, position, size, shape, angle, color, or material.
All the patents and applications referred to herein are hereby specifically, and totally incorporated herein by reference in their entirety in the instant specification. | Processes for making toners, and in particular, emulsion aggregation (EA) toners. These toners exhibit a low melt temperature while simultaneously exhibiting excellent relative humidity sensitivity regarding charging properties. In embodiments, the process comprises the preparation of the latex emulsion comprising high ratio resin compositions by injection of steam and neutralization agent vapors into the latex emulsion. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION/PRIORITY CLAIM
[0001] The present patent application is a continuation of co-pending U.S. patent application Ser. No. 10/666,463, filed on Sep. 19, 2003, which is hereby incorporated by reference into the present application.
BACKGROUND
[0002] In many conventional situations, various non-electronic versions of documents are often used to record, store, track, analyze and/or process data derived from service operations performed on a variety of inspected items. In the context of service operations performed on a machine, for example, such non-electronic documents may be used during periodic machine inspections and maintenance, fluid change procedures, fluid sampling procedures, load bank tests, repair assessments and cost estimates, and other like service operations. Machines and components can lose useful operational life in connection with a number of factors including, for example, failure or inability to plan, prepare, and/or adhere to prescribed maintenance schedules; failure to perform proper tests of fluids employed in machines; ineffectiveness or absence of means for collecting, storing, analyzing and/or processing data associated with equipment operation; poor communication between/among service technicians, distributors, customers and other service providers regarding issues with machine operation; as well as other factors related to inefficient and/or ineffective service operations performed on machines and their components. The inefficiencies attendant upon non-electronic methods, systems and documents often contribute or aggravate the effect of these factors.
[0003] Examples of other contexts in which there is prevalent use of non-electronic documents and processes include the healthcare industry and the financial industry, among others. Manual data entry errors reflect one example of a source of error and potential harm arising from use of non-electronic documents and processes in these industries. In addition, many electronic documentation systems and procedures lack connectivity, and thus do not address lack of communication between/among the various entities associated with service operations performed on inspected items. Furthermore, non-electronic documents are often inflexible in their design, development, and/or application to performance of service operations on inspected items.
[0004] Thus, conventional products and services may benefit from improved methods, systems and products for collecting, storing, analyzing and/or processing data in association with service operations performed on inspected items. Improved communications between/among service administrators, service technicians, distributors, customers and/or other service providers are also needed to enhance the efficiency and effectiveness of service operations performed on inspected items.
SUMMARY
[0005] In one embodiment of the present embodiments, a system is provided for performing at least one service operation in association with at least one inspected item. The system includes a service data device configured for displaying at least one data screen including at least one checklist configured for operative use in connection with performance of the service operation on the inspected item, the data device being portable and being configured for processing at least one communication; a service administrator having at least one data storage medium configured for storing at least one of the checklists displayed on the data device, the service administrator further having at least one server for enabling at least one communication between the service administrator and the data device; at least a portion of at least one of the checklists being customizable by at least the service administrator; and, at least a portion of at least one of the checklists being electronically interactive in association with performance of the service operation on the inspected item.
[0006] In another embodiment of the present embodiments, a method is provided for performing at least one service operation in association with at least one inspected item. The method includes displaying at least one data screen on a service data device, including displaying at least one interactive checklist configured for operative use in connection with performance of the service operation on the inspected item, the data device being portable and being configured for processing at least one communication; storing at least one of the checklists displayed on the data device on at least one data storage medium of a service administrator; and, customizing at least a portion of at least one of the checklists with the service administrator.
[0007] In another embodiment of the present embodiments, a computer-readable medium is provided including instructions for performing a method for performing at least one service operation in association with at least one inspected item. The medium includes instructions for displaying at least one data screen on a service data device, including instructions for displaying at least one interactive checklist configured for operative use in connection with performance of the service operation on the inspected item, the data device being portable and being configured for processing at least one communication; instructions for storing at least one of the checklists displayed on the data device on at least one data storage medium of a service administrator; and, instructions for customizing at least a portion of at least one of the checklists with the service administrator.
[0008] In another embodiment of the present embodiments, a label product structured for placement on an object having a radius is provided. The label product includes a data presentation portion including information associated with at least one service operation performed on an inspected item; at least one bar code portion including a bar code having a vertical axis and a horizontal axis; one or more bar code indicia imprinted on the bar code, the bar code indicia being representative of at least a portion of the information associated with the service operation performed on the inspected item; and, the horizontal axis of the bar code being dimensioned as a function of the radius of the object.
[0009] In another embodiment of the present embodiments, a bar code product for use in association with scanning an object having a radius with a bar code scanner is provided. The bar code product includes one or more bar code indicia printed on the bar code product; and, at least one of the bar code indicia having an effective width dimensioned as a function of an arcuate distance of the bar code indicia away from a central axis of the bar code scanner.
[0010] In another embodiment of the present embodiments, a bar code product for use in association with scanning an object having a radius with a bar code scanner is provided. The bar code product includes one or more bar code indicia printed on the bar code product; and, at least one of the bar code indicia having a first thickness and second thickness, the second thickness being greater than the first thickness to provide an effective width dimensioned as a function of an arcuate distance of the bar code indicia away from a central axis of the bar code scanner.
[0011] Other embodiments of the present invention will become apparent to one skilled in the art upon review of the following drawings and detailed description. It is intended that all such additional embodiments be included within this description, be within the scope of the present invention, and be protected by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 includes a schematic diagram illustrating various example aspects of the present embodiments;
[0013] FIG. 2 includes a process flow diagram illustrating various example aspects of the present embodiments;
[0014] FIG. 3 includes example data screens provided in association with one or more aspects of the present embodiments;
[0015] FIG. 4 includes example data screens provided in association with one or more aspects of the present embodiments;
[0016] FIG. 5 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0017] FIG. 6 includes example data screens provided in association with one or more aspects of the present embodiments;
[0018] FIG. 7 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0019] FIG. 8 includes example data screens provided in association with one or more aspects of the present embodiments;
[0020] FIG. 9 includes example data screens provided in association with one or more aspects of the present embodiments;
[0021] FIG. 10 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0022] FIG. 11 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0023] FIG. 12 includes example data screens provided in association with one or more aspects of the present embodiments;
[0024] FIGS. 13A-13B include an example tabulation of data processed in association with one or more aspects of the present embodiments;
[0025] FIG. 14 includes an example data screen and schematic samples of labels provided in association with one or more aspects of the present embodiments;
[0026] FIG. 15 includes various schematic diagrams provided in association with one or more aspects of the present embodiments;
[0027] FIG. 16 includes example data screens provided in association with one or more aspects of the present embodiments;
[0028] FIG. 17 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0029] FIG. 18 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0030] FIG. 19 includes example data screens provided in association with one or more aspects of the present embodiments;
[0031] FIG. 20 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0032] FIG. 21 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0033] FIG. 22 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0034] FIG. 23 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0035] FIG. 24 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0036] FIG. 25 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0037] FIG. 26 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0038] FIG. 27 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0039] FIG. 28 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0040] FIG. 29 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0041] FIG. 30 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0042] FIG. 31 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0043] FIG. 32 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0044] FIG. 33 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0045] FIG. 34 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0046] FIG. 35 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0047] FIG. 36 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0048] FIG. 37 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0049] FIG. 38 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0050] FIG. 39 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0051] FIG. 40 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0052] FIG. 41 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0053] FIG. 42 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0054] FIG. 43 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0055] FIG. 44 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0056] FIG. 45 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0057] FIG. 46 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0058] FIG. 47 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0059] FIG. 48 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0060] FIG. 49 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0061] FIG. 50 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0062] FIG. 51 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0063] FIG. 52 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0064] FIG. 53 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0065] FIG. 54 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0066] FIG. 55 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0067] FIG. 56 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0068] FIG. 57 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0069] FIG. 58 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0070] FIG. 59 includes an example data screen provided in association with one or more aspects of the present embodiments;
[0071] FIG. 60 includes a schematic of an example network architecture provided in accordance with one or more aspects of the present embodiments;
[0072] FIG. 61 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0073] FIG. 62 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0074] FIGS. 63A-63B include an example network site page provided in accordance with one or more aspects of the present embodiments;
[0075] FIG. 64 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0076] FIG. 65 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0077] FIGS. 66A-66C include an example network site page provided in accordance with one or more aspects of the present embodiments;
[0078] FIG. 67 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0079] FIG. 68 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0080] FIG. 69 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0081] FIG. 70 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0082] FIG. 71 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0083] FIG. 72 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0084] FIG. 73 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0085] FIG. 74 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0086] FIG. 75 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0087] FIGS. 76A-76B include an example network site page provided in accordance with one or more aspects of the present embodiments;
[0088] FIG. 77 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0089] FIG. 78 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0090] FIG. 79 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0091] FIGS. 80A-80B include an example network site page provided in accordance with one or more aspects of the present embodiments;
[0092] FIGS. 81A-81B include an example network site page provided in accordance with one or more aspects of the present embodiments;
[0093] FIG. 82 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0094] FIGS. 83A-83B include an example network site page provided in accordance with one or more aspects of the present embodiments;
[0095] FIG. 84 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0096] FIG. 85 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0097] FIG. 86 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0098] FIG. 87 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0099] FIGS. 88A-88B include an example network site page provided in accordance with one or more aspects of the present embodiments;
[0100] FIG. 89 includes an example network site page provided in accordance with one or more aspects of the present embodiments;
[0101] FIGS. 90A-90B include an example network site page provided in accordance with one or more aspects of the present embodiments;
[0102] FIGS. 91A-90B include an example network site page provided in accordance with one or more aspects of the present embodiments; and,
[0103] FIGS. 92A-92B include an example network site page provided in accordance with one or more aspects of the present embodiments.
DESCRIPTION
[0104] As applied herein, an “inspected item” includes any equipment, document, product, article of manufacture, inanimate object, animate object (e.g., people, animals, and/or other living organisms), and/or any other item suitable for use in accordance with one or more aspects of the present embodiments. In one example aspect, the inspected item can include, without limitation, a “machine” suitable for application to one or more aspects of the present embodiments. Examples of “machines” as applied herein can include, for example and without limitation, a lubrication system, engines, diesel engines, large-scale diesel engines, motors, rotating equipment, generators, emergency machines, emergency generators, compressors, earth-moving equipment, excavation equipment electrical power generation equipment (“EPG” or “EPGs”), equipment that includes a machine (e.g., such as mining equipment, construction equipment, marine equipment, and the like), and/or other like equipment and/or equipment components. It can be appreciated, however, that the scope of the present embodiments may encompass other types of inspected items such as financial documents (e.g., including loan processing in association with the financial documents), patients (e.g., including examination of patients at a health care facility). In addition, it can be appreciated that various aspects of the present embodiments may be readily adapted/configured/structured for applicability to a wide variety and plurality of different inspected items.
[0105] As applied herein, the terms “service operation” and “service operations” include, for example and without limitation, any function, method, process and/or other like activity performed in association with an inspected item. In the context of an inspected item which includes a machine, for example, service operations performed can include, for example and without limitation, maintenance, installation, repair, replacement, overhaul, inspection, fluid changes, and/or any other similar operations, functions and/or activities performed in association with one or more of the machines. In another aspect, in the context of an inspected item which includes a financial document, for example, service operations performed can include, without limitation, data entry, application processing, document storage and retrieval, document transmission, and/or any other similar operations, functions and/or activities performed in association with one or more of the financial documents. In another aspect, in the context of an inspected item which includes a patient, for example, service operations performed can include, without limitation, physical examination, administration of medicine to the patient, receiving/storing/analyzing/processing patient data, health care facility admitting procedures, collection of patient fluids (e.g, blood), and/or any other similar operations, functions and/or activities performed in association with one or more patients.
[0106] As applied to various data device embodiments described herein, the term “interactive” includes the capacity for a user to manipulate data, data fields including data entry fields, buttons, radio buttons, and/or other functions available in the various data device embodiments described herein.
[0107] As applied herein to various embodiments, the term “CSA” can be used to refer to one or more aspects of a calendaring and scheduling application and/or may include any method, system, apparatus, device, product and/or computer-readable media embodiment configured for data collection, processing, storage, and/or analysis in accordance with one or more of the present embodiments.
Operational Examples
[0108] The following operational examples are intended to illustrate, by way of example, various embodiments and aspects provided in accordance with the present method, system, product, and computer-readable media embodiments. The intention of providing these operational examples is to teach one skilled in the art how to make, use and/or practice various embodiments of the present invention. The intention of providing the operational examples is not, however, to limit the scope of the present embodiments to any particular details or aspects of the operational examples as described herein.
[0109] Where appropriate, to promote convenience of disclosure and clarity of illustration, detailed discussion included for a first operational example may or may not be repeated for a second, third or other operational example. For example, it will be apparent to those skilled in the art that many aspects of the first operational example described herein with respect to service operations for machines (i.e., “Operational Example 1—Machines”) can be readily and analogously applied to their substantially equivalent and/or functionally equivalent aspects in the subsequently described operational examples (i.e., “Operational Example 2—Patients” and “Operational Example 3—Financial Documents”).
Operational Example 1
Machines
[0110] Referring now to FIG. 1 , in one example embodiment of the present embodiments, various types of machines 2 can be positioned at a service site 4 . The machines 2 can include, for example and without limitation, one or more types of electrical power generation equipment (“EPGs”) 2 A, one or more varieties of earth-moving equipment 2 B, and/or one or more other machines 2 C for which one or more service operations are to be performed. In one aspect, one or more service data devices 6 can be employed by a service technician, for example, in association with service operations performed on the machines 2 at the service site 4 . Examples of service data devices 6 can include, as shown, a personal digital assistant 6 A (PDA), a laptop 6 B, a pen-based computer system 6 C, and/or a telephone 6 D (such as wireless telephones including cellular phones, for example, or a wireline telephone). In various aspects, a suitable type of data device 6 includes a capacity for portability such as for performing one or more field service operations, for example. In addition, in accordance with various of the present embodiments, a given data device 6 can be structured/configured for performing communications including, for example, real-time wireless communication, communicating with a computer system to synchronize through a cradle or other equivalent apparatus, storing data as a stand alone device and then subsequently communicating the collected data to another location (i.e., store and forward applications), and/or a reasonable combination of these communications, and/or another suitable form of communication.
[0111] One or more local data storage media 8 can be operatively associated with one or more of the service data devices 6 to receive and store data collected during execution of one or more service operations on the machines. In one aspect, at least one of the local data storage media 8 can serve as temporary storage for collected service operation data. In another aspect, such temporarily stored data may serve as a backup source of data in the event of malfunction or failure of the service data device 6 , for example. In another aspect, the local data storage media 8 can include one or more removable data storage media 8 A. In addition, in another example embodiment of the present embodiments, one or more printing devices 10 can be operatively associated with one or more of the service data devices 6 . In one aspect, at least one of the printing devices 10 can be employed to print a label, for example, associated with a service operation performed on one of the machines 2 . In an example aspect, the label or other item printed with the printing device 10 can include indicia associated with data collected during the service operation such as, for example, two-dimensional bar code indicia including data obtained from a fluid change service operation. It can be appreciated that other information displayed on the data device 6 can be printed on one or more of the printing devices 10 such as, for example, a summary report of data obtained from service operations performed on an inspected item.
[0112] In another aspect of the present embodiments, the service data devices 6 can be configured for operative communication with a service administrator 12 through one or more communication media 14 . In various embodiments, the communication media 14 can include one or more wireless networks 14 A, one or more wireline networks, and/or a reasonable combination of one or more of the wireless networks 14 A with one or more of the wireline networks 14 B. The service administrator 12 can include one or more computer systems 16 such as, for example, a web server 16 A configured to host an network site, for example; a data server 16 B configured for receiving, processing and/or directing the storage of data, such as data related to service operations performed on the machines 2 communicated by one or more of the service data devices 6 ; and/or one or more other computer systems 16 C. In one aspect, data processed by the web server 16 A, the data server 16 B, and/or the other computer systems 16 C of the service administrator 12 can be stored in one or more data storage media 18 operatively associated with the computer systems 16 of the service administrator 12 . In one aspect, activation of one of the service data devices 6 can include synchronization of the service data device 6 through the communication media 14 with one or more computer systems 16 of the service administrator 12 to update information displayed or stored on the service data device 6 , for example. In another aspect, one or more communications can be enabled between the data device 6 and the service administrator 12 , for example.
[0113] In further examples of the present embodiments, one or more of a distributor 20 , a customer 22 , and/or a service provider 24 can be operatively configured to communicate with the service administrator 12 such as to obtain, review, and/or analyze data associated with service operations performed on the machines 2 . In one aspect, the distributor 20 can be an entity that maintains a relationship with an original equipment manufacturer (OEM) for the marketing, sale and/or service of one or more of the machines 2 and/or their associated components. In another aspect, the customer 22 can be an entity such as a construction company, for example, employing the machines 2 to perform excavation work at a construction site, for example. In other aspects, one or more other service providers 24 , such as a laboratory facility performing analysis on fluid change/fluid sample data, for example, can be configured to communicate with, and access service operation data from, the service administrator 12 .
[0114] In another aspect, the distributor 20 can be operatively associated with a service cost system 26 that can be configured to provide cost estimates such as for recommended repairs (“RRs”) for one or more of the machines 2 , such as when an inquiries are received from the service data devices 6 , for example, for such cost estimates. In one example configuration, the service cost system 26 includes one or more data servers 26 A operatively associated with one or more cost data storage media 26 B. In one operational aspect, the service data devices 6 can communicate one or more service reports to the service cost system 26 of the distributor 20 to solicit cost estimate information for performing one or more recommended repair, installation, replacement, and/or other maintenance activities for one or more of the machines 2 .
[0115] In various embodiments discussed herein, data input for the service data device 6 can be performed substantially automatically by communication of the service data device 6 with one or more of the computer systems 16 of the service administrator 12 . In other embodiments, data input for the service data device 6 can be conducted partially by manual data entry and/or partially through substantially automatic data retrieval from one or more of the data storage media 18 of the service administrator 12 by means of communication of the service data device 6 with the service administrator 12 through one or more of the communication media 14 . In one example, entering a serial number as a key identifier into a data manipulation screen of the service data device 6 can execute a retrieval program to access, collect and pre-populate the data screen with other data associated with the entered serial number such as, for example, customer name, last service type, last service date, and other data linked to the serial number. In other embodiments, a machine can be equipped with a bar code label that includes data such as a machine serial number, for example. In these embodiments, data entry for the service data device 6 can be performed by scanning the bar code label, RFID tag, or other indicia with a bar code reader, for example, to input data represented by the bar code label into the service data device 6 .
[0116] In various of the present embodiments, the service data device 6 can be programmed/configured to retrieve, display and/or communicate various data manipulation screens, including at least one interactive data screen, in association with collecting, processing, storing and/or analyzing data obtained from one or more service operations performed on one or more of the machines 2 . Referring now to FIGS. 1 and 2 , one illustrative overview method embodiment is provided in accordance with the present embodiments. In step 202 , the service data device 6 is accessed, such as by a conventional login procedure, for example. In step 204 , the service data device 6 is synchronized with data stored, for example, within one or more data storage media 18 of the service administrator 12 . In one embodiment, synchronization between the data device 6 and the service administrator 12 of step 204 can be structured/configured to occur prior to the login procedure of step 202 .
[0117] In step 206 , one or more service operations can be performed on one or more machines in connection with the function of the service data device 6 . In various example aspects, performing service operations in step 206 can include performing one or more assigned work orders in step 206 A and/or performing one or more unassigned or new tasks in step 206 B. Either or both of steps 206 A and 206 B may involve completing one or more checklists in step 206 C. In addition, in step 206 D and in association with performing one or both of steps 206 A and 206 B, data are input to the service data device 6 . As shown, examples of types of data input in step 206 D can include, without limitation, text entered by keyboard, text entered by use of a pen-based computer system, verbal communications recorded by one or more microphones including one or more microphones configured to eliminate, reduce and/or filter background noise for a recording, verbal communications received and transcribed into text format, digital photograph data and associated annotations, populated data provided through communication of the service data device 6 with the service administrator 12 , for example, and/or other types of suitable data input. In various aspects, one or more types of input data (e.g., text entries) can be stored for subsequent retrieval such that recurring, repetitive service operations (e.g., warranty repairs) can be cataloged to corresponding input data and retrieved/displayed for subsequent service operations. As applied herein, a “repetitive” service operation can include any set of service operations wherein at least one data field, at least one portion of a report, or other data are replicated across multiple service operations. It can be seen that such capability minimizes the need for a service technician, for example, to replicate data entry particularly in the context wherein multiple, at least substantially identical service operations are performed on multiple inspected items. Other service operations performed in step 206 can include performing one or more load bank tests in step 206 E, performing one or more fluid change or fluid sampling operations in step 206 F and generating one or more labels in step 206 G as a result of the processing of step 206 F, and/or calculating a cycle time associated with performance of service operations in step 206 H. In addition, and in view of specific example embodiments described hereinafter, it can be appreciated that other types of service operations can be performed in step 206 I.
[0118] In step 208 , one or more service reports reflecting data collected and processed during performance of the service operations in step 206 can be generated. In step 210 , service reports generated in step 208 can be communicated to an appropriate destination such as to the service administrator 12 , for example, the distributor 20 , the customer 22 , or another service provider 24 , for further processing of data included within the service reports. In another aspect, various portions of various reports (such as reports described herein) can be stored, displayed, and/or edited on the data device 6 prior to establishing communication (e.g., synchronization) between the data device 6 and the service administrator 12 , for example, to transmit data collected during a service operation to the service administrator 12 . In other aspects, various labels, reports, and/or other documents, or portions thereof, described herein can be stored, displayed and/or manipulated entirely in bar code format or another suitable scanner symbology format.
[0119] In one embodiment, a service technician, for example, can access the service data device 6 at the service site 4 to initiate communication with the service administrator 12 through one or more of the communication media 14 using the login screen 302 shown in FIG. 3 . The service technician logs-in by entering technician identification and a password into the login screen 302 . In one aspect, entry of technician identification information can be performed by scanning an identification badge of the technician, for example, such as by use of a bar code scanning apparatus or system. Once the service administrator 12 verifies that access is authorized for the service technician, a confirmation screen 304 can be displayed on the service data device 6 to confirm successful login for the service technician. As shown in FIG. 4 , a data screen 402 can be displayed on the service data device 6 to advise that an initial synchronization of the service data device 6 should be performed with one or more of the data storage media 18 of the service administrator 12 to acquire the most currently available service operation information. Once synchronization is completed, a confirmation data screen 404 can be displayed to confirm the number and type of changes, for example, that have occurred since the last time the service technician logged into the service data device 6 . In another aspect, the service data device 6 can be configured to establish communication with the service administrator 12 to perform such synchronization functions on a substantially automated basis upon initial login by a service technician with the service data device 6 .
[0120] Referring now to FIG. 5 , a data screen can include a “Main” button 452 that permits a user of the data device 6 to display a navigation menu 454 including a variety of optional functions that can be accessed through the data device 6 . In one aspect, a “New Workorder” function 454 A permits a user to navigate to one or more data screens where assigned, unassigned and/or other types of work orders can be processed for a machine by a service technician, for example. In one aspect, by selecting a customer and a machine serial number, for example, information can be pre-populated into the data screens permitting a service technician, for example, to enter machine hours/miles, complete one or more checklists, and/or perform/complete other service operations. An “S.O.S. Labels” function 454 B permits the user to navigate to one or more data screens where labels including a variety of data associated with the machine can be generated and/or printed for service operations (e.g., fluid sampling operations as described above with reference to step 206 F) performed in connection with the machine. A “Service Report” function 454 C permits the user to navigate to one or more data screens associated with generating one or more aspects of reports including information gathered during one or more service operations performed on the machine. A “Load Bank” function 454 D guides the user to one or more data screens that include functionality for performing various aspects of load bank testing such as in connection with an electrical generator, for example. A “CSA Photo” function 454 E permits a user to take a digital photograph or digital image of at least a portion of a machine for which service operations are performed. A “Review W/O” function 454 F permits the user to navigate to one or more data screens wherein a previously completed, or at least partially completed, work order for a machine can be viewed by the user.
[0121] Referring now to FIG. 6 , in an example embodiment provided in accordance with the present embodiments, the service technician can access a work order data screen 502 , which includes a list of assigned work orders to be completed by the service technician. In one aspect, one or more work orders assigned to the service technician can be sorted and displayed by a scheduled date of service, for example, and accessed by means of a conventional drop-down menu feature 502 A, for example. In other aspects, a “New Unassigned” button 502 B and a “Start Assigned” button 502 C can be provided on the work order data screen 502 . Activating the “New Unassigned” feature provides a data input screen 504 in which, among other functions, the service technician can select a customer name 504 A, a type of equipment 504 B (e.g., “Earth Moving” or “Power Systems”), and/or a serial number 504 C for a machine on which unscheduled or unassigned service operations are to be performed. As shown, data for a given machine can be input to the service data device 6 such as by use of a conventional bar code scanning technology, an RFID technology, or other functionally equivalent and suitable technology. In one aspect, the customer name 504 A, the type of equipment 504 B (e.g., “Earth Moving” or “Power Systems”), and/or the serial number 504 C for a machine can be input by reading a bar code label installed on the machine such as by means of a bar code scanner, for example. Referring now to FIGS. 6 and 7 , when a “W/O Notes” button 506 D is pressed, the information associated with a given work order is displayed as shown in FIG. 7 .
[0122] Activating the “Start Assigned” button 502 C, or deciding to “Continue” from the data input screen 504 , displays a data entry screen 506 , which is pre-populated with various data associated with a machine. Among other data that can be selected on the data entry screen 506 , a service type 506 B (e.g., expressed as a number of hours, mileage, and/or other like indicators) can be selected to determine which service operation checklist is to be applied for servicing the machine. Data such as the number of hours/miles shown on an hours meter or odometer operatively associated with the machine, for example, can also be collected/entered into the “Hours Meter” field 506 C portion of the data entry screen 506 . In one aspect, the service data device 6 can compare the hours entered in field 506 C, through communication with the service administrator 12 , to the date/time of a prior inspection or other service operation performed for the machine. For example, if the prior service operation was a 500-hour service performed on a date prior to the current service operation, the service administrator 12 can increment to the next interval of predetermined service operation time due for the machine, such as to a 750-hour service interval, for example. In another aspect of this operational example, given that the 500-hour service has been previously performed, the service data device 6 can confirm through communication with the service administrator 12 that a 750-hour service checklist should be presented in association with service operations to be performed on the machine. In another aspect, the service technician may elect to override the current service interval determined by the service administrator 12 and perform service operations in accordance with a different service interval. It can be appreciated that service intervals for service operations can be configured by the service administrator 12 . It is emphasized that the examples of service intervals applied herein are provided merely for convenience of disclosure. In various aspects, service intervals can be scheduled at varying intervals, with any degree of frequency or non-periodicity, as a function of machine type, environment of machine use, life cycle of machine, and/or other potentially relevant factors.
[0123] Once data input is completed for the data entry screen 506 , a checklist 508 A of activities and/or inspection items for the service technician to perform/inspect can be displayed on the checklist data screen 508 . In various aspects, the checklist 508 A includes a number of predetermined and customized work items that a customer, for example, requires to be performed for a machine. This, the customer can customize the type, content, and/or number of questions/items to be included on the checklist 508 A. In addition, a service technician or other user of the data device 6 who accesses the checklist 508 A may readily edit the checklist by use of drop-down menus and/or data entry fields that are structured/configured to reflect data collected during a service operation on a machine for a given inspection.
[0124] The checklist 508 A can include one or more items such as items 508 B, 508 C, 508 D, 508 E to be inspected during a service operation that includes periodic maintenance, for example. The service technician can select the appropriate entry for each item (e.g., such as “YES”, “NO”, “OK”, or “RR”, among others). In various aspects, entries available for each item can be customizable by the service administrator 12 (as discussed/illustrated hereinafter in more detail). In example aspects, each checklist item can be defaulted to a “NO” or “YES” designation to promote effective completion of all checklist items by the service technician and to allow single-touch toggle of entries (i.e., compare to a first touch to provide a drop-down menu, for example, and then a second touch to make a selection of an entry). In another aspect, the selection of “RR” for a checklist item (such as item 508 B) is interpreted as “Repair Recommended” by the service data device 6 . In various aspects, logic programmed through the service administrator 12 can specify that a given checklist item is applicable on a “less than or equal to” basis with respect to the service interval to which the checklist item is assigned. For example, a checklist item designated for a 1000 service interval and designated on a “less than or equal to” basis is applicable and can be applied to any service operation performed at a service interval equal to or less than the 1000 service interval (e.g., service intervals of 250, 500, 750 and 1000 can be included in one example checklist). In other aspects, entries can include a variety of different types of data fields including, for example and without limitation, calculated fields, manual text entry fields, radio button fields, and/or other types of data fields.
[0125] As shown in FIG. 8 , the “RR” checklist entry on the data screen 508 can result in association of indicia such as a colored “N” box 508 F, for example, indicating that one or more explanatory notes have been associated with the “RR” checklist item. In various aspects, any checklist item can include an associated note, in addition to annotated “RR” checklist items. A note providing details on the selection of the “RR” designation, for example, can be included on a data entry screen 602 . In other aspects, notes and other data entered by the service technician can be entered/categorized on a “Recommended Repairs” data screen 604 , an “Urgent Repairs” data screen 606 , and/or on an “Other Notes” data screen 608 . In addition, completion of service operations on a given work order can be acknowledged by entering/capturing the signature of one or both of a technician and a customer associated with a particular machine in a data entry screen 610 . In one aspect, any checklist items including items for which repair is recommended (i.e., designated with an “RR”), for example, can be selected and consolidated into a summary portion of a service report generated in association with completion of the checklist items. In another aspect, the service report including the summary of recommended repairs can be communicated to one or more of the distributor 20 , the customer 22 , the service administrator 12 , and/or the other service providers 24 for review, analysis and/or further processing to be conducted pursuant to the issues raised in the service report.
[0126] In other aspects of the various embodiments described herein, a percentage complete status field can be included on various of the data manipulation screen displays associated with checklists processed and completed during field service operations. In one example aspect, for a given checklist, percentage complete can be based on comparing the number of currently uncompleted checklist items to the total number of items included on the checklist. In addition, time/date information associated with initiation of a service operation can be collected, stored, and compared to time/date information associated with completion of the service operation. In various aspects, time/date information can be collected/stored on a per checklist item basis to provide cycle time information for each checklist item as completed by the operation. In other aspects, the sequence in which checklist items are completed by a service technician, for example, can be collected/stored for later analysis to identify an optimum sequence or sequences for completing various service operations. In this manner, cycle times for various service operations can be calculated and employed to compare the cycle time for completion of a service operation performed by a first service technician, for example, to the cycle time for completion of the same service operation by other service technicians. It can be appreciated that such cycle time comparisons can be useful as management/training tools, for example, for improving the performance and effectiveness of service operations.
[0127] In various embodiments herein, data entered into the service data device 6 by a technician, a customer, or another entity or entities providing information associated with service operations can be received/captured into the service data device 6 in a variety of ways. In one aspect, data entry can be performed by use of a keyboard or other similar data input device. In another aspect, data entry can be performed using a pen-based or wand-based data entry system, in which a graphics file including the handwritten note of a technician, for example, is recorded/captured by the data service device 6 . In another aspect, a verbal description of an issue arising from a service operation can be captured and recorded as a voice data file (e.g., through one or more microphones operatively associated with the service data device 6 , wherein the microphone or microphones can be configured for filtering noise to eliminate or reduce background noise that arises during a recording) and/or transcribed into text from the verbal description of the issue by software programmed on the service data device 6 and/or stored in one or more of the local data storage media 8 . In one operational example, a service report generated upon completion of a given maintenance checklist includes an association to one or more voice, text, and/or data files including information gathered during service operations.
[0128] Referring now to FIG. 9 , once signature data is captured in the data entry screen 610 , a service report screen display 702 can be generated and displayed on the service data device 6 . In various aspects, the service report shown on the screen display 702 includes various data collected and stored during service operations performed using the service data device 6 . In various aspects, any portion of the service report can be communicated through the communication media 14 to one or more of the computer systems 16 of the service administrator 12 . In another aspect, the service report can be remotely printed (e.g., at the remote location of a service site where service operations are performed), such as by use of an appropriate portable printing device 10 . Once work with the service report is completed, the work order screen 502 can be accessed again as shown, such as in the event of a service technician accessing an additional assigned task for which service operations are required, for example. In other aspects of the present embodiments, service reports can be communicated and/or automatically routed to distributors 20 , customers 22 , or other service providers 24 for storage, analysis, and/or further processing of data obtained from service operations. During synchronization with the service administrator 12 , for example, updated service operations data can be communicated to distributors 20 to permit the distributors 20 to act on issues identified in the service report such as by notifying management, sales representatives, and/or service technicians, for example. In one example aspect, the service report including the summary of recommended repairs can be communicated through the communication media 14 , in electronic format or another desired format, to the service cost system 26 of the distributor 20 for generation of cost estimates for resolving issues identified in the service report. Such cost estimates can be further communicated, for example, to the customer 22 for the machine or machines 2 , or components thereof, associated with the service report.
[0129] In another embodiment of the present methods and systems, zone/location information 802 A can be accessed through use of the service data device 6 to display a zone/location screen display 802 , as shown in FIG. 10 . The zone/location information 802 A can indicate a site where a machine is being employed to perform work, which work site may also be a suitable service site, in one aspect. In addition, the zone/location information 802 A can also be associated with one or more other data fields such as, for example, work order number 802 B, service type 802 C, and/or model/serial number information 802 D.
[0130] Referring now to FIG. 11 , in another embodiment of the present methods and systems, a service type screen display 902 can be provided. As shown, the service type screen display 902 can include information for a machine such as, for example, work order number 902 A, model number 902 B, serial number 902 C, customer name 902 D, an indication 902 E of the type of machine (e.g., “Electrical”), an hours field 902 F for receiving entry of a current hour meter reading for the machine, a service type (expressed as hours) 902 G representing the number and kind of service operations to be performed for the machine, an indication of the last service type 902 H performed for the machine, and/or a date 902 I of the most recent service operations performed on the machine. In one aspect, a service technician can override the service type 902 G to perform one or more service operations that may be necessary outside usual maintenance schedules. In one example, the service technician can override the service type 902 G to perform service operations that may be missed in the future because of an expected period of operation of the machine without the opportunity to perform service operations during that period of operation.
[0131] In another embodiment of the present methods and systems, one or more labels (such as Scheduled Oil Service (“SOS”) labels, for example) can be generated in connection with one or more fluid change type and/or fluid sampling type service operations. In one aspect, the “SOS Label” button 902 J on the screen display 902 can be activated to display the data entry screen display 1002 (see FIG. 12 ). In another aspect, the label function can be configured to require data entry for machine hours, for example, before labels may be generated, completed, and/or printed. As shown, the data entry screen display 1002 , and an associated data entry screen display 1004 , include various data options that can be selected/entered by a service technician, for example, in connection with an oil change and/or oil sampling service operation performed on a machine. In various aspects, printed labels can include one or more adhesive surfaces for securement of the label to an appropriate object or machine, for example. In other aspects, printed labels can be provided with one or more non-adhesive surfaces.
[0132] In another aspect, once a machine serial number is entered for a service operation, the service administrator 12 can determine which compartment samples are required and display the required compartments on the data device 6 . It can be appreciated that the particular examples of oil changes/oil sampling are described herein merely for purposes of illustration; it can be further appreciated that other types of fluid change/sampling service operations can be performed in accordance with the present methods and systems. Examples of other fluid change/sampling service operations include, without limitation, transmission fluid, hydraulic fluid, fuels, and other types of fluids employed during operation of a machine. In one aspect, an indication 1002 A of whether or not oil was both changed and sampled at the time of data collection can be entered into the data entry screen display 1002 . It can be seen that information concerning the timing of fluid changes (e.g., a “YES” response entered as the indication 1002 A) such as oil changes, for example, can be communicated to the service administrator 12 to be incorporated into future periodic maintenance schedules, for example, for the machine. In one aspect, intervals such as the time, for example, between “YES” indications 1002 A, for example, can be calculated by the service administrator 12 to determine hour/mileage intervals between service operations for a given compartment, and to determine when another fluid change should be performed for the machine. In addition, because additional types of fluid change/sampling processes are within the scope of the present methods and systems, it can be appreciated that calculations between “YES” indications, for example, can be distinctly performed on a compartment-by-compartment basis. Thus, analysis of the need to perform a transmission fluid change, for example, can be performed in addition to, and independently from, similar calculations performed in association with oil change/sampling service operations.
[0133] FIGS. 13A-13B display a sample tabulation of stored results obtained, in various aspects of the present embodiments, from various service operations including one or more fluid sampling operations. As shown, data associated with fluid sampling operations can include a serial number of the machine for which service operations are being performed; a compartment identification (e.g., engine, transmission, hydraulic, and others) and can be individually identified on the label, eliminating or reducing the need for a manually-annotated tabulation of checklist items; an amount of oil added, if any, to the compartment; a time/date stamp for the fluid sampling operation; a meter reading for the machine; an “hours on oil” number; a designation of degree of application severity for the machine (e.g., light, medium, heavy, and others); a fluid identifier (e.g., engine oil, transmission oil, hydraulic oil, and others); a fluid viscosity identifier; and/or an “oil changed” indication that records whether or not a fluid change operation has been performed in addition to the fluid sampling operation. Once selections are chosen for a particular machine serial number, or other primary key or identifier, such selections can be configured to become default settings (which can be overridden as described herein) for future fluid operations performed on the same machine to reduce the need for repetitive data entry selections for the future fluid operations. In various aspects, it can be seen that application of various aspects of the present embodiments may increase the available, usable area of a label by incorporating compartment selection into data entry processes on the data device 6 and by including compartment information in association with label generation/printing.
[0134] Referring now to FIG. 14 , in other aspects of the present embodiments, a label manager screen display 1102 can be provided for managing the generation, completion and printing of labels associated with fluid change/sampling service operations performed on a machine. In one aspect, an icon can be configured to appear on the screen display 1102 once a label has been completed and is ready to be printed, if desired. As shown, an engine related fluid compartment 1102 A can be selected and data associated with oil sampled from the engine can be compiled and generated on a label 1104 or on a label 1106 . In one aspect, a “Print Selected SOS Labels” button 1102 B can be activated on the label manager screen display 1102 to transmit an electronic version of the label 1104 and/or the label 1106 to one or more of the printing devices 10 to generate the label 1104 and/or the label 1106 in a tangible medium such as may be suitable for placement on a bottle, for example, or other container that holds the oil sample associated with the label 1104 . In another aspect, the particular printing device 10 employed to print the label 1104 can be operatively and remotely associated with a laboratory facility, for example, or other service providers 24 that are to conduct analysis of the oil sample.
[0135] In other aspects of the present embodiments, a label including a bar code portion can be pre-printed at a first location and transported for use in connection with one or more service operations at a second location or other locations, such as one or more field service locations, for example. The bar code portion of the label can be pre-populated with various data associated with a machine for which service operations are to be performed. In one example, the label can include pre-populated data such as machine serial number among other machine data. In addition, one or more portions of the label can be configured, for example, for entry of a date, a number of machine hours, a number of miles and/or other pertinent information associated with a service operation. The label can then be affixed, as desired, to a chart, a report, a container, and/or another suitable medium. In another aspect, to resist unauthorized personnel from viewing machine data, the label can include only a bar code portion representing the machine data. It can be seen that printing of labels at a first location permits a service technician, for example, at a second location to benefit from the various embodiments described herein with or without having the capacity to print labels at the second location or other site where service operations such as fluid operations, for example, are performed.
[0136] In other aspects, a label including a bar code portion, for example, can be employed as a means for promoting security of data collected during service operations. In one aspect, data can be stored in the bar code portion for retrieval only by a predetermined and permissible bar code scanning apparatus, system and/or method. Thus, certain data can be stored in the bar code portion of the label that are not visually discernible by a service technician and are configured to be accessible only through an approved bar code scanning apparatus, system and/or method. In other aspects, a label with a bar code portion can be adhered directly to a portion of a machine for which service operations are provided. In this context, the label may serve as a visual reminder of future service operations, for example, to be performed for the machine. In another aspect, one or more labels can be printed on-site with respect to the machine to provide an indication of such future service operations that can be placed on the machine.
[0137] As shown in FIG. 14 , in other aspects of the present embodiments, the label 1106 can include a data presentation portion 1108 and one or more bar code portions, such as bar code portion 1110 as shown. In one aspect, the bar code portion 1110 includes a bar code 1112 having a vertical axis 1112 A and a horizontal axis 1112 B, wherein the vertical axis 1112 A of the bar code 1112 is structured/configured to be greater in length in comparison to the horizontal axis 1112 B of the bar code 1112 to enhance available, usable area of the label 1106 that can be employed as the data presentation portion 1108 . In various aspects, one or more bar code indicia 1114 are imprinted on the bar code 1112 and may be representative of various information and data associated with a machine, for example, and/or service operations performed on the machine. In various aspects, the horizontal axis 1112 B of the bar code 1112 is structured to be in general parallel alignment with a transverse plane of a variety of objects including, for example and without limitation, machine surfaces, documents, and/or radiused objects such as containers, for example, on which the label 1106 , or at least the bar code portion, is positioned for use. For example, a radiused container 1116 can include at least one transverse plane such as transverse plane 1118 , for example, that can be in general parallel alignment with the horizontal axis of a bar code positioned on a label (e.g., such as label 1106 ) positioned on the container 1116 . In one aspect, the orientation of the horizontal axis 1112 B of the bar code 1112 can be configured in association with a comparatively larger vertical axis 1112 A of the bar code 1112 to derive benefits from enhancing available, usable area in the data presentation portion 1108 of the label 1106 for including and displaying relevant machine data, service operation data, and/or other information.
[0138] It can be appreciated that the bar code 1112 and the bar code indicia 1114 are structured/configured to be read/scanned by a conventional bar code scanning apparatus or system. In various aspects, the length of the horizontal axis 1112 B of the bar code 1112 is dimensioned as a function of a surface area portion of an object to which the label is applied. In the context of an object having a radius, for example, such as a bottle-type container, for example, the length of the horizontal axis portion of the bar code is minimized to a sufficient degree to account for scanning of the bar code and to mitigate the problems attendant upon scanning a radiused object or any object having an arcuate or rounded outside surface area portion. In one aspect, the label 1106 can be die cut or die stamped such as during production of a blank version of the label 1106 , for example, to form a perforation 1122 , for example, or other like structure that permits ready detachment of the bar code portion 1110 from the data presentation portion 1108 of the label 1106 .
[0139] Referring now to FIG. 15 , in other embodiments of the present embodiments, methods and systems are provided for scanning a bar code 1152 imprinted on a cylindrical object 1154 (such as a bottle type container for fluid samples, for example), generally cylindrical portion of an object, or other arcuate or generally arcuate portion of an object having a radius and/or a circumference. In the example shown, applying a central axis 1156 of a conventional bar code scanner or system (not shown) to the bar code 1152 imprinted on the generally arcuate surface of the container 1154 may result in one or more beams that do not reflect effectively back to the bar code scanner or system after striking bar code indicia imprinted on the bar code. It can be appreciated that such errant beams may provide no results or incorrect results when the bar code on the container is scanned for information. In one embodiment of the present embodiments, at least one bar code indicium 1157 is imprinted along an arcuate portion of the container extending a distance A ( 1158 ) to provide an effective width w e ( 1160 ) sufficient to permit an effective reading of the bar code indicia 1157 by a bar code scanning apparatus or system. In various aspects, the bar code indicia 1157 can be provided with the enhanced effective width w e ( 1160 ), in the event that the indicia 1157 are located outside the range of a cone of scanning beams extending from the central axis 1156 of the bar code scanner within an alpha range 1162 of degrees on a first side of the central axis 1156 and/or within a beta range 1164 of degrees on a second side of the central axis 1156 .
[0140] In another embodiment, bar code indicia 1172 are imprinted along an arcuate portion of the container with a first thickness 1174 and a second thickness 1176 . As shown, the thicknesses 1174 , 1176 can be structured to provide a scanning surface 1178 with an effective width w e ( 1180 ) sufficient to permit an effective reading by a bar code scanning apparatus or system. It can be further appreciated that the difference in magnitude of the thicknesses 1174 , 1176 can be adjusted to provide a generally flat surface for receiving one or more scanning beams, for example, transmitted from a bar code scanning apparatus or system.
[0141] In other embodiments of the present methods and systems, one or more load bank tests can be performed in connection with use of the service data devices 6 and one or more of the machines 2 which include electrical power generation (EPG) equipment. Referring now to FIG. 16 , in one example embodiment, a load bank test setup display screen 1202 is shown. The load bank test setup screen is configured to receive data including, for example, a load bank type 1202 A (i.e., whether the machine is a single-phase or three-phase electrical machine), a length of test 1202 B, a testing interval 1202 C, and an option 1202 D to elect an alarm notification in association with the time that each testing interval occurs. It can be appreciated, in accordance with other discussion of customization of checklists presented herein, that one or more data screens associated with load bank testing, or portions thereof, can be customized to address customer requirements. Based on selection of the option 1202 D for an alarm notification, the service data device 6 can generate a notification, such as the dialog box 1204 , at a predetermined time before or after elapse of a testing interval. In one aspect, the data device 6 can be configured to “awaken” automatically when a subsequent load bank test reading is required. In other aspects, the data device 6 can “awaken” from an off state of the data device 6 , or can generate a notification or other prompt in an on-state of the data device 6 , that a subsequent test reading is needed, if the data device 6 is currently powered down or in use for another type of service operation. The dialog box 1204 provides the option for a service technician, for example, to be directed to a load bank test screen display 1302 for single phase testing (see FIG. 17 ) or to a load bank test screen display 1402 (see FIG. 18 ) for three-phase testing. As can be seen and appreciated, various data associated with load bank testing can be entered into the load bank test screen displays 1302 , 1402 of the service data device 6 during the test period. In another aspect, upon completion of load bank testing, load bank test results can be displayed such as in the example load test result screen displays 1502 , 1504 shown in FIG. 19 . In another aspect, load bank test results can be communicated from the service data device 6 through the communication media 14 to one or more computer systems 16 and/or data storage media 18 of the service administrator 12 for storage, analysis, scheduling of service operations, and/or other processing activities.
[0142] In other embodiments of the present methods and systems, a service report module can be programmed within the service data device 6 in which data are collected and stored during one or more service operations performed on a machine. Referring now to FIG. 20 , a service report data screen 1602 can be provided with various data associated with a machine such as, for example, dealer code 1602 A, work order number 1602 B, customer name 1602 C, model/SN (serial number) 1602 D, equipment location 1602 E, among other data elements as shown. In one aspect of the service report module as shown in FIG. 21 , an incidents screen display 1702 displays components identified as requiring repair, replacement or other service during service operations performed on the machine. In the example shown, a part number 1702 A, a part name 1702 B associated with the part number 1702 A, and a quantity 1702 C of the part number reflect an incident reported during a service operation by a service technician. As shown in FIG. 22 , in another aspect of the example, a part number responsible screen display 1802 can be displayed including a description code 1802 A associated with the type of problem presented by the part number (e.g., “G—General Repair”). In addition, data associated with parts/components related to the part number can be displayed in data fields 1802 B, 1802 C, for example. In another aspect, in data field 1802 D, data can be entered by a service technician, for example, providing an indication of whether or not the incident makes the product (e.g., machine) inoperable. In another aspect, a parts screen display 1902 (see FIG. 23 ) can also be employed to indicate whether parts were left with the customer (data field 1902 A), whether parts were scrapped (data field 1902 B), and/or whether the service operation was completed (data field 1902 C). In addition, if parts are to be returned, a data field 1902 D can be provided for data entry of a return number associated with any returned parts.
[0143] In other aspects of the service report module, one or more screen displays can be provided for data entry of comments and other descriptions of problems identified during one or more service operations performed on a machine. In one aspect shown in FIG. 24 , a data entry screen 2002 can be provided wherein information associated with a “What did you find wrong:” query can be entered into the service data device 6 . In another aspect shown in FIG. 25 , a data entry screen 2102 can be provided wherein information associated with a “What was done to repair the problem:” query can be entered into the service data device 6 . In another aspect shown in FIG. 26 , a data entry screen 2202 can be provided wherein information associated with a “What in your opinion caused the problem:” query can be entered into the service data device 6 . In another aspect shown in FIG. 27 , a data entry screen 2302 can be provided wherein information associated with a “What were the operational test results:” query can be entered into the service data device 6 . In another aspect shown in FIG. 28 , a data entry screen 2402 can be provided wherein information associated with “Customer Remarks:” query can be entered into the service data device 6 . As described herein, text can be entered by keyboard, attached as a graphic file (e.g., a .pdf file), entered through graffiti text functions, entered through conversion of voice data, and/or a variety of other types of data entry methods. In another aspect, once entry of service operation related data and remarks is completed, signatures can be captured electronically from one or both of a service technician and a customer, for example, by use of the signature data entry screen 2502 configured for the service report module (see FIG. 29 ). In other aspects, many of the service report fields can be pre-populated as a part of the service report assignment function. This pre-population of data feature can be beneficial in situations where repetitive service operations are to be performed for multiple machines such as, for example, in the event of warranty repair/replacement required for multiple machines. In various embodiments, and in accordance with prior discussion above, it can be appreciated that data can be entered in the foregoing data entry screens by use of, for example and without limitation, a keyboard, a voice recognition/transcription software, a microphone for recording verbal communications and associated software for storing such communications as voice data files, capture of pen-based data entry in a graphics file, and/or another suitable means for data entry.
[0144] As can be applied to various of the method and system embodiments described hereinabove, the service data device 6 can include a camera, for example, or another operatively associated video apparatus suitable for capturing visual digital data associated with a machine for which service operations are performed. As shown in FIG. 30 , a photograph data screen 2602 can be used to display a digital image or digital picture of a machine, or portions of a machine, such as portions which are affected by disrepair or other conditions (e.g., corrosion). In one aspect, visual digital data can automatically be made part of the machine inspection or service report, thus obviating the need for a separate attachment or manual download of the visual digital data to create an association with the machine inspection or service report. It can be appreciated that once a digital photograph or digital image of a machine is captured using the service data device 6 , data associated with the picture can be communicated through the communication media 14 to the service administrator 12 . In one aspect, picture or image data can be stored in one or more of the data storage media 18 of the service administrator 12 and manipulated in connection with one or more other service data elements collected, stored and/or processed in association with performance of service operations for the photographed machine. In another aspect, a pen-based system can be operatively associated with the service data device 6 to permit markings, text and other annotations to be added to a digital photograph (as shown) or other image by a service technician, for example, for storage and use in connection with the digital photograph.
[0145] Referring now to FIGS. 31 and 32 , in another embodiment of the present embodiments, a data screen can be provided that permits a user of the data device 6 to add a new machine for a given customer using the data device 6 . In the example shown, service operations are to be performed for a new earth-moving machine of a given customer. On the data screen, a customer field can be selected and a machine serial number can be specified in a serial number field. In addition, service operations associated with a given service interval can be selected for the new machine by entering a service interval designation in a service interval field. In one aspect, data can be entered or populated into the data device 6 by use of a bar code scan function provided on the data screen. The data screen of FIG. 32 displays a confirmation function that can be employed to confirm adding the new machine on the data device 6 .
[0146] In another embodiment of the present embodiments, data associated with other new and/or unassigned machines can be recorded by use of the service data device 6 . Referring now to FIGS. 33 and 34 , data entry screens 2702 , 2802 can be provided for adding one or more EPG machines, such as an engine and a generator, for example, for use by the service data device 6 . The data entry screens 2702 , 2802 can include various data fields such as, for example, a data field 2702 A for entry of an engine serial number, a data field 2802 A for generator make, a data field 2802 B for generator model, among other pertinent data fields associated with specifications and other information for the engine and the generator to be added.
[0147] With reference to FIGS. 35 and 36 , in other aspects, filter data screens 3002 , 3102 are provided with various data fields, as shown, for entry of data related to, for example, an oil filter, air filter, and a fuel filter. With reference to FIG. 37 , in another aspect, a component data screen 3202 is provided with various data fields, as shown, for entry of data related to belts, oil and/or coolants, for example. With reference to FIGS. 38 and 39 , in other aspects, battery data screens 3302 , 3402 are provided with various data fields, as shown, for entry of data related to battery chargers, battery charging, and/or batteries. With reference to FIG. 40 , in another aspect, a block heater data screen 3502 is provided with various data fields, as shown, for entry of data related to a block heater. With reference to FIG. 41 , in another aspect, a starter data screen 3602 is provided with various data fields, as shown, for entry of data related to a starter. With reference to FIG. 42 , in another aspect, a transfer switch data screen 3702 is provided with various data fields, as shown, for entry of data related to a transfer switch. With reference to FIG. 43 , in another aspect, a miscellaneous data screen 3802 is provided with various data fields, as shown, for entry of data related to other machines, components of machines, or other aspects of machines. In various embodiments, it can be appreciated that data entered into the various data fields of the data screens of FIGS. 33 through 43 can be accomplished manually, electronically by use of a bar code scanner, for example, and/or remotely communicated from a data source external with respect to the service data device 6 , such as through communication of data received from the service administrator 12 , for example. In addition, in various embodiments, it can be appreciated that data entered into the various data fields of the data screens of FIGS. 33 through 43 can be used to add a new machine for a given customer, update profile information for a given machine, providing a format for data collection by service technicians, and/or other functions associated with service operations. As shown in FIG. 44 , in one aspect of the present embodiments, a confirmation message can be displayed confirming that information for the new machine has been added to a memory storage of the data device 6 .
[0148] Referring now to FIGS. 45 and 46 , in other embodiments of the present embodiments, a data screen can be provided that permits a service technician, for example, to perform one or more service operations associated with an unassigned work order for a given customer. In operation, a customer can be selected in a customer field and a serial number for a machine for which unassigned service operations are to be performed can be selected in a serial number field. As shown in FIG. 46 , the service technician can proceed to enter an hours number in the hours meter field and/or select a service interval in the service type field, among other data selections such as a work order number, for example, and can then proceed to perform service operations on a previously unassigned work order for the selected machine. In various aspects, banner information can be pre-populated into one or more data fields of the data screens described herein such that, in one example aspect, a service technician need only enter machine hours/miles and a work order number to initiate service operations for an inspected item. In one aspect, unassigned work orders can employ a system of identity ranges to ensure unique identifiers for each work order performed regardless of a work order number entered by a service technician, for example. In another aspect, multiple service operations can be associated with a common work order number, which may be useful for tracking and accounting activities, such as accounting activity associated with warranty service operations, for example.
[0149] Referring now to FIGS. 47 and 48 , in other embodiments of the present embodiments, examples of data screens that can be used to display and view previously completed work orders are provided. FIG. 47 illustrates how accessing the “Main” function provides a “Review WO” function, among other provided options. FIG. 48 displays a list of previously completed work orders in a data display field that can be accessed to facilitate display and/or modification of one or more of the previously completed work orders.
[0150] Referring now to FIGS. 49 through 57 , example screen displays are provided that illustrate pre-population aspects of the present embodiments. In the context of performing warranty replacement and/or repair work on machines, for example, it can be seen that pre-population of the data screens with conditions expected to be found on a machine for which warranty work may be required can increase the efficiency of service operations performed pursuant to the warranty work. FIG. 58 illustrates a data screen that can be employed for a customer and a service technician to acknowledge that work has been completed (in accordance with prior discussion hereinabove). FIG. 59 illustrates a confirmation message that can be displayed once the service report (including data for service operations performed pursuant to warranty work, for example) is completed for the machine. In another aspect, a prompt or other notification can be generated for display in the event that one or more checklist items are not completed, for example, or one or more signatures are not provided, for example. In one aspect, the prompt can be provided as a dialog box notifying a technician of the missing or incomplete information and can be provided with or without navigational functionality to return to the portion or portions of the data screen or screens where the missing or incomplete information should be entered.
[0151] It can be seen that service intervals may be developed and revised based on the data collected and processed through practice of various aspects of the foregoing embodiments. A service interval of 250, for example, and its associated checklist items may be adjusted to a different service interval to account for the practical aspects actual maintenance and repair operations performed on a machine, for example.
[0152] Referring now to FIGS. 60 and 61 , in other embodiments of the present embodiments, a sample illustration of a network site 3901 operatively associated with the web server of the service administrator is provided. In the example configuration shown, the network site 3901 includes a main page 3902 for obtaining authorized access to the network site 3901 . The network site 3901 also includes an administration module 3904 having one or more operatively associated administration module components 3906 , a customer module 3908 having one or more operatively associated customer module components 3910 , and a CSA module 3912 having one or more operatively associated CSA module components 3914 . An example embodiment of a screen display for the main page 3902 is shown in FIG. 61 . The main page 3902 can include buttons, for example, that permit a user to access the administration module 3904 , the customer module 3908 , and/or the CSA module 3912 .
[0153] Referring now to FIG. 62 , an illustrative screen display for a main page 4102 of the administration module 3904 is shown. The administration module main page 4102 includes links to various administrative functions that can be performed on the network site 3901 . As shown in FIGS. 63A-63B , a user administration page 4202 can be provided to add, remove or edit information associated with various users of the network site 3901 . FIG. 64 illustrates a division page 4302 including administrative functionality associated with editing one or more division descriptions. In one aspect, division types can include “Earth Moving” and “Power Systems” (or EPG), for example, among other types of potential division designations. FIG. 65 illustrates a role administration page 4402 that can be employed to configure the roles of various users of the network site 3901 . Examples of roles can include administrator, technician, clerk, among other types of roles. FIGS. 66A-66C illustrate a fluid administration page 4502 that can be used to configure data associated with one or more types of fluids such as oil, for example, employed in various service operations for various machines.
[0154] Referring now to FIG. 67 , a template administration page 4602 is shown which displays various templates that are available, by division, for use on the network site 3901 . In one aspect, a template can form the basis for developing and designing a customized checklist for use in a service operation, for example, which is designed to meet the needs of a particular customer, for example. The page 4602 displays all available templates by division and permits creation and/or deletion of templates to be initiated. In other aspects, template administration functions can be employed in association with customizing one or more data screens associated with one or more load bank testing service operations.
[0155] Referring now to FIG. 68 , a template detail page can be provided to permit a user to create a new template or edit an existing template. A template can be selected for edit/creation as a function of division type, and an edited/created template can be designated as a default template, as shown. As illustrated in FIG. 69 , a new template can be given an appropriate designation (e.g., a name) and a “Create” button can be accessed to initiate the template creation process. As shown in FIG. 70 , one or more inspection types are provided that represent headers for grouping on various reports. The inspection types and their associated checklist questions can be established on a checklist administration page to reflect various questions that a customer needs to have addressed during service operations performed on a machine, for example. In one aspect, the association between inspection types and a given template can be established on a template administration page.
[0156] As shown in FIG. 71 , once an inspection type is selected, one or more questions associated with that inspection type can be selected for the template. In one aspect, the service interval for a given question may be shown adjacent to the question for convenience of creating the new template. In another aspect, once selection of questions is completed, a “Create Template” button can be selected to finalize creation of the new template. FIG. 72 illustrates how questions are added to the template during the process of template creation.
[0157] Referring now to FIG. 73 , a sample template administration page is illustrated. The template administration page displays checklist questions for various inspection types including the service interval associated with each checklist question.
[0158] FIG. 74 illustrates a compartment administration page 4702 which can include information on various fluid compartments such as, for example, oil compartments, transmission fluid compartments, hydraulic fluid compartments, among other types of compartments used in association with machine service operations. FIG. 75 includes a description code administration page 4802 that can be employed to generate various types of codes used to describe issues associated with machines and/or their components. FIGS. 76A-76B illustrate a product family administration page 4902 that can be used to configure various machines, or components of machines, within a particular product family group designation.
[0159] Referring now to FIG. 77 , an example embodiment of a customer module main page 5002 is shown. The customer module main page 5002 includes information for various customers of machines for which service operations are performed.
[0160] FIG. 78 illustrates a customer detail page 5102 which includes various detailed data associated with one or more of the customers displayed on the customer module main page 5002 .
[0161] FIG. 79 illustrates a contracts page 5202 which includes agreement numbers and customer contacts, for example, for service contracts associated with service operations performed on customer machines.
[0162] FIGS. 80A-80B illustrate a contract administration page 5302 which includes detailed data relating various machines to contract data such as contact information, length of contract, service area, and other data as shown.
[0163] FIGS. 81A-81B illustrate an equipment page 5402 which relates customer equipment (such as machines, for example) to data obtained and stored by the service administrator 12 in association with service operations performed on the customer equipment. The equipment page 5402 includes one or more links to data such as, for example, equipment specifications, CSA inspections, service reports, and recommended repairs data.
[0164] FIG. 82 illustrates an equipment detail page 5502 which includes various data fields associated with a particular customer machine.
[0165] FIGS. 83A-83B are an example of a power systems equipment detail page 5602 provided in connection with a customer machine characterized as a power systems (EPG) machine.
[0166] FIG. 84 illustrates a pictures and audio notes page 5702 that provides, for example, digital photographic images and/or audio recordings association with service operations performed on a customer machine.
[0167] FIG. 85 includes an illustrative load bank test page 5802 that includes information obtained from one or more load bank tests performed on a machine.
[0168] FIG. 86 illustrates an inspection type notes page 5902 including notes recorded by a service technician, for example, derived from service operations performed on a machine.
[0169] FIG. 87 includes a sample inspection checklist item notes page 6002 including notes recorded by a service technician, for example, derived from service operations performed on a machine.
[0170] FIGS. 88A-88B illustrate a sample service reports page 6102 which includes data collected and communicated from service operations performed on a machine.
[0171] FIG. 89 includes a required repair reports page 6202 that includes checklist items identified with an “RR” designation during one or more service operations performed for a machine.
[0172] FIGS. 90A-90B include a CSA inspection report page 6302 which illustrates various checklist responses entered by a service technician, for example, performing one or more service operations on a machine. In one aspect, one or more checklist items can be associated with a note or notes entered by a user and stored for subsequent retrieval. As shown, a note or notes can be accessed through one or more hyperlinks, for example, or other links to the data underlying the stored note or notes (hyperlinks are represented as underlined text as shown in FIGS. 90A-90B ).
[0173] Referring now to FIGS. 91A-91B , in association with the CSA module 3912 , an embodiment of a create CSA inspection page 6402 is shown. As can be readily appreciated, the create CSA inspection page 6402 permits the service administrator 12 , in conjunction with the customer 22 , to develop a customized approach to performance of service operations for customer machines. Various functions shown on the create CSA inspection page 6402 include designating the type of machine (e.g., “Earth Moving” or “Power Systems”), loading a pre-designed template as a basis for the template being currently developed, adding questions to a checklist for inspection operations, determining service intervals, among other customizable features as shown in FIGS. 91A-91B .
[0174] In addition, with reference to FIGS. 92A-92B , a list of assigned inspections can be generated and displayed on an assigned CSA inspection page. Created CSA inspections and their associated service operations can be assigned based on, for example, a technician desired for a particular machine, work order identification, date/time a service operation is required or desired, and/or other factors. In various aspects, one or more assigned CSA inspections can be edited in the event of changes in dates, service intervals, and/or other information changes or updates.
[0175] In other embodiments of the present embodiments, data communicated between the service administrator 12 and the data device 6 , for example, can be communicated in one or more languages such as, for example, and without limitation, English, French, German, Spanish, and/or any other language used for communication between parties. A data screen including a checklist, for example, can be translated using a conventional language translation software, for example, into any suitable language for use on the data device 6 based on the geographical location, culture, and/or preferred language choice, among other factors of the location of service operations. In one aspect, the checklists can be customized such that a given checklist item is provided with a unique identifier (e.g., a numerical identifier) that survives translation of the checklist item into a different language. In this manner, data communicated to the service administrator 12 , for example, as a result of completion of the checklist item (which checklist item may have been completed in a variety of different languages, e.g., different countries, different regions of the world, and so forth), can be filtered based on the unique identifier regardless of the language into which the checklist item was translated and employed in service operations. It can be seen that, in this manner, data from a checklist item can be consolidated in a data storage medium, for example, despite the origin of the checklist data from potentially a diversity of different languages.
[0176] In another aspect, one or more viewing screens can be provided on the data device 6 and/or at the service administrator 12 to permit viewing of a checklist, for example, in a variety of languages. For example, checklists can be communicated to data devices around the world by the service administrator 12 in a non-English language and completed checklists communicated back to the service administrator in English. Functionality can be provided on either the data device 6 and/or the service administrator 12 , in connection with a conventional language translation software, to view translations of checklist items, for example, from one language to at least one other language. In one example aspect, checklists and other data screens can be translated initially into selected multiple languages for subsequent convenience of movement between and among the selected multiple languages.
Operational Example 2
Patients
[0177] In another operational example, an inspected item can include a patient arriving at a healthcare facility such as a hospital emergency room, for example, to receive medical treatment for a head injury, for example. As noted above, it can be seen that various aspects of the present embodiments applicable to machine service operations described above are equally and analogously applicable to the present operational example.
[0178] In one aspect, a social security number (compare serial number for machines—see above) of a patient can be a key identifier for automatically populating a data screen with information regarding the patient. Data such as patient name, patient address, patient phone number, patient date of birth, sex of the patient, patient next of kin, and other like personal information can be collected on a data screen, stored locally on the data device, communicated to a service administrator operatively associated with the healthcare facility, and/or otherwise processed in accordance with various aspects of the present embodiments described above. In one aspect, once patient data is initially collected and stored, the patient data can be subsequently retrieved and displayed upon entry of the social security number of the patient, for example, or another suitable key identifier. In another aspect, bar code scanning of patient data can occur as the patient is processed through the healthcare facility permitting, for example, patient identity recognition, quality assurance for administered medications, confirmation of proper patient location within healthcare facility, among other functions. In one example aspect, bar code scanning can be employed to reduce the possibility of medication interactions, improper dosaging, patient allergies to medications, and/or the potential for other adverse consequences that may affect the patient.
[0179] Customized checklist questions can be transmitted to a data device employed by a doctor, for example, or other healthcare professional, to inspect or diagnose the condition of the patient. Examples of checklist questions are provided as follows (with various data entry options such as drop-down menu selections, for example, illustrated in parenthesis next to each question as shown, with the process flow assuming that a head injury is selected for the first checklist question):
[0180] Social Security Number: (Enter number)
[0181] Nature of injury (head injury, cut, knee, stomach pain, broken arm, broken leg, ankle sprain)
[0182] How did injury occur? (fall, home injury, sports accident)
[0183] How long have symptoms been present? (Enter data)
[0184] Are you allergic to any medications? (penicillin, aspirin, codeine)
[0185] Is vision blurry? (YES/NO)
[0186] Do you have a headache now? (YES/NO)
[0187] If “YES” where in head is pain? (front, back, side)
[0188] Are headaches a common problem for you? (YES/NO)—How often? (weekly, monthly, yearly)
[0189] Signs of any cuts? (YES/NO)
[0190] Are you sick in stomach, nauseous? (YES/NO)
[0191] Was there any vomiting following the head injury? (YES/NO)
[0192] Did you pass out at any time? (YES/NO)
[0193] When did you last eat? (Select hours ago: 2, 4, 6, 8)
[0194] When was your last X-ray? (Enter date)
[0195] When was your last MRI? (Enter date)
[0196] Are you pregnant? (YES/NO/Not applicable)
[0197] Routing next: (ER, CAT scan, Admit to hospital for further testing/observation, Discharge)
[0198] Medications recommended: (morphine, aspirin, codeine)
[0199] In accordance with aspects and embodiments of the present embodiments described above, a signature of the patient can be captured on the data device such as to ensure informed consent of the patient to receive medical treatment, for example. In addition, the signature of the attending physician, nurse, or other healthcare professional can be captured and stored in association with a service report generated during examination/inspection of the patient as a quality control measure, for example.
[0200] It can be appreciated by those skilled in the art that various aspects of the present embodiments described hereinabove with respect to machines can be functionally and analogously applied to the present operational example within the scope of the present embodiments.
Operational Example 3
Financial Documents
[0201] In another operational example, an inspected item can include the financial information such as loan application information for a mortgage, for example, for a borrower seeking to procure the mortgage from a financial institution. As noted above, it can be seen that various aspects of the present embodiments applicable to the machine service operations and the patient treatment operations described above are equally and analogously applicable to the present operational example.
[0202] In one aspect, a social security number (compare serial number for machines—see above) of a borrower can be a key identifier for automatically populating a data screen with information regarding the borrower. Data such as borrower name, borrower address, borrower phone number, borrower date of birth, and other like personal information can be collected on a data screen, stored locally on the data device, communicated to a service administrator operatively associated with the financial institution, and/or otherwise processed in accordance with various aspects of the present embodiments described above. In one aspect, once borrower data is initially collected and stored, the borrower data can be subsequently retrieved and displayed upon entry of the social security number of the borrower, for example, or another suitable key identifier.
[0203] Customized checklist questions can be transmitted to a data device employed by a loan officer, for example, or other financial professional, to inspect or evaluate the financial condition of the borrower. Examples of checklist questions are provided as follows (with various data entry options such as drop-down menu selections, for example, illustrated in parenthesis next to each question as shown):
[0204] Social Security Number: (Enter Number)
[0205] Employer: (Enter Employer Name)
[0206] Current position/job: (Enter Data)
[0207] How long have you worked there: (more than two years, less than two years)
[0208] Annual Salary: (Enter Data)
[0209] Other Income: (Enter Data)
[0210] Total Income: (Can be calculated field)
[0211] Provide three credit references: (Enter Data)
[0212] Bank references: (Enter Bank Information)
[0213] Debts:
[0214] Installment loans: (Enter outstanding amount owed)
[0215] Car loan: (Enter outstanding amount owed)
[0216] Credit Cards: (Visa, American Express, MasterCard, Discover) other)
[0217] Other debt: (Enter total outstanding amount owed)
[0218] Total Debt: (Can be calculated field)
[0219] Assets:
[0220] Securities, Cash, Savings: (Enter Total Amount)
[0221] Stocks: (Enter Total Amount)
[0222] Bonds: (Enter Total Amount)
[0223] Other Assets: (Enter Total Amount)
[0224] Total Assets: (Can be calculated field)
[0225] Are you guarantor to any debts of others? (YES/NO)
[0226] Are there any liens on your home: (YES/NO)
[0227] Are there any liens on any assets in your portfolio: (YES/NO)
[0228] Current debt payments per month: (Can be calculated field)
[0229] Current Income per month: (Can be calculated field)
[0230] Ratio of current debt to current income: (Can be calculated field)
[0231] % of income available for mortgage: (Can be calculated field)
[0232] In accordance with aspects and embodiments of the present embodiments described above, a signature of the borrower can be captured on the data device such as to warrant completeness and accuracy of financial information provided by the borrower, for example. In addition, the signature of the loan officer or other financial professional can be captured and stored in association with a service report generated during inspection of the financial information of the borrower.
[0233] It can be appreciated by those skilled in the art that various aspects of the present embodiments described hereinabove with respect to machines can be functionally and analogously applied to the present operational example within the scope of the present embodiments.
[0234] In other example aspects of the present embodiments, use of the time/date stamping functionality associated with login, completion of checklists, and/or other functions performed on a data device 6 can provide a time card function for an organization or other entity employing aspects of the present embodiments. The time card function can include one or more data screens for receiving and/or storing relevant information associated with the service technician, details of service operations to be performed, hours worked on service operations, mileage information, mileage charge data, time/date information, cycle time information, overtime hours worked on service operations, salary rates, and/or other time card related information. The time card function can be used to record, review and track employee work performance and activities such as, for example, a cycle time or times associated with work activities of a maintenance person performing one or more service operations on an inspected item.
[0235] In other example aspects of the present embodiments, the time/date when a service technician logs into a data device in response to a customer complaint about an inspected item can be collected and stored. Based on the time/date of the customer complaint, the time/date of the technician login responding to the complaint, and/or other factors, the service administrator 12 , for example, can communicate a prompt to the service technician as reminder of the need to perform a follow-up activity in association with the customer complaint. Follow-up activities can include, without limitation, a prompt for the service technician to call the customer to discuss the customer complaint and what was done in response to the customer complaint, a reminder to close out a work order number, and/or other types of follow-up activities. In another aspect, the elapsed time from initiation of customer complaint to a follow-up activity notifying the customer of resolution of the complaint can be tracked, stored, and/or analyzed as a customer response time calculation suitable for assessing customer service effectiveness of an entity/organization providing service operations to the customer.
[0236] The term “computer-readable medium” is defined herein as understood by those skilled in the art. It can be appreciated, for example, that method steps described herein may be performed, in certain embodiments, using instructions stored on a computer-readable medium or media that direct a computer system to perform the method steps. A computer-readable medium can include, for example, memory devices such as diskettes, compact discs of both read-only and writeable varieties, digital versatile discs of all varieties (e.g., DVD's), optical disk drives, and hard disk drives. A computer-readable medium can also include memory storage that can be physical, virtual, permanent, temporary, semi-permanent and/or semi-temporary. A computer-readable medium can further include one or more data signals transmitted on one or more carrier waves.
[0237] As used herein, a “computer” or “computer system” may be, for example and without limitation, either alone or in combination, a personal computer (PC), server-based computer, main frame, microcomputer, minicomputer, laptop, personal data assistant (PDA), cellular phone, pager, processor, including wireless and/or wireline varieties thereof, and/or any other computerized device capable of configuration for processing data for either standalone application or over a networked medium or media. Computers and computer systems disclosed herein can include memory for storing certain software applications used in obtaining, processing, storing and/or communicating data. It can be appreciated that such memory can be internal or external, remote or local, with respect to its operatively associated computer or computer system. The memory can also include any means for storing software, including a hard disk, an optical disk, floppy disk, ROM (read only memory), RAM (random access memory), PROM (programmable ROM), EEPROM (extended erasable PROM), and other like computer-readable media.
[0238] In accordance with various embodiments discussed herein, wireless communication may be, for example and without limitation, communicated by satellite communications, infrared frequency, radio frequency, and/or communicated in accordance with a protocol such as IEEE 802.11, for example, among other types of wireless communication suitable for application to the present methods and systems.
[0239] It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, other elements. Those of ordinary skill in the art will recognize, however, that these and other elements may be desirable. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein.
[0240] It can be appreciated that, in some embodiments of the present methods and systems disclosed herein, a single component can be replaced by multiple components, and multiple components replaced by a single component, to perform a given function or functions. Except where such substitution would not be operative to practice the present methods and systems, such substitution is within the scope of the present invention.
[0241] Examples presented herein are intended to illustrate potential implementations of the present method and system embodiments. It can be appreciated that such examples are intended primarily for purposes of illustration. No particular aspect or aspects of the example method and system embodiments described herein are intended to limit the scope of the present invention.
[0242] Use of language, nomenclature, numbering, and/or formatting is not intended to limit the scope of the present embodiments. Use of the “RR” for designation of “recommended repair” situation, for example, can be readily replaced by another functionally equivalent designation based on language, culture, customs, trade or industry practices, or other factors of a given environment in which service operations on an inspected item are performed.
[0243] It should be appreciated that figures presented herein are intended for illustrative purposes and are not intended for use as construction drawings. Omitted details and modifications or alternative embodiments are within the purview of persons of ordinary skill in the art. Furthermore, whereas particular embodiments of the invention have been described herein for the purpose of illustrating the invention and not for the purpose of limiting the same, it will be appreciated by those of ordinary skill in the art that numerous variations of the details, materials and arrangement of parts may be made within the principle and scope of the invention without departing from the invention as described in the claims. | In one embodiment, a system is provided for performing at least one service operation in association with at least one inspected item. The system includes a service data device configured for displaying at least one data screen including at least one checklist configured for operative use in connection with performance of the service operation on the inspected item, the data device being portable and being configured for processing at least one communication; a service administrator having at least one data storage medium configured for storing at least one of the checklists displayed on the data device, the service administrator further having at least one server for enabling at least one communication between the service administrator and the data device; at least a portion of at least one of the checklists being customizable by at least the service administrator; and, at least a portion of at least one of the checklists being electronically interactive in association with performance of the service operation on the inspected item. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR §1.72(b). | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to generally to refrigerated housings and more particularly to those refrigerated housings suited for the storage of cadavers. The invention is specifically related to a rotational cadaver system which utilizes a rotational storage rack to store the cadavers.
It is well known that hospitals utilizes refrigerated compartments to store cadavers prior and subsequent to the performance of an autopsy. This is necessary to preserve the body and prolong the natural decomposition process which would normally take place without refrigeration.
Typical cadaver refrigeration units also utilize a telescoping tray assembly with each cadaver stored on an individual tray stored within the refrigeration unit. In order to remove a cadaver from such an assembly, it is typically required that an orderly or other personnel physically lift the cadaver and place it on a cart. The reverse is also true when the cadaver is to be placed in the refrigeration unit. Such activities can often be the cause of work related injuries, especially in cases where the cadaver to be moved is heavy. While numerous storage means exist, none are particularly suited for use with cadavers in a post mortem setting. Accordingly, there is a need for efficient storage and retrieval of cadavers.
The prior art discloses numerous refrigerated systems and rotational storage devices. For example, U.S. Pat. No. 143,059 issued on Sep. 23, 1873 to Camp discloses a refrigerator which is constructed such that the interior parts may be readily removed for cleaning. The refrigerator includes a hollow perforated shaft with four-armed plates or spiders and a plurality of swinging shelves. The shelves are pivotally mounted to the four-armed plates so that items may be readily placed or removed from the shelves.
U.S. Pat. No. 1,785,954 issued on Dec. 23, 1930 to Hayes discloses a dispensing refrigerator which is mainly designed to dispense bottled beverages. The refrigerator includes a rotary member which is disposed in a cooling chamber. A plurality of racks or trays are suspended to the rotary member and are capable of holding the bottles or articles placed therein. The racks are connected to the rotating member such that they assume an upright position irrespective of their location relative to the rotary member.
U.S. Pat. No. 2,592,038 issued on Apr. 8, 1952 to Kimsey discloses a refrigerated display case. The display case includes a plurality of supports which are circumferentially spaced. The supports pivotally suspend a plurality of food trays therefrom.
U.S. Pat. No. 3,269,569 issued on Aug. 30, 1966 to Brauner discloses a rotary vehicle parking apparatus. The apparatus includes a frame structure which is rotatably supported between pins or stub shafts. The frame structure has a plurality of platforms which are each adapted to support a vehicle. Means are provided for rotating the structure in order to bring each of the platforms to ground level in a successive manner.
U.S. Pat. No. 3,356,233 issued on Dec. 5, 1967 to De Filippis discloses a rotatable parking apparatus for motor vehicles. The apparatus includes a rotatable portion which includes a wheel housing and individual carriers that are supported by the wheel housing. The individual carriers are pivotally supported in order to facilitate loading and unloading the vehicles.
U.S. Pat. No. 3,927,772 issued on Dec. 23, 1975 to Borner discloses a vehicle parking and rotary elevator assembly. The assembly includes a wheel which has a pair of axially spaced, coaxial ring gears. The ring gears are supported for rotation about a common horizontal axis. Vehicle carrying platforms are pivotally suspended to the ring gears. A plurality of vehicle parking floors extend into an edgewise adjoining relationship relative to the circumferential periphery of the ring gears and at different levels relative to the common axis. Parking floor portions are arranged radially and centrally relative to the platforms. Idler rollers are used to support the ring gears at the top and bottom thereof.
U.S. Pat. No. 4,952,112 issued on Aug. 28, 1990 to Piacenza discloses a mechanical storage multi-level carpark the carpark includes a gantry structure formed by a set of uprights and cross-beams. The uprights and cross-beams define a space inside of which a vertical carousel structure is supported. The vertical carousel structure is further provided with car housing supports.
U.S.S.R. Patent # 452,730 published on December 1974 discloses a refrigerator chamber for biological testing. The chamber has a heat insulated housing and rotating sample containers and an evaporator. The heat insulated housing is cylindrical and the evaporators are evenly placed within the housing. A drive shaft rotates the container system while a plurality of arms are used to support the cradles. The cradles are hinged to the arms so that they continually occupy a horizontal position.
None of the prior art is seen to describe the present invention as claimed. Therefore, a rotational cadaver system which facilitates the storage and retrieval of cadavers would be beneficial.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a rotational storage rack capable of supporting multiple items.
It is another object of this invention to provide an autopsy assembly.
It is yet another object of this invention to provide a rotational cadaver system utilizing a rotational storage rack.
It is a further object of this invention to provide a rotational storage system which utilizes a stacker for placement and removal of cadavers from the rotational storage rack.
It is yet a further object of this invention to provide a means for mechanically turning the rotational storage rack.
It is a still further object of this invention to provide a method of processing a cadaver.
In accordance with an object of this invention, a rotational storage rack is provided for removably storing a plurality of items. The rotational storage rack is especially suited for the storage of cadavers. The rotational storage rack includes a base, two legs, a first shaft, and a second shaft.
The base has a generally rectangular shape with a hollow interior. The rectangular shape of the base defines two long sides and two short sides. The first leg is vertically positioned at about the midpoint of one of the short sides of the base. The first leg is then secured to the corresponding short side of the base. The second leg is similarly positioned and secured to the remaining short side of the base.
The first and second shafts are respectively positioned proximate the first and second legs in a horizontal manner which is parallel to the long sides of the base. The first and second shafts are then rotatably mounted to the first and second legs. A spool is mounted on the first and second shafts. The length of the spool is shorter than the distance between the first and second legs and each of its ends terminates in an outwardly extending flange. A wheel is positioned at each end of the spool and secured to a corresponding flange. The wheels are also secured to the first and second shafts.
A plurality of branches are secured to each of the wheels. Each of the wheels receives the same number of branches. The wheels are further oriented such that when viewed along the centerline of the first and second shafts, each branch from the first wheel is aligned with a corresponding branch from the second wheel. An arm is pivotally attached at one end to each of the branches. A number of trays are provided for supporting the items being stored. The trays are designed with a predetermined length corresponding to the distance between a corresponding pair of arms from the first and second wheel. Consequently, each tray is supported by one pair of arms.
In accordance with another object of the invention, an autopsy assembly is provided which includes an autopsy tray, an autopsy cart, and an autopsy station. The autopsy tray includes a plurality of apertures while the autopsy cart includes a plurality of receptors for insertably engaging the autopsy tray. The autopsy cart also includes a latching mechanism for securing it to the autopsy station. The autopsy tray includes a plurality of peripherally disposed suction and irrigation ducts. Quick disconnect fittings integrally attached to the autopsy tray are used for providing fluid and ventilation during the autopsy.
In accordance with another object of the invention, a rotational cadaver system is provided which utilizes a rotational storage rack. The rotational cadaver system consists of a refrigerated housing, a rotational storage rack, means for removing the contents of the rotational storage rack, a cadaver carrier, an autopsy cart, and an autopsy station.
The rotational storage rack of the system includes a base which has a generally rectangular shape with a hollow interior, thus defining two long sides and two short sides. The first and second legs are vertically positioned at about the midpoint of each of the short sides of the base and respectfully secured thereto. The first and second shafts are respectively positioned proximate the first and second legs in a horizontal manner which is parallel to the long sides of the base. The first and second shafts are then rotatably mounted to the first and second legs.
A plurality of bearings are provided to facilitate the rotational mounting of the first and second shafts. Two bearings are secured to each the first leg and the second leg by a bearing mount. The first and second shafts are then inserted through the inner races of the bearings and allowed to ride thereon.
A spool is mounted on the first and second shafts. The spool has ends which terminate in an outwardly extending flanges. A wheel is positioned at each end of the spool and secured to a corresponding flange. Each wheel is further secured to the first and second shafts, respectively.
A plurality of branches is secured to each of the wheels. Each of the wheels receives the same number of branches and, when viewed along the centerline of the first and second shafts, each branch from the first wheel is aligned with a branch from the second wheel. An arm is pivotally attached at one end to each of the branches. A number of trays of predetermined length are provided for supporting the cadavers being stored. The length of each tray corresponds to the distance between each corresponding pair of arms on the first and second wheel. Thus, each tray is supported by a corresponding pair of arms. Each tray further includes a plurality of apertures. In preferred embodiments of the invention, each wheel is comprised of a first and second plate and the branches are sandwiched therein.
The cadaver carrier of the system includes a frame which has a generally rectangular shape and defines two long sides and two short sides. The cadaver carrier also includes four upstanding legs, each of which is attached at one corner of the base in a vertical manner. Casters are attached to the lower end of each leg in order to facilitate movement. Most preferably, the cadaver carrier includes a rigid cover and shroud to shield a hospital's patients, employees and visitors from viewing the outline of a cadaver as it is being transported through a hospital to the hospital's morgue. A plurality of receptors are provided to correspondingly engage the apertures contained in the tray.
The autopsy cart of the system includes a frame which has a generally rectangular shape and defines two long sides and two short sides. The autopsy cart also includes four upstanding legs, each of which is attached at one corner of the base in a vertical manner. Casters are attached to the lower end of each leg in order to facilitate movement. A plurality of receptors are provided to correspondingly engage the apertures contained in the tray. The autopsy cart also includes means for securing it to the autopsy station. Furthermore, the two upstanding legs of the autopsy cart, to which the securing means are attached, are most preferably 1 inch shorter than the opposite two upstanding legs. As such, the tray is sloped in a downward direction toward the autopsy station when the autopsy cart is secured thereto, for purposes of facilitating drainage of fluids arising during the course of an autopsy.
In accordance with another object of the invention, a stacker is provided as the means for placing and removing the contents of the rotational storage rack. The stacker of the system is designed as a hydraulic lifting apparatus and may be a forklift in preferred embodiments of the invention. The stacker includes wheels, casters, or other appropriate means of facilitating movement along a surface. The stacker may also include means for an operator to govern the movement of the stacker, such as a steering mechanism or a drive control mechanism. The stacker has loading means upon which objects may be positioned. The stacker further includes means for lifting and lowering objects, such as the tray of the present system, placed upon the loading means. In preferred embodiments of the rotational cadaver system, the loading means of the stacker is a pair of prongs which are spaces apart by a predetermined distance. Each of the trays includes a pair of channels which are spaced apart by a distance corresponding to the distance between the prongs of the stacker.
In accordance with another object of the invention, a motor is provided for turning the rotational storage rack. The motor includes means for selectively turning it on and off, and means for transmitting its output to the second shaft of the rotational storage rack. In order to transmit its output to the rotational storage rack, the motor includes a drive shaft which is in turn connected to a trans reduction case for reducing the effective velocity of the drive shaft. A drive gear is mounted on the output shaft of the trans reduction case while a driven gear is mounted on the second shaft of the rotational storage rack. Means such as belt or chain are provided to interrelate the drive gear and the driven gear.
In accordance with another object of the invention, a method is provided for processing a cadaver for an autopsy. The first step of the process is to place the cadaver in a refrigerated housing for a predetermined length of time, or until an appropriate official is ready to perform the autopsy. When appropriate, the cadaver is removed from the refrigerated housing. In order to remove the proper cadaver, it may be necessary to turn the rotational storage stack so that the tray containing the required cadaver is properly positioned for removal. Next, the tray supporting the cadaver is removed from the rotational storage rack and placed on an autopsy cart. The autopsy cart may then be moved to the location where the autopsy is to be performed. The autopsy cart is then secured to the autopsy station, at which time an autopsy can be performed.
The above and many other objects, features and advantages of this invention will be better understood from the ensuing description of selected preferred embodiments, which should be read in conjunction with the accompanying Drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the rotational storage rack of the present invention.
FIG. 2 is a front elevational view of the wheel of the rotational storage rack.
FIG. 3 is a perspective view of an alternative embodiment of the wheel of the rotational storage rack.
FIG. 4 is a perspective view of a rotational cadaver system according to the present invention.
FIG. 5 is an enlarged front elevational view of the first leg of the rotational storage rack used in the rotational cadaver system.
FIG. 6 is an enlarged front elevational view of the second leg and motor of the rotational storage rack used in the rotational cadaver system.
FIG. 7 is a cross-section illustrating the motor of the rotational cadaver system.
FIG. 8 is a perspective view of the tray being supported by a stacker.
FIG. 9 is a perspective view of the cadaver carrier of the rotational cadaver system.
FIG. 10 is a perspective view of the autopsy cart of the rotational cadaver system.
FIG. 11 is a perspective view of a preferred embodiment of an autopsy assembly which includes a free standing autopsy station.
FIG. 12 is a perspective view of a preferred embodiment of an autopsy assembly which includes a wall mounted autopsy station.
FIG. 13 is a cross section of the tray.
FIG. 14 is a perspective view of an alternative embodiment of an autopsy assembly which includes a free standing autopsy station.
FIG. 15 is a perspective view of an alternative embodiment of an autopsy assembly which includes a wall mounted autopsy station.
FIG. 16 is a flowchart illustrating the processing of a cadaver in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the Drawing, and initially to FIG. 1, there is shown a rotational storage rack 10 in accordance with the present invention. The rotational storage rack 10 includes a base 12 which has a generally rectangular shape. The base 12 is formed from a plurality of members 13 which are rigidly secured to each other. The rectangular shape of the base 12 defines two short sides and two long sides.
A first leg 14 is vertically positioned at about the midpoint of one of the short sides of the base 12. The first leg 14 is then secured to the corresponding short side of the base 12 by appropriate means such as a weld. The second leg 16 is similarly positioned at about the midpoint of the remaining short side of the base 12 and secured thereto. The first and second shafts 18 are respectively positioned proximate the first and second legs 14, 16 in a horizontal manner which is parallel to the long sides of the base 12. The first and second shafts 18 are then rotatably mounted to the first and second legs 14, 16.
A spool 20 is mounted on the first and second shafts 18. Furthermore, each of the ends of the spool 20 terminates in an outwardly extending flange 22. The flanges 22 at the ends of the spool 20 extend along a plane which is perpendicular to the centerline of the first and second shafts 18 and the spool 20. A wheel 24 is positioned at each end of the spool 20 and secured to a corresponding flange 22. Wheel 24 is seen to be comprised of a first and second plate 24(a), 24(b). The wheels 24 are also secured to the first and second shafts 18.
With continued reference to FIG. 1 and particular reference to FIG. 3, the wheels 24 are shown to be secured to the flanges 22 with fasteners 38. This, however is not a requirement. The wheels 24 may be secured in numerous ways including welding, which is the preferred means for securing. A plurality of branches 26 are sandwiched between first and second plates 24(a) and 24(b). Fasteners 38 such as bolts are used to secure each branch 26 between first and second plates 24(a), 24(b). Each of the wheels 24 receives the same number of branches 26. The branches 26 are oriented in a radial manner with respect to the center of their respective wheel 24. Furthermore, the wheels 24 and branches 26 are oriented and secured in such a manner that when viewed along the centerline of the first and second shafts 18, each branch 26 from the first wheel 24 is aligned with a corresponding branch 26 from the second wheel 24. An arm 30 is pivotally attached to each of the branches 26 via a pin 28. A number of trays 34 are provided for supporting the items being stored. The trays 34 are designed with a predetermined length corresponding to the distance between the pairs of arms 30 in the first and second wheel 24. Each tray 34 further includes a plurality of apertures disposed along two of its sides.
A plurality of receptors 30(a) are rigidly secured to the free end of each arm 30 in order to support the trays 34. As illustrated in FIGS. 1 and 3, the receptors are generally hook shaped. This allows the receptors 30(a) to insertably engage the apertures contained in the tray 34. Accordingly, each tray 34 is supported by one arm 30 from the first wheel 24 and a corresponding arm 30 from the second wheel 24. As seen by intuitively examining the different branches and arms 26, 30 in FIG. 3, the pins 28 allow the arms 30 to pivot with reference to the branches 26. As the first and second shafts 18 are rotated, they correspondingly rotate the wheels 24. The arms 30, in turn pivot in accordance to the degree of rotation so as to continually maintain the trays 34 in a horizontal manner, thereby not spilling the contents of the trays 34.
FIG. 2 illustrates a preferred embodiment of the wheel of the present invention. The wheel 50 is seen to be comprised of a first and second plate 52, 54. A plurality of branches 56 are sandwiched between the first and second plates 52, 54. Fasteners 38 such as bolts are used to secure each branch rigidly between the two plates 52, 54. Alternatively, the branches 56 could be welded to the plates 52, 54. Each branch 56 is positioned in a radial manner with respect to the center of the first and second plates 52, 54. The first and second (not shown) shafts 18 extend through each wheel 50. The second plate 54 of the wheel 50 is secured to the flange 22 of the spool 20 by a plurality of fasteners 38. The first and second plates 52, 54 of the wheel 50 are respectively secured to the first and second shafts 18, preferably by welding. Each branch 56 also includes an arm 60 which is pivotally mounted thereto via a pin 58. Each arm further includes a plurality of receptors 60(a) which are generally hook shaped in order to effectuate support of the tray 34.
Turning to FIG. 4, a rotational cadaver system 100 which utilizes a rotational storage rack 110 is illustrated. The rotational cadaver system 100 additionally includes a refrigerated housing (not shown), means for removing the contents of the rotational storage rack, a cadaver carrier 166, and an autopsy cart (not shown).
The rotational storage rack 110 of the system includes a base 112 which has a generally rectangular shape and a hollow interior. The rectangular shape of the base 112 accordingly defines two long sides and two short sides. The rotational storage rack 110 also includes a first and second leg 114, 120 which are each vertically positioned at about the midpoint of each of the short sides of the base 112 and appropriately secured thereto by welding. A first and second shaft 122 are horizontally positioned proximate the first and second legs 114, 120. As seen in FIG. 4, the orientation of the first and second shafts 122 is parallel to the long sides of the base 112. The first and second shafts 122 are then rotatably mounted to the first and second legs 114, 120, respectively.
As seen more particularly with reference to FIG. 5, a plurality of bearings 118 is used to facilitate the rotational mounting of the first shaft 122. A bearing mount 116 is used to secure the bearings 118 to the first leg 114. Each bearing 118 includes an outer race and an inner race (not shown). The outer race of each bearing 118 is rigidly secured to the bearing mount 116. The first shaft 122 is then mounted within the inner race of the bearings 118 so that it may rotate with the inner race. A plurality of fasteners 144 are used to secure the bearing mount 116 to the first leg 114. The second shaft 122 is similarly mounted to the second leg 120.
A spool 124 is mounted on the first and second shafts 122. As seen in FIG. 4, the first and second shafts penetrate a predetermined distance within the spool 124. Each of the ends of the spool 124 further terminates in an outwardly extending flange 126. A first wheel 130 is positioned at the end of the spool 124 proximate the first leg 114 and appropriately secured with fasteners 144. Similarly, a second wheel 146 is positioned at the opposite end of the spool 124, proximate the second leg 120, and secured to the corresponding flange with fasteners 144.
A plurality of branches 136 are secured to the first and second wheels 130, 146. As is apparent in FIG. 4, each of the wheels 130, 146 receives an equal number of branches 136. The branches 136 are further aligned in a radial manner with respect to their corresponding wheel, such that each branch 136 would pass through the midpoint of its corresponding wheel. Furthermore, the first and second wheels 130, 146 are cooperatively aligned such that when viewed along the centerline of the first and second shafts 122, each branch 136 from the first wheel 130 is seen to be aligned with a branch 136 from the second wheel 146. This arrangement also defines corresponding pairs of branches 136 in the rotational storage rack 110.
Referring again to FIG. 5 with particularity, the first wheel 130 is seen to be comprised of a first and second plate 132. Each of the two plates 132 is positioned on opposite sides of the branches 136 corresponding to the first wheel 130. Although various equivalent means exist, fasteners 144 are used to secure the first and second plates 132 and the branches 136 as a unitary structure. This preferred arrangement of the first wheel 130 allows the flange 126 of the spool 124 to be rigidly secured to one of the plates 132. Furthermore, the first shaft 122 is secured to each plate 132 of the first wheel 130 preferably by welding. With continued reference to FIG. 4, an arm 140 is shown attached to the end of each of the branches 136. The arms 140 are attached in a pivotal manner by means of a pin 138. The pivotal connection of the arms 140 insures that they occupy a vertical orientation regardless of their radial position with respect to the first and second wheels 130, 146. The arms 140 generally retain this orientation even as the first and second shafts 122, and consequently the first and second wheels 130, 146, are rotated. Furthermore, each arm 140 associated with the first wheel 130 is paired with an arm 140 associated with the second wheel 146.
A number of trays 160 are provided for supporting the cadavers being stored on the rotational storage rack 110. The length of the trays 160 is predetermined to be generally equivalent to the distance between each corresponding pair of arms 140 on the first and second wheels 130, 146. Thus, each tray 160 is partially supported at one end by an arm 140 from the first wheel 130 and at the other end by a corresponding arm 140 from the second wheel 146. While various means exist to provide support of the trays 160, the arms 140 are preferred to include a receptor 142 rigidly secured to their ends. The receptors 142 are positioned so that they support the trays 160 in a generally flat orientation. As illustrated in FIG. 4, the receptors 142 are generally hook shaped. In order effectuate this support, each tray 160 includes a plurality of apertures corresponding to the receptors 142. Thus, the receptors 142 of each arm 140 insertably engage the apertures in the tray 160. Since the nature of the connection of the arms 140 to the branches 136 forces the arms 140 to occupy a vertical orientation, the receptors 142 accordingly cause the trays 160 to maintain a flat orientation regardless of their position on the rotational storage rack 110. Each tray 160 further includes two channels 162 superimposed to the bottom surface thereof, with the channels 162 being spaced apart by a predetermined distance.
The second shaft 122 is secured to the second leg 120 in a manner similar to that of the first leg 114, as illustrated in FIG. 6. A bearing mount 116 is used to secure a plurality of bearings 118 to the second leg 120 via fasteners 144. The bearing mount 116 retains the outer races of the bearings 118 in a fixed position while allowing the inner races to rotate freely. The second shaft 122 is then mounted within the inner races of the bearings 118 and allowed to rotate in accordance therewith. FIG. 6 also shows a mechanical drive 145 system which is the preferred method of turning the rotational storage rack 110. The mechanical drive system includes a motor 146 and means for transmitting the output of the motor 146 to the second shaft 122. The motor 146 is rigidly secured to the second leg 120. The motor 146 also includes a drive shaft which extends therefrom. A trans reduction case 147 receives the drive shaft of the motor 146 and serves as a means of reducing the rotational velocity of the motor 146. The trans reduction case 147 includes an output shaft 148 which has a drive gear 150 mounted thereon, as seen with additional reference to FIG. 7. In preferred embodiments of the invention, the trans reduction case 147 achieves a 1200:1 reduction ration. The second shaft 122 includes a driven gear 152 mounted thereon. A chain 154 is used to interrelate the output of the output shaft 148 to the driven gear 152 and consequently the second shaft 122. As seen in the illustration, the drive gear 150 and the driven gear 152 each include a plurality of sprockets in order to mesh with the chain 154. It should be appreciated, however, that various other transmission means exist, such as a system employing a plurality of pulleys and a belt.
In preferred embodiments of the invention, a third leg 156 is also provided for further supporting the second shaft 122. The third leg 156 is positioned in a similar manner as the first and second legs 114, 120 beneath the second shaft 122. A support block 155 is rigidly secured to the second and third legs 120, 156. The motor 146 is subsequently secured to the support block 155. A bearing mount 116 secures a bearing 118 to the third leg 156 via fasteners 144. The terminal end of the second shaft 122 is mounted on the inner race of the bearing 118 on the third leg 156. The third leg 156 is provided in order to relieve some of the stress which is placed on the bearings 118 mounted on the second leg 120. The stresses arise due to the tension placed on the second shaft 122 from the drive train. The motor also includes switching means (not shown) for selectively providing power thereto, and consequently turning the first and second shafts 122 and the first and second wheels 130, 146 in order to position a selected cadaver for removal. Furthermore, braking means are provided so that the rotational storage rack 110 will not move while the power is selectively switched off.
FIG. 8 illustrates the stacker 178 of the rotational cadaver system 100. The stacker includes a plurality of casters 182 to facilitate movement along the ground. The stacker 178 also includes two pronged extensions 180 for supporting the trays 160. Each pronged extension 180 has a tapered end 184. The distance between each prong 180 of the stacker 178 corresponds to the distance between the channels 162 of the trays 160. In order to remove the trays from the receptors 142, the prongs 180 of the stacker 178 engage the channels 162 of the trays 160. The tapered ends 184 help facilitate and guide the prongs 180 into the channels 162. As illustrated by the phantom lines in FIG. 8, the stacker 178 is capable of vertically adjusting the position of the prongs 180 so that it may remove or place the trays 160 from or onto the receptors 142.
Once removed from the rotational storage rack 110, the tray 160 may be placed on a cadaver carrier 166, as illustrated in FIG. 9. The cadaver carrier 166 includes a frame 170 which is formed from a plurality of rigid members. The frame 170 has a generally rectangular shape which defines two long sides and two short sides. The cadaver carrier 166 also includes four upstanding legs 172, each of which is attached at one corner of the frame 170 in a vertical manner. Casters 168 are attached to the lower ends of each upstanding leg 172 in order to facilitate movement. A plurality of receptors 174 are secured to the short sides of the frame 170. The receptors 174 allow the tray 160 to be placed securely on the cadaver carrier 166. The cadaver carrier 166 also includes a rigid cover 184 and a shroud 186. The cover 184 and shroud 186 are used to give the perception that a box or crate is being transported as opposed to a cadaver.
Turning again to FIG. 4, the rotational storage rack 110 is seen to include a pathway generally indicated by the numeral 198. The pathway 198 is sized to correspond to the width of the stacker 178. In operation, the stacker 178 is moved into the pathway 198 in order to place or remove a tray 174. As the stacker 178 enters the pathway, it is forced into an alignment which facilitates the engagement of the prongs 180 with the channels 172 of the trays 174. Once removed from the rotational storage rack 110, the tray 160 may be taken to the location of the autopsy and placed on an autopsy cart 200, which may be seen more particularly with reference to FIG. 10. The autopsy cart 200 is then secured to the autopsy station. The autopsy cart 200 includes a frame 210 which is formed from a plurality of rigid members. The frame 210 has a generally rectangular shape which defines two long sides and two short sides. The autopsy cart 200 also includes 2 sets of two upstanding legs 212 and 212(a), each of which is attached at one corner of the frame 210 in an vertical manner. Upstanding legs 212(a) are most preferably 1 inch shorter than upstanding legs 212. As such, tray 160 is sloped in a downward direction toward latching mechanism 332 and autopsy station 250, for purposes of facilitating the drainage of fluids arising during the course of an autopsy. Casters 214 are attached to the lower ends of each upstanding leg 212 in order to facilitate movement. A plurality of receptors 216 are secured to the short sides of the frame 210. The receptors 174 allow the tray 160 to be placed securely on the autopsy cart 200. The autopsy cart 200 further includes means for securing it to various types of autopsy stations, including stand-alone and wall mounted units.
FIGS. 11-13 illustrate preferred embodiments of the invention. The tray 320 is provided with a pair of channels 322 superimposed to the bottom surface thereof, with the channels 322 being spaced apart by a predetermined distance. A plurality of peripherally disposed ventilation and irrigation ducts 324, 326 are provided on the tray 320. A first quick disconnect fitting 328 is provided for directing fluid to the tray 320. A second quick disconnect fitting 330 is provided for removing vapors from the vicinity of the tray 320. A latching mechanism 332 is also provided for securing the autopsy cart 300 to the autopsy station 250, 350. The autopsy cart 300 includes a frame 310 which is formed from a plurality of rigid members. The frame 310 has a generally rectangular shape which defines two long sides and two short sides. The autopsy cart 300 also includes four upstanding legs 312, each of which is attached at one corner of the frame 310 in an vertical manner. Casters 314 are attached to the lower ends of each upstanding leg 312 in order to facilitate movement. A plurality of receptors 316 are secured to the short sides of the frame 310. FIG. 11 illustrates a free standing autopsy station 250 which includes a sink 252 and a faucet assembly 254. The autopsy station 250 is supported by a pedestal 260. The sink 252 and faucet assembly 254 are integrally formed with the pedestal 260. The autopsy station 250 also includes a vacuum means 256 for suctioning vapors from the tray 320 through the ventilation ducts 324. FIG. 12 illustrates a wall mounted autopsy station 350 which includes a sink 352 and a faucet assembly 354. The autopsy station 350 is integrally attached to a wall 370. The sink 352 and the faucet assembly 354 are also integrally attached to the wall 370. The autopsy station 350 also includes a vacuum means 356 for suctioning vapors from the tray 320 through the ventilation ducts 324.
FIGS. 14 and 15 illustrate alternative embodiments of the invention wherein the tray 320 is provided with a pair of channels 322 superimposed to the bottom surface thereof, with the channels 322 being spaced apart by a predetermined distance. A latching mechanism 332 is also provided for securing the autopsy cart 300 to the autopsy station 250, 350. The autopsy cart 400 includes a frame 410 which is formed from a plurality of rigid members. The frame 410 has a generally rectangular shape which defines two long sides and two short sides. The autopsy cart 400 also includes four upstanding legs 412, each of which is attached at one corner of the frame 410 in an vertical manner. Casters 414 are attached to the lower ends of each upstanding leg 412 in order to facilitate movement. FIG. 14 illustrates a free standing autopsy station 450 which includes a sink 452 and a faucet assembly 454. The autopsy station 450 is supported by a pedestal 460. The sink 452 and faucet assembly 454 are integrally formed with the pedestal 460. The autopsy station 450 also includes a vacuum means 456 for suctioning vapors from the tray 320 through the ventilation ducts 324. An irrigation rack 462 is swivably mounted to the sink 452. The irrigation rack 462 may be lifted in order to position the autopsy cart 400 and then lowered when the autopsy is to be performed. FIG. 15 illustrates a wall mounted autopsy station 470 which includes a sink 472 and a faucet assembly 474. The autopsy station 470 is integrally attached to a wall 480. The sink 472 and the faucet assembly 474 are also integrally attached to the wall 480. The autopsy station 470 also includes a vacuum means 476 for suctioning vapors from the tray 420. The autopsy station 470 also includes a swivably mounted irrigation rack 482.
FIG. 16 outlines the various steps associated with processing the cadaver with the rotational cadaver system 100. The first step of the process is to store the cadaver in a refrigerated housing for a predetermined length of time, or until an appropriate official is ready to perform the autopsy. When appropriate, the cadaver is removed from the refrigerated housing. In order to remove the proper cadaver, it may be necessary to turn the rotational storage stack so that the tray containing the required cadaver is positioned for removal. A switch is used to selectively provide power to the motor thereby turning the rotational storage rack. The stacker is then moved into the pathway of the rotational storage rack and aligned with the tray. The prongs of the stacker are inserted into the channels of the tray and raised vertically so that the tray is lifted from the receptors. Next, the tray containing the cadaver is placed on an autopsy cart. The tray with cadaver is then transported by means of the autopsy cart to the location where the autopsy is to be performed. The autopsy cart is then positioned near a stand alone or wall mounted autopsy station, and secured thereto. Finally, the autopsy is performed.
While the invention has been described with reference to selected preferred embodiments, it should not be limited to those embodiments. Rather, many modifications and variations will become apparent to those skilled in the art without departure from the scope and spirit of this invention as defined in the appended claims. For example, one of ordinary skill in the art will readily appreciate that a second rotational storage rack could be placed in a side by side alignment with a first rotational storage rack, wherein both racks are driven by the same motor. | A rotational cadaver system is disclosed which incorporates a rotational storage rack. The rotational storage rack includes a first and second shaft and two wheels mounted thereto. The shaft is rotationally mounted on a plurality of legs. A number of branches are radially secured to each wheel and arms are pivotally secured to each branch. The arms include means for receiving a tray upon which a cadaver may be placed. The trays includes means for engagement with mechanical placement and retrieval means. The tray also include means for securing them to various types of autopsy tables. A motor is also provided for turning the shaft varying the position of the cadavers. A method is also disclosed for utilizing the system in conjunction with the performance of an autopsy. | 0 |
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