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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 07/820,473, filed Jan. 14, 1992 now U.S. Pat. No. 5,173,994.
FIELD OF THE INVENTION
The present invention relates to an apparatus and process for cleaning foreign matter from fiber.
BACKGROUND OF THE INVENTION
In harvesting, seed cotton is stripped or picked from the plant, deposited in a trailer or other vehicle, and transported to a cotton gin. The cotton gin has apparatus for receiving the seed cotton, removing the seeds, cleaning the cotton fiber, and pressing the fiber into bales for transport to textile mills or compresses for further operation.
Prior to the present invention, trash or foreign matter in cotton fiber, or lint, presented significant problems to cotton producers and textile mills. High trash contents reduces the price the producer receives for the product. Efforts to further clean the fiber in the gin to reduce trash levels caused fiber damage by breaking and tangling the fiber. This fiber damage decreases the quality of the resulting yarn and cloth. The present invention performs the fiber cleaning needed by the producer for good returns without causing damage to the fiber which would reduce the quality of textiles made from the fiber.
U.S. Pat. No. 4,528,725 to Horn et al discloses a gin lint cleaner that utilizes a feed plate to direct the ginned fiber onto a downstream saw cylinder Horn et al then uses sharp-edged grid bars to further engage the ginned fiber with the downstream cylinder. The action of a second downstream saw cylinder and deflector remove the lint from the first cylinder and deposit the lint onto a second cylinder. Horn et al then uses round blunt bars, a seating bar, sharp-edged grid bars, a trash bar, and a combing bar. Between the feed plate, saw to saw interaction, and the combing bars, the ginned fiber is subject to considerable abrasion which tends to cause more fiber breakage. Therefore, there is still a need in the art for more efficient gin fiber cleaning with a capable of cleaning fiber with lower levels of the fiber breakage and at lower energy costs.
SUMMARY OF THE INVENTION
In accordance with the present invention, there are provided fiber cleaning processes and apparatus which solve the problems identified above with regard to cleaning fiber. In describing the cylinders to the present invention, it will be understood that each cylinder rotates about an axis. Various bar devices are positioned adjacent and along the cylinders, parallel the axes.
The present invention combines the use of guiding means (including feed control bars) and flow deflecting means (including air control bars) to produce fiber cleaning that uses less power, breaks fewer fibers and results in less tangling of the fiber.
Doffing brush cylinders mechanically remove the ginned fiber from an upstream saw cylinder and transfers the fiber to the next downstream fiber cleaning saw cylinder, or in the case of the last downstream doffing brush cylinder, to a bale press. The transfer of ginned fiber takes place such that the flow of the fiber changes direction at the pinch point between the downstream saw cylinder and the doffing brush cylinder. The pinch point is the point of contact or nearest proximity of an upstream cylinder with the next downstream cylinder. The tangential speed to the outer periphery of the doffing brush cylinders is preferably set between 1.25 and 2 times the tangential speed of the outer periphery of the upstream saw cylinder.
As the ginned fiber is being rotated on the doffing brush cylinder and about to be transferred to a downstream cleaning saw cylinder the ginned fiber has a tendency to lift off the doffing brush cylinder before reaching the pinch point. Guiding means, including feed control bars, and provided by the present invention to help keep the ginned fiber on the doffing brush cylinder and guide the transfer of the ginned fiber from the doffing brush cylinder to the next downstream cleaning saw cylinder up to the pinch point.
Normally, entrained air along the outer periphery of the doffing brush cylinders continues to rotate beyond the pinch point of the downstream cleaning saw cylinder. The entrained air continues to flow to the point where the doffing brush cylinder again removes ginned fiber from an upstream saw cylinder. If fiber is allowed to travel with the entrained air back to the pinch point of the upstream saw cylinder and the doffing brush cylinder, the recirculated fiber increases the tangling of all the fiber, and thereby adversely affects the nep count of the fiber.
The present invention provides flow deflecting means including air control bars to deflect a substantial portion of the flow of entrained air from flowing around the doffing brush cylinder toward an upstream cleaning saw cylinder. By use of the air control bars, the entrained air will instead be deflected to flow counter rotationally around the next downstream cleaning saw cylinder. The air control bar is placed opposite the flow control bar adjacent the pinch point of the doffing brush cylinder and a fiber cleaning saw cylinder, on the non-fiber flow side of the pinch point.
In addition, an air control bar is placed immediately downstream of the point where the ginned fiber is removed from the last doffing brush cylinder and removed from the grinned fiber cleaning housing.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawings, which are not necessarily to scale.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a side elevation view of a preferred gin fiber cleaner of the present invention.
FIG. 2 is a large scale side view of a feed control bar of the present invention which has a substantially triangular cross-section with the hypotenuse being an arcuate surface which is parallel to the outer peripheral surface of the immediate upstream doffing brush cylinder.
FIG. 3 is a front view of a feed control bar of the present invention.
FIG. 4 is a side view of an air control bar of the present invention, shown in large scale.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a typical cotton gin process flow, cotton is harvested in the field and transported to the location of a cotton gin building. The delivered cotton, which is sometimes referred to as seed cotton, contains foreign matter or trash, which may include stalks, stems, leaves, bark, and boll pieces. The foreign matter may also include small pebbles, dirt, sand, weeds, seeds and other trash which the harvesting equipment may have picked up.
The seed cotton is fed to one or more gin stand saw cylinders where the seeds are separated from the lint, or fiber cotton. The ginned cotton fiber still contains foreign matter after being processed by the gin stand cylinder. Therefore, the ginned cotton fiber is transported to a fiber cleaner, and from the fiber cleaner to a lint bale press (not shown).
FIG. 1 shows a preferred embodiment of a cotton fiber cleaner of the present invention. The figure shows a first ginning means for separating fiber and seed, including a gin housing having a gin saw cylinder 1 (i.e. gin stand cylinder), as well as fiber cleaning means including two fiber cleaning saw cylinders 3 and 5. The gin stand saw cylinder and two fiber cleaning saw cylinders are rotationally driven by a manner well known in the art, such as a motor connected by a drive belt to a drive pulley which is integrally attached to the cylinder.
For clarity, only the cotton fiber feed assembly is shown in FIG. 1. Likewise, much of the structure shown in FIG. 1, such as the sheet metal walls forming the trash disposal, and airflow control ducts and brackets for mounting are not shown. Those skilled in the art will be able to supply the necessary frame, covers, baffles, duct-work, mounting brackets and other omitted structure based on the disclosure herein and knowledge of the gin lint cleaning art.
With regard to the figures hereof, it will be understood that the arrows inside each cylinder represent the direction of rotation of that cylinder, and hence the direction of teeth or other structure attached thereon. Arrows outside the cylinders represent the direction of flow of trash and foreign matter or air flow, as appropriate. The flow of fiber is shown as a herringbone band on the outer periphery of the cylinders. Cylinders 1, 4 and 5 are rotating clockwise, while cylinders 2, 3 and 6 are rotating counter-clockwise as viewed in FIG. 1.
Cylinders 2, 4 and 6 are doffing brush cylinders which are part of fiber transporting or removing means. The doffing brush cylinders are preferably constructed as a solid spiral-wrapped brush. The doffing brush cylinders mechanically remove the ginned cotton fiber from the respective upstream saw cylinder 1, 3 and 5. The transfer of ginned cotton fiber takes place such that the flow of cotton fiber abruptly changes direction at the pinch point between a downstream cleaning saw cylinder and the next upstream doffing brush cylinder. The tangential speed of the outer periphery of the doffing brush cylinders is preferably between 1.25 and 2 times the tangential speed of the outer periphery of the respective upstream saw cylinder.
The fibers, which are attached to gin saw cylinder 1 after being separated from the seed (ginned), are doffed by doffing brush cylinder 2 at the pinch point between cylinders 1 and 2. The fibers exit the pinch point tangentially and proceed substantially in a straight line until impacting containment 9. The fibers continue on the surface of containment 9 and feed control bar 10, being propelled by the induced air near the brush surface until engaged by the teeth of cleaning saw cylinder 3. The feed control bars 10 and 16 have an arcuate surface which is parallel to the outer peripheral surface of the doffing brush cylinders 2 and 4, respectively, adjacent to the pinch point. The feed control bars 10 and 16 are substantially triangular in cross-section with the hypotenuse of the triangle being the arcuate surface (FIG. 2). The feed control bars 10 and 16 extend substantially the entire length of the doffing brush and cleaning saw cylinders and are attached at each end to the gin housing (FIG. 3). The feed control bars 10 and 16 form a sharp point adjacent to the pinch point. The feed control bars 10 and 16 are placed as close as practical to the cleaning saw cylinders 3 and 5, respectively, as well as close as practical up to the pinch point between the doffing brush cylinder and the next downstream cleaning saw cylinder.
In the present invention, flow deflecting means, including air control bars 11, 17 and 24, are used to deflect the flow of entrained air from continuing to flow around the doffing brush cylinder. Instead the air is deflected toward the next downstream cleaning saw cylinder. For example, the air control bar 11, located between doffing brush cylinder 2 and cleaning saw cylinder 3 deflects the flow of entrained air from continuing around doffing brush cylinder 2 to flowing in the annular space between cleaning saw cylinder 3, which is rotating in the opposite direction to the flow of deflected air, and containment 15 (FIG. 4). Air control bar 11 has an arcuate surface which is parallel to the outer peripheral surface of the next downstream cleaning saw cylinder.
Without the flow deflecting means, entrained air along the outer periphery of the doffing brush cylinder continues to rotate beyond the pinch point of the downstream cleaning saw cylinder. The entrained air would continue to rotate along the outer periphery to the point where the doffing brush cylinder again removes ginned fiber from an upstream cylinder. It is believed that this entrained air promotes tangling of the fiber, thereby increasing the nep count.
The air control bar 11 prevents substantially all of the air from continuing to flow in the annular space between cylinder 2 and containment 12. Any air that does flow in the annular space between cylinder 2 and containment 12 is directed tangentially in a manner which does not alter the path of the fiber being doffed at the pinch point between cylinders 1 and 2. Eventually, most of the deflected air will be entrained around the outer periphery of doffing brush cylinder 4 (FIG. 1). The air control bar 17 has an arcuate surface which is substantially parallel to the outer peripheral surface of the doffing brush cylinder 4 adjacent to the pinch point. Containment 18 and fiber guide 14 prevent entrainment of trash which was previously thrown out. Fiber guide 14, which runs the length of doffing brush cylinder 4, prevents the doffing brush cylinder from contacting the fiber until the fiber is near the pinch point, thereby aiding in the doffing action. Air flow continues in the annular space between cleaning saw cylinder 5 and containment 22, and is entrained with the fiber between doffing brush cylinder 6 and containment 23. The entrained air exits the gin housing in lint flue 25. The air control bars 11, 17 and 24 are substantially triangular in cross-section with the hypotenuse of the triangle being the arcuate surface. The air control bars 11, 17 and 24 extend substantially the entire length of the doffing and cleaning cylinders. The air control bars 11 and 17 form a sharp point adjacent the pinch point. The air control bars 11, 17 and 24 are placed as close as practical to the doffing brush cylinder. The air control bars 11 and 17 are placed as close as practical up to the pinch point between the doffing brush cylinder and the downstream cleaning saw cylinder. The air control bars 11 and 17 are placed opposite the feed control bars 10 and 16 between the pinch point of the doffing brush cylinder and the fiber cleaning saw cylinder on the non-fiber flow side of the pinch point. Also, the arcuate surface of each of the air control bars 17 and 24 is parallel to the outer peripheral surface of the next upstream doffing brush. Both the feed control bars and the air control bars define: a first planar rectangular surface, a second planar rectangular surface oriented at approximately a right angle to the first surface, and an arcuate surface joined to both said first and second surfaces.
In addition, an air control bar 24 is placed downstream of the point where the ginned fiber is removed from the last doffing brush cylinder and removed from the gin housing. The air control bar 24 is placed such that it is immediately downstream of, and substantially mates with, the last downstream doffing brush cylinder.
Transferring and inverting the ginned fiber between two counter-rotating cleaning saw cylinders exposes both sides or surfaces of the ginned fiber to cleaning devices. For example, the cleaning bars 13 and 21 in FIG. 1, which are situated adjacent to the cleaning saw cylinders in the moting area, clean the side of the fiber facing away from the cleaning saw cylinder. The fiber is inverted during transfer from one cleaning saw cylinder to another, and additional cleaning takes place during transfer at the pinch point. Thus, in addition to providing more peripheral area for the use of cleaning devices, the use of two or more cleaning saw cylinders permits cleaning of both sides of the fiber. More peripheral area for cleaning is also available on gin cylinder 1 with cleaning bars 7 and 8.
Cleaning bars 13 and 21 are mounted to the housing and are parallel the axes, adjacent to the cleaning saw cylinders 3 and 5. The bars 13 and 21 have sharp edges parallel the cylinder axes. As the cleaning saw cylinders move the cotton fiber past the bars 13 and 21, the fiber is scrubbed against the edges. This disturbance of the fiber, in combination with centrifugal force and gravity, loosens foreign matter from the cotton fibers in the layer. The trash is then carried to a trash conveyor (not shown). The bars 13 and 21 are placed an effective distance from the cleaning saw cylinders. That is, at a distance which is effective for removing trash from the fiber, but not so close as to result in fiber damage.
Referring to FIG. 1, it may be seen that the pinch points are each radially separated by more than 180 degrees. This results in the staggered, or zig-zag arrangement of the cleaning and doffing brush cylinders. This staggered arrangement exposes more of the periphery of the cleaning saw cylinders in the path of the layer for the installation and utilization of cleaning devices such as the cleaning bars previously described.
It will be understood that additional fiber cleaning saw cylinders could be placed downstream of doffing brush cylinder 6 for additional cleaning capacity. In addition, for minimal cleaning capacity, the gin building housing could be constructed with only cylinders 1, 2, 3 and 4. However, in the preferred embodiment shown in FIG. 1, two fiber cleaning saw cylinders are used so that each side of the cotton fiber is cleaned once.
It will also be understood that the terms "upstream" or "downstream" are dependent upon the position of the referenced cylinder. The terms "upstream" and "downstream" are not restricted to the first or last cylinders, respectively.
Each of the fiber cleaning saw cylinders 3 and 5 have drive means connected thereto (not shown) for rotating the cylinders counter to each other. Each of the fiber cleaning saw cylinders has a plurality of saw teeth attached to and spaced over a surface thereof. An appropriate frame (not shown) supports the mounted cylinders and structure positioned thereabout.
The operation of the cotton gin of FIG. 1 is as follows. The cotton fiber enters the gin housing and is fed to the gin saw cylinder 1 (i.e. gin stand cylinder). The seed is separated from the fiber whereupon the ginned fiber is removed from the gin saw cylinder by counter rotating doffing brush cylinder 2. The ginned fiber is then transferred to a first fiber cleaning saw cylinder 3. Saw cylinder 3 is rotating in the same (counter-clockwise) direction as doffing brush cylinder 2. The ginned fiber thereby changes directions when it is transferred from doffing brush cylinder 2 to saw cylinder 3 at the pinch point. One side of the ginned fiber is then cleaned by cleaning bar 13 as the ginned fiber rotates past them. The ginned fiber is then removed and inverted from the first fiber cleaning saw cylinder 3 by a second counter rotating doffing brush cylinder 4. The ginned fiber is then transferred to a second fiber cleaning saw cylinder 5 at the pinch point between cylinders 4 and 5. Cylinder 5 is rotating in the same direction (clockwise) as doffing brush cylinder 4. Therefore, the ginned fiber changes direction as it is transferred from the second doffing brush cylinder 4 to the second fiber cleaning saw cylinder 5 at the pinch point. Containment 19 and adjustable fiber guide 20 prevent excess fiber loss. The other side of the ginned fiber is then cleaned by the cleaning bars 21 as the ginned fiber rotates past them. The ginned fiber is then removed from the second fiber cleaning saw cylinder 5 by third doffing brush cylinder 6. The cleaned ginned fiber is then removed from the third doffing brush cylinder 6 and removed to downstream baling apparatus via lint flue 25.
FIG. 3 is a front view of feed control bar 10 in relation to cleaning saw cylinder 3. The bar is attached to the gin housing by attachment means 30.
Various changes and modifications may be made in this invention, as may be apparent to those skilled in the art. Such changes and modifications are within the scope of this invention, as defined by the claims appended hereto.
INDEX OF ELEMENTS DESIGNATED BY A NUMERAL
1 gin saw cylinder
2 doffing brush cylinder
3 fiber cleaning saw cylinder
4 doffing brush cylinder
5 fiber cleaning saw cylinder
6 doffing brush cylinder
7 cleaning bar
8 cleaning bar
9 containment
10 feed control bar
11 air control bar
12 containment
13 cleaning bar
14 fiber guide
15 containment
16 feed control bar
17 air control bar
18 containment
19 containment
20 adjustable fiber guide
21 cleaning bar
22 containment
23 containment
24 air control bar
25 lint flue
30 attachment means
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The present invention is drawn to fiber cleaning utilizing an alternating series of cleaning saw cylinders and doffing brush cylinders. The doffing brush cylinders transfer ginned fiber from an upstream cleaning saw cylinder to the next downstream cleaning saw cylinder in such a way that the flow of the fiber changes direction at the pinch point between the downstream cleaning saw cylinder and the doffing brush cylinder. Guiding means including control bars are provided to help guide the ginned fiber from the doffing brush cylinder to the next downstream cleaning saw cylinder at the pinch point. Flow deflecting means including air control bars are provided to deflect a substantial portion of the flow of entrained air from flowing around the doffing brush cylinder.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application Ser. No. 61/412,149, entitled “SmartLoader Contact Data Management System,” filed Nov. 10, 2010, the contents of which are incorporated herein by reference.
BACKGROUND
This application relates to a data management system.
Reliable and rapid delivery of large numbers of text messages is important to enterprises, public safety agencies, universities, and others with a need to quickly notify interested parties.
Multi-modal broadcast alert platforms (also known as notification platforms) are widely used to provide alert notifications to members of a community. For instance, federal, state, and local entities; businesses; and educational institutions (collectively referred to herein as institutions) make use of notification platforms to send messages efficiently to members of their respective communities.
Notification platforms administer the distribution of short message service (SMS) messages or other electronic communications to subscribers to the notification platform. A notification platform is administered by a messaging administrator. To send a message to subscribers, the messaging administrator generates a notification event within the notification platform. The notification event contains the text of the message that is to be sent to the subscribers. When a notification event is generated, the notification platform sends a message to each subscriber.
In general, a notification platform relies on the members of the institution employing the platform to enroll in the platform in order to receive notification messages relevant to the institution. The enrollment process typically calls upon a member to complete several, if not all, of the following steps:
1. Visit a website associated with the institution 2. Provide credentials or other personally identifying information to prove that the member is authorized to receive the institution's notifications 3. Provide one or more contact points (e.g., a mobile telephone number, a landline telephone number, an email address, an instant messenger handle, or another contact point) at which the member wishes to receive notification messages 4. Acknowledge the terms of use of the notification platform 5. Complete a confirmation process to confirm that the member owns or controls the designated contact point(s)
SUMMARY
In a general aspect, a computer-implemented method includes receiving, via an input interface of a notification platform, updated subscriber data; comparing, using a comparison module of the notification platform, the updated subscriber data with existing subscriber data stored in a subscriber database; and, based on the results of the comparing, modifying, using a modification module of the notification platform, the existing subscriber data stored in the subscriber database.
Embodiments may include one or more of the following.
The method further includes verifying, using a verification module, an integrity of the updated subscriber data. An integrity of the updated subscriber data includes an integrity of a file containing the updated subscriber data.
The method further includes validating, using a validation module, a quality of the updated subscriber data. The method further includes generating, using a report module, a report indicative of the results of the validating.
The method further includes generating, using a report module, a report indicative of the results of the modifying of the existing subscriber data. The report has a format that corresponds to a format of a file containing the updated subscriber data. The method further includes providing the report to an administrator of the notification platform. The report is indicative of an error in the modifying.
The updated subscriber data includes at least one of a subscriber identifier and a subscriber contact point.
The subscriber database is located on the notification platform.
The method further includes sending, using a messaging module of the notification platform, a message to a mobile communications device associated with each subscriber included in the modified subscriber database.
In another general aspect, a system includes an input interface configured to receive updated subscriber data; a comparison module configured to compare the updated subscriber data with existing subscriber data stored in a subscriber database; and a modification module configured to, based on the results of the comparing, modify the existing subscriber data stored in the subscriber database.
Embodiments may include one or more of the following.
The system further includes a verification module configured to verify an integrity of the updated subscriber data.
The system further includes a validation module configured to validate a quality of the updated subscriber data. The system further includes a report module configured to generate a report indicative of the results of the validating.
The system further includes a report module configured to generate a report indicative of the results of the modifying of the existing subscriber data.
The subscriber database, the comparison module, and the modification module are co-located on a notification platform.
The system further includes a messaging module configured to send a message to a mobile communications device associated with each subscriber included in the modified subscriber database
The systems and methods disclosed herein offer a number of advantages.
The data management subsystem and associated methods can make use of contact information that has already been collected by an institution for its members, thus eliminating a redundant step of collecting contact information for the explicit purpose of the notification platform. A notification platform making use of this data management subsystem thus may achieve a high subscription rate among members of its associated institution, thus helping to ensure that the vast majority of the members of the institution will receive messages generated by a notification event. In particular, because members of the institution do not need to actively complete an enrollment process, it is not necessary to make them aware of the enrollment process. Furthermore, no time or effort is required from members of the institution to enroll in the notification platform, and thus members are less likely to be discouraged from enrolling.
The contact information can be loaded into the notification platform directly. The robustness of the data management subsystem helps to ensure that the resulting database is high quality, error free, and stable.
Data discrepancies that may arise when managing subscriber data across multiple systems and interfaces is avoided. This in turn reduces mistakes, such as the sending of messages to the wrong recipients or wrong contact points or missing entire segments of an institute's population.
The data management subsystem described herein involves minimal manual manipulation of the data. Thus, staff at the corresponding institution are freed from the need to manage member information, including parsing and exporting data from various systems in order to meet data management criteria of a particular notification platform. Furthermore, the staff does not need to determine which information in a subscriber database needs to be added, removed, or modified within the database to ensure that the database reflects the current communications preferences of the institution and its members. Rather, such determinations are made by the data management subsystem.
The reduction of manual and institution-level data manipulation allows the institution's staff to interact with the data only at a high level. More detailed data manipulation and system integration work, such as processes that involve a deep understanding of the challenges of multi-modal messaging and strategies to mitigate such challenges, are undertaken by the data management subsystem itself. This automation can help reduce errors and frees up resources for the institution.
Other features and advantages of the invention are apparent from the following description and from the claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram of a notification platform.
FIG. 2 is a flowchart of the operation of a data management subsystem.
DETAILED DESCRIPTION
Referring to FIG. 1 , a notification platform 100 associated with an institution 102 administers the distribution of short message service (SMS) messages or other electronic communications, such as emails or voice messages, to subscribers 104 of the notification platform. Subscribers 104 receive notification messages from the notification platform. For instance, university students subscribed to their university's safety alert notification platform receive messages relevant to public safety at their university. Residents of a city and/or commuters to that city may choose to subscribe to a local traffic alert group to receive traffic status messages.
In some cases, enrollment in notification platform 100 is initiated by subscriber via an independent subscription process 106 . In other cases, a subscription to the notification platform associated with a particular institution 102 is automatic and/or mandatory for members or affiliates of the institution. For example, any university student who provides a mobile or landline telephone number or email address to the university may be automatically enrolled into the public safety notification platform for the university without any action on the part of the student. Subscriber information, such as the subscriber's mobile and/or landline telephone number(s), mobile carrier(s), email address(es), and preferred mobile communication device or method, is stored in a subscriber database 108 on notification platform 100 .
Notification platform 100 is administered by a messaging administrator at the corresponding institution 102 . To send an SMS message to subscribers, the messaging administrator generates a Notification Event within notification platform 100 . The Notification Event contains the text of the message (e.g., “Exit 20 of Interstate 90 is closed. Seek alternate route.”). The Notification Event may also include other information, such as a percentage of messages that are to be successfully delivered in order for the Notification Event to be closed. When a Notification Event is generated, the notification platform sends a notification message to each subscriber according to the subscriber information stored in subscriber database 108 . The messaging functionality of the notification platform 100 is managed by a business functionality platform 110 and data relevant to the messaging functionality is stored in a messaging database 112 .
A data management subsystem 150 manages subscriptions that are administered by the institution 102 associated with the notification platform 100 . In general, data management subsystem 150 receives subscriber data from the institution and verifies the integrity and validity of the data. Data management subsystem also processes the data such that correct, updated data for each subscriber is ultimately stored in subscriber database 108 . Data management subsystem 150 also provides a data reporting functionality which returns reports to institution 102 at the conclusion of the processing of data provided by the institution. These functionalities are described in greater detail below.
Data Receipt and Integrity Check
Referring to FIGS. 1 and 2 , the institution 102 associated with notification platform 100 submits subscriber data, such as identification and contact information, to data management subsystem 150 . Data is transferred from the institution to the data management subsystem (step 200 ) via a data interface, either via a direct connection (as shown) or via the Internet. In particular, an input file 114 is stored by the institution 102 on a shared access directory 116 , such as a WEBDAV (Web-based Distributed Authoring and Versioning) system, hosted by notification platform 100 . Alternatively, data may be provided via other electronic means. For instance, subscriber data may be formatted as an XML document and transferred to the notification platform as a web-service request.
In an exemplary embodiment, the messaging administrator of institution 102 creates a comma separated value (CSV) spreadsheet containing subscriber data, such as subscriber identification and contact information and contact preferences. Data management subsystem 150 may request that the CSV file be provided in a pre-defined format to facilitate data processing. Subscriber identification information may include data such as, e.g., first name, last name, or a user identifier. Contact information for a subscriber may include data such as, e.g., mobile telephone number(s), landline telephone number(s), email addresses, instant messenger handles, or other common contact points. In addition, subscriber preferences regarding use of the various contact points may be included (e.g., a subscriber may note that all communication should be via SMS message to the provided mobile telephone number rather than via email or voice message).
Upon receipt of the input file 114 , data management subsystem 150 checks the integrity of the data to ensure that it can be read and processed (step 202 ). If the data is unusable for any reason (e.g., the file is corrupted or the file is incorrectly formatted), the input file 114 is rejected in its entirety, in order to avoid improper manipulation of the data (step 204 ).
Data Differential Processing
Data management subsystem 150 may impose criteria on the format and content of the input data file 114 in order to simplify generation of the load file that is used to update subscriber database 108 . In particular, the data management subsystem may request that the data included in input file 114 describe the desired end state of the subscriber database 108 rather than changes to be made to the subscriber database. That is, the input data preferentially includes a list of all subscribers and associated contact points and alerting preferences, rather than a list of changes to be made to preexisting data stored on the notification platform.
Once in receipt of the input file 114 , the data management subsystem 150 compares the contents of the input file with the contents of subscriber database 108 (step 206 ) to identify what information is to be added to, removed from, or modified within the database. Based on the comparison, the subscriber database is updated according to the contents of the input file (step 207 ).
This differential approach relieves the messaging administrator from performing these complex comparative calculations before providing the input data to the notification platform. In addition, the differential approach eliminates the possibility for the institution's subscriber database to become out of sync from the notification platform's subscriber database 108 .
In some embodiments, individual subscribers are given the ability to update their own information via a subscriber interface. The data management subsystem 150 will defer to additions and changes made by subscribers over data provided by the institution 102 , under the assumption that the data provided by the subscriber is more likely to be correct than data provided by an intermediary (the institution).
Data Validation
The data management subsystem 150 applies lower-level data validation steps (step 208 ) to maximize the likelihood that a notification message will be successfully delivered to a subscriber's contact point. These checks include, for instance:
Evaluating email addresses to confirm that they conform to email address format criteria Confirming that email domains (i.e., emailhandle@emaildomain) are properly formatted, exist as routable domains, and do not contain common typographical errors Referring to third-party managed databases (e.g., a mobile carrier database 120 ) via a carrier lookup function 122 to identify the mobile carrier supporting a particular mobile telephone number, and adding and/or updating mobile carrier information in subscriber database 108 . Implementing these validation checks within the data management subsystem rather than at the institution level allows for the leveraging of domain-specific knowledge embedded into the notification platform without the need for such knowledge to be developed in house at the institution. Furthermore, centralization of data management and validation avoids the possibility of contending approaches to the management of messaging data compromising the success of a notification event.
Reporting
As the data contained in input file 114 is processed, data management subsystem 150 generates a report 124 that identifies the actions taken while processing the record for each subscriber (step 210 ). The report identifies the record processed and the outcome of processing the record. For instance, the report may state that a mobile telephone number previously stored in subscriber database 108 for a particular subscriber was deleted and replaced with a newly provided mobile telephone number. The report may also indicate that the carrier lookup function on the new mobile telephone number revealed that a different mobile carrier supports the new number, and that an appropriate update was made to the mobile carrier entry for that subscriber.
Once all the data contained in input file 114 is processed, the completed report is returned to the messaging administrator at the institution (step 212 ). For instance, the report may be stored on the WEBDAV system 116 . Alternatively, the report may be sent (e.g., emailed) to the messaging administrator. The messaging administrator at the institution reviews the report, notes any processing errors or warnings indicated on the report, and takes appropriate action to resolve the errors. For instance, the messaging administrator may contact a subscriber to resolve a user-generated error indicated on the report.
The format of the report 124 matches the format of input file 114 . Thus, the messaging administrator can resolve errors directly within the report and resubmit the updated file to the data management subsystem 150 for reprocessing, thereby simplifying data clean-up activities.
Implementation
The notification platform runs on a computing platform, such as, for instance, a multi-threaded computing environment interfaced with external messaging delivery channels and mobile carrier databases via the Internet.
The notification platform can be applied to any messaging technology, including, for instance, SMPP (Short Message Peer-to-Peer protocol) via SMS aggregators, SMPP direct to carriers, SMTP (Simple Mail Transfer Protocol) direct to carriers, SIP (Session Initiation Protocol), SOAP/XML (Simple Object Access Protocol/Extensible Markup Language), or CAP (Common Alerting Protocol).
The techniques described herein can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. The techniques can be implemented as a computer program product, i.e., a computer program tangibly embodied in an information carrier, e.g., in a machine-readable storage device or in a propagated signal, for execution by, or to control the operation of, data processing apparatus, e.g., a programmable processor, a computer, or multiple computers. A computer program can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program can be deployed to be executed on one computer or on multiple computers at one site or distributed across multiple sites and interconnected by a communication network.
Method steps of the techniques described herein can be performed by one or more programmable processors executing a computer program to perform functions of the invention by operating on input data and generating output. Method steps can also be performed by, and apparatus of the invention can be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit). Modules can refer to portions of the computer program and/or the processor/special circuitry that implements that functionality.
Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. Information carriers suitable for embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in special purpose logic circuitry.
To provide for interaction with a user, the techniques described herein can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer (e.g., interact with a user interface element, for example, by clicking a button on such a pointing device). Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input.
The techniques described herein can be implemented in a distributed computing system that includes a back-end component, e.g., as a data server, and/or a middleware component, e.g., an application server, and/or a front-end component, e.g., a client computer having a graphical user interface and/or a Web browser through which a user can interact with an implementation of the invention, or any combination of such back-end, middleware, or front-end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), e.g., the Internet, and include both wired and wireless networks.
The computing system can include clients and servers. A client and server are generally remote from each other and typically interact over a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the appended claims. Other embodiments are within the scope of the following claims.
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In a general aspect, a computer-implemented method includes receiving, via an input interface of a notification platform, updated subscriber data; comparing, using a comparison module of the notification platform, the updated subscriber data with existing subscriber data stored in a subscriber database; and, based on the results of the comparing, modifying, using a modification module of the notification platform, the existing subscriber data stored in the subscriber database.
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CROSS REFERENCE TO RELATED APPLICATIONS
This patent claims priority of German Patent Application No. 10 2006 010 936.8, filed Mar. 9, 2006, which application is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a process and device for controlling and/or regulating an automated clutch, in particular in the drive train of a vehicle.
BACKGROUND OF THE INVENTION
Automated clutches are increasingly finding use in modern motor vehicles. The control or regulation of the clutch is usually done with the aid of a characteristic curve which specifies the clutch torque as a function of the position of an actuating element. The actuating element is moved by an actuator into the position corresponding to the transmissible clutch torque desired in each case.
A problem occurring in clutch control or regulation lies in the fact that in the torque characteristic curve there are one or more ranges in which the transmissible clutch torque changes very sharply when there is a change of the position of the actuating element so that great demands are placed on the actuator moving the actuating element and the control or regulation of the actuator.
SUMMARY OF THE INVENTION
The invention is based on the objective of specifying a clutch control or regulation process in which, despite reduced complexity in the control or regulation, a high quality of control or regulation is achieved.
In a process according to the invention and for controlling and/or regulating an automated clutch, in particular in the drive train of a vehicle, an actuating element, whose position determines the clutch torque transmissible by the clutch, is actuated for setting a predefined clutch torque according to a characteristic curve, where the actuating element is actuated according to a characteristic curve which in a first range of the clutch torque specifies the clutch torque as a function of the position of the actuating element and in a second range of the clutch torque specifies the clutch torque as a function of the force applied to the clutch by the actuating element.
With the process according to the invention it is achieved that the clutch torque's change, as a function of the control variable determining the position of the actuating element, is held in a manageable range, e.g., one as small as possible, so that at the precision with which the control variable of an actuator actuating the actuating element is controlled or regulated, no demands are made which can only be met with great effort.
Advantageously, in the clutch torque range in which one uses the characteristic curve which specifies the clutch torque as a function of the force, the change of the clutch torque associated with a predefined change of the position of the actuating element is greater than in the other clutch torque range.
In a process according to the invention a force/path characteristic curve of the actuating element can be incorporated, where via the characteristic curve the clutch torque/force characteristic curve and the clutch torque/path characteristic curve can be adapted to one another.
In a device according to the invention which is for controlling and/or regulating an automated clutch, in particular in the drive train of a vehicle, and which comprises an actuator for moving an actuating element for the clutch and an electronic control device which controls the actuator as a function of operational parameters and according to characteristic curves stored in the electronic control device, at least two characteristic curves are stored in the control device, where one of the two characteristic curves includes the transmissible clutch torque as a function of the position of the actuating element and the other characteristic curve includes the transmissible clutch torque as a function of the force applied to the clutch by the actuating element and in the control device a change-over device is provided which changes over the control of the actuator from one characteristic curve to the other.
In at least one range of the transmissible clutch torque one of the two characteristic curves is activated and in another range of the transmissible clutch torque the other characteristic curve is activated.
The change-over device activates, for example, the characteristic curve which specifies the clutch torque as a function of the force in a range of the clutch torque in which the change of the clutch torque associated with a predefined change of the position of the actuating element is greater than in the other range of the clutch torque.
The clutch can, for example, be a clutch put into the closed position.
Furthermore, the clutch can advantageously be a clutch of a parallel shift gearbox. Such parallel shift gearboxes are known per se and comprise two sub-transmissions, each of which is assigned its own clutch, where each of the parallel shift gearboxes operates at the transmission ratio which is set in the transmission paths whose clutch is closed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained with the aid of schematic drawings as examples and with additional details, in which:
FIG. 1 is a schematic representation of a clutch-actuating device; and,
FIGS. 2 to 5 illustrate different characteristic curves to explain the invention.
DETAILED DESCRIPTION OF THE INVENTION
According to FIG. 1 a clutch designated overall by 10 is connected, via a transmission mechanism designated overall by 12 , to an actuator, in the given example, electric motor 14 .
The transmission mechanism comprises actuating element 16 which is connected directly, via additional coupling elements, or via a hydraulic transmission path connection to clutch lever 18 whose position determines the torque which can be transmitted by the clutch.
Actuating element 16 is connected in the manner of a hinge to segmented wheel 20 , which is mounted in such a manner that it can rotate about axis A in housing 22 . Housing 22 can be connected in a fixed manner to the housing of the clutch or to a transmission housing.
Segmented wheel 20 comprises on circumferential area toothing 24 which meshes with spiral threading 28 formed on output shaft 26 of electric motor 14 . To detect turning of output shaft 26 increment counter 30 is provided.
Electronic control device 32 with a microprocessor and associated storage devices serves to control electric motor 14 , where one input is connected to increment counter 30 and additional inputs are connected, in given cases via a bus, to outputs of sensors or another control device, where via these outputs, control device 32 is supplied with data relevant to the operation of the clutch. One output of control device 32 is connected to electric motor 14 .
The ability of segmented wheel 20 to turn is limited by at least one stop 34 which stop face 36 of the segmented wheel abuts at the end of the actuation path of actuating element 16 during the turning of segmented wheel 20 in the counterclockwise direction. The ability of segmented wheel 20 to turn in the clockwise direction is limited by the fact that additional stop face 38 comes to abut stop 34 .
The design and function of the arrangement described are known per se and are thus not explained in detail in so far as they are known.
In control device 32 at least one characteristic curve is stored which specifies the torque which can be transmitted by clutch 10 as a function of the position of clutch lever 18 or of that of actuating element 16 . The position of actuating element 16 is known by using increment counter 30 , whose counter state is indexed by absolute calibration of the counter state, as needed or periodically, by, for example, segmented wheel 20 being moved up to abutment with stop 34 so that from the counter state the position of actuating element 16 can be deduced. Other possibilities for updating the characteristic curve repeatedly consist in updating the closed state of the clutch or its point of engagement by slip and/or torque measurement of the clutch and the assignment of the counter state to predefined function states of the clutch.
Depending on the springs used in the clutch, the kinematic transmission ratios, and the type of construction of the clutch (closed or open), the transmissible clutch torque as a function of the path or the position of actuating element 16 can have the most varied forms. FIG. 2 shows an example of such a characteristic curve, which runs relatively flat in the range between a transmissible torque from 0 to 100 Nm and above 100 Nm becomes increasingly steeper. FIG. 3 shows the characteristic curve for this exemplary clutch, said characteristic curve specifying the transmissible clutch torque as a function of the force applied to actuating element 16 or clutch lever 18 . The curve of the transmissible torque over the force, in the given example the disengagement force, is relatively flat in the range above 100 Nm. Below this value the curve is no longer single-valued since the force runs through a maximum as a consequence of the kinematics of the clutch.
According to the invention, both characteristic curves are stored in storage device 32 and the control or regulation of the clutch below a predefined transmissible clutch torque is done with the aid of the clutch torque/path characteristic curve of FIG. 2 and above this transmissible torque, e.g., 100 Nm, according to the clutch torque/force characteristic curve of FIG. 3 . FIG. 4 shows the control characteristic curves combined from FIGS. 2 and 3 in reversed form, that is, the clutch torque is plotted on the horizontal axis. The path is plotted on the left ordinate, the force on the right ordinate. Should the clutch torque to be controlled by control device 32 lie under 100 Nm, the left part of the characteristic curve is used. Above 100 Nm the right part of the characteristic curve is used. Through adaptation of the characteristic curves as needed or cyclically, or immediately, a force/path characteristic curve not represented is generated in control device 32 , with which it is ensured that the two characteristic curve sections of FIG. 4 pass smoothly into one another.
If processing is done with a path-controlled clutch torque, control device 32 sets the position of actuating element 16 with the aid of increment counter 30 . If the transmissible clutch torque is set by the force to be applied to the clutch, electric motor 14 is driven, e.g., under voltage control, since the force exerted by it on actuating element 16 is a function of the voltage with which electric motor 14 is energized.
With driving of clutch 10 , by way of example by means of hydraulic pressure, a pressure sensor detecting the hydraulic pressure is used, with whose aid the pressure of the hydraulic medium is controlled. It is understood that the force applied to clutch 10 can also be measured directly with any suitable force sensor, according to whose output signal electric motor 14 is driven.
The process according to the invention, in which in different ranges there is a change-over to different control processes, e.g., force control, path control, pressure control, etc., is particularly well-suited when there is a harmonic curve of the force/path characteristic curve of the clutch, as there is, for example, with closed, dry clutch or also wet-running clutches.
Advantageously, processing in each case is done with the characteristic curve in which the clutch torque to be set has little dependence on the variable set directly by the actuator (position of the actuating element, force exerted on the actuating element).
FIG. 5 shows an example of a force/path characteristic curve of a clutch whose actuation force does not exceed 1400 Nm and with an actuation path reaching from approximately 4 mm to approximately 10 mm. Between these positions the actuation force runs through a minimum.
The value ranges and curves described above are only exemplary. The invention is suitable for all the types of clutches with clutch torque/path characteristic curves and clutch torque/force characteristic curves of different slopes, where advantageously the slope of the clutch torque/path characteristic curve is large in a clutch torque range in which the slope of the clutch torque/force characteristic curve is small and conversely. Also for reasons, for example, of poor controllability of the voltage in a predefined voltage range or for reasons of rapidity advantages of a voltage control vis-à-vis path control there can be change-over between different types of control. In each case, the change-over can take place at a predefined position of actuating element 16 , which, for example, is detected via increment counter 30 , when there is a predefined voltage present at electric motor 14 or also when there is a predefined transmissible torque of clutch 10 , which can be detected by registering the torque and the rotary speed of a motor connected to the drive shaft of the clutch as well as the slip of the clutch.
LIST OF REFERENCE NUMBERS
10 Clutch
12 Transmission mechanism
14 Electric motor
16 Actuating element
18 Clutch lever
20 Segmented wheel
22 Housing
24 Toothing
26 Output shaft
28 Spiral threading
30 Increment counter
32 Control device
34 Stop
36 Stop face
38 Stop face
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In a process which is for controlling and/or regulating an automated clutch, in particular in the drive train of a vehicle, and in which an actuating element, whose position determines the clutch torque transmissible by the clutch, is actuated for setting a predefined clutch torque according to a characteristic curve, the actuating element is actuated according to a characteristic curve which in a first range of the clutch torque specifies the clutch torque as a function of the position of the actuating element and in a second range of the clutch torque specifies the clutch torque as a function of the force applied to the clutch by the actuating element.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
The U.S. Government may have an interest in the subject matter of this disclosure as provided for by the terms of contract number N00019-02-C- 3003 , awarded by the United States Navy, and contract number F33615-03-D-2345 DO-0009, awarded by the United States Air Force.
BACKGROUND
1. Technical Field
The disclosure generally relates to gas turbine engines.
2. Description of the Related Art
A typical gas turbine engine incorporates a compressor section and a turbine section, each of which includes rotatable blades and stationary vanes. Within a surrounding engine casing, the radial outermost tips of the blades are positioned in close proximity to outer air seals. Outer air seals are parts of shroud assemblies mounted within the engine casing. Each outer air seal typically incorporates multiple segments that are annularly arranged within the engine casing, with the inner diameter surfaces of the segments being located closest to the blade tips.
SUMMARY
Gas turbine engines and related systems involving blade outer air seals are provided. In this regard, an exemplary embodiment of a blade outer air seal assembly for a gas turbine engine, the engine having a longitudinal axis and rotatable blades, each of the blades having a blade tip, the blade outer air seal assembly comprising: an annular arrangement of outer air seal segments, each of the segments having ends, the segments being positioned in an end-to-end orientation such that each adjacent pair of the segments forms an intersegment gap therebetween, each intersegment gap being angularly offset with respect to a longitudinal axis of the gas turbine engine.
An exemplary embodiment of a gas turbine engine comprises: a compressor; a combustion section; a turbine operative to drive the compressor responsive to energy imparted thereto by the combustion section, the turbine having a rotatable set of blades, the compressor and the turbine being oriented along a longitudinal axis; and a blade outer air seal assembly positioned radially outboard of the blades, the outer air seal assembly having an annular arrangement of outer air seal segments with intersegment gaps being located between the segments, each intersegment gap being angularly offset with respect to the longitudinal axis.
An exemplary embodiment of a blade outer air seal segment for a set of rotatable blades comprises: a blade arrival end; and a blade departure end; each of the blade arrival end and the blade departure end being angularly offset with respect to a longitudinal axis about which the blades rotate.
Other systems, methods, features and/or advantages of this disclosure will be or may become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features and/or advantages be included within this description and be within the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is a schematic diagram depicting an exemplary embodiment of a gas turbine engine.
FIG. 2 is a partially cut-away, schematic diagram depicting a portion of the embodiment of FIG. 1 .
FIG. 3 is a partially cut-away, schematic diagram depicting a portion of the shroud assembly of the embodiment of FIGS. 1 and 2 as viewed along section line 3 - 3 .
FIG. 4 is a partially cut-away, schematic diagram depicting a portion of the shroud assembly of the embodiment of FIGS. 1 and 2 as viewed along section line 4 - 4 .
FIG. 5 is a partially cut-away, schematic diagram depicting a portion of another embodiment of a shroud assembly.
DETAILED DESCRIPTION
Gas turbine engines and related systems involving blade outer air seals are provided, several exemplary embodiments of which will be described in detail. In some embodiments, the ends of the outer air seal segments are angularly offset with respect to a longitudinal axis of the gas turbine in which the segments are mounted. In some of these embodiments, the ends of two adjacent segments are shaped to correspond to the mean camber line of the blades at the blade tips. In this manner, a pressure differential between the suction side and the pressure side of a blade as that blade crosses the adjacent ends of the segments tends to be stabilized. In particular, the location of the highest pressure differential during blade passage may tend to wander less along the gap formed between the adjacent segments and/or the rate of hot gas ingestion into the gap may be reduced. Notably, stabilizing of the transient nature of the pressure differential as each blade crosses the gap may allow for a decrease in overall cooling air applied to cool the segments. This may be the case because the region of highest hot gas ingestion along a segment, which corresponds to at least one of a highest temperature of hot gas and a highest volume of hot gas, may be relatively stationary. Thus, increased cooling air can be specifically directed to those regions and less cooling air can be directed to others.
Referring now in more detail to the drawings, FIG. 1 is a schematic diagram depicting an exemplary embodiment of a gas turbine engine. As shown in FIG. 1 , engine 100 incorporates a fan 102 , a compressor section 104 , a combustion section 106 and a turbine section 108 . Various components of the engine are housed within an engine casing 110 , such as a blade 112 of the low-pressure turbine, that extends along a longitudinal axis 114 . Although engine 100 is configured as a turbofan engine, there is no intention to limit the concepts described herein to use with turbofan engines as various other configurations of gas turbine engines can be used.
A portion of engine 100 is depicted in greater detail in the schematic diagram of FIG. 2 . In particular, FIG. 2 depicts a portion of blade 112 and a corresponding portion of a shroud assembly 120 that are located within engine casing 110 . Notably, blade 112 is positioned between vanes 122 and 124 , detail of which has been omitted from FIG. 2 for ease of illustration and description.
As shown in FIG. 2 , shroud assembly 120 is positioned between the rotating blades and the casing. The shroud assembly generally includes an annular mounting ring 123 and an annular outer air seal 125 attached to the mounting ring and positioned adjacent to the blades. Various other seals are provided both forward and aft of the shroud assembly. However, these various seals are not relevant to this discussion.
Attachment of the outer air seal to the mounting ring in the embodiment of FIG. 2 is facilitated by interlocking flanges. Specifically, the mounting ring includes flanges (e.g., flange 126 ) that engage corresponding flanges (e.g., flange 128 ) of the outer air seal. Other attachment techniques may be used in other embodiments.
With respect to the annular configuration of the outer air seal, outer air seal 125 is formed of multiple arcuate segments, portions of two of which are depicted schematically in FIG. 3 . As shown in FIG. 3 , adjacent segments 140 , 142 of the outer air seal are oriented in an end-to-end relationship, with an intersegment gap 150 located between the segments. Notably, blade 112 is depicted in solid lines, with the direction of rotation of blade 112 being indicated by the overlying arrow. A predicted position of blade 112 after the blade tip 113 rotates past the intersegment gap is depicted in dashed lines.
Portions defining the intersegment gap include a blade departure end 152 of segment 140 and a blade arrival end 154 of segment 142 . As shown in FIG. 4 , the intersegment gap 150 located between the ends of the segments is angularly offset with respect to longitudinal axis 114 . In this embodiment, the angular offset (θ), which is defined along a line extending between the leading edge (e.g., edge 153 ) and trailing edge (e.g., 155 ) of a segment end, corresponds to the angular offset exhibited by the chord 156 of blade 112 at the blade tip. Note that chord 156 is defined by a line extending between the leading edge 158 and the trailing edge 160 of the blade. Thus, during blade passage, the leading and trailing edges of the blade of this embodiment transit the gap simultaneously, or nearly so.
The aforementioned configuration may tend to reduce hot gas ingestion and corresponding distress exhibited by the ends of the segments. Notably, the advancing suction side of each rotating blade (e.g., side 170 of blade 112 ) tends to promote a radial inboard-directed flow of cooling air (depicted by the solid arrow) from the intersegment gap. In contrast, the retreating pressure side of each rotating blade (e.g., side 172 of blade 112 ) tends to promote a radial outboard-directed ingestion flow of hot gas (depicted by the dashed arrow) into the intersegment gap. By providing an angular offset of the intersegment gap, as defined by the ends of the outer air seal segments, radial penetration of hot gas along the intersegment gap may be reduced. This characteristic may be attributable to a reduction in the length of the intersegment gap over which the instantaneous axial pressure gradient occurs.
In other embodiments, various angular offsets other than those directly corresponding to the blade chord can be used. By way of example, angular offsets of between approximately 5° and approximately 70°, preferably between approximately 20° and approximately 60°, and most preferably between approximately 30° and approximately 45°, can be used. Notably, passage of an intersegment gap by the leading and trailing edges of a blade may occur separately in some embodiments.
Another aspect of the embodiment of FIGS. 1-4 relates to the degree to which a transiting blade tends to obstruct an intersegment gap during passage of the gap. That is, unlike conventional gaps, which tend to be aligned with the longitudinal axis of a gas turbine engine, the angular offset tends to orient the gap so that more of the gap is obstructed by the blade tip during blade passage. Such a physical obstruction tends to reduce the rate and/or volume of hot gas moving past the blade tip for ingestion into the gap.
FIG. 5 is a partially cut-away, schematic diagram depicting a portion of another embodiment of a shroud assembly. In FIG. 5 , portions of adjacent outer air seal segments 202 , 204 defining an intersegment gap 206 are depicted. Specifically, blade departure end 208 of segment 202 and blade arrival end 210 of segment 204 define intersegment gap 206 . Notably, intersegment gap 206 is angularly offset with respect to a longitudinal axis 212 of a gas turbine in which the segments are to be mounted. In this embodiment, the angular offset (θ), which is defined along a line extending between the leading edge (e.g., edge 214 ) and trailing edge (e.g., edge 216 ) of a segment end, corresponds to the angular offset of the chord 217 of blade 218 at the blade tip 219 . Note that chord 217 is defined by a line extending between the leading edge 220 and the trailing edge 222 of the blade. Thus, during blade passage of the gap, the leading and trailing edges of the blade of this embodiment transit the gap simultaneously, or nearly so.
In contrast to the embodiment of FIGS. 1-4 , the gap 206 of the embodiment of FIG. 5 is not linear. Specifically, gap 206 includes a blade passage region 230 , a leading edge region 232 and a trailing edge region 234 .
In this embodiment, blade passage region 230 of the gap exhibits a shape that generally corresponds to the mean camber line of the blade at the blade tip (i.e., a line defined by points equidistant from the suction side and pressure side surfaces of the blade tip). The leading and trailing edge regions, which are axially located fore and aft, respectively, of the blade passage region, continue the curvature of the blade passage region. In other embodiments, various other types of curvature can be used for forming an intersegment gap. By way of example, an intermediate portion of the gap (e.g., that portion of the gap located adjacent to the blade tips) can exhibit a shape that generally corresponds to the mean camber line of the blades, while the portions of the gap in the vicinity of the leading and trailing edges can be oriented generally axially. Such a shape may tend to reduce hot gas ingestion, particularly at the leading edge of the gap as the gap shape would not match the airflow direction coming off of the tips of the passing blades.
It should be noted that the angular offset of blade arrival end 154 of segment 142 is depicted in FIG. 4 , whereas the angular offset of blade departure end 208 of segment 202 is depicted in FIG. 5 . In those embodiments, the ends of the respective adjacent segments exhibit similar angular offsets. However, variations due to manufacturing tolerances, for example, may be present.
It should be emphasized that the above-described embodiments are merely possible examples of implementations set forth for a clear understanding of the principles of this disclosure. Many variations and modifications may be made to the above-described embodiments without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the accompanying claims.
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Gas turbine engines and related systems involving blade outer air seals are provided. In this regard, a representative blade outer air seal segment for a set of rotatable blades includes: a blade arrival end; and a blade departure end; each of the blade arrival end and the blade departure end being angularly offset with respect to a longitudinal axis about which the blades rotate.
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[0001] This application claims the benefit of Korean Applications No. P2003-51511 filed on Jul. 25, 2003, P2003-51512 filed on Jul. 25, 2003, and P2003-72247 filed on Oct. 16, 2003, which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a washing machine, and more particularly, to a method of performing a spinning operation for a washing machine.
[0004] 2. Discussion of the Related Art
[0005] Generally, a washing machine performs washing by executing a washing operation, a rinsing operation, and a spinning operation. The spinning operation includes a load pre-balancing cycle, a load weighing cycle, a load balancing cycle, and a main spinning cycle.
[0006] According to the principles of the related art, before the main spinning cycle, a microprocessor determines a load weight of wet clothes to measure spinning operation parameters, which helps to balance the load in the tub. However, it is very likely that some wet clothes in the washing machine become tangled one another by a nature of the mechanism of a drum washing machine. Consequently, an unevenly distributed load of the clothes in the washing machine creates an unnecessary moment about the center of a tub, which makes the motor irregularly rotate. For example, when a chunk of the wet clothes spins from a top to a bottom of the tub in the washing machine, the moment created by a gravity of the chunk forcibly rotates the motor over its limit. On the other hand, when the chunk spins from the bottom to the top, it creates an opposite rotational force that prevents the motor from rotating in the right direction. Therefore, the entanglement of the clothes causes a vibration of the tub, a nose, and a walking of the washing machine, all of which resulted in inaccuracy of the load weight of the wet clothes. As a result, the inaccurate load weight causes the inaccurate spinning operation parameters, which influence a performance of the main spinning operation.
[0007] According to the principles of the related art, after the load weighing cycle, the rotational speeds up the tub with a constant acceleration regardless of the load weight to perform the load balancing cycle. Speeding with the constant acceleration has caused a problem of the vibration of the tub, the walking of the washing machine, and the poor performance of the main spinning cycle. For example, if 10 kg clothes are not evenly distributed and a relatively low speed is used to redistribute them, it will be very difficult for the relatively low speed to not only balance the 10 kg load evenly but also reach a desired speed quickly. So to speak, the 10 kg unbalanced load creates the moment about the center of the tub. The moment then causes the vibration of the motor, the noise, the walking of the washing machine, and a lagging of the cycle. Thus, the load balancing cycle needs to last longer, meaning that more power is needed and inefficiency of the spinning operation is occurred.
[0008] During the load balancing cycle, the microprocessor determines an unbalancing value, which represents how irregularly the load of the wet clothes is distributed in the washing machine. Even though the microprocessor determines whether the main spinning operation can be carried out dependent upon the unbalancing value, the load is not likely to be evenly balanced for the smooth performance of the main spinning cycle because the unbalanced distribution levels are determined below a resonance frequency range. It is realized that the unbalanced distribution levels alter prominently within the resonance frequency range. Therefore, the unbalance load determined below the resonance frequency range is not accurate, which influences the performance of the main spinning cycle.
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention is directed to a washing machine that substantially obviates one or more problems due to limitations and disadvantages of the related art.
[0010] An object of the present invention is to provide more accurate washing parameters such as load weight of wet clothes, acceleration rates while balancing a load of the wet clothes, and to minimize the unbalanced distribution level of the wet clothes within a tub so that the performance of the spinning operation can be improved.
[0011] Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0012] To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a method of controlling a spinning operation of a washing machine includes the steps of measuring the load weight of the wet clothes contained in the tub to be spun, determining an optimal acceleration rate based upon the measured load weight, and increasing a rotational speed of the tub to a first predetermined speed at the optimal acceleration rate in order to minimize unbalanced distribution of the wet clothes within the tub.
[0013] In another aspect of the present invention, a method of controlling a spinning operation of a washing machine includes the steps of measuring a load weight of wet clothes contained in a tub to be spun, selecting at least two distinct optimal acceleration rates if the measured load weight belongs to a particular acceleration range, and increasing the rotational speed of the tub to a first predetermined speed at the selected optimal acceleration rates alternately in order to minimize unbalanced distribution of the wet clothes within the tub.
[0014] In another aspect of the present invention, a method of controlling a spinning operation of a washing machine includes the steps of measuring a load weight of wet clothes contained in a tub to be spun, determining an optimal acceleration rate based upon the measured load weight, and increasing a rotational speed of the tub to a first predetermined speed at the optimal acceleration rate in order to minimize unbalanced distribution of the wet clothes within the tub. The method further includes the steps of measuring an unbalanced distribution level of the wet clothes within the tub while rotating the tub at the first predetermined speed, and interrupting the spinning operation of the washing machine when the measured unbalanced distribution level is greater than a predetermined value.
[0015] In another aspect of the present invention, a method of controlling a spinning operation of a washing machine includes the steps of measuring a first unbalanced distribution level of wet cloths contained within the tub while rotating the tub at a first speed, and interrupting the spinning operation of the washing machine when the first unbalanced distribution level is greater than a first predetermined value. The method further includes the steps of measuring a second unbalanced distribution level of the wet clothes while rotating the tub at a second speed selected from a resonance frequency range of the washing machine, and interrupting the spinning operation of the washing machine when a difference between the first and second unbalanced distribution levels is greater than a second predetermined value.
[0016] In another aspect of the present invention, a method of controlling a spinning operation of a washing machine includes the steps of measuring a load weight of the wet clothes contained in a tub to be spun, determining an optimal acceleration rate based upon the measured load weight, and increasing the rotational speed of the tub to a first speed at the optimal acceleration rate in order to minimize unbalanced distribution of the wet clothes within the tub. The method further includes the steps of measuring a first unbalanced distribution level of the wet clothes while rotating the tub at the first speed, interrupting the spinning operation of the washing machine when the first unbalanced distribution level is greater than a first predetermined value, measuring a second unbalanced distribution level of the wet clothes while rotating the tub at a second speed selected from a resonance frequency range of the washing machine, and interrupting the spinning operation of the washing machine when a difference between the first and second unbalanced distribution levels is greater than a second predetermined value.
[0017] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings;
[0019] FIG. 1 illustrates a prospective side view of a washing machine in accordance with the present invention;
[0020] FIG. 2 is a flowchart illustrating one embodiment of the method of controlling a spinning operation of the washing machine in accordance with the present invention;
[0021] FIG. 3 is a graph illustrating a spinning operation of the washing machine including a load balancing cycle;
[0022] FIG. 4 is a graph illustrating a spinning operation of the washing machine including a first load balancing cycle and a second load balancing cycle;
[0023] FIG. 5 is a flowchart illustrating another embodiment of the method of controlling a spinning operation of the washing machine in accordance with the present invention; and
[0024] FIG. 6 is a graph illustrating a spinning operation of the washing machine, in which the unbalanced distribution level of the wet clothes is measured more than once.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0026] FIG. 1 illustrates a prospective side view of a washing machine in accordance with the present invention. According to FIG. 1 , the washing machine includes a cabinet 5 , a tub 3 , and a drum 9 . The drum 9 includes a drum axle 13 , which transmits a driving force of a DC motor 6 to the drum 9 . For smooth operation of the motor 6 , the drum axle 13 is equipped with bearings 12 at its both ends, which are placed in a bearing housing (not illustrated). The motor 6 itself contains a stator 7 and a rotor 8 which is directly connected to the drum 9 and rotates it. The washing machine also includes a hanging spring 4 which functions as a support between an inner top of the cabinet 5 and an outer top of the tub 3 . In order to reduce vibration of the tub 3 , the washing machine includes a friction damper 10 provided between an inner bottom of the cabinet 5 and the outer bottom of the tub 3 . In addition, the washing machine includes a motor sensor 11 which measures a number of the rotor 8 rotation, which represents the speed of the motor 6 .
[0027] FIG. 2 is a flow chart illustrating a method of controlling a spinning operation of the washing machine shown in FIG. 1 according to one embodiment of the present invention. According to FIG. 2 , a microprocessor (not illustrated) of the washing machine initially increases the rotational speed of the tub 3 from zero to a second predetermined speed. It then measures an acceleration time that it takes for the rotational speed to reach the second predetermined speed from zero.
[0028] Finally, it determines the load weight of the wet clothes based upon the measured acceleration (S 201 ). Measuring the load weight of the wet clothes improves the performance of the washing machine by obtaining more accurate washing parameters. An example of the washing parameters is the acceleration rate at which the microprocessor increases the rotational speed. The microprocessor determines the optimal acceleration rate based on the measured load weight and increases the rotational speed at the determined optimal acceleration rate (S 202 ).
[0029] According to the present invention, the corresponding acceleration rate now helps rebalance the load of the clothes so efficiently that it saves time and neither vibrates the tub 3 nor creates a noise. Thus, the load balancing cycle is shortened. Now, the motor 6 rotates at the corresponding acceleration rate to balance the load and the microprocessor determines the unbalanced distribution level, which represents how irregularly the load is distributed in the tub 3 (S 203 ). If the unbalanced distribution level is less than the reference value (S 204 ), then it moves onto the main spinning cycle to perform. (S 205 ). Otherwise, the microprocessor interrupts the spinning operation and shuts off a power supply to the motor 6 that rotates the tub 3 for a predetermined time (S 206 ) and goes back to the step of increasing the rotational speed at the determined optimal acceleration rate upon the measured load weight (S 202 ).
[0030] FIG. 3 is a graph illustrating a spinning operation including a determined optimal acceleration rate during a load balancing cycle in accordance with the present invention. During the load balancing cycle, the motor 6 rotates up to 108 RPM at the determined acceleration rate based upon the load measured weight. According to the present invention, table 1 below shows how the acceleration rate differentiates upon the load weight.
TABLE 1 Acceleration rate varies dependent upon load weight. Load Weight Acceleration Rate (RPM/ms) Light 1/160, 1/190 (alternate rotation) Medium Light 1/150 Medium Heavy 1/180 Heavy 1/200
[0031] As tabulated in the table 1, the microprocessor determines the acceleration rate which corresponds to the load weight. A plurality of the acceleration rates is predetermined for a plurality of the load weight ranges. Each load weight range is assigned to a certain acceleration rate. Exceptionally, for the light load, the microprocessor alternately increases the rotational speed of the tub 3 to a predetermined speed by selecting the two determined optimal acceleration rates one by one in order to minimize the unbalanced distribution of the wet clothes within the tub 3 . The acceleration rate noticeably varies as the load weight changes in order to optimize efficiency of the load balancing cycle. To be more specific, the acceleration rate is inversely proportional to the load weight. The acceleration rate helps to quickly lower the unbalanced distribution level. Then, it will proceed to the main spinning cycle if the unbalanced distribution level is less than the reference value. As a note, the unit of the acceleration rate is RPM/ms, meaning that the speed of the motor increases by 1 revolution per minute (RPM) in 1 millisecond.
[0032] In addition to the load balancing cycle specified above, it may include an additional step of a load balancing cycle prior to the load weighing cycle. The additional step helps to measure the load weight more accurately by reducing other side effects such as the vibration of the motor and the walking of the washing machine. For example, FIG. 4 is a graph illustrating a spinning operation including the additional step of a first load balancing cycle prior to the load weighing cycle, and a step of a second load balancing cycle with the determined acceleration rate. It is realized that the rotational speed needs to be approximately as low as 46 RPM due to the fact that below 50 RPM a gravity of the load prevails over a centrifugal force of the motor so that the load moves freely and gets balanced easily. During the first load balancing cycle, the motor alternately rotates with the load at the predetermined speed at least one cycle in each direction, a first direction and a second direction.
[0033] It is likely that at the predetermined speed the load reaches a top of the tub 3 , it falls down to a bottom of the tub 3 due to the gravity, instead of sticking to a wall of the tub 3 and spinning with it by the centrifugal force. Fallen by the gravity, the unbalanced load is evenly spread out in the tub 3 . For example, a heavy chunk of the tangled load is spinning around in the tub 3 causing the vibration of the motor. The microprocessor can spread out the heavy chunk of the tangled load by free-falling from the top and being hit on the bottom of the tub 3 , continuously.
[0034] FIG. 5 is a flowchart illustrating a spinning operation including a plurality of unbalanced distribution levels in accordance with the present invention. The microprocessor measures a first unbalanced distribution level at a first speed below a resonance frequency range of the motor (S 501 ). The resonance frequency range of the washing machine is usually from 170 rpm to 250 rpm and the main spinning cycle is frequently performed above 300 rpm. The first unbalanced distribution level is determined by measuring a speed variation of a motor that rotates the tub 3 . For example, if the motor rotates at 100 rpm, the microprocessor measures how much the speed fluctuates at 100 rpm. It then determines if the first unbalanced distribution level is less than a first reference value (S 502 ). It interrupts the spinning operation of the washing machine and shuts off the power supply to the motor 6 that rotates the tub 3 for a predetermined time when the first unbalance value is greater than a first reference value (S 505 ). If the first unbalanced distribution level is less than the first reference value, the microprocessor measures a second unbalanced distribution level (S 503 ). The important is that it measures the second unbalanced distribution level at a second speed selected from the resonance frequency of the washing machine.
[0035] Now, the microprocessor determines difference between the first unbalanced distribution level and the second unbalanced distribution level. It may calculate the difference by dividing the first unbalanced distribution level by the second unbalanced distribution level, as a ratio. Or, it may simply subtract one from the other. It then compares the difference to a second reference value to determine if the difference is less than the second reference value. (S 504 ). It interrupts the spinning operation of the washing machine and shuts off the power supply to the motor 6 for the predetermined time when the difference is greater than the second reference value (S 505 ). If the difference is less than the second reference value, then it proceeds to the main spinning cycle (S 506 ).
[0036] FIG. 6 is a graph illustrating a spinning operation including a plurality of unbalanced distribution levels in accordance with the present invention. The present invention measures the plurality of unbalanced distribution levels. For example, as shown in FIG. 6 , a first unbalanced distribution level is measured at 108 rpm below the resonance frequency range. “A” denotes a last minute drain-out stage during which the microprocessor speeds up the motor to 170 rpm for a predetermined time in order to drain out leftover water in the tub 3 . If the first unbalanced distribution level is less than the first reference value, the microprocessor stores the first unbalance distribution level and determines a second unbalance distribution level at 170 rpm selected from the resonance frequency range.
[0037] As experimentally proved, the first unbalanced distribution level determined below the resonance frequency range is prominently different from the second one within the resonance frequency range. If proceeding to the main spinning cycle is determined based on the only first unbalanced distribution level, the washing machine will be unstably performed causing the vibration, walking of the washing machine, and noises from it. Determining a difference between the first and the second determined unbalanced distribution levels and considering it as the unbalanced distribution level, the present invention obtains smoother and improved performance of the washing machine. The microprocessor performs the last minute drain-out stage at 300 rpm.
[0038] Therefore, according to the present invention, the spinning operation includes the optional load first balancing cycle which untangles the load, the load weighing cycle which measures the load weight, the load balancing cycle which balances the load, and the main spinning cycle.
[0039] 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 spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A method of performing a spinning operation of a washing machine is disclosed. First, a load weight of wet clothes contained in a tub is measured, and an optimal acceleration rate is calculated based upon the measured load weight. Finally, a rotational speed of the tub is gradually increased up to a predetermined speed at the calculated optimal acceleration rate such that the unbalanced distribution of the wet clothes within the tub is minimized.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates generally to logging of subsurface reservoirs and more particularly to pipe conveyed logging.
[0005] 2. Description of the Related Art
[0006] Ordinarily, gravity is used to pull logging tools along and into a well borehole for conducting logging operations. When a well is highly deviated from vertical, the force exerted by gravity may not be sufficient to draw the logging tool through a deviated portion of the well. Many oil wells are deviated. For example, an offshore platform commonly has many wells drilled from the platform into various portions of a targeted formation that surrounds the location of the platform. While some of the wells might be approximately vertical, most of the wells extending from the platform will deviate at various angles into the formations of interest and some may involve deviations up to, or above, horizontal. Gravity conveyed logging tools supported on wirelines lose the effect of gravity for forcing the tool through the hole and simply do not have sufficient motive force to traverse the deviated hole to the zone to be logged. In many instances, the logging tool must be pushed through the deviated well to the zone of interest to ensure that the logging tool is located at the requisite location in the deviated hole. It is desirable therefore that the logging tool be fixed to the end of a string of sufficiently stiff pipe to log along the deviated well at the zone of interest. In many cases, this requires using large pipe, such as drill pipe, to have the stiffness required for logging these sections.
[0007] A known method for logging highly deviated wells, disclosed in U.S. Pat. No. 4,457,370, to Wittrisch, consists of the following steps. A well logging tool is secured to the bottom of a section of drill pipe, inside a protective sleeve, and the tool is lowered into the well as additional sections of pipe are assembled. An electrical connector attached to the end of a wireline cable is then inserted into the drill pipe, the cable is passed through a side entry sub mounted on top of the drill string and the connector is pumped down through the drill pipe into engagement with a mating connector attached to the logging tool to effect connection of the tool to the cable and therefore the surface control equipment. Then other sections of drill pipe are added, the portion of the cable above the side entry sub running outside the drill pipe, until the tool reaches the bottom of the section to be logged. Then the logging operation is performed as the drill pipe is moved through the desired section.
[0008] The running of the cable and the additional care and complexity required to protect the cable during pipe movement increase the time required to obtain a log. In addition the making of a wet connect is commonly prone to failure requiring additional time and effort to correct.
[0009] There is a demonstrated need for providing an apparatus and method for logging a highly deviated wellbore that does not require the running of a wireline cable or the making of a wet connect.
SUMMARY OF THE INVENTION
[0010] In one aspect of the present invention, an apparatus for evaluating a formation comprises a tubular string deployed into a wellbore penetrating the formation, where the tubular string has a longitudinal flow passage therethrough. A flow sub in the tubular string provides fluid communication between the longitudinal flow passage in the tubular string and an annulus between the tubular string and a wall of the wellbore. A wireline tool is attached proximate a bottom end of the flow sub. A telemetry module proximate the flow sub provides communication between the wireline tool and a surface system, without the use of a wireline to the surface.
[0011] In another aspect, a method for evaluating a formation comprises deploying a tubular string into a wellbore penetrating the formation. Fluid communication is provided between a longitudinal flow passage in the tubular string and an annulus between the tubular string and a wall of the wellbore using a flow sub attached to the tubular string. A parameter of interest is measured with a wireline tool attached to the tubular string below the flow sub. Communication between the wireline tool and a surface system is accomplished without the use of a wireline.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For detailed understanding of the present invention, references should be made to the following detailed description of the embodiments, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals, wherein:
[0013] FIG. 1 is a drawing of a logging system according to at least one embodiment of the present invention;
[0014] FIG. 2 is a blown up portion of bottom assembly 30 of FIG. 1 ;
[0015] FIG. 3 is a drawing showing an example of multiple sample tanks in a formation test tool; and
[0016] FIG. 4 is a block diagram of the interrelationship of several components of the present invention.
DESCRIPTION OF EMBODIMENTS
[0017] FIGS. 1 and 2 show an exemplary embodiment of the present invention. Rig 5 supports a string 13 of jointed pipe in borehole 15 , also called a wellbore, that extends through formation 20 . As shown, borehole 15 is highly deviated and may include substantially horizontal sections. As used herein, highly deviated refers to wellbores that are deviated from vertical by about 70 degrees, or more. String 13 is made up of pipe sections 10 joined together at threaded connections 12 . The pipe may be drill pipe of the type known in the art. String 13 extends in borehole 13 into a subterranean formation 20 . Bottom assembly 30 is attached to the bottom of string 15 and comprises telemetry module 35 , and flow sub 31 . Attached below flow sub 31 are wireline logging tools 32 A and 32 B. As one skilled in the art will appreciate, and as used herein, a wireline tool is intended to be a tool designed to be commonly deployed into and out of the wellbore on an electrical wireline cable, and is distinguished from tools designed for use during measurement while drilling (MWD) operations. Commonly, wireline tools are not designed to survive the shock, vibration, and torsion of the drilling operation, as required by MWD tools. It is understood, in the context of the present invention, that minor mechanical modifications to a wireline tool to mechanically interface the tool for the present invention, do not alter the nature of the tool as a wireline tool.
[0018] As shown, tool 32 A is a formation test tool. Logging tool 32 B comprises a logging tool that may include, but is not limited to, at least one of: a nuclear magnetic resonance logging tool (NMR); a resistivity tool; and a nuclear density tool. Such tools are used to determine various parameters of interest of the formation including, but not limited to: formation resistivity, formation porosity, and formation permeability. Multiple wireline logging tools may be connected together in a logging string below flow sub 31 . It should be noted that there is no significance to the specific location of particular logging tools in the logging string. For example, if multiple wireline tools are connected below flow sub 31 , formation test tool 32 A may be located at any location in the logging string.
[0019] Surface pump 3 pumps fluid 38 through string 13 and down through bottom assembly 30 . Fluid 38 exits through flow port 50 in flow sub 31 into the annulus between the string 13 and the wall 14 of borehole 15 where it returns to the surface. While only one flow port 50 is shown, additional ports are located around the circumference of flow sub 31 . Energy conductor 51 is disposed within the body of flow sub 31 and enables power and information to be communicated between wireline logging tools 32 A and 32 B and pulser 53 , described below. Alternatively, multiple conductors may be routed in similar fashion.
[0020] Fluid 38 provides flow energy to power turbine/alternator 52 (shown in cutaway inside telemetry module 35 , and in FIG. 2 ) to generate sufficient electrical power to operate the downhole logging tools and other downhole devices described herein. Such turbine/alternators are known in the art and are not discussed, in detail, here.
[0021] Telemetry module 35 also contains oscillating shear valve pulser 53 , see FIG. 2 , wherein rotor 60 oscillates proximate stator 61 to restrict a portion of flow of fluid 38 thereby generating pressure signals 41 that propagate to the surface through fluid 38 . Pressure signals 38 are detected by transducer 7 that is in fluid communication with the output flow line of pump 3 . Transducer 7 is commonly a pressure transducer of a kind known in the art. Alternatively, transducer 7 may be a flow transducer in line with the pump output detecting changes in flow related to pressure signals 41 . For additional details of the operation of oscillating shear valve pulser 53 , see U.S. Pat. No. 6,626,252, assigned to the assignee of this application and which is incorporated herein by reference. While described herein as used with a shear valve pulser, any suitable downhole mud pulser is intended to be within the scope of the present invention. Such pulsers include, but are not limited to: positive pulsers, negative pulsers, and continuous, also called siren, pulsers. In addition, surface located downlink pulser 4 transmits pulses 42 from the surface controller 8 to the downhole system. Pulses 42 contain instructions and status information used for operating the downhole system.
[0022] Alternatively, other types of transmission schemes known in the art, that do not employ a wireline connection between the surface and the wireline tool, are intended to be within the scope of the present invention. These include, but are not limited to: acoustic transmission through the pipe wall and electromagnetic telemetry.
[0023] In one embodiment, wireline tool 32 A is a formation test tool such as those described in U.S. Pat. Nos. 5,303,775; 5,377,755; 5,549,159; 5,587,525; 6,420,869; 6,683,681; 6,798,518; and published application US 2004/0035199 A1, each of which is assigned to the assignee of this application, and each of which is incorporated herein by reference. Anchors 36 and sample probe 34 are extendable from the body of tool 32 A to force sample probe 34 into contact with wellbore wall 14 and hence into fluid communication with formation 20 . In one embodiment, as illustrated in FIG. 3 , the tool 32 A of FIG. 1 is shown to incorporate a bi-directional piston pump mechanism shown generally at 124 which is illustrated schematically. Within the tool 32 A is also provided at least one and preferably a plurality of sample tanks such as exemplary tanks 126 and 128 , which may be of identical construction if desired. The piston pump mechanism 124 defines a pair of opposed pumping chambers 162 and 164 which are disposed in fluid communication with the respective sample tanks via supply conduits 134 and 136 . Discharge from the respective pump chambers to the supply conduit of a selected sample tank 126 or 128 is controlled by electrically energized three-way valves 127 and 129 or by any other suitable control valve arrangement enabling selective filling of the sample tanks. The respective pumping chambers are also shown to have the capability of fluid communication with the subsurface formation of interest via pump chamber supply passages 138 and 140 which are defined by the sample probe 34 of FIG. 1 and which are controlled by appropriate valving. The supply passages 138 and 140 may be provided with check valves 139 and 141 to permit overpressure of the fluid being pumped from the chambers 162 and 164 if desired. While described with two sample tanks, additional sample tanks may be added as desired. Additional details of the operation and design of tool 32 A are contained in the incorporated references. Parameters of interest of the sampled fluid and the formation may be determined with sensors such as, for example, optical sensors, density sensors, pressure sensors, and temperature sensors incorporated in tool 32 A. The parameters include, but are not limited to, formation pressure, sample fluid refractive index, sample fluid bubble-point, sample fluid density, sample fluid resistivity, and sample fluid composition.
[0024] In one embodiment, see block diagram in FIG. 4 , wireline tools 32 A-D are substantially unmodified for use in the present invention. As such, the power, commands, and data transmission to and from wireline tools 32 A-D are substantially the same as if the tools were connected by a conventional wireline to the surface. This capability allows use of a variety of off-the-shelf logging tools in the present invention. Downhole controller 405 contains suitable circuitry in interface module 406 to emulate the appropriate functions necessary to operate and control wireline tools 32 A-D. Controller 405 also comprises a processor 407 and memory 408 . At least a portion of memory 408 contains programmed instructions for use by interface module 406 in the control of the operation of wireline tools 32 A-D. Additional circuitry (not separately shown) is adapted to receive power form turbine-alternator 52 and appropriately distribute the power to the downhole components. Additional circuitry and instructions stored in downhole controller 405 are used to process the measurement data received form wireline tools 32 A-D and to format this information for transmission by the mud pulse system to the surface. In addition, because the volume of data collected by the wireline tools 32 A-D is commonly orders of magnitude greater than the capacity of the telemetry channel 401 , when using mud pulse, the measurement data or suitable subsets thereof may be stored in memory 408 for later retrieval when the tools are returned to the surface. Programmed instructions resident in controller 405 are used to determine the appropriate transmission and storage protocols.
[0025] In one embodiment, surface system 400 contains surface controller 8 that sends commands via downlink pulser 4 to command initiation of various downhole functions, such as, for example performing a formation test. The commands, encoded as pulses 42 are received by a suitable sensor in telemetry module 35 , such as for example, a pressure sensor (not separately shown). Once the commands are received and interpreted, downhole controller 405 assumes substantially autonomous control of the formation test. This may include data acquisition and interpretation to determine that a suitable result is obtained. Instructions and decision rules programmed into controller 405 are used to control this operation. Other downlink commands may, for example, cause changes in the encoding and pulsing format to enhance detection at the surface.
[0026] While described herein as a system used in a highly deviated wellbore, it is intended that the invention described herein is also to be used for deploying heavy wireline tools, or heavy strings of tools, that may be too heavy to be safely conveyed into and out of wellbores that are not highly deviated, including vertical wellbores.
[0027] The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible. It is intended that the following claims be interpreted to embrace all such modifications and changes.
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An apparatus and method for evaluating a formation is presented. The apparatus comprises a tubular string deployed into a wellbore penetrating the formation, where the tubular string has a longitudinal flow passage therethrough. A flow sub in the tubular string provides fluid communication between the longitudinal flow passage in the tubular string and an annulus between the tubular string and a wall of the wellbore. A wireline tool is attached proximate a bottom end of the flow sub. A telemetry module proximate the flow sub provides communication between the wireline tool and a surface system, without the use of a wireline to the surface.
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FIELD OF THE INVENTION
The present invention relates to a pickup truck cab extending tonneau cover, and more particularly to a pickup truck cab extending tonneau cover including a relatively rigid deck which can be conveniently lifted and removed to expose the cargo area of the pickup truck.
BACKGROUND OF THE INVENTION
Owners of pickup truck style motor vehicles often desire to provide a cover over the bed or cargo area of their pickup truck in order to conceal the cargo from view or protect it from weather. Accordingly, many different designs of tonneau covers and toppers are presently available. Many of the prior tonneau covers and toppers provide desired aesthetics when attached to a pickup truck. A drawback, however, is that they often do not look like a natural extension of the vehicle. Furthermore, they can be difficult to remove when it is necessary to load a large item in the cargo area. Another popular accessory for pickup trucks is a cab extension, sometimes called a cab fairing. This accessory generally provides the pickup truck with the appearance that the cab extends farther rearwardly than it actually does.
Devices have been designed which incorporate some of the features of tonneau covers and cab extensions. For example, see U.S. Pat. Nos. 3,954,296 to Patnode; 4,061,394 to Vodin; Des. U.S. Pat. No. 281,487 to Chapman; Des. U.S. Pat. No. 324,195 to Ueno; and Des. U.S. Pat. No. 323,479 to Akashi et al.
SUMMARY OF THE INVENTION
A cab extending tonneau cover for attachment to a pickup truck is provided by the present invention. The cab extending tonneau cover includes a cab extension and first and second arms. The cab extension being constructed and arranged to extend rearwardly of a pickup truck cab. The first and second arms being constructed and arranged to attach to the left and rights pickup sidewalls. A deck is provided between the first and second arms of the frame and can be rotated to provide access to a pickup truck cargo area. Advantageously, the deck can easily be removed from the frame. By easily removed, it is meant that one person can lift the deck away from the frame.
A pickup truck is provided by the present invention which includes a cab, a cargo area, and a cab extending tonneau cover attached thereo.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the pickup truck cab extending tonneau cover according to the principles of the present invention shown mounted on a pickup truck;
FIG. 2 is an exploded view of the cab extending tonneau cover of FIG. 1 showing how the various regions thereof interrelate;
FIG. 3 is a perspective view of the cab extending tonneau cover of FIG. 1 where the deck is in the open position;
FIG. 4 is a perspective view showing the attachment of the cab extending tonneau cover of FIG. 1 to a pickup truck;
FIG. 5 is a view of the drainage system of the cab extending tonneau cover of FIG. 1;
FIG. 6 is a view of the hinge connection between the deck and the frame of the cab extending tonneau cover of FIG. 1;
FIG. 7 is an elevation side view of the cab extending tonneau cover of FIG. 1;
FIG. 8 is an elevation rear view of the cab extending tonneau cover of FIG. 1; and
FIG. 9 is a forward view of an alternative embodiment of the cab extending tonneau cover according to the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiments of the invention are now described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to the preferred embodiments does not limit the scope of the invention which is limited only by the scope of the claims attached hereto.
Referring to FIGS. 1-3, a pickup truck cab extending tonneau cover in accordance with the present invention is depicted at 10 and is mounted to a pickup truck 12. It should be understood that the pickup truck cab extending tonneau cover 10 may be referred to herein as the cab extending tonneau cover or more simply as the cover. The cab extending tonneau cover 10 is shown mounted over the bed or cargo area 14 of the pickup truck 12. As shown, the cab extending tonneau cover 10 is attached to the pickup truck left sidewall 18 and right sidewall 20, and extends over the tailgate 16. Thus, the cab extending tonneau cover 10 is shown, in FIG. 1, completely concealing the pickup truck bed or cargo area 14.
For purposes of the description herein, the terms "left," "right," "rear," and "forward" refer to the orientation provided in FIG. 1. Alternatively stated, the orientation is provided to reflect that perceived by a driver of the pickup truck seated in the driver's seat. Thus, the left sidewall 18 and the right sidewall 20 are provided on the left rear and right rear sides, respectively, of the pickup truck 12. Furthermore, the pickup truck 12 includes a cab 24 having a rear edge 22 against which the forward edge 26 of the cab extending tonneau cover abuts.
The cab extending tonneau cover 10 includes three general parts or regions which interact with each other. These general parts or regions include a shell or body region 28; a hatch or cargo area access region 30; and a liner or interior region 32. The three regions fit together to form the cab extending tonneau cover 10 of the present invention. The shell or body region 28 provides the overall framework or structure of the cab extending tonneau cover 10 and includes a frame 29 which in turn includes a cab extension 34 and left mounting rail 36 and right mounting rail 38. It is these rails which attach to the pickup truck 12. The liner or interior region 32 fits within the cab extension 34 to provide a finished interior surface 40 and a shelf 42. The hatch or cargo area access region 30 includes a deck 44 and hinges 46 about which the deck can rotate upwards in order to expose the pickup truck bed or cargo area 14. As shown in FIG. 2, gas cylinders 48 can be provided to help lift and hold the deck 44 in an open position. FIG. 2 shows the deck 44 in an open position, thereby exposing the pickup truck bed or cargo area 14. FIG. 1 shows the deck 44 in a closed position with the tailgate flange 50 extending over the top surface of the tailgate 16.
It should be readily apparent to one skilled in the art that an advantage of the present invention is the ability to lock or secure the pickup truck bed or cargo area 14 by the present invention. The lock 52 can be used to lock the deck 44 to the shell or body region 28. Furthermore, the tailgate flange 50 extends over the tailgate to a degree sufficient to prevent opening the tailgate when the cab extending tonneau cover 10 is closed. Because certain models of pickup trucks do not include a lock on the tailgate, the present invention provides an alternative way of locking the tailgate. If desired, the tailgate flange 50 can be reduced or removed to allow access to the pickup truck bed or cargo area 14 via the tailgate 16 while the cab extending tonneau cover 10 is in the closed position. This may be a desired feature when, for example, the tailgate is provided with a separate locking device.
Now referring to FIGS. 4 and 5, a more detailed description of the shell or body region 28 is provided. As discussed above, the shell or body region 28 includes a frame 29 which generally provides the structural integrity for the entire cab extending tonneau cover. Once the frame is attached to the pickup truck, it is generally desired to leave it in place. As will be discussed in more detail, the deck 44 can be conveniently removed from the cab extending tonneau cover 10 in order to open up the pickup truck bed or cargo area 14. Accordingly, the frame 29 can be considered a rather permanent accessory. In an alternative embodiment, the frame can be provided with a releasable connection to the pickup truck by, such as, a clamping system.
FIG. 4 shows how the left mounting rail 36 of the frame 29 attaches to the left sidewall 18 of the pickup truck 12. It should be appreciated that the attachment of the right mounting rail 38 to the right sidewall 20 is provided in a similar fashion to that described for the left mounting rail 36. The left mounting rail 36 rests on the top surface 52 of the left sidewall. The depending flange 54 extends downward as part of the left mounting rail 36 and provides an area for connection to the inside surface of the left sidewall 18. Bolts/nuts 56 pass through the depending flange 54, a spacing 58, and the interior depending wall 60 of the left sidewall 18. It is expected that about two to three bolts/nuts 56 per side should be sufficient to hold the cab extending tonneau cover 10 in place on the pickup truck 12. The spacer 58 is provided because the pickup truck bed or cargo area 14 is tapered. It should be appreciated that various models of pickup trucks provide varying degrees of taper. Accordingly, the thickness of the spacer 58 can be adjusted to accommodate various models of pickup truck. The rear end of the left mounting rail 36 is cut away so that the tailgate 16 of the pickup truck can close. The slot 66 is provided for locking the deck 44 to the frame 29. Thus, by turning the lock 52, an arm engages the slot 66 in order to lock the deck 44 and frame 29 together.
The frame 29 includes a rain gutter 62 which extends the interior length of the deck 44 and collects water runoff. As shown in FIG. 5, a tube 63 can be provided at a drain basin 65 in from the rain gutter 62, preferably near the forward end of the rain gutter, in order to provide a drain to the exterior of the pickup truck. In many pickup truck models, a hole is provided in the pickup truck cargo area through which rain water normally drains. The tube 63 can be adapted to run through that hole in order to convey water outside of the truck.
An important feature of the invention is the trim flange 64 which extends downward and is provided along the lower exterior edge of the cab extending tonneau cover 10. The trim flange 64 is important because it hides the seam between the cab extending tonneau cover 10 and the pickup truck 12. In most prior art toppers, the seam between the topper and the pickup truck is exposed, thereby detracting from its appearance. By providing the trim flange 64, a cleaner and more custom look can be provided. Furthermore, the trim flange 64 can be adjusted and/or modified to reflect or follow the trim characteristics of various pickup truck models.
The forward portion of the frame includes the cab extension 34. When provided on a pickup truck 12, the cab extension 34 extends away from the rear edge 22 of the pickup truck cab 24. The cab extension 34 includes a rear window 68 and brake light 70. The window 68 is recessed into the cab extension 34 in order to provide a finished appearance and a more secure placement of the window. As shown in FIG. 7, the forward edge 26 of the cab extension 34 includes a gasket adhered thereto. Preferably, the gasket 71 is a closed cell foam which is compressed between the rearward edge 22 of the cab 24 and the forward edge 26 of the cab extension 34. It is the gasket 71 which provides a seal between the cab 24 and the cab extension 34 in order to keep out weather and prevent knocking and rattling. The gasket 71 additionally allows the cab and the cover 10 to move relative to each other. Thus, the gasket 71 is preferably provided along the entire circumference of the cab extension region 34 within the seam between the cab 24 and the cab extending touneau cover 10. By providing a sufficient seal, it should be appreciated that the pickup truck rear window can be removed thereby actually extending the cab into the cab extending tonneau cover. Furthermore, the window 68 can be made from any conventionally used motor vehicle window material, including, clear or smoked glass, plastic, etc., and can include heating elements in order to enhance visibility therethrough.
An alternative embodiment of the invention is shown in FIG. 9 where the window 200 is hinged and includes an extension arm 202 which allows the window 200 to open. Alternative ways of opening the window can be provided.
The frame 29 is preferably manufactured from Fiberglas. In order to provide a finished surface within the cab extension 34, the liner or interior region 32 is provided. This region fits within the cab extension 34 and provides a finished interior surface 40 and a shelf 42. It should be understood that the shelf 42 can be omitted if it is desired to provide access from the cab to the pickup truck bed or cargo area 14. Furthermore, the liner or interior region 32 can be provided with a lower shelf if it is desired to provide a larger storage area which is separate from the pickup truck bed or cargo area 14 and which can be accessed from the pickup truck cab. The additional storage area can be used, for example, for storage of various accessories, placement of speakers, etc.
The hatch or cargo area access region 30 includes a deck 44 and hinges 46 which allow the deck to rotate upwards in order to expose the pickup truck bed or cargo area 14. As shown in FIG. 2, a structural reinforcement panel 80 can be provided and embedded within the deck 44 in order to provide desired rigidity. In a preferred embodiment, the reinforcement panel can be constructed of plywood. It should be understood that the deck 44 is fairly rigid which means that it does not fold and would be considered a hard surface. A preferable material for manufacturing the deck 44 is fiberglass because it is light. It should be appreciated, however, that the three regions of the invention can be manufactured from materials other than fiberglass, such as, plastics. However, fiberglass is a desired material because of its light weight and ease of handleability.
The deck 44 is provided with a rear spoiler 82 which provides a gripping surface 84 that allows one to push against it in order to open the bed or cargo area 14. In addition, the spoiler 82 enhances the overall appearance of the cab extending tonneau cover.
As shown in FIG. 6, the deck 44 is attached to the frame 29 at hinges 46. The hinge 46 is preferably a releasable type hinge which allows the deck to rotate to a certain position, then allows the deck to be removed completely from the frame. Once the deck 44 is rotated upward to a predetermined rotational degree, the tongue 85 can slide free of the hinge bar 87, and the deck 44 can be removed. Thus, the cab extending tonneau cover of the invention provides for convenient removal of the deck.
Again referring to FIG. 4, the gas cylinders 48 are provided to assist in opening the pickup truck bed or cargo area 14. An exemplary air cylinder which can be used according to the present invention is available from "Spring Lift Corporation of Monticello, Ariz." The air cylinder 48 includes an arm 90 which attaches to the depending flange 54 via bracket 92 and rotational socket 94. When removing the deck 44 from the frame 29, the air cylinder 48 can be removed by popping the socket 94 off. According to the invention, the deck 44 is "easily removable" which means that it can be quickly and easily removed by one person. The deck preferably weighs between about 30 and 80 pounds, and more preferably between about 50 and 75 pounds.
The above specification provides a complete description of the manufacture and use of the present invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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A cab extending tonneau cover for attachment to a pickup truck cargo area sidewalls and extending rearwardly of a pickup truck cab, the cover comprising a frame including a cab extension and first and second arms, the cab extension being constructed and arranged to extend a pickup truck cab rearwardly, the first and second arms being constructed and arranged to attach to left and right pickup truck sidewalls, a deck provided between the first and second arms of said frame, said deck including a hinge system for rotating said deck between open and closed portions, wherein said deck is readily removable from said frame.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to devices for cellular telephone transmission equipment and more particularly to a self-contained cellular antenna site adapted to be small in footprint, quickly assembled without the use of heavy equipment, and easily disassembled for transporting.
[0002] The continued proliferation and widespread use of wireless telecommunications equipment has brought with it the need for more self-contained cellular antenna sites. Typical methods of deploying cellular antennas are on permanent structures such as towers or monopoles, or on rooftops. When based on the ground, the permanent structures are normally supported on conventional foundations such as reinforced concrete slabs or pads, and often the concentrated weight of a tall antenna tower has required a relatively substantial and separate foundation member such as a deep reinforced concrete pier. Therefore, these structures often require special zoning and permitting, soil core sampling, engineering, excavation, and the use of heavy equipment and cranes to perform installation, all of which may be costly and time consuming. In addition, the time required to pour and cure a concrete foundation may delay the erection of an antenna and ultimately the operation of the cellular site. Further, such a permanent tower or monopole is not readily removed and redeployed at another site, and even if the tower or monopole itself is removed, the permanent foundation remains.
[0003] U.S. Pat. No. 6,131,349 [Hill] illustrates an attempt in the prior art to eliminate the need for construction of a separate foundation to support a cellular antenna tower. However, the apparatus disclosed utilizes the supporting foundation of the adjacent telecommunications equipment enclosure to provide load bearing support for the cellular antenna tower and therefore this design is not self-contained, is integrally connected to a permanent foundation, and cannot be quickly assembled or easily removed and relocated.
[0004] Developments in the newer generations of wireless systems have allowed both the antenna systems and the signal processing electronics packages to become smaller. A smaller antenna atop a pole of approximately 6 to 12 inches in diameter and a total height of 30 feet to 60 feet can now provide reasonable cellular coverage, enabling the design of cellular sites with decreased visual impact and decreased wind loading requirements. The present invention is designed to take advantage of these developments to provide a cellular antenna site which is much more flexible in its deployment than sites presently available.
[0005] Therefore, it is an object of the present invention to provide a cellular antenna site that is modular and inexpensive, and can be easily and quickly assembled, disassembled, and moved by hand without the use of heavy equipment. It is another object of the present invention to provide a cellular antenna site that is sufficiently anchored to support a small diameter 60 foot tall antenna pole under the sufficient loading to meet a 100 mile per hour wind speed rating. It is a further object of the present invention to provide a cellular antenna site that requires only a small footprint and can be situated on any relatively level and flat piece of ground.
[0006] It is yet another object of the present invention to provide a cellular antenna site that creates minimal environmental and visual impact in order to potentially ease zoning and permitting requirements and in order to allow for deployment in environmentally sensitive areas. It is still a further object of the present invention to provide a cellular antenna site that can accommodate an electrical cabinet and other required equipment, enclosures, or shelters, within a fenced and secure area.
[0007] Other objects will appear hereinafter.
SUMMARY OF THE INVENTION
[0008] The present invention overcomes the disadvantages inherent in the types of cellular antenna sites known in the prior art. The cellular antenna site of the present invention is of a modular construction that can be assembled from components and pre-fabricated sub-structures that are small and light enough to be manipulated by a team of two people. The cellular antenna site does not penetrate the ground on which it rests and can be situated on any relatively level and flat piece of ground, including a parking lot, a gravel lot, or a patch of grass or undeveloped land.
[0009] The base of the cellular antenna site of the present invention does not require any excavation or permanent foundation, but is instead anchored to the ground by a ballast comprising either concrete blocks, crushed gravel, poured concrete, or an equivalent material. Except in the case of poured concrete ballast, the entire cellular antenna site can be completely disassembled into its original component parts and removed from the location without leaving a trace of its having been installed. In the case of poured concrete ballast, the cellular antenna site may still be removed but it may require the removal of the entire base as one piece instead of disassembling the base into its component modules.
[0010] The cellular antenna site of the present invention, when assembled with three base modules each measuring 10 feet long by 3 feet 4 inches wide by 1 foot high and outfitted with a 6 to 12 inch diameter antenna pole ranging in overall height between 30 and 60 feet, has a nominal weight of approximately 2000 to 3000 pounds and a nominal footpring of 10 feet by 10 feet. When loaded with a ballast of concrete blocks, the site increases to a weight of about 10,000 pounds and is capable of achieving a 75 mile per hour wind speed rating. When loaded with a ballast of poured concrete, the site increases to a weight of about 15,000 pounds and is capable of achieving a 100 mile per hour wind speed rating.
[0011] In view of the preceding example, it is noted that due to the modular construction of the base, the site can be assembled into a wide variety of configurations and footprint dimensions, depending on the requirements of the specific deployed location. Expansion of the cellular antenna site base can be achieved by bolting additional base modules to any of the four sides of the base. It is also noted that the design concept of the cellular antenna site of the present invention can be applied using base modules of any nominal dimensions. It is further noted that the base modules need not be of rectangular shape and could in fact be of any geometric shape with straight edges to allow for interconnecting and mating with other base modules, including cooperating triangular and hexagonal shapes.
[0012] The base of the cellular antenna site of the present invention provides integral means for securing an electrical cabinet which houses the required telecommunications electronics, as well as means for mounting any other auxiliary enclosures, cabinets, or shelters. The base also includes integral means for mounting the hinged antenna base, so that the antenna may be first attached in a horizontal position and then erected by simply hoisting it into a vertical position about a hinge, avoiding any need for a crane. Once erected, the hinged antenna base can be secured to maintain the antenna in the vertical position. A simple weatherproof wiring harness electrically connects the antenna to the electrical cabinet. Additionally, the base of the cellular antenna site provides means for connection of a grounding stake to ensure that the entire apparatus of the present invention is properly grounded.
[0013] The base of the cellular antenna site further provides integral means for the mounting of fence posts to support a fence, e.g., wire mesh or wooden post, encircling the base and surrounding the antenna, electrical cabinet, and any auxiliary equipment, in addition to a hinged gate allowing easy access to the site while providing a measure of security, personnel safety, and protection of the wireless telecommunications equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0015] [0015]FIG. 1 is a perspective view of the temporary cellular antenna site of the present invention.
[0016] [0016]FIG. 2 is a top view of the temporary cellular antenna site of the present invention shown with concrete block used as the anchoring ballast.
[0017] [0017]FIG. 2A is a top view of the temporary cellular antenna site of the present invention shown with poured concrete used as the anchoring ballast.
[0018] [0018]FIG. 2B is a top view of the temporary cellular antenna site of the present invention shown with gravel used as the anchoring ballast.
[0019] [0019]FIG. 3 is a side view of the temporary cellular antenna site of the present invention.
[0020] [0020]FIG. 4 is a front view of the temporary cellular antenna site of the present invention.
[0021] [0021]FIG. 5 is a perspective view of a partially assembled base of the temporary cellular site comprising a number of base modules attached to one another by fastening means in a predetermined configuration.
[0022] [0022]FIG. 6 is a perspective view of a base assembly of a second embodiment of the temporary cellular site comprising a number of base modules having a trapezoidal configuration arrayed around a smaller number of base modules having a diamond configuration attached to one another by fastening means in the arrangement shown.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The follis of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings.
[0024] Referring now to the drawings in detail, where like numerals refer to like parts or elements, there is shown in FIG. 1 a perspective view of the temporary cellular antenna site apparatus 10 . The apparatus 10 is of modular construction comprising a base 16 , an antenna system 18 , an electrical cabinet 12 , fencing 38 , and a grounding means (not shown). An additional component required for the functioning of the apparatus 10 is anchoring ballast, which may be in the form of concrete blocks 40 , poured concrete 40 a, crushed gravel 40 b, or another equivalent material, as shown in FIGS. 2, 2A, and 2 B, respectively.
[0025] The apparatus 10 is fabricated as a set of components, some of which are pre- assembled into sub-structures to facilitate onsite deployment. The apparatus 10 is easily transported to a required location and can be fully assembled and commissioned by two workers in a single day. Each base module 20 is approximately 10 feet long by 3 feet 4 inches wide by 1 foot high. The dimensions of a base module 20 are constrained to keep within a manageable weight and size, noting that many other sizes, shapes, and aspect ratios could be fabricated within the same weight range. The antenna pole 14 is available in lengths from 30 feet to 60 feet. Although a single length is preferred, the antenna pole 14 may be comprised of one or more segments. The antenna pole, or elongated support means 14 , may be manufactured of metal, fiberglass, or composite materials and may be configured as either a monopole or as a lattice work tower, however for descriptive purposes, a monopole type antenna support 14 will serve as a model encompassing all of the other configurations.
[0026] Prior to assembly of the apparatus 10 , a location should be selected that is relatively flat and level. Acceptable site locations include a parking lot, a gravel lot, a flat rooftop capable of supporting the required weight, and a relatively flat and level patch of grass or undeveloped ground. A temporary and non-damaging installation may be achieved by using an anchoring ballast of concrete blocks 40 or gravel 40 b. A slightly more permanent installation may be achieved by using an anchoring ballast of poured concrete 40 a. When using the concrete block ballast 40 or the gravel ballast 40 b, a 60 foot antenna pole 14 is capable of achieving a 75 mile per hour wind speed rating. When using the poured concrete ballast 40 b, the wind speed rating for a 60 foot antenna pole 14 is increased to 100 miles per hour.
[0027] The detailed construction of the base 16 is best described in reference to FIG. 1 and the top view shown in FIG. 2. The base 16 is assembled from a combination of similar base modules 20 . Each rectangular base module 20 comes pre-assembled and is formed by joining the ends of two side rails 22 with the ends of two end rails 24 . The rails are joined by bolting, welding, or other equivalent joining means. Each side rail 22 and each end rail 24 is a galvanized steel C-channel member, although a similar lightweight and strong form such as a rectangular tube or I-beam may be used. When assembled to form the frame of a base module 20 , a side rail 22 thereof is capable of being butted up against and bolted to the side rail 22 or the end rail 24 of another base module 20 ; likewise an end rail 24 thereof is capable of being butted up against and bolted to the end rail 24 or the side rail 22 of another base module 20 . In this manner, base modules 20 may be interconnected to create a base 16 of various sizes, shapes, and aspect ratios. See FIG. 5.
[0028] Further comprising each base module 20 is an expanded metal grating or screen 26 which is rigidly attached along all four of its edges to the underside of the side rails 22 and the end rails 24 thereof to form a lightweight mesh bottom of the base module 20 . The mesh bottom formed by the metal grating 26 is capable of supporting and retaining the ballast material 40 , 40 a, or 40 b.
[0029] Fence post sleeves 28 , integrally secured along the inner edges of the side rails 22 and the end rails 24 of the base 16 , provide a means for mounting the perimeter fencing 38 . Pre- drilled mounting holes 46 at various positions along the side rails 22 are adapted for bolting the base plate and hinged antenna base 44 and the electrical cabinet support members 42 . Optional mounting support members 42 may be connected across any base module 20 between the side rails 22 thereof, also utilizing the mounting holes 46 , to provide additional structural integrity and to provide means to mount auxiliary equipment cabinets, enclosures, or shelters as desired.
[0030] Thus, each base module 20 is a rectangular frame comprising the two side rails 22 , the two end rails 24 , the metal grating 26 across the bottom thereof, the fence post sleeves 28 facing vertically upward, and the mounting means 46 to attach the hinged antenna base 44 , the electrical cabinet support members 42 , and the optional support members 42 , as required. Once each base module 20 is positioned where desired on the ground, multiple base modules 20 are interconnected to form the base 16 . The base may be of various configurations. For example, in FIG. 1, four base modules 20 are connected side-to-side to form the base 16 . In another example, in FIG. 2, six base modules 20 are interconnected in a three by two configuration with two sets of three base modules 20 each connected side-to-side and then the two sets of three connected to each other end-to-end to form the base 16 . See also, FIG. 5. Other similar, and different geometric configurations may be conceived.
[0031] Before continuing with a further description of the base assembly 16 of the temporary cellular site, a second arrangement of interconnected base modules can be assembled. This arrangement of base modules 120 in a hexagonal base 116 is shown in FIG. 6. There are two types of base modules in this arrangement, a trapezoidal base module 120 a and a diamond base module 120 b. The trapezoidal base modules 120 a are arrayed around three central diamond base modules 120 b. The diamond base modules 120 b are shown having like triangular sections of equal length legs with a support member 142 extending along the common base of the triangular sections. The dimensional relationship of this base assembly 116 is similar to the rectangular base assembly 16 in that the overall dimension across the hexagonal shape is a similar twenty ( 20 ) feet taken along a line directly through the center of the hexagon from an interconnection point between two adjacent trapezoidal base modules 120 a to the same interconnection point between two adjacent trapezoidal base modules 120 a on the opposite side of the hexagon. In this way the dimensional footprint of the temporary cellular antenna site remains substantially the same regardless of the base assembly configuration.
[0032] Each triangular section of the diamond base modules 120 b has an external sidewall 122 for interconnecting to the outer ring of trapezoidal base modules 120 a and to the other diamond base modules 120 b. Likewise, each of the trapezoidal base modules 120 a has an external sidewall 122 for interconnecting to the other trapezoidal base modules 120 a and to the diamond base modules 120 b. The trapezoidal base modules 120 a also have an external sidewall 122 facing outward forming one base of the trapezoid shape. The other base of the trapezoid shape is dimensioned to be of equal length to one of the legs of a triangular section of the diamond base modules 120 b such that the external sidewalls 122 of the base modules 120 a, 120 b fit tightly together. The interconnecting sidewalls 122 are held together by fastening means as described in connection with the other base assembly 16 .
[0033] At the center of the interconnected diamond base modules 120 b are three segmented antenna base members 144 a, b, c, each such segment being mounted to one of the three diamond base modules 120 b. The three segments of the antenna base 144 a, b, and c cooperatively engage to form a hexagonal base member 144 to which the antenna pole 14 is bolted through the respective mounting holes. To support the antenna base 144 and to keep the base from tilting from the horizontal position, support arms 150 are arranged to extend adjacent to and beneath the edges of the antenna base member 144 . The support arms 150 extend between interconnecting sidewalls 122 of adjacent triangular sections of each diamond base module 120 b, supported at their respective approximate midpoints by the support members 142 extending across the diamond base modules 120 b. At the center of the antenna base member 144 is a triangular reinforcing member 145 to provide added stabilization to the base connection for support of the antenna tower 14 .
[0034] Extending across the distance between the bases of the trapezoidal base modules 120 a are support members 142 to provide substantial rigidity to the sidewalls 122 of the base modules. This strengthening of the base 116 provides the rigidity to withstand deformation or distortion of the base from wind forces against the elongated support member 14 and the antenna 15 . Along the downward facing edges of the sidewalls 122 of the base modules 120 a, 120 b metal grating 126 is attached to retain anchoring ballast to provide a sufficient weight factor to withstand the wind or shear forces exerted against the antenna tower.
[0035] Although this embodiment has a different configuration than that of FIGS. 1 - 5, the similar elements permit for the assembly of the base systems along with the peripheral elements described more fully below in connection with the first embodiment. It is to be understood that each of the elements described below can be fitted to be used with the hexagonal base assembly 116 in a similar fashion and being attached or mounted in a similar way as that described below.
[0036] The next step in assembly of the temporary cellular antenna site apparatus 10 is to anchor the base 16 at its desired location. A temporary and easily removable anchoring ballast of concrete blocks 40 or crushed gravel 40 b may be used. A more permanent but still removable ballast of poured concrete 40 a may be used, since the metal grating 26 creates a floor for the poured concrete form that prevents the concrete from binding to the surface below.
[0037] Once the base 16 is constructed and anchored with the ballast material 40 , 40 a, or 40 b, the electrical cabinet 12 is mounted. The electrical cabinet support members 42 are connected across a base module 20 and secured between the side rails 22 thereof using mounting means 46 , at the position on the base 16 where the electrical cabinet 12 will be located. The members 42 provide structural support for mounting the electrical cabinet 12 within the perimeter fencing 38 surrounding the base 16 . The cabinet 12 may also be free standing outside of the perimeter fencing 38 , if the size of the electrical cabinet 12 and the physical constraints of the mounting location on the base 16 are exceeded. The electrical cabinet 12 is secured to the cabinet support members 42 . A grounding stake (not shown), electrically connected to the electrical cabinet 12 , is used to provide an earth ground for the electrical cabinet 12 as well as for the entire apparatus 10 . External wiring 52 connects the electrical cabinet components to the antenna 15 as described below.
[0038] Prior to installing the perimeter fencing 38 , the antenna system 18 is installed. First, the hinged antenna base 44 is positioned in a desired location on the base 16 and the bottom portion of the hinged antenna base 44 is secured to the side rails 22 of the base module 20 at that location using mounting holes 46 . The tapered aluminum antenna pole 14 is attached in a horizontal position to the top pivoting portion of the hinged antenna base 44 . The antenna pole 14 is then erected to its standing position by being hoisted in a hinged fashion about the hinge of the antenna base 44 . Once erected, the antenna pole 14 is secured in a vertical position by bolting, clamping, or equivalent removable securing means. Signal connections are accomplished between the antenna 15 , along the antenna pole 14 and into the electrical cabinet 12 by means of a weatherproof electrical wiring harness 52 .
[0039] Perimeter fencing 38 may be erected by inserting the fence posts 30 into the fence post sleeves 28 and securing the desired fencing material 32 to the fence posts 30 around the perimeter of the base 16 . The fencing may be of wire mesh, wooden post, or any similar fencing material providing securable access to the antenna system on the temporary cellular antenna system 18 , etc. A hinged access gate 36 is provided to fit between one pair of fence posts 30 to provide for personnel access to the antenna system 18 , to the electrical cabinet 12 if it is inside the perimeter fencing 38 , and to the interior of the fenced space of the apparatus 10 .
[0040] After assembling the base 16 from the base modules 20 , anchoring the base 16 with the ballast material 40 , 40 a, or 40 b, mounting the electrical cabinet 12 , erecting the antenna system 18 , connecting the wiring harness 52 between the antenna 15 and the electrical cabinet 12 , and erecting the fencing 38 around the perimeter of the base 16 , the temporary cellular antenna site apparatus 10 is ready for use. The only external connections required are the power and communication links. The apparatus 10 can be operated for as long as is required. If and when it is desired to remove the apparatus 10 for use in another location or in favor of a more permanent cellular antenna site, the apparatus 10 may be disassembled into its component parts and removed.
[0041] Disassembly of the apparatus 10 is the reverse of assembly. The perimeter fencing 38 is removed by detaching the fence 32 and the hinged access gate 36 from the fence posts 30 and by removing the fence posts 30 from the fence post sleeves 28 . The wiring harness 52 is detached from the antenna 15 and the electrical cabinet 12 . The antenna pole 14 is lowered by pivoting about the hinge of the hinged antenna base 44 and is disconnected from the antenna base 44 and disassembled from the hinged base 44 . The antenna base 44 is then removed from the side rails 22 of the base module 20 to which it was mounted. The electrical cabinet 12 is removed from its support members 42 , and the support members 42 are disconnected from the side rails 22 of the base module 20 to which they were mounted. The grounding stake (not shown) disconnected from the electrical cabinet 12 and is pulled from the ground.
[0042] If a temporary ballast such as concrete blocks 40 or gravel 40 b was used, this ballast is removed and the base modules 20 are disconnected from each other. If a more permanent ballast such as poured concrete 40 a was used, removal of the ballast and disconnection of the base modules 20 from each other may not be possible and the base 16 may need to be removed as one piece. The components of the apparatus 10 may be relocated and reassembled as described previously.
[0043] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein.
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A small-footprint portable modular cellular antenna site capable of being deployed on any substantially level, flat piece of ground, the cellular antenna site being easily assembled, disassembled, and moved without the aid of heavy equipment. The cellular antenna site does not require a permanent foundation, but instead is anchored by weighting with a non-damaging ballast material sufficient to support a small diameter 30 to 60 foot high antenna pole at wind speed ratings up to 100 miles per hour. The cellular antenna site includes a modular base configurable in different geometric arrangements that retains the ballast material and supports a segmented monopole antenna, an electrical cabinet, perimeter fencing with an access gate, and any auxiliary cabinets, enclosure, or shelters as may be required.
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BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates generally to automotive vehicle convertible roofs and more particularly to a convertible roof actuation mechanism.
Traditional soft-top convertible roofs for automotive vehicles typically employ four or five roof bows spanning transversely across the vehicle for supporting a vinyl, canvas or polyester fiber pliable roof cover. The number one roof bow is mounted to a pair of front roof rails and is typically latched to a stationary front header panel of the automotive vehicle body disposed above a windshield. A number two roof bow is typically mounted to a pair of center roof rails which are pivotably coupled to the front roof rails. Furthermore, the number three, four and optional five roof bows are commonly mounted to a pair of rear roof rails which are pivotably coupled to the center roof rails. For example, reference should be made to U.S. Pat. Nos. 5,225,747 entitled "Single-Button Actuated Self-Correcting Automatic Convertible Top" which issued to Helms et al. on Jul. 6, 1993; 5,161,852 entitled "Convertible Top with Improved Geometry" which issued to Alexander et al. on Nov. 10, 1992; 4,948,194 entitled "Flexible Roof for a Convertible Motor Vehicle, Provided with a Safety Hook for the Rear Arch of the Roof Frame" which issued to Dogliani on Aug. 14, 1990; 4,720,133 entitled "Convertible Top Structure" which issued to Alexander et al. on Jan. 19, 1988; 4,537,440 entitled "Vehicle with a Convertible Top" which issued to Brockway et al. on Aug. 27, 1985; and 2,580,486 entitled "Collapsible Top for Vehicles" which issued to Vigmostad on Jan. 1, 1952.
Traditional soft-top convertible roofs possess an inherent drift problem. In other words, when the convertible roof is moved to its fully raised position, the forwardmost or number one roof bow is positioned against the front header panel for subsequent latching. However, the stretched fabric cover acts to pull the number one roof bow in an unintended and undesired rearward direction such that it drifts away from the front header. This drifting situation is especially apparent in new convertible roofs. Accordingly, the vehicle occupant must then physically pull down upon a handle attached to the number one roof bow thereby pulling it against the front header panel for subsequent latching. This manual action presents a crude and unrefined operational perception. This drifting problem is also present between a rearmost or number five roof bow and an adjacent tonneau cover. The number five roof bow is often raised to an upward position while the tonneau cover is returned from a substantially vertical position to a substantially horizontal position; the number five roof bow is then pivoted to its lowered position against an upper surface of the tonneau cover for latching thereto. However, the stretched fabric covering tends to pull the number five roof bow in a forward manner thereby causing it to drift away from the tonneau cover. This situation is inconvenient to remedy due to the difficulty of an occupant accessing this rear area when seated in the front seat.
In accordance with the present invention, the preferred embodiment of a convertible roof actuation mechanism includes a pliable roof cover, a top stack mechanism supporting the roof cover, and at least one roof bow of the top stack mechanism independently movable relative to the remainder of the top stack mechanism for selectively reducing and increasing tension of the roof cover during latching. In another aspect of the present invention, at least one roof bow is retracted closer to a bottom pivot of a rear roof rail when stowed to optimize packaging space within a convertible roof storage compartment. In a further aspect of the present invention, a rigid backlite is attached to a pliable roof cover. Still another aspect of the present invention provides a rear edge of the roof cover being stationarily affixed to a body of the automotive vehicle throughout all of the positions of the convertible roof.
The convertible roof actuation mechanism of the present invention is advantageous over conventional devices in that the present invention reduces drifting of the raised convertible roof away from the front header panel and, alternately, a tonneau cover by selectively reducing and then increasing tension or tautness of the roof cover. Furthermore, packaging space of the stowed convertible roof is optimized in the storage compartment by retracting movement of a number four roof bow forward in the vehicle from where it would otherwise be if it were pivoted about a fixed pivot point mounted directly on the rear roof rail or on the main pivot bracket, as is done in traditional vehicles; this allows for placement of a very large and rigid backlite in a relatively small storage compartment, thereby avoiding the creasing and discoloration disadvantages commonly associated with folded flexible backlites made of plastic. The present invention is also advantageously employed in combination with stationary affixation of the rear edge of the roof cover to the body where front header panel latching drift and tension problems are often exacerbated. Additional advantages and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view showing the preferred embodiment of a convertible roof actuation mechanism of the present invention;
FIG. 2A is a side elevational view, partially in section, showing a forward portion of the preferred embodiment of the convertible roof actuation mechanism, disposed in a fully extended and latched position;
FIG. 2B is a side elevational view, partially in section, showing the preferred embodiment of the convertible roof actuation mechanism, disposed in a fully extended and latched position;
FIG. 3 is an enlarged side elevational view, taken within circle 3--3 of FIG. 2B, showing the preferred embodiment of the convertible roof actuation mechanism;
FIG. 4, is a fragmentary front perspective view showing the preferred embodiment of the convertible roof actuation mechanism, disposed in a fully raised position;
FIG. 5 is a side elevational view showing the forward portion of the preferred embodiment of the convertible roof actuation mechanism, disposed in an unlatched and pivoted position;
FIG. 6 is a side elevational view showing a rear portion of the preferred embodiment of the convertible roof actuation mechanism, disposed in an intermediate position;
FIG. 7 is a side elevational view showing the preferred embodiment of the convertible roof actuation mechanism, disposed in a partially retracted position; and
FIG. 8 is a side elevational view showing the preferred embodiment of the convertible roof actuation mechanism, disposed in a fully retracted and stowed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As can be observed in FIGS. 1, 2A and 2B, a soft-top convertible roof for an automotive vehicle includes a top stack mechanism 21 and a pliable roof cover 23. Top stack mechanism 21 employs a number one roof bow 25, a number two roof bow 27, a number three roof bow 29 and a number four roof bow 31. Front roof rail 25 is preferably integrally cast from a magnesium alloy with a pair of front roof rails 33. A pair of center roof rails 35 are pivotably coupled to front roof rails 33 by over-center control linkage assemblies 37. A pair of rear roof rails 39 are coupled to center roof rails 35 by pivots 41. A bottom pivot 51 of each rear roof rail 39 is coupled for movement to a main pivot bracket 53 which is bolted or welded onto a stationary structure affixed to a body 55 of the automotive vehicle. A pair of balance links 57 each have a first end pivotably coupled to bracket 53 and a second end pivotably coupled to each center roof rail 35. Over-center control linkage assembly 37 is connected between front roof rail 33 and rear roof rail 39. Accordingly, the convertible roof can be automatically moved from a fully extended or raised position, as is shown in FIGS. 1-2B, to a fully retracted position, as is shown in FIG. 8, within a storage compartment or boot well 61. Boot well 61 is longitudinally located between a front occupant seat 63 and a trunk 65. Rear roof rail 39 is preferably die cast and subsequently machined from a magnesium alloy while balance link 57 and the roof bows are made from a carbon steel tubing with swaged ends. Main pivot bracket 53 is stamped from steel or is cast from aluminum or magnesium.
Roof cover 23 is in a stretched and tensioned condition when the convertible roof is in its fully raised condition, as is shown in FIGS. 1-2B. In the fully raised position, an electric motor actuator 71, centrally mounted to number one roof bow 25, is energized to pivotably drive a pair of outboard J-hooks 73 through sets of reduction gears 75. J-hooks 73 are rotated in a fore-and-aft manner along a generally vertical plane to engage latching receptacle structures mounted to a front header panel 79 disposed above a windshield. A set of microswitches 81 are employed to sense the latching position of J-hooks 73 thereby sending an electric signal to a microprocessor, analog or solid state based electronic control unit (not shown). Levers 83, having bifurcated ends, act in conjunction with fulcrums 85 for downwardly and upwardly pivoting front roof rails 33 relative to center roof rails 35 in an automatic manner operably driven by electric motor 71. This latching device is disclosed in further detail in U.S. patent application Ser. No. 08/912,821 entitled "Latching and Control Apparatus for an Automotive Vehicle Convertible Roof," which was invented by Sheryar Durrani and is filed concurrently herewith; this patent application is incorporated by reference herein. Since the convertible roof actuation mechanism of the present invention is essentially symmetrically identical on both sides of the vehicle, only one side will be further discussed hereinafter.
Referring now to FIGS. 2B, 3 and 4, a bell crank 101 has a first pivot 103 mounted on rear roof rail 39. A lower pivot 105 of number four bow 31 is also pivotably coupled to an opposite end of bell crank 101, while a center driving pivot 107 of bell crank 101 is coupled to a linearly moving piston rod 109 of a hydraulic fluid powered piston-type actuator 111 by a ball and socket arrangement. Piston 111 is fluidically coupled to a hydraulic pump 113 and is electrically connected to a rear roof rail-to-bracket position sensing microswitch 115, a front roof rail-to-center roof rail position sensing microswitch 116 (only on one side) (see FIG. 5), an occupant accessible top up/down switch and the electronic control unit. Piston 111 is allowed to pivot about a clevis at pivot point 117 in relation to the vehicle's body 55.
A roller pin 119 transversely projects from a flat face of bell crank 101. Bell crank 101 is preferably made from a sheet of steel, is injection molded from an engineering grade of polymeric material or may be die cast from a zinc alloy, aluminum or magnesium. An upstop 131 is affixed for movement with rear roof rail 39 and acts to limit the upward travel of bell crank 101 in relation to rear roof rail 39.
A locking structure is provided on rear roof rail 39. The locking structure includes an arcuate slot 133 being open to the rear of roof rail 39, and a torsion spring or leaf spring biased aluminum hook 135 rotatably coupled to rear roof rail 39. Hook 135 also has an upstop 137 which abuts against a ledge on the main pivot bracket for limiting the upward rotational movement of hook 135.
The retracting operation of the convertible roof actuation mechanism of the present invention will now be discussed. First, the convertible roof is moved from the position of FIGS. 2A and 2B to that shown in FIG. 5, while maintaining the fully raised position of rear roof rail 39. This is achieved by unlatching hook 73 from the front header panel and by automatically causing lever 83 to pivot front roof rail 33 and number one roof bow 25 relative to the currently stationary center roof rail 35. Second, FIGS. 2B and 6 illustrate the subsequent retraction movement of the convertible roof. Piston rod 109 is caused to linearly retract downward into piston 111 thereby causing bell crank 101 to pivot about pivot 103 while rear roof rail 39 is maintained in its fully raised position. This action concurrently causes number four bow 31 to rotate downwardly and away from the upper section of rear roof rail 39 until pin 119 fully engages in locking slot 133 of rear roof rail 39. Thus, number four bow 31 is moved independently from rear roof rail 39 in this positional range.
Third, subsequent retracting movement of piston rod 109 causes top stack mechanism 21, including rear roof rail 39, to retract and pivot about main or bottom pivot 51 of rear roof rail 39 in concert with continued movement of number four bow 31, due to the interface of pin 119 in the locking structure. Pin 119 is further retained in locking slot 133 by engagement with hook 135 thereby preventing pin 119 from inadvertently disengaging when slot 133 is inverted. Therefore, piston 111 serves to also retract the top stack mechanism simultaneously with number four bow 31 in this second positional range for collapsing the entire top stack mechanism.
Fourth, the convertible roof is moved from the partially retracted position of FIG. 7 to the fully retracted position of FIG. 8. Piston rod 109 is fully retracted into piston 111 thereby causing bell crank 101 and the lower pivot of number four roof bow 31 to have rotated more than 180 degrees from their fully raised positions. In the fully retracted and stowed position of FIG. 8, lower pivot 105 of number four roof bow 31 is generally located no further rearward in the automotive vehicle than it was in its fully raised position of FIG. 2B. Lower pivot 105 of number four roof bow 31 is also located within approximately three inches of bottom pivot 51 of rear roof rail 39, as measured in a fore-and-aft or longitudinal direction of the automotive vehicle, when the convertible roof is disposed in its fully retracted position. This number four roof bow positioning optimizes packaging of the folded components within boot 61 such that a much larger than standard rigid, glass backlite can be stored within the relatively small sized boot well 61. Backlite 151 has a length of at least 300 millimeters as measured along a vertical fore-and-aft plane and is three-dimensionally curved, however, number four roof bow 31 is fully retracted forward of a majority of backlite 151. Backlite 151 is secured to roof cover 23 as is disclosed in U.S. patent application Ser. No. 08/916,820 entitled "Backlite Retention System for Use in an Automotive Vehicle Convertible Roof," which was invented by Steven G. Laurain and Michael T. Willard and is being filed concurrently herewith; this application is incorporated by reference herein.
In reverse operation of the convertible roof from the stowed and retracted position to the fully raised position, piston rod 109 will linearly advance for driving bell crank 101 out of boot well 61. This causes number four bow 31, rear roof rail 39 and the rest of top stack mechanism 21 to upwardly pivot as a single unit about bottom pivot 51. Next, number four roof bow 31 is allowed to independently rotate relative to the fully raised rear roof rail 39 by further advancing of piston rod 109 and bell crank 101, after front roof rail 33 is downwardly pivoted from the position of FIG. 5 to that of FIG. 2A, and after latching hook 73 engages the front header panel. This advancing action of number four roof bow 31, from its intermediate position of FIG. 6 to its fully raised position of FIG. 2B, causes tightening, tensioning or stretching of roof cover 23 after latching so as to easily achieve convertible roof-to-body fastening but then subsequently provide the desired taut roof cover appearance and function.
While various aspects of the convertible roof actuation mechanism have been disclosed, it will be appreciated that many other variations may be employed without departing from the scope of the present invention. For example, multiple roof bows can be moved independently from the fully raised and static top stack mechanism to selectively reduce and increase the roof cover tension to assist with latching. Furthermore, movement of the number four bow can also be employed to assist with latching an optional number five bow (not shown) attached to a movable rear edge of the roof cover, to the vehicle body. It is alternately envisioned that an electric motor can be employed to directly rotate a bell crank or other mechanically advantageous member to move the number four roof bow relative to the remainder of the top stack mechanism in place of a linear hydraulic actuator. A linearly driven, telescoping number four bow, with a stationary lower pivot axis, can also be employed. Various materials and linkages have been disclosed in an exemplary fashion, however, other materials and linkages may of course be employed. It is intended by the following claims to cover these and any other departures from the disclosed embodiments which fall within the true spirit of this invention.
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A convertible roof actuation mechanism includes a pliable roof cover, a top stack mechanism supporting the roof cover, and at least one roof bow of the top stack mechanism independently movable relative to the remainder of the top stack mechanism for selectively reducing and increasing tension of the roof cover during latching. In another aspect of the present invention, at least one roof bow is retracted closer to a bottom pivot of a rear roof rail when stowed to optimize packaging space within a convertible roof storage compartment.
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RELATED PATENTS AND APPLICATIONS
This invention is related to U.S. Pat. No. 3,760,094 entitled AUTOMATIC FINE TUNING WITH PHASE-LOCKED LOOP AND SYNCHRONOUS DETECTION, abandoned application Ser. No. 494,448, filed Aug. 5, 1974, entitled COLOR TELEVISION RECEIVER WITH IMPROVED TUNING CHARACTERISTICS and Ser. No. 503,220, filed Sept. 5, 1974, entitled OSCILLATION SYSTEM FOR INTEGRATED CIRCUIT all of which are in the name of Peter C. Skerlos and assigned to Zenith Radio Corporation and all of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates to color television receivers and in particular to those which incorporate synchronous demodulators. The typical television receiver has a tuner which frequency converts the received information bearing signal by the familiar heterodyning process. A local oscillator is adjusted to produce an oscillatory signal a given frequency above that of a received television signal for converting the sound and video carriers in the received signal to corresponding intermediate frequency carriers which are supplied to frequency selective intermediate frequency amplifiers. The output of these amplifiers drives a detector which recovers the modulation from the carriers.
Due to its close frequency relationship to the suppressed chrominance subcarrier sidebands, the sound carrier in receivers not employing synchronous demodulation must be drastically attenuated in the video IF channel prior to detection of the video IF signal to preclude the production of the well known 920 kHz beat resulting from the presence in the detector of the chrominance and sound information. The effect of this interference on the displayed picture is highly objectionable and such color receivers generally include separate detectors for the luminance-chrominance information, and for the sound information.
The separate detection permits substantial trapping or attenuation of the sound information in the luminance-chrominance channel and minimization of the chrominance-sound beat. The sound trap is typically located in the frequency selective portion of the intermediate frequency amplifier at a point after the sound information has been coupled to the sound detector. The arrangement yields satisfactory reproduction of the televised picture provided the frequency conversion of the tuner is precise enough to insure accurate positioning of the sound carrier within the sound trap. However, significant limitation on the degree of mistuning which may be tolerated is imposed.
While "exact tuning" of a television receiver generally suffices, it is often desirable to adjust the tuner and alter the frequency of the intermediate frequency signal. For example, preferential adjustment of the picture characteristics may be obtained by changing the effect of the intermediate frequency amplifiers on the luminance components or on local extraneous interference signals; or relaxed tuning requirements may be obtained.
As is well known, mistuning of the tuner oscillator moves the intermediate frequency signals, and their corresponding modulation components, within the intermediate frequency filter response characteristic. In receivers employing conventional envelope-type detectors this results in severe chrominance-sound (920 kHz) beat in one direction and loss of color in the other direction.
With currently used highly selective non-linear sound traps phase distortions are produced in signals coupled through them. These phase distortions are, of course, of little significance for the sound information being trapped. However, for chrominance information, which must be accurately reproduced in both phase and amplitude, the effects of these phase distortions are highly objectionable in the displayed picture.
Synchronous demodulators achieve significant reduction in the amount of chrominance-sound beat and are distinguishable from the more conventional envelope demodulators in that they are gated or switched at the carrier frequency by a separate reference carrier. They require close frequency correlation between the demodulator switching signal and the IF carrier.
A television receiver with a synchronous demodulator, as described in the above mentioned U.S. Pat. No. 3,760,094, includes a fixed reference oscillator which produces a reference signal, free of harmonics and modulation components for switching the detectors. Such synchronous demodulators minimize the chrominance-sound beat to such an extent that sound trapping is not required and the television system of the patent does not include sound trapping in the IF amplifier. It does, however, include a frequency control system, operative on the receiver tuner, for maintaining the intermediate frequency signal at the same frequency as the reference oscillator. Therefore, no significant mistuning of the tuner oscillator, whether for preferential tuning reasons or for relaxed tuning requirements, is possible with the system of the above mentioned patent.
Another television receiver system with a synchronous demodulator, described in copending application (Skerlos II), includes a variable frequency reference oscillator to switch the detectors. The reference signal is maintained, by the action of a closed loop APC system, in frequency synchronization and at a predetermined phase with the IF carrier despite its frequency variations. The receiver includes an intermediate frequency amplifier having a response curve which is not distorted by the presence of sound carrier trapping and thus permits substantial deviations in the IF signal frequency without introducing objectionable color distortion or 920 kHz sound beat. The resulting advantage is two-fold. Firstly, the viewer may be provided with a control for preferentially adjusting the characteristic of the color picture reproduced on the receiver without introducing noticeable distortion therein, and secondly the receiver produces an acceptable color picture even though not "accurately tuned". The television receiver may be corrected to a conventional "exact tuning" receiver if desired by incorporating one of the many currently used AFC systems, which however, require additional components that must be properly aligned.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved color television receiver.
It is a more particular object of the present invention to provide an improved synchronous detector-type color television receiver operable in either an "exact tuning" mode or in an "extended tuning" mode which requires a minimum of additional components and adjustments.
DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel are set forth with particularlity in the appended claims. The invention, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connnection with the accompanying drawing(s), in the several figures of which like reference numerals identify like elements, and in which:
FIG. 1 is a block diagram representation of a color television receiver constructed in accordance with the present invention;
FIG. 2 is a partial block diagram, partial schematic diagram of a portion of the color television receiver of FIG. 1; and
FIG. 3 is a schematic diagram of another portion of the color television receiver of FIG. 1.
SUMMARY OF THE INVENTION
A television receiver includes a voltage controllable tuner having a variable frequency local oscillator converting a received modulation bearing signal to an intermediate frequency signal and modulation recovery means including, variable frequency oscillation means producing a reference carrier, and a synchronous detector, responsive to the reference carrier and the intermediate frequency signal, recovering the modulation. The television receiver may be operated in either a first mode in which the frequency of the local oscillator is determined by the variable frequency oscillation means or in a second mode in which the frequency of the variable frequency oscillation means is determined by the local oscillator.
When operating in the first mode the television receiver has independent gain adjustable AC and DC control loops for the variable frequency oscillation means and the local oscillator, respectively which provide for enhanced pull in and system locking characteristics.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a tuner 10 includes a radio frequency amplifier (R.F. Amp.), a mixer (MIX) and a variable frequency local oscillator (L.O.) for receiving a television signal, converting it to an intermediate frequency signal and supplying the connected signal to an intermediate frequency filter 11. A fine tune block 8 indicates a viewer adjustable control coupled to tuner 10 for preferentially adjusting the frequency of the local oscillator. It will be appreciated that for one aspect of the invention, i.e., exact tuning, this block may be eliminated. The frequency selective circuitry in filter 11 couples the intermediate frequency signal to a synchronous detector 14 and to a limiter 12. A reference oscillator 15 generates a constant amplitude sinusoidal voltage which is coupled to synchronous detector 14. The output signal of limiter 12, comprising a portion of the intermediate frequency signal free of amplitude variations, and a sample of the output voltage of reference oscillator 15 are applied to an APC detector 13. APC detector 13 is coupled, via a low pass filter 16 and an AC coupling means 7 to reference oscillator 15. A switch SB bypasses AC coupling means 7. A low pass filter (LPF) 6 is coupled directly to detector 13 and via a switch SA to tuner 10. Switches SA and SB are shown separately but jointly operable, as indicated by the dashed line joining them and are of the "make before break" variety for best mode transition, but it should be understood that a single two pole switch mechanism may be used. The output of synchronous detector 14, comprising recovered modulation components of luminance, chrominance, deflection synchronizing signals and a sound signal is coupled to a signal processor 17, wherein the luminance and chrominance components are further processed and applied to the control electrodes of a CRT 22. A sound processor 23 recovers the sound information and amplifies it to a level sufficient to drive a speaker 24. A sync system 18 recovers the deflection synchronizing signals for controlling a conventional deflection system 19. Deflection system 19 supplies vertical and horizontal rate deflection voltages to a yoke 21 for scanning a CRT 22. A high voltage generator 20 responds to the horizontal rate portion of the output of deflection system 19 to produce the required accelerating voltages for CRT 22.
The intermediate frequency signal at the output of filter 11 comprises a "composite signal" having a video carrier amplitude modulated with components of luminance, chrominance and deflection synchronization and a frequency modulated sound carrier. As is well known, this composite signal has a maximum modulation level of 87.5 percent leaving a 12.5 percent portion of the video carrier which is free of amplitude variations. Limiter 12 contains circuitry which recovers this unmodulated portion of the video carrier by limiting its output signal excursions to less than the variations due to modulation components. The well-known limiter circuits fulfilling this function typically include an amplifier having such gain and output capability that the input signal derived from intermediate frequency filter 11 causes limiting or clipping of the output signal excursions. Also included within limiter 12 is a phase shifting network causing the output signal to be 90° output of phase with the output signal of intermediate frequency filter 11 to compensate for a 90° offset inherent in APC detector 13 which will be explained below in detail.
For proper operation of a synchronous detector the switching signal has the same frequency and phase as the amplitude modulated carrier. In the present invention receiver reference oscillator 15 is synchronized to the intermediate frequency signal by virtue of the closed loop control system fed by limiter 12, or alternatively, the frequency of the local oscillator tuner 10 is synchronized to the output of reference oscillator 15. These two synchronization methods define the alternate modes of operation for the receiver of the present invention.
The first mode, defined by the intermediate frequency signal controlling the frequency of reference oscillator 15, results when switch SA is open and SB is closed. Under these conditions AC coupling 7 is shorted and the closed loop system (indicated by dashed line 9) formed by APC detector 13, low pass filter 16 and reference oscillator 15 maintains the output of reference oscillator 15 in frequency synchronization and at a fixed place with the output signal of limiter 12.
The frequency and phase synchronization results from the well-known process of product detection, performed by detector 13, in which signals of different frequencies generate a "beat signal" output. The beat signal varies in amplitude at a rate determined by the frequency difference between the two input signals and is non-symmetrical. It therefore contains AC and DC components both of which are applied to oscillator 15. The DC components cause the oscillator to change frequency to reduce the frequency difference between input signals until synchronization or "lock" results. Because the beat signal is applied exclusively to oscillator 15 during first mode operation, the phase and frequency of oscillator 15 will "track" or follow that of the intermediate frequency signal. When the frequency of the intermediate frequency signal is varied (e.g., by fine tuning the receiver or as a result of tuning system errors), the required synchronization of the switching signal is maintained.
It is a characteristic of such closed loop automatic phase control systems that synchronization or lock is achieved when the compared signals are of the same frequency and in phase quadrature. Closed loop system 9, therefore, locks or synchronizes reference oscillator 15 at a phase 90° from that required to correctly switch synchronous detector 14. Phase shifting the limiter signal by 90° cancels the inherent offset of closed loop system 9.
The second mode of operation of the present invention is defined when switch SA is closed and SB is open. AC coupling 7 applies only the AC components of the beat signal produced by detector 13 to reference oscillator 15 and only the DC components pass through LPF 6 for application to the local oscillator of tuner 10. The exclusion of the DC component from reference oscillator 15 allows it to vary about its natural oscillation frequency of 45.75 MHz (corresponding to the video IF carrier) as a function of the AC beat signal, which effectively frequency modulates the oscillator output.
In a manner similar to that described above, APC detector 13 produces the non-symmetrical beat signal having both AC and DC components in response to limiter 12 and reference oscillator 15. The DC component, being a function of the average frequency difference, alters the frequency of the local oscillator in tuner 10 until the intermediate frequency signal corresponds to the natural frequency of reference oscillator 15. As a result, the receiver intermediate frequency is locked to 45.75 MHz and exact tuning results.
It should be noted that splitting the AC and DC components for application to separate oscillators yields attractive operational and design advantages over conventional automatic frequency control systems.
It is well known that the oscillator pull-in range, that is, the frequency difference which can be overcome, in a conventional automatic frequency control system is determined in part by the system's AC loop gain while hold-in or lock characteristics are determined substantially by DC loop gain. Since both the AC and DC components are active upon a common oscillator, both loop gains cannot be simultaneously optimized. As a result, conventional designs are generally a compromise between the desired AC and DC loop gains. Another significant limitation in pull-in range arises in conventional automatic frequency control systems because the AC loop is operative on the tuner and therefore includes the IF amplifiers which, due to their delay characteristics, severely limit pull-in range.
In contrast, the separate AC and DC control loops in accordance with the present invention permit optimization of both loop gains. Further, because the AC control loop does not include the IF amplifier, the delay characteristics inherent in the intermediate frequency amplifier are immaterial. This is of particular importance where acoustic surface wave devices, which have even greater delay characteristics than the more conventional filters, are used as intermediate frequency filters.
FIG. 2 shows a detailed circuit schematic of limiter 12 and synchronous detector 14. Closed loop control system 9 is shown in FIG. 2 in block diagram form (it is shown in detail in FIG. 3) to simplify the explanations of the limiter and synchronous detector. Limiter 12, closed loop control system 9 and synchronous detector 14 are preferably fabricated on a single monolithic integrated circuit, but should be obvious that similar discrete component apparatus can be constructed.
Limiter 12 comprises a differential amplifier formed by a pair of differentially connected transistors 28 and 29 having a common emitter connection coupled to ground by a transistor 30 and its emitter resistor 42. The base of transistor 30 is maintained at a fixed potential V 2 causing it to function as a constant current source. The intermediate frequency signal from intermediate frequency filter 11 is applied via a terminal 46 and an emitter follower transistor 35 to the base of transistor 29. Because the base of transistor 28 is held at a fixed potential by the combined actions of transistors 25, 26 and 27 and resistor 39 and capacitor 43, signal variations at the base of transistor 29 cause differential conduction variations in transistors 28 and 29. The differential current hus developed flows through load resistors 36 and 37 producing a differential output signal.
A pair of transistors 31 and 32 having their respective base collector junctions shorted form a pair of cross coupled diodes between the collectors of differential transistors 28 and 29 which conduct on alternate polarity signal excursions to limit the amplitude of signal developed. As a result, while the full extent of amplitude variations present in the intermediate frequency signal are coupled to differential transistors 28 and 29 the output signals produced are limited or clipped. A broadly tuned parallel resonant circuit, formed by an inductor 49 and a capacitor 50, is coupled between the collectors of transistors 28 and 29 for filtering the output signal. Thus a portion of the intermediate frequency signal substantially free of amplitude variations is coupled to terminals 44 and 45 of closed loop control system 9.
By actions to be described below in conjunction with FIG. 3, closed loop control system 9 produces a reference oscillator output identical in phase and frequency to the applied limiter signal. The reference oscillator output is coupled to terminals 191 and 192 of synchronous detector 14. Transistors 171-177 together with resistors 182-187, all within synchronous detector 14, form a doubly balanced multiplier circuit in which the respective differential currents through load resistors 180 and 181 develop the output voltage of the detector. The reference oscillator signal is applied with one phase to the bases of transistors 171 and 174 and with an alternate phase to the bases of transistors 172 and 173.
Transistors 171 and 174 operate together during one interval of the reference signal and transistors 172 and 173 during the alternate interval. Because the collectors of the transistor pairs thus formed are cross coupled, both load resistors (180 and 181) are alternately coupled to the collectors of the differential transistors 175 and 176, the emitters of which are coupled to ground by transistor 177. The base of transistor 177 is maintained at a fixed potential, V 2 , causing it to function as a constant current source. During the first portion of the oscillator signal, transistors 171 and 174 are in conduction and couple load resistors 180 and 181 to the collectors of transistors 176 and 175, respectively. The intermediate frequency signal applied to the base of transistor 176, while transistor 175 remains at a fixed potential, causes a differential current flow developing voltages across resistors 180 and 181. During the alternate portion of the oscillator signal, transistors 172 and 173 are driven conductive, coupling load resistors 180 and 181 to transistors 175 and 176, respectively (in effect switching the connections). Again, the intermediate frequency signal applied to the base of transistor 176 causes a differential current to flow developing voltages across resistors 180 and 181. As discussed below the output signal of the reference oscillator is maintained at a constant amplitude, causing the voltages developed across resistors 180 and 181 to be solely a function of the amplitude variations of the intermediate frequency signal.
It should be noted that current flows only during selected intervals within each period of the video carrier, therefore, only those signal components which are in phase with the applied reference oscillator signal cause current variations through load resistors 180 and 181. As a result, the differential voltage developed comprises recovered modulation components of luminance, chrominance and sound together with deflection synchronizing signals, essentially free of chrominance-sound beat.
In FIG. 3, closed loop control system 9 is shown in detail. APC detector 13 comprises a doubly balanced multiplier circuit similar that that described for synchronous detector 14 in which transistors 63-69 form the dual differential amplifier configuration and the respective differential currents in load resistors 93 and 99 are controlled by cross coupled transistors 63 and 65 and transistors 64 and 66. The output of reference oscillator 15, coupled by emitter followers 79 and 80 with one phase to the bases of transistors 66 and 63 with an alternate phase to the bases of transistors 64 and 65, respectively, switches load resistors 93 and 99 between the collectors of transistors 67 and 68. In contrast to the above-described synchronous detector, the limiter output signal at terminals 44 and 45 is coupled to the bases of both differential transistors (67 and 68) by emitter followers 61 and 62, respectively. Resistors 92 and 98, together with the input capacities of transistors 61 and 62, phase shift the limiter signal and in combination with the effect of the limiter tank circuit (inductor 49 and capacitor 40 in FIG. 4) provide a 90° phase shift to insure proper keying of synchronous detector 14.
Because the differential current flow in resistors 93 and 99 is a function of the relative phase and frequency relationship between the limiter and reference oscillator signals, it is a balanced control voltage suitable for synchronizing the reference oscillator. A transistor 70 couples one portion of the control signal through a transistor 73 and a resistor 108, causing one phase inversion, to the parallel combination of a capacitor 139 and switch SB. The alternate portion of the control signal is coupled through transistors 71, 72 and 75 and resistor 108 to capacitor 139 and switch SB, causing two phase inversions. The signal portions thus coupled are in phase or additive and are combined and coupled to a low pass filter 16 formed by the series combination of a resistor 134 and a capacitor 135, which is coupled to the base of transistor 83.
Reference oscillator 15 and its associated frequency control circuitry described below are the subject of the above mentioned copending application Ser. No. 503,220.
Three transistors 81, 82 and 85 comprise a differential amplifier configuration in which the collector of transistor 82 is coupled to the base of transistor 81 and the collector of transistor 81 is coupled to the base of transistor 82 to form a cross coupled differential oscillator circuit. The collectors of transistors 81 and 82 are each coupled to a source of positive voltage by resistors 118 and 119, respectively. A tank circuit 140 formed by an inductor 136 and the series connected capacitors 137 and 138, is coupled between the respective collectors of transistors 81 and 82. The junction of capacitors 137 and 138 is coupled to ground. Transistor 85 coupled the emitters of transistors 81 and 82 to ground through a resistor 122. The base of transistor 85 is connected to source of constant potential +V 2 causing a constant current to flow in transistor 85.
Transistors 84, 87 and 86 form a differential control amplifier in which current is alternatively conducted around or through the oscillator. The control signal at the junction of low pass filter 16 and the base of transistor 83 is applied to the base of transistor 84. In the absence of control signal the conduction of transistor 83 is determined by resistor 141 coupling its base to the emitter of transistor 78. Since the base of transistor 87 is maintained at a fixed potential, transistor 84 differentially determines the relative conductions between transistors 82 and 84 and hence the amount of current flow through oscillator transistors 81 and 82, thus controlling the oscillator frequency. The differential oscillator output signal developed between the collectors of transistors 81 and 82 is filtered by the action of tank circuit 140 to remove any harmonic components. Emitter followers 89 and 90 are buffer stages which couple the derived oscillator signal to terminals 191 and 192 of synchronous detector 14 to provide the keying signal.
What has been shown is a novel television receiver, operable in an exact tuning mode or an extended range variable frequency mode which provides the benefits of synchronous demodulation. The receiver also provides for optimization of automatic frequency control pull-in and holding characteristics.
While particular embodiments of the invention have been shown and described it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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A color television receiver has a tuner converting the received signal to an intermediate frequency and fine tuning means for varying the converted frequency. An intermediate frequency filter couples the converted signal to a synchronous demodulator which includes a variable frequency reference oscillator in a closed loop control system which tracks the IF frequency thereby providing an extended range of tuning adjustment. A two pole switch is operable to couple the DC component of the closed loop control system error signal to the tuner and the AC component of the error signal to the reference oscillator thereby providing an "exact tuning" operation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of Application of U.S. patent application Ser. No. 13/783,225, filed Mar. 1, 2013 and issued as U.S. Pat. No. 8,571,672 on Oct. 29, 2013, entitled Package for an Implantable Neural Stimulation Device; which is a divisional application of U.S. patent application Ser. No. 11/924,709, filed Oct. 26, 2007 and issued as U.S. Pat. No. 8,374,698 on Feb. 12, 2013, entitled Package for an Implantable Neural Stimulation Device; which is a divisional application of U.S. patent application Ser. No. 11/893,939, entitled Package for an Implantable Neural Stimulation Device, filed Aug. 18, 2007 and issued as U.S. Pat. No. 8,412,339 on Apr. 2, 2013; which application claims benefit of provisional Application Ser. No. 60/838,714, filed on Aug. 18, 2006, entitled Package for an Implantable Neural Stimulation Device and of provisional Application Ser. No. 60/880,994, filed on Jan. 18, 2007, entitled Package for an Implantable Neural Stimulation Device the disclosures of both are incorporated herein by reference.
GOVERNMENT RIGHTS NOTICE
This invention was made with government support under grant No. R24EY12893-01, awarded by the National Institutes of Health. The government has certain rights in the invention.
FIELD OF THE INVENTION
The present invention is generally directed to neural stimulation and more specifically to an improved hermetic package for an implantable neural stimulation device.
BACKGROUND OF THE INVENTION
In 1755 LeRoy passed the discharge of a Leyden jar through the orbit of a man who was blind from cataract and the patient saw “flames passing rapidly downwards.” Ever since, there has been a fascination with electrically elicited visual perception. The general concept of electrical stimulation of retinal cells to produce these flashes of light or phosphenes has been known for quite some time. Based on these general principles, some early attempts at devising prostheses for aiding the visually impaired have included attaching electrodes to the head or eyelids of patients. While some of these early attempts met with some limited success, these early prosthetic devices were large, bulky and could not produce adequate simulated vision to truly aid the visually impaired.
In the early 1930's, Foerster investigated the effect of electrically stimulating the exposed occipital pole of one cerebral hemisphere. He found that, when a point at the extreme occipital pole was stimulated, the patient perceived a small spot of light directly in front and motionless (a phosphene). Subsequently, Brindley and Lewin (1968) thoroughly studied electrical stimulation of the human occipital (visual) cortex. By varying the stimulation parameters, these investigators described in detail the location of the phosphenes produced relative to the specific region of the occipital cortex stimulated. These experiments demonstrated: (1) the consistent shape and position of phosphenes; (2) that increased stimulation pulse duration made phosphenes brighter; and (3) that there was no detectable interaction between neighboring electrodes which were as close as 2.4 mm apart.
As intraocular surgical techniques have advanced, it has become possible to apply stimulation on small groups and even on individual retinal cells to generate focused phosphenes through devices implanted within the eye itself. This has sparked renewed interest in developing methods and apparati to aid the visually impaired. Specifically, great effort has been expended in the area of intraocular retinal prosthesis devices in an effort to restore vision in cases where blindness is caused by photoreceptor degenerative retinal diseases; such as retinitis pigmentosa and age related macular degeneration which affect millions of people worldwide.
Neural tissue can be artificially stimulated and activated by prosthetic devices that pass pulses of electrical current through electrodes on such a device. The passage of current causes changes in electrical potentials across visual neuronal membranes, which can initiate visual neuron action potentials, which are the means of information transfer in the nervous system.
Based on this mechanism, it is possible to input information into the nervous system by coding the sensory information as a sequence of electrical pulses which are relayed to the nervous system via the prosthetic device. In this way, it is possible to provide artificial sensations including vision.
One typical application of neural tissue stimulation is in the rehabilitation of the blind. Some forms of blindness involve selective loss of the light sensitive transducers of the retina. Other retinal neurons remain viable, however, and may be activated in the manner described above by placement of a prosthetic electrode device on the inner (toward the vitreous) retinal surface (epiretinal). This placement must be mechanically stable, minimize the distance between the device electrodes and the visual neurons, control the electronic field distribution and avoid undue compression of the visual neurons.
In 1986, Bullara (U.S. Pat. No. 4,573,481) patented an electrode assembly for surgical implantation on a nerve. The matrix was silicone with embedded iridium electrodes. The assembly fit around a nerve to stimulate it.
Dawson and Radtke stimulated cat's retina by direct electrical stimulation of the retinal ganglion cell layer. These experimenters placed nine and then fourteen electrodes upon the inner retinal layer (i.e., primarily the ganglion cell layer) of two cats. Their experiments suggested that electrical stimulation of the retina with 30 to 100 μA current resulted in visual cortical responses. These experiments were carried out with needle-shaped electrodes that penetrated the surface of the retina (see also U.S. Pat. No. 4,628,933 to Michelson).
The Michelson '933 apparatus includes an array of photosensitive devices on its surface that are connected to a plurality of electrodes positioned on the opposite surface of the device to stimulate the retina. These electrodes are disposed to form an array similar to a “bed of nails” having conductors which impinge directly on the retina to stimulate the retinal cells. U.S. Pat. No. 4,837,049 to Byers describes spike electrodes for neural stimulation. Each spike electrode pierces neural tissue for better electrical contact. U.S. Pat. No. 5,215,088 to Norman describes an array of spike electrodes for cortical stimulation. Each spike pierces cortical tissue for better electrical contact.
The art of implanting an intraocular prosthetic device to electrically stimulate the retina was advanced with the introduction of retinal tacks in retinal surgery. De Juan, et al. at Duke University Eye Center inserted retinal tacks into retinas in an effort to reattach retinas that had detached from the underlying choroid, which is the source of blood supply for the outer retina and thus the photoreceptors. See, e.g., E. de Juan, et al., 99 Am. J. Ophthalmol. 272 (1985). These retinal tacks have proved to be biocompatible and remain embedded in the retina, and choroid/sclera, effectively pinning the retina against the choroid and the posterior aspects of the globe. Retinal tacks are one way to attach a retinal electrode array to the retina. U.S. Pat. No. 5,109,844 to de Juan describes a flat electrode array placed against the retina for visual stimulation. U.S. Pat. No. 5,935,155 to Humayun describes a retinal prosthesis for use with the flat retinal array described in de Juan.
US Patent Application 2003/0109903 to Peter G. Berrang describes a Low profile subcutaneous enclosure, in particular and metal over ceramic hermetic package for implantation under the skin.
U.S. Pat. No. 6,718,209, US Patent Applications Nos. 2002/0095193 and 2002/0139556 and US Patent Applications Nos. 2003/0233133 and 2003/0233134 describe inter alia package for an implantable neural stimulation device. Further descriptions of package for an implantable neural stimulation device can be found inter alia in U.S. Pat. No. 7,228,181; and US Patent Applications Nos. 20050288733 and 20060247754, all of which are assigned to a common assignee and incorporated herein by reference.
BRIEF SUMMARY OF THE INVENTION
The present invention is an improved hermetic package for implantation in the human body. The implantable device of the present invention includes an electrically non-conductive substrate including electrically conductive vias through the substrate. A circuit is flip-chip bonded to a subset of the vias. A second circuit is wire bonded to another subset of the vias. Finally, a cover is bonded to the substrate such that the cover, substrate and vias form a hermetic package.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the implanted portion of the preferred retinal prosthesis.
FIG. 2 is a side view of the implanted portion of the preferred retinal prosthesis showing the strap fan tail in more detail.
FIG. 3 is a perspective view of a partially built package showing the substrate, chip and the package wall.
FIG. 4 is a perspective view of the hybrid stack placed on top of the chip.
FIG. 5 is a perspective view of the partially built package showing the hybrid stack placed inside.
FIG. 6 is a perspective view of the lid to be welded to the top of the package.
FIG. 7 is a view of the completed package attached to an electrode array.
FIG. 8 is a cross-section of the package.
FIG. 9 is a perspective view of the implanted portion of the preferred retinal prosthesis.
FIG. 10 is a cross-section of the three stack package.
FIG. 11 is a cross-section of the three stack package.
FIG. 12 is a cross-section of the two stack package.
FIG. 13 is a cross-section of the two stack package.
FIG. 14 is a cross-section of the two stack package.
FIG. 15 is a cross-section of the one stack package.
FIG. 16 is a cross-section of the folded stack package.
FIG. 17 is a cross-section of the package.
FIG. 18 is a cross-section of the package.
FIG. 19 is a cross-section of the lid shaping package.
FIG. 20 is a cross-section of the lid shaping package.
FIGS. 21 and 22 are cross-sections the package showing interconnects in detail.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
The present invention is an improved hermetic package for implanting electronics within a body. Electronics are commonly implanted in the body for neural stimulation and other purposes. The improved package allows for miniaturization of the package which is particularly useful in a retinal or other visual prosthesis for electrical stimulation of the retina.
FIG. 1 shows a perspective view of the implanted portion of the preferred retinal prosthesis. A flexible circuit includes a flexible circuit electrode array 10 which is mounted by a retinal tack (not shown) or similar means to the epiretinal surface. The flexible circuit electrode array 10 is electrically coupled by a flexible circuit cable 12 , which pierces the sclera in the pars plana region, and is electrically coupled to an electronics package 14 , external to the sclera. Further an electrode array fan tail 15 is formed of molded silicone and attaches the electrode array cable 12 to a molded body 18 to reduce possible damage from any stresses applied during implantation.
The electronics package 14 is electrically coupled to a secondary inductive coil 16 . Preferably the secondary inductive coil 16 is made from wound wire. Alternatively, the secondary inductive coil 16 may be made from a flexible circuit polymer sandwich with wire traces deposited between layers of flexible circuit polymer. The electronics package 14 and secondary inductive coil 16 are held together by the molded body 18 . The molded body 18 holds the electronics package 14 and secondary inductive coil 16 end to end. This is beneficial as it reduces the height the entire device rises above the sclera. The design of the electronic package (described below) along with a molded body 18 which holds the secondary inductive coil 16 and electronics package 14 in the end to end orientation minimizes the thickness or height above the sclera of the entire device. This is important to minimize any obstruction of natural eye movement.
The molded body 18 may also include suture tabs 20 . The molded body 18 narrows to form a strap 22 which surrounds the sclera and holds the molded body 18 , secondary inductive coil 16 , and electronics package 14 in place. The molded body 18 , suture tabs 20 and strap 22 are preferably an integrated unit made of silicone elastomer. Silicone elastomer can be formed in a pre-curved shape to match the curvature of a typical sclera. However, silicone remains flexible enough to accommodate implantation and to adapt to variations in the curvature of an individual sclera. The secondary inductive coil 16 and molded body 18 are preferably oval shaped. A strap 22 can better support an oval shaped secondary inductive coil 16 .
Further it is advantageous to provide a sleeve or coating 50 that promotes healing of the scleratomy. Polymers such as polyimide, which may be used to form the flexible circuit cable 12 and flexible circuit electrode array 10 , are generally very smooth and do not promote a good bond between the flexible circuit cable 12 and scleral tissue. A sleeve or coating of polyester, collagen, silicon, GORETEX®, or similar material would bond with scleral tissue and promote healing. In particular, a porous material will allow scleral tissue to grow into the pores promoting a good bond.
It should be noted that the entire implant is attached to and supported by the sclera. An eye moves constantly. The eye moves to scan a scene and also has a jitter motion to improve acuity. Even though such motion is useless in the blind, it often continues long after a person has lost their sight. By placing the device under the rectus muscles with the electronics package in an area of fatty tissue between the rectus muscles, eye motion does not cause any flexing which might fatigue, and eventually damage, the device.
FIG. 2 shows side view of the implanted portion of the retinal prosthesis, in particular, emphasizing the strap fan tail 24 . When implanting the retinal prosthesis, it is necessary to pass the strap 22 under the eye muscles to surround the sclera. The secondary inductive coil 16 and molded body 18 must also follow the strap 22 under the lateral rectus muscle on the side of the sclera. The implanted portion of the retinal prosthesis is very delicate. It is easy to tear the molded body 18 or break wires in the secondary inductive coil 16 or electrode array cable 12 . In order to allow the molded body 18 to slide smoothly under the lateral rectus muscle, the molded body 18 is shaped in the form of a strap fan tail 24 on the end opposite the electronics package 14 .
FIG. 3 shows the hermetic electronics package 14 is composed of a ceramic substrate 60 brazed to a metal case wall 62 which is enclosed by a laser welded metal lid 84 . The metal of the wall 62 and metal lid 84 may be any biocompatible metal such as Titanium, niobium, platinum, iridium, palladium or combinations of such metals. The ceramic substrate is preferably alumina but may include other ceramics such as zirconia. The ceramic substrate 60 includes vias (not shown) made from biocompatible metal and a ceramic binder using thick-film techniques. The biocompatible metal and ceramic binder is preferably platinum flakes in a ceramic paste or frit which is the ceramic used to make the substrate. After the vias have been filled, the substrate 60 is fired and lapped to thickness. The firing process causes the ceramic to vitrify biding the ceramic of the substrate with the ceramic of the paste forming a hermetic bond. Thin-film metallization 66 is applied to both the inside and outside surfaces of the ceramic substrate 60 and an ASIC (Application Specific Integrated Circuit) integrated circuit chip 64 is bonded to the thin film metallization on the inside of the ceramic substrate 60 .
The inside thin film metallization 66 includes a gold layer to allow electrical connection using wire bonding. The inside film metallization includes preferably two to three layers with a preferred gold top layer. The next layer to the ceramic is a titanium or tantalum or mixture or alloy thereof. The next layer is preferably palladium or platinum layer or an alloy thereof. All these metals are biocompatible. The preferred metallization includes a titanium, palladium and gold layer. Gold is a preferred top layer because it is corrosion resistant and can be cold bonded with gold wire.
The outside thin film metallization includes a titanium adhesion layer and a platinum layer for connection to platinum electrode array traces. Platinum can be substituted by palladium or palladium/platinum alloy. If gold-gold wire bonding is desired a gold top layer is applied.
The package wall 62 is brazed to the ceramic substrate 60 in a vacuum furnace using a biocompatible braze material in the braze joint. Preferably, the braze material is a nickel titanium alloy. The braze temperature is approximately 1000° Celsius. Therefore the vias and thin film metallization 66 must be selected to withstand this temperature. Also, the electronics must be installed after brazing. The chip 64 is installed inside the package using thermocompression flip-chip technology. The chip is underfilled with epoxy to avoid connection failures due to thermal mismatch or vibration.
FIGS. 4 and 5 show off-chip electrical components 70 , which may include capacitors, diodes, resistors or inductors (passives), are installed on a stack substrate 72 attached to the back of the chip 64 , and connections between the stack substrate 72 and ceramic substrate 60 are made using gold wire bonds 82 . The stack substrate 72 is attached to the chip 64 with non-conductive epoxy, and the passives 70 are attached to the stack substrate 72 with conductive epoxy.
FIG. 6 shows the electronics package 14 is enclosed by a metal lid 84 that, after a vacuum bake-out to remove volatiles and moisture, is attached using laser welding. A getter (moisture absorbent material) may be added after vacuum bake-out and before laser welding of the metal lid 84 . The metal lid 84 further has a metal lip 86 to protect components from the welding process and further insure a good hermetic seal. The entire package is hermetically encased. Hermeticity of the vias, braze, and the entire package is verified throughout the manufacturing process. The cylindrical package was designed to have a low profile to minimize its impact on the eye when implanted.
The implant secondary inductive coil 16 , which provides a means of establishing the inductive link between the external video processor (not shown) and the implanted device, preferably consists of gold wire. The wire is insulated with a layer of silicone. The secondary inductive coil 16 is oval shaped. The conductive wires are wound in defined pitches and curvature shape to satisfy both the electrical functional requirements and the surgical constraints. The secondary inductive coil 16 , together with the tuning capacitors in the chip 64 , forms a parallel resonant tank that is tuned at the carrier frequency to receive both power and data.
FIG. 7 shows the flexible circuit, includes platinum conductors 94 insulated from each other and the external environment by a biocompatible dielectric polymer 96 , preferably polyimide. One end of the array contains exposed electrode sites that are placed in close proximity to the retinal surface 10 . The other end contains bond pads 92 that permit electrical connection to the electronics package 14 . The electronic package 14 is attached to the flexible circuit using a flip-chip bumping process, and epoxy underfilled. In the flip-chip bumping process, bumps containing conductive adhesive placed on bond pads 92 and bumps containing conductive adhesive placed on the electronic package 14 are aligned and melted to build a conductive connection between the bond pads 92 and the electronic package 14 . Leads 76 for the secondary inductive coil 16 are attached to gold pads 78 on the ceramic substrate 60 using thermal compression bonding, and are then covered in epoxy. The electrode array cable 12 is laser welded to the assembly junction and underfilled with epoxy. The junction of the secondary inductive coil 16 , array 1 , and electronic package 14 are encapsulated with a silicone overmold 90 that connects them together mechanically. When assembled, the hermetic electronics package 14 sits about 3 mm away from the end of the secondary inductive coil.
Since the implant device is implanted just under the conjunctiva it is possible to irritate or even erode through the conjunctiva. Eroding through the conjunctiva leaves the body open to infection. We can do several things to lessen the likelihood of conjunctiva irritation or erosion. First, it is important to keep the over all thickness of the implant to a minimum. Even though it is advantageous to mount both the electronics package 14 and the secondary inductive coil 16 on the lateral side of the sclera, the electronics package 14 is mounted higher than, but not covering, the secondary inductive coil 16 . In other words the thickness of the secondary inductive coil 16 and electronics package should not be cumulative.
It is also advantageous to place protective material between the implant device and the conjunctiva. This is particularly important at the scleratomy, where the thin film electrode cable 12 penetrates the sclera. The thin film electrode array cable 12 must penetrate the sclera through the pars plana, not the retina. The scleratomy is, therefore, the point where the device comes closest to the conjunctiva. The protective material can be provided as a flap attached to the implant device or a separate piece placed by the surgeon at the time of implantation. Further material over the scleratomy will promote healing and sealing of the scleratomy. Suitable materials include DACRON®, TEFLON®, GORETEX® (ePTFE), TUTOPLAST® (sterilized sclera), MERSILENE® (polyester) or silicone.
FIG. 8 shows the package 14 containing a ceramic substrate 60 , with metallized vias 65 and thin-film metallization 66 . The package 14 contains a metal case wall 62 which is connected to the ceramic substrate 60 by braze joint 61 . On the ceramic substrate 60 an underfill 69 is applied. On the underfill 69 an integrated circuit chip 64 is positioned. On the integrated circuit chip 64 a ceramic hybrid substrate 68 is positioned. On the ceramic hybrid substrate 68 passives 70 are placed. Wirebonds 67 are leading from the ceramic substrate 60 to the ceramic hybrid substrate 68 . A metal lid 84 is connected to the metal case wall 62 by laser welded joint 63 whereby the package 14 is sealed.
FIG. 9 shows a perspective view of the implanted portion of the preferred retinal prosthesis which is an alternative to the retinal prosthesis shown in FIG. 1 .
The electronics package 14 is electrically coupled to a secondary inductive coil 16 . Preferably the secondary inductive coil 16 is made from wound wire. Alternatively, the secondary inductive coil 16 may be made from a flexible circuit polymer sandwich with wire traces deposited between layers of flexible circuit polymer. The electronics package 14 and secondary inductive coil 16 are held together by the molded body 18 . The molded body 18 holds the electronics package 14 and secondary inductive coil 16 end to end. The secondary inductive coil 16 is placed around the electronics package 14 in the molded body 18 . The molded body 18 holds the secondary inductive coil 16 and electronics package 14 in the end to end orientation and minimizes the thickness or height above the sclera of the entire device.
Lid 84 and case wall 62 may also contain titanium or titanium alloy or other metals and metal alloys including platinum, palladium, gold, silver, ruthenium, or ruthenium oxide. Lid 84 and case wall 62 may also contain a polymer, copolymer or block copolymer or polymer mixtures or polymer multilayer containing parylene, polyimide, silicone, epoxy, or PEEK™ polymer. Via substrate may be preferably contain alumina or zirconia with platinum vias.
FIG. 15 shows one stack assembly. One stack means that all of the parts including discretes 102 and chip 112 are on the ceramic substrate 60 , with our without a separate demux 108 . A via substrate 60 is placed on the bottom below a flip IC which includes RF Transceiver, power recovery, drivers, and an optional demux 108 .
FIG. 12 , FIG. 13 and FIG. 14 show two stack assemblies. FIG. 16 shows a folded stack assembly. FIG. 12 shows a ceramic substrate 104 next to RF transceiver/power recovery chip 114 and both placed on a flipchip driver/demux 108 . FIG. 13 shows ceramic substrate 104 on a flipchip driver/demux 108 . RF transceiver/power recovery chip 1144 is provided on the ceramic substrate 104 . FIG. 14 shows ceramic substrate 104 on a flipchip driver/demux 108 . RF transceiver/power recovery chip 114 is provided not directly on the ceramic substrate 60 . The difference between FIG. 13 and FIG. 14 is that in FIG. 13 the ceramic substrate 104 is in direct contact with RF transceiver/power recovery chip 114 but not in FIG. 14 . The substrate 104 can be ceramic but also any kind of polymer or glass. FIG. 16 shows a folded flex substrate 116 and a flipchip demux 108 on the bottom and an IC 106 placed on the flip chip demux 108 . The substrate 116 is folded twice.
FIG. 10 and FIG. 11 show a three stack assembly. A three stack demux flip-chip 108 bonded to substrate 104 with chip 106 and hybrid with discrete passives 102 wire-bonded above is preferred. FIG. 10 shows a ceramic substrate 104 on a IC 106 including a RF transceiver/power recovery drivers and the IC is placed on a flipchip driver/demux 108 . FIG. 11 shows a similar assembly as FIG. 10 however the ceramic substrate 104 is placed on pedestal 110 which is placed between the substrate 104 and the IC 106 .
FIG. 17 and FIG. 18 show additional flip chip configurations. Both figures have a similar assembly. However, in FIG. 17 the IC 106 is bonded to flipchip demux by a bump bond. In FIG. 18 , a double-sided multilayer ceramic substrate 104 is bonded to the IC by a bump bond.
They can be two stack or folded stack and could be one or two-sided. It may be passive on the substrate next to IC. A pedestal is useful but optional to make room for wire bonds. A through via means that via goes through the IC. A bump bond to IC and then bump bond to IC to passive substrate or demux is possible. Bond pads on IC to line up with vias to eliminate the inside metallization can be provided. Driver IC flipchip can be bonded to substrate with passives. Demux flip-chip can be bonded to via substrate and the two substrates can be wire-bonded or flex circuit bonded together. Driver portion can be moved to demux chip and everything else to a separate chip to reduce interconnect lines. Two stack chip can be provided with smaller chip (RF and demux) and hybrid above. It may include wire-bonds directly from the Hybrid to the chip. Chip may include a demux driver on the same wafer.
FIG. 19 and FIG. 20 show different variations of the lid shape. Possible is a concave lid to conform to eye.
FIG. 21 and FIG. 22 are cross-sections the package showing redistribution routing and interconnect traces 66 in detail. Both figures show redistribution routings and interconnect traces 66 on the top and the bottom of via substrate 60 . Redistribution routing on top of the via substrate and the braze stop on top of the via substrate contain preferably metals like Ti, Zr, Fe, Ru, Co, Rh, Ir, Ni, Pd, Pt, Cu, Ag, Au, mixtures, layers or alloys thereof. The top layer of the top redistribution routing is gold or gold alloy. Redistribution routing on bottom of the via substrate and the braze stop on top of the via substrate contain preferably metals like Ti, Zr, Fe, Ru, Co, Rh, Ir, Ni, Pd, Pt, Cu, Ag, Au, mixtures, layers or alloys thereof. The top layer of the top redistribution routing is platinum or platinum alloy. Interconnect and redistribution routing is the connection the bond between flexible circuit and via substrate on the bottom of the substrate and a connection between the flip chip circuit 64 and the substrate on top of the substrate. Additional braze stop traces 102 surround the redistribution and interconnect traces 66 to prevent the braze metal 104 from running into the redistribution and interconnect traces 66 . The walls in FIG. 22 show the same braze metal 104 as mentioned before as a flange.
Accordingly, what has been shown is an improved method making a hermetic package for implantation in a body. While the invention has been described by means of specific embodiments and applications thereof, it is understood that numerous modifications and variations could be made thereto by those skilled in the art without departing from the spirit and scope of the invention. It is therefore to be understood that within the scope of the claims, the invention may be practiced otherwise than as specifically described herein.
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An implantable device, including a first electrically non-conductive substrate with a plurality of electrically conductive vias. The device also includes a flip-chip multiplexer circuit attached to the electrically non-conductive substrate using conductive bumps, the circuit being electrically connected to at a subset of the plurality of electrically conductive vias. Another a flip-chip driver circuit is attached to the flip-chip multiplexer circuit using conductive bumps while a second electrically non-conductive substrate attached to the flip-chip driver circuit using conductive bumps. Discrete passives are attached to the second electrically non-conductive substrate and a cover is bonded to the first electrically non-conductive substrate. The cover, the first electrically non-conductive substrate and the electrically conductive vias form a hermetic package.
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FIELD OF THE INVENTION
The present invention relates to a natural draft cooling tower that employs an air cooled condenser. The aforementioned cooling tower operates by natural draft and achieves the exchange of heat between two fluids such as atmospheric air, ordinarily, and another fluid which is usually steam. The aforementioned cooling tower operates by natural draft which utilizes buoyancy via a tall chimney. Warm, air naturally rises due to the density differential to the cooler outside ambient air. Warm air is indeed obviously less dense than colder ambient air at the same pressure.
BACKGROUND OF THE INVENTION
Cooling towers are heat exchangers of a type widely used to emanate low grade heat to the atmosphere and are typically utilized in electricity generation, air conditioning installations and the like. In a natural draft cooling tower for the aforementioned applications, airflow is induced via hollow chimney-like tower by the density difference between cool air entering the bottom of the tower and warm air leaving the top. This difference is due to heat transfer from the fluid being cooled, which is passed through the interior of the tower. Cooling towers may be wet or dry. Dry cooling towers can be either “Direct Dry,” in which steam is directly condensed by air passing over a heat exchange medium containing the steam or an “Indirect Dry” type natural draft cooling towers, in which the steam first passes through a surface condenser cooled by a fluid and this warmed fluid is sent to a cooling tower heat exchanger where the fluid remains isolated from the air, similar to an automobile radiator. Dry cooling has the advantage of no evaporative water losses. Both types of dry cooling towers dissipate heat by conduction and convection and both types are presently in use. Wet cooling towers provide for direct air contact to a fluid being cooled. Wet cooling towers benefit from the latent heat of vaporization which provides for very efficient heat transfer but at the expense of evaporating a small percentage of the circulating fluid.
In addition to types of cooling tower designs described above, cooling towers can be further classified as either cross-flow or counter-flow. Typically in a cross-flow cooling tower, the air moves horizontally through the fill or packing as the liquid to be cooled moves downward. Conversely, in a counter-flow cooling tower air travels upward through the fill or packing, opposite to the downward motion of the liquid to be cooled.
In a direct dry cooling tower, the turbine steam exhaust is condensed directly in an air-cooled condenser. Approximately five to ten times the air required for mechanical draft evaporative towers is necessary for dry cooling towers. This type of cooling is usually used when little or no water supply is available. This type of system consumes very little water and emits no water vapor plume.
To accomplish the cooling required the condenser requires a large surface area to dissipate the thermal energy in the gas or steam and presents several problems to the design engineer. It is difficult to efficiently and effectively direct the steam to all the inner surface areas of the condenser because of nonuniformity in the delivery of the steam due to system ducting pressure losses and velocity distribution. Therefore, uniform steam distribution is desirable in air cooled condensers and is critical for optimum performance. Therefore it would be desirous to have a condenser with a strategic layout of ducting and condenser surfaces that would ensure an even distribution of steam throughout the condenser, while permitting a maximum of cooling airflow throughout and across the condenser surfaces.
Another problem with the current air cooled condensers is the expansion and contraction of the ducts and cooling surfaces caused by the temperature differentials. Pipe expansion joints may be employed at critical areas to compensate for the thermal movement. A typical type of expansion joint for pipe systems is a bellow which can be manufactured from metal (most commonly stainless steel). A bellow is made up of a series of one or more convolutions, with the shape of the convolution designed to withstand the internal pressures of the pipe, but flexible enough to accept the axial, lateral, and/or angular deflections. In all but the smallest of applications, branching of the steam ducting is required to distribute the steam to the various coil sections of the condenser. The very nature of branching breaks the steam flow into different directions which necessarily introduces thermal expansion in different directions. These expansion accommodating devices are expensive. Therefore it would be additionally desirous to have a condenser arrangement in which the thermal expansion and contraction is simply and inexpensively managed.
The natural draft cooling tower typically has a hollow, open-topped shell of reinforced concrete with an upright axis of symmetry and circular cross-section. The thin walled shell structure usually comprises a necked, hyperbolic shape when seen in meridian cross-section or the shell may have a cylindrical or conical shape. Openings at the base of the tower structure enable ingress of ambient air to facilitate heat exchange from the fluid to the air. Forced draft cooling towers are also known, in which the airflow is produced by fans. These devices usually do not incorporate a natural draft shell because the fans replace the chimney effect of the natural draft cooling towers. However, forced draft fans may be incorporated in a natural draft design to supplement airflow where the density difference described above is not sufficient to produce the desired airflow.
It is known that improving cooling tower performance (i.e. the ability to extract an increased quantity of waste heat in a given surface) can lead to improved overall efficiency of a steam plant's conversion of heat to electric power and/or to increases in power output in particular conditions. Cost-effective methods of improvement are desired. The present invention addresses this desire. Equivalent considerations can apply in other industries where large natural draft cooling towers are used.
Additionally, large natural draft cooling towers are high-capital-cost, long-life fixed installations, and it is desirable that improvements be obtainable without major modifications, particularly to the main tower structure. The method and apparatus of the present invention are applicable to the improvement of existing natural draft cooling towers, as well as to new cooling towers.
In cooler weather the return temperature of a fluid from the cooling tower and/or freezing a fluid in the heat exchanger is a major concern. When the airflow has the capacity to exchange more heat than desired the airflow must be reduced. Airflow dampers are known to be used is series with heat exchangers. The dampers may be throttled to restrict the airflow. However, even in the wide open position a pressure loss through the damper occurs. This pressure loss reduces the total airflow and thus the cooling capacity of the tower.
Additionally, due to temperature and humidity extremes, a natural draft cooling tower may extract too much heat energy out of the heated liquid or have the liquid to be cooled freeze up. For example, a dry cooling tower may extract too much thermal energy away from the heated liquid condensate, which would require extra heating energy from a boiler or heat source to reheat the liquid back to its optimal temperature, thus lowering the system's efficiency. A wet tower on the other hand is susceptible to ice formation in cold weather. In particular ice may form and build up in the fill and cause structural damage to the fill and/or the supporting structure.
Therefore it would desirous to have an economical, efficient natural draft cooling tower in which the cooling airflow could also be controlled, while keeping the effects of thermal expansion and contraction of the condenser and ducting at a minimum, thus simplifying and reducing the cost maintenance.
SUMMARY OF THE INVENTION
Embodiments of the present invention advantageously provides for a fluid, usually steam, ducting system and method for an direct dry cooling tower and an air bypass system and method which can be applied to direct or indirect cooling towers.
An embodiment of the invention includes a natural draft cooling tower that cools an industrial fluid which has an air cooled steam condenser and an outer shell having a perimeter that extends vertically about a vertical axis, wherein the air cooled steam condensers are disposed therein. The embodiment further has a horizontal duct that receives the industrial fluid to be heated, a central riser duct in fluid communication with said horizontal duct, a radial manifold in fluid communication with the central riser duct supported by a central fixed point structure and at least one radial duct that extends radially from said radial manifold. It further includes a terminal duct in fluid communication with said at least one radial duct, a peripheral manifold in fluid communication with said terminal duct and at least one finned tube bundle in fluid communication with said peripheral manifold.
Another embodiment is for a method for cooling an industrial fluid using a natural draft cooling tower, the method comprising flowing the industrial fluid to be cooled through a horizontal duct and flowing the industrial fluid to be cooled through a central riser duct supported by a fixed point and flowing the industrial fluid to be cooled through a radial manifold. The method further includes flowing the industrial fluid to be cooled through at least one radial duct and a terminal duct to a peripheral manifold and flowing the industrial fluid to be cooled through the peripheral manifold to at least one finned tube bundle and passing an airflow over the finned tube bundles and inducing heat exchange on the industrial fluid via said airflow.
Another embodiment is for a natural draft cooling tower that cools an industrial fluid that comprises an air cooled condenser of the dry-type with an exterior outer shell having a perimeter that extends vertically about a vertical axis, wherein the air cooled steam condensers are disposed therein, a horizontal duct that receives the industrial fluid to be cooled and a central riser duct in fluid communication with said horizontal duct. It further includes a radial manifold in fluid communication with the central riser duct, at least one radial duct that extends radially from said radial manifold, a terminal duct in fluid communication with said at least one radial duct and a peripheral manifold in fluid communication with said at least one radial duct. It also includes at least one finned tube bundle in fluid communication with said peripheral manifold and a cooling tower support structure, further comprising a chimney section, a base section, wherein said base section comprises a first airflow inlet at a first vertical position and a second airflow inlet located at second vertical position below the first vertical position, wherein said second airflow comprises an air regulating means that translate between an open and closed position.
Another embodiment of the present invention is for a system with flowing an industrial fluid to be cooled through a horizontal duct with means for flowing the industrial fluid to be cooled through a central riser duct and means for flowing the industrial fluid to be cooled through a radial manifold and means for flowing the industrial fluid to be cooled through at least one radial duct and a terminal duct to a peripheral manifold. The embodiment further includes means for flowing the industrial fluid to be cooled from the peripheral manifold to at least one finned tube bundle and means for passing an airflow over the finned tube bundles and inducing heat exchange on the industrial fluid via said airflow.
There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description of various embodiments of the disclosure taken in conjunction with the accompanying figures.
FIG. 1 is a schematic steam/water circuit diagram of a simplified electric power generating installation in which an embodiment of the present invention that may be used.
FIG. 2 illustrates a simple schematic illustration of an embodiment of the invention in which the output of a steam turbine is directly coupled to the condenser tower.
FIG. 3 is a plan view of an embodiment the present invention illustrating a steam duct connecting radial ducting arms and bundles.
FIGS. 4A and 4B are a side view of an embodiment illustrating the ducting orientation of an embodiment of the present invention and an exaggerated depiction of the radial movement of the present system.
FIG. 5 illustrates the radial ducting arm manifold in accordance with an embodiment of the present invention.
FIG. 6A illustrates the bifurcated ducting and a portion of the cooling annular ring section in accordance with an embodiment of the present invention and also illustrates the radial movement of the system.
FIG. 6B illustrates an alternative arrangement for connecting the radial arm to the cooling annular ring section.
FIG. 7 illustrates the cooling structure comprising a base stratum section, a cooling annular ring section, an angular roof section and a chimney section in accordance with an embodiment of the present invention.
FIG. 8 is a side view orientation of the stratum section and the cooling annular ring of the present invention.
FIG. 9 illustrates a single set of the finned tube bundles attachment to the peripheral manifold to a steam box located in accordance with an embodiment of the present invention and also illustrates the radial and angular movements of the system grossly exaggerated.
FIG. 10 illustrates the lower section of the finned tube bundle and the collector in accordance with an embodiment of the present invention.
FIG. 11A illustrates a cooling tower in which an air inlet bypass is closed and air through the heat exchanger is maximized in accordance with an embodiment of the present invention.
FIG. 11B illustrates a cooling tower in which an air inlet bypass located inside a structure is closed and air through the heat exchanger is maximized in accordance with an embodiment of the present invention.
FIG. 12A illustrates a cooling tower in which an air inlet is open and air through the heat exchanger is reduced in accordance with an embodiment of the present invention.
FIG. 12B illustrates a cooling tower in which an air inlet bypass located inside a structure is open and air through the heat exchanger is reduced in accordance with an embodiment of the present invention.
FIG. 13 illustrates a cooling tower in which the air bypass is closed and air through the heat exchanger is maximized, wherein the heat exchanger is located outside the tower shell structure, in accordance with an embodiment of the present invention.
FIG. 14 illustrates a cooling tower in which the air bypass is open and air through the heat exchanger is reduced, wherein the heat exchanger is located outside the tower, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof and show by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice them, and it is to be understood that other embodiments may be utilized, and that structural, logical, processing, and electrical changes may be made. It should be appreciated that any list of materials or arrangements of elements is for example purposes only and is by no means intended to be exhaustive. The progression of processing steps described is an example; however, the sequence of steps is not limited to that set forth herein and may be changed as is known in the art, with the exception of steps necessarily occurring in a certain order.
FIG. 1 is a schematic diagram of the steam/water circuit 1 of a greatly-simplified electric power generating installation. A boiler 2 produces steam which travels via a duct 3 to a steam turbine 4 which drives a generator 5 . The boiler 2 may fired with fossil fuel such as coal or natural gas to provide heat or the heat source may be a nuclear reactor (not shown). Wet steam exiting the steam turbine 4 is condensed in a heat exchanger 6 and exits as water, which is recirculated as feed water to the boiler 2 via a feed water pump 7 .
A separate cooling water supply is provided to heat exchanger 6 via a duct 8 and exits at an elevated temperature via a duct 9 , being pumped by cooling water pumps 10 . In some installations, a large supply of water is available from a lake, river or artificial cooling pond for use as cooling water. However, in cases where supply is not available, cooling water may be directly recirculated as shown in FIG. 1 , passing through a cooling tower 11 to lower its temperature before returning to the heat exchanger 6 via duct 8 . This arrangement avoids the need for a large natural supply of cooling water. It is to be understood that circuit 1 is for illustrative purposes only. In a practical power generating facility, (not shown) there may be additional components, such as economisers, superheaters, and (usually) multiple boilers and turbines and ducting to accommodate them.
Wet or evaporative cooling towers are heat exchangers of the type in which a liquid as shown in FIG. 1 is cooling water is passed into a space through which a gas atmospheric air is flowing and in that space is cooled by direct contact with the cooler air and by partial evaporation. To give sufficiently long liquid residence times and gas/liquid interface areas. The liquid is often sprayed into the space, falling downward or being splashed onto a large-surface-area fixed structure (known for example as “packing”) at the base of the tower, finally collecting in a basin below the packing. In small cooling towers of the sizes used in air conditioning and similar applications, the flow of gas is normally produced by fans, typically integral with the cooling tower itself. However, in the largest cooling towers, typical of electric power generation applications, natural draft is often relied on to provide the airflow.
FIG. 2 illustrates a simple schematic of an embodiment of the present invention wherein output of a steam turbine is directly coupled to an air cooled condenser. The boiler 2 heats a fluid, for example water until it becomes a gas (steam). The steam leaves the boiler 2 via a steam duct 3 and enters the steam turbine 4 , which is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion. This rotary motion, for example, may turn a generator 5 to produce electricity. In this example, the steam turbine is a condensing turbine. This type of steam turbine exhausts steam in a partially condensed state, typically of a quality near 90%, at a pressure well below atmospheric to an air cooled condenser tower 14 via duct 12 . The air cooled condenser tower 14 further extracts thermal energy away from the steam producing a liquid with a temperature just below boiling which is collected and pumped back to the boiler 2 via pump 16 through water return duct 18 .
Now, with reference to FIGS. 3-6 showing a generator 30 is operated by steam turbine 32 . The steam may be generated in any of a numerous ways, for example, a coal fired boiler or a nuclear reactor. As the waste steam egresses the turbine 32 , it enters a first end of horizontal duct 34 . The other end of the horizontal duct 34 is affixed to a central riser duct 36 which is located in the middle of the tower and terminates into a radial manifold 38 . Four radial ducts 40 emanate from the radial manifold 38 . Each radial duct is connected to a terminal duct as shown as a Y-duct 42 in FIG. 6A . The other sides of the Y-duct 42 are connected to the peripheral manifold 46 , which is continuous about the perimeter of the tower. The peripheral manifold 46 is connected to the finned tube bundles 48 via a bundle duct 50 . The system of bundles produces a circular pattern, producing the annular ring 52 . It should be noted that depending on the performance needs and the size of the cooling system, the radial ducts can be any number. For example, there may be six or eight radial ducts emanating from the central riser duct 36 to the peripheral manifold in additional embodiments. FIG. 6B illustrates an alternative embodiment for connecting the radial duct 40 to the peripheral manifold 46 which employs an eased tee duct 43 .
FIG. 3 illustrates a series of columns 53 supporting shell 62 . In this embodiment, the ducting system hangs from the bottom of the shell and is not supported from underneath. FIG. 6A is a close in view of FIG. 3 . The radial arm ducts 40 are hanging from the bottom of tower shell 62 . Turning to FIGS. 4A and 4B , they depict duct supports 35 to support the horizontal duct 34 . The ducting is rigidly fixed to the support in the center of the tower and is designated 37 . These figures also depict any exaggerated radial movement of the present system. In a preferred embodiment, the coil tubes, ducting, and piping material are all carbon steel, thus providing an economic alternative to the more expensive material.
As with any physical body in which goes through temperature variations, it will expand or contract in accordance with its temperature. An advantage of using the peripheral manifold in a big loop with a fixed point center riser arrangement is that its thermal dilatation is purely radial and there is no need of bellows. Maximum radial expansion is approximately 1 inch. This movement is introduced at the top of the coil which is purposely not constrained at the top from radial movement as the top of the bundles are only connected to the steam box and the peripheral duct. Because the coils are so tall, the radial movement will induce only a slight inclination of the coils. Not only does this save cost in construction by not having to employ bellows, but the bellows will not become a point of failure for the system, nor will they need to be replaced at a regular maintenance interval. An additional advantage of the above arrangement is that it allows an engineer to design an easy and inexpensive cleaning system that can be hung on a rail located on the perimeter of the cooling annular ring and above the bundles owing to the fact the tube bundles are arranged in a circumferentially oriented outward face as opposed to a pleated or zigzag arrangement.
Turning to FIG. 7 , a cooling structure 56 comprises a base section 54 with its annular ring section 52 , an angular roof section 60 and a chimney section 62 . The base section's 54 annular ring section 52 is made up from a plurality of finned tube bundles 48 placed in a circular arrangement continuous about the perimeter as shown in FIG. 3 . The angular roof section 60 is essentially a warm air director between the finned tube bundles 48 and chimney section 62 and may be steel cladding or any other cooling structure building material.
As can be seen, the bottom of the base stratum section 54 is at ground level and has air inlet with an airflow regulator installed. In this example, the airflow regulator is shown as louvers 55 , which translate between an open and closed position to control airflow through the cooling structure 56 . The louvers discussed throughout the present application can be replaced with any air flow regulation device. For example, the louvers can be replaced with roll up doors, hinged doors, sliding doors or any variable structure to limit airflow through an opening. An optional access door 59 is also shown. The chimney section depicted is cylindrical; however, it can be any shape that allows for air efficient traversal through the chimney section. For example, the chimney section can be in the shape of a hyperboloid, which is the shape most people associate with nuclear power generation stations.
FIG. 8 is an additional side view of the present invention which better illustrates the base stratum section 54 and the annular ring section 52 . FIG. 9 is a side view of a slice of the finned tube bundles 48 . The finned tube bundles 48 are attached to the peripheral manifold 46 via the bundle duct 50 . A steam box 51 may be located on top of the finned tube bundle 48 to facilitate movement of the steam. A steam box in this particular embodiment, may distribute the exhaust steam across the top of the set of finned tube bundles 48 to aid in the condensing of the steam. To better appreciate the dimension of the present embodiment, a measurement AA, represents height of the finned tube bundle's 48 and is also illustrated on FIG. 7 . FIG. 9 also depicts the radial and angular movement of the present system grossly exaggerated for illustrative clarity.
As the steam traverses through the finned tube bundles 48 , it cools and reverts back into its liquid form. The liquid reaches the bottom of the finned tube bundle 48 into to a collector 49 and the liquid leaves via water return 64 , as shown in FIG. 10 . Also shown in FIG. 9 is a slice of the base stratum section 54 depicting where the louvers 55 could be positioned in one embodiment of the present invention.
As illustrated in FIG. 8 , the louvers 55 are positioned below the finned tube bundles 48 to provide a second air path and enable air to by-pass the bundles in order to control the cooling capacity of the system. The louvers 55 are installed vertically and create “windows” in the vertical sealing cladding 57 located below the bundles. When the louvers are closed, the cooling capacity of the tower is maximized and all the cooling air is flowing through the bundles and the draft is at its maximum. When the louvers are in the open position, the capacity of the dry cooling tower is reduced due to two effects. The first effect is due to the reduction of cooling air flowing through the finned tube bundles. The second is due to the reduction of the total airflow related to the reduction of draft (chimney effect) in the tower section due to the lower temperature inside the tower created by the mixing of hot air generated by the heat of the air going through the bundles along with the cold air passing through the louvers. This is turn allows the user to control the rate and the capacity of the dry cooling tower, therefore the user can control the steam turbine back pressure.
The present embodiment has many advantages. For example, the louvers provide an inexpensive control system. The louvers are less costly than isolating valves which have to be installed on the steam ducting to neutralize the exchange surface by segments or partitions. The present invention needs a relatively low amount of louvers, approximately 50% of the face area of the bundles need to be covered with louvers to be effective. Additionally, the actuators of the louvers are located on ground level enabling an easy maintenance. However, the air bypass could be located above the tube bundles and have similar air flow regulating characteristics.
Turning now to FIGS. 11A and 12A , each illustrates louvers functionality in an alternative embodiment for a counter flow natural draft cooling tower. For example, FIG. 11A illustrates an airflow inlet with a set of air bypass louvers 66 a in a closed position and the airflow through the heat exchanger 76 is then maximized. The heat exchanger 76 is often made up of evaporative cooling fill in a wet tower configuration. The ambient air 70 enters at the base of the tower 65 through the airflow inlet with and all the of the ambient air 70 passes through the heat exchanger 76 . The heat exchange 76 can be any type of heated fluid distribution system in which thermal energy is removed from the heated liquid. The heated air 72 rises due to convection. Convection above a hot surface occurs because hot air expands, becomes less dense, and rises as described in the Ideal Gas Law.
Turning now to FIGS. 11B and 12B , in an alternative embodiment, the airflow inlet's set of air bypass louvers 66 a ( FIG. 11A ) can be replaced with an internal airflow bypass louvers 66 b , which is located inside the tower 65 . This design is less likely to be affected by adverse weather, for example, sleet or freezing rain. The first airflow inlet's bypass louvers 66 a and the internal airflow bypass louvers 66 b are generally louvers which translate between an open and closed position. The louvers for all embodiments can be mounted immediately inside the cooling tower support structure, flush to cooling tower heat exchanger or immediately outside the cooling tower heat exchanger. In additional embodiments, the louvers can be exchanged for door type inlet control.
In FIGS. 12A and 12B , the airflow inlet's set of air bypass louvers 66 a or 66 b is open and air through the heat exchanger 76 is reduced. Ambient air 70 enters at the base of the tower 65 and the ambient air 70 is passed through the heat exchanger 76 and becomes heated air 73 . Additionally, ambient air 70 enters the tower 65 above the heat exchanger 76 and mixes somewhat with the heated air 73 and exits out the top of the tower 65 and thus, the amount of air flowing through the tower is reduced.
In FIG. 12 , the first air bypass louvers 66 a (or 66 b ) are open and air through the heat exchanger 76 is reduced. Ambient air 70 enters at the base of the tower 65 and the ambient air 70 is passed through the heat exchanger 76 and becomes heated air 73 . Additionally, ambient air 70 enters the tower 65 above the heat exchanger 76 and mixes somewhat with the heated air 73 and exits out the top of the tower 65 and thus, the amount of airflowing through the tower is reduced.
Now turning now to FIGS. 13 and 14 , each illustrates louvers functionality in an alternative embodiment for a natural draft cooling tower, wherein heat exchanger 74 , located outside of the tower, may be used. For example, FIG. 13 illustrates the first air bypass louvers 78 a is closed and air through the heat exchanger 74 is maximized. The ambient air 70 passes through the heat exchanger 74 into the tower. The heated air 72 rises and leaves out the top of the tower 65 . In an alternative embodiment, the first air bypass louvers 78 a can be replaced for a second air bypass louvers 78 b , which is located between the tower 65 and the heat exchanger 74 .
In FIG. 14 , the first air bypass 78 a is open and air through the heat exchanger 74 is reduced. Ambient air 70 enters at the base of the tower 65 and the ambient air 70 is passed through the heat exchanger 74 and becomes heated air 72 . Additionally, with the second air bypass louvers 78 b , ambient air 70 enters the tower 65 beyond the heat exchanger 74 and mixes with the heated air 72 and exits out the top of the tower 65 and thus the amount of air flowing through the tower is reduced.
The louvers as described in the aforementioned description and figures may be replaced by other means to regulate air flow such as but not limited to roll up doors, hinged doors, sliding doors, or butterfly valves.
The processes and devices in the above description and drawings illustrate examples of only some of the methods and devices that could be used and produced to achieve the objects, features, and advantages of embodiments described herein and embodiments of the present invention can be applied to indirect dry, direct dry and wet type heat exchangers. Thus, they are not to be seen as limited by the foregoing description of the embodiments, but only limited by the appended claims. Any claim or feature may be combined with any other claim or feature within the scope of the invention.
The many features and advantages of the invention are apparent from the detailed specification, and, thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and, accordingly, all suitable modifications and equivalents may be resorted to that fall within the scope of the invention.
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The present invention relates to a natural draft cooling tower that employs an air cooled condenser. The aforementioned cooling tower operates by natural draft and achieves the exchange of heat between two fluids such as atmospheric air, ordinarily, and another fluid which is usually steam. The aforementioned cooling tower utilizes a central steam duct riser supplying steam to perimeter ducting via radial ducting.
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[0001] This application claims priority under 35 U.S.C. §119 to German patent application no. 10 2010 005 168.3, filed Jan. 20, 2010, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The disclosure relates to a preferably electro-magnetically actuated valve and in particular to a low-pressure valve, as used, for example, in a hydraulic machine.
[0003] Valve-controlled hydraulic machines of this type are known, for example, from EP 1 537 333 B1. The European patent document shows a hydraulic machine of axial or radial piston construction which can be operated in principle as a motor or as a pump, with the volumetric delivery or capacity being adjustable via the valve timing gear. In an exemplary embodiment which is described, the hydraulic machine is embodied in the form of an axial piston machine, wherein a multiplicity of pistons arranged in a cylinder is supported on a rotatably mounted swash plate. Each piston together with the associated cylinder space delimits a working space which can be connected via a valve on the low-pressure side and a valve on the high-pressure side to a pressure medium inlet or to a pressure medium outlet.
[0004] In the known solution, the two valves are embodied in the form of electrically releasable or lockable nonreturn valves which are actuable via the pump timing gear in order to operate the particular working space in “full mode”, in “partial mode” or in “idle mode”. As a result, the volumetric delivery or capacity can be adjusted in an infinitely variable manner from a maximum value to 0. The hydraulic machine is operated in accordance with a regulating algorithm via a control unit in order to obtain a total volumetric delivery flow (pump) or total capacity flow (motor) with as few pulsations as possible. The volumetric flow is frequently adjusted by a phase-gating control, but may also be adjusted by a phase-chopping control.
[0005] Hydraulic machines with a capacity/volumetric delivery which can be changed via the valve timing gear are also referred to as digital displacement units (DDU). All positive displacement principles are basically applicable in this case. However, piston machines, in particular of radial piston construction, are advantageous, since said piston machines make it possible to separately form and therefore actively control the input and output for each positive displacer. In this case, it may be highly expedient to differentiate between pump and motor operation such that then the control element may differ in appearance for the low-pressure and high-pressure connections.
[0006] A prerequisite for the above-described type of control (DDU) is that the valves on the low-pressure and high-pressure sides can be switched in highly dynamic fashion such that the above-described pressure medium flow paths can be very rapidly blocked off or opened up for flow. The control elements on the low-pressure side or high-pressure side can be embodied in the form of, for example, switching valves, preferably of seat-type construction, which are preferably actuable by a magnetic actuator. Various and sometimes contradictory requirements are imposed on a valve of this type. A hydraulic machine which is minimized in respect of construction space requires a valve, the overall dimensions of which are small and which has a flow cross section with is as large as possible and is therefore low in resistance. However, such a large flow cross section requires a greater valve lift, this contradicting the requirement for high valve dynamics with as little electrical power consumption as possible. Furthermore, the requirements imposed on the valve vary at different operating points of the hydraulic machine. For example, large volumetric flows and requirements for low switching times arise from high rotational speeds, and low rotational speeds are associated with long switching-on periods for the magnet coils. The mechanical loads and requirements imposed on the sealing system also change via the pressure prevailing at the particular connection.
[0007] U.S. Pat. No. 7,077,378 B2 discloses a valve on the low-pressure side for a hydraulic machine of this type, wherein an annular throughflow opening is closed by an approximately cup-shaped valve element. Said annular throughflow opening is bounded by an inner and an outer sealing seat, and therefore the specific surface pressure on the sealing edge is comparatively low compared to a conventional valve cone. In the known solution, the platelike or cup-shaped valve element is prestressed into an open position via a spring and can be adjusted by means of a magnetic actuator into its closed position in which the valve element rests on the above-described sealing seats and the throughflow opening is blocked. During flow through said valve, the platelike valve element, which is prestressed in the opening direction thereof, can be acted upon by flow forces effective in the closing direction, and therefore the throughflow cross section is reduced and, correspondingly, the pressure loss is increased. Although said undesirable closing movement could be countered by a more powerful opening spring, the valve dynamics would deteriorate as a result or a more powerful magnetic coil together with associated power electronics would be necessary. To avoid this drawback, use is made, according to U.S. Pat. No. 7,077,378 B2, of a permanent magnet which acts upon the valve element in the open position thereof with a magnetic force. When the magnetic actuator is energized, the field of the permanent magnet is neutralized and, in addition, a magnetic force which is effective in the closing direction is generated. With a solution of this type, a correspondingly more efficient magnetic actuator is therefore required. In addition, this solution does not exhibit the desired dynamics either, since the field of the permanent magnet has to be weakened first before the valve element can be moved in the direction of the closed position thereof. Furthermore, a relatively high contact pressure force is required between the valve element and valve seat in order to ensure adequate tightness of the valve in the closed state.
SUMMARY
[0008] By contrast, the disclosure is based on the object of providing a low-pressure valve of this generic type, the valve having improved functionality. Furthermore, a hydraulic machine equipped therewith is to be provided.
[0009] This object is achieved by means of a low-pressure valve with the features of the present disclosure and a hydraulic machine according to the present disclosure.
[0010] According to the disclosure, the electromagnetically actuated valve of the low-pressure-valve type is formed with a valve body which is assigned to a valve seat, is prestressed in a first direction, preferably the opening direction, and can be adjusted by means of a magnetic actuator in a second direction, preferably the closing direction. The valve is provided with a flat, preferably two-edge sealing system. This means that a flat or planar (plane) annular contact surface is formed on the valve body and can be brought into sealing contact with the likewise planar (plane) valve seat. The planar contact surfaces can be produced in a simple manner, ensure a fluidtight contact connection between the valve body and valve seat, and reduce the surface pressure.
[0011] It is advantageous to divide the contact surface of the valve body radially into an outer and inner sealing edge by an encircling (annular) groove. Said groove (weakening in the material) brings about easier axial movability of the inner sealing edge (sealing surface) with respect to the outer sealing edge (sealing surface) such that the two sealing edges can easily move relative to each other in the axial direction. The tightness of the valve can thereby be improved.
[0012] A preferred development of the disclosure makes provision for a relative tilting movement to be possible between a valve tappet or magnet armature and the valve body mounted thereon. This is structurally achieved by a bore in the valve body having a radial excess size in relation to the valve tappet or magnet armature such that the valve body is held on/at the valve tappet with radial play. The valve body or the planar contact surfaces thereof can thereby be placed in a sealing manner on the (planar) valve seat even if the valve seat is aligned with respect to the valve tappet with relatively great tolerances. The outlay on production can be further reduced as a result.
[0013] According to a particular aspect of the disclosure, the valve tappet is formed or provided with only one magnet armature, wherein the valve seat bushing itself has a guide bore for the axially displaceable mounting of the valve tappet. Said guide bore forms the sole mounting of the valve tappet, and therefore tolerance chains caused by components which are used for the mounting of the valve tappet and are constructed next to one another are not produced. By this means, the functional capability of the valve is improved and the outlay on manufacturing reduced.
[0014] According to a further particular aspect of the disclosure, the low-pressure or outlet valve equipped with a flat, preferably two-edge sealing system is formed merely with the valve seat bushing and without an outer valve housing, wherein the valve seat bushing is screwed directly into the housing of the hydraulic machine. That is to say, in this case, all of the fluid flow passages which are assigned to the low-pressure valve and to date were formed in the valve housing or the outer valve bushing are now formed in the housing of the hydraulic machine. It is thereby possible to increase the flow cross sections in the valve because of the omission of the outer valve bushing and therefore to realize an increased volumetric flow. In this case, the valve may have the multiple magnet-armature construction or the simplified individual magnet-armature construction.
[0015] Finally, according to the disclosure, a hydraulic machine with preferably actively controllable valves on the low-pressure side and with valves on the high-pressure side is proposed. At least one of the valves on the low-pressure side is designed as a low-pressure valve according to one of the preceding aspects.
[0016] At this juncture, it should also be pointed out that the active controllability of the valves on the high-pressure side is not required if only pump operation is to be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The disclosure is explained in more detail below using preferred exemplary embodiments and with reference to the accompanying drawings, in which:
[0018] FIG. 1 shows a longitudinal section through a valve on the low-pressure side of a hydraulic machine (for example of a swash plate compressor or radial piston compressor/motor) in the open state in the form of a reference valve,
[0019] FIG. 2 shows a partial longitudinal section of a valve according to a first exemplary embodiment in which the structural features differing from the reference valve are illustrated,
[0020] FIG. 3 shows an enlargement of the connecting section between the closing element and armature tappet of the valve according to the disclosure from FIG. 2 ,
[0021] FIG. 4 shows a longitudinal section through a valve on the low-pressure side according to a second exemplary embodiment of the disclosure, and
[0022] FIG. 5 shows a longitudinal section through a modified valve according to the second preferred exemplary embodiment of the disclosure.
DETAILED DESCRIPTION
[0023] FIG. 1 shows the basic construction of a nonreturn valve on the low-pressure side, in the form of a reference valve for the subject matter of the disclosure, said valve corresponding to the outlet valve in a hydraulic motor. In a pump, the valve would be the inlet valve or suction valve.
[0024] According to FIG. 1 , the low-pressure valve or outlet valve 22 has a valve body 40 which is prestressed into an open position by a spring 38 and can be adjusted by means of a magnetic actuator 30 into a closed position against a valve seat 42 such that an annular throughflow cross section 44 is blocked. The outlet valve 22 is embodied in the form of a “disk valve”, the valve element 40 having a tappet 46 which bears an approximately mushroom-shaped closing disk 48 on the lower end section thereof in FIG. 1 . When the throughflow cross section 44 is open (view according to FIG. 1 ), a pressure medium connection between a connecting passage A on the inlet side and a passage B opening in a working space 8 of the hydraulic machine is opened, and therefore pressure medium can flow from the inlet passage A into the working space 8 or in the opposite direction, from the working space 8 to the passage A. During passage of the flow from A to B, virtually no flow forces effective in the closing direction occur, and therefore the valve disk 48 could in principle be held in the open position thereof solely by the force of the spring 38 . Upon flow from B to A, the forces resulting from the pressure medium flow act in the closing direction, and therefore the spring 38 is no longer sufficient by itself in order to hold the valve disk 48 in the open position thereof. In order to fix the open position, which is illustrated in FIG. 1 , of the valve disk 48 , the actuating magnet 30 is formed, according to the disclosure, with a main coil 50 and a secondary coil 52 to which a main armature 54 and a secondary armature 56 are respectively assigned. According to the disclosure, the valve disk 48 is held in the open position thereof by the secondary coil 52 being energized. The latter, upon being energized, generates a magnetic field by means of which—as explained in more detail below—the valve body 48 is held in the open position thereof.
[0025] According to the disclosure, in the illustrated basic position of the low-pressure valve or outlet valve 22 , the main coil 50 can also be energized. The magnetic field generated in the process acts in the closing direction on the valve disk 48 —but in the relative position illustrated, the force acting on the valve disk 48 via the coil 50 is smaller than the force generated via the secondary coil 52 , and therefore the valve disk 48 is held in the illustrated open position when the coils 50 , 52 are energized simultaneously.
[0026] The valve 22 has a valve bushing/collet 58 which can be screwed into a corresponding bore in a hydraulic machine housing 2 . The valve bushing 58 opens axially via the passage B in the working space 8 and furthermore has a star-shaped radial bore 60 opening in the passage B. A seat bushing 62 , in the circumferential wall of which an outlet passage 64 opening at one end toward the passage A and at the other end toward the valve seat 42 is formed, is screwed into the valve bushing 58 . A multiplicity of connecting webs 66 dividing the annular outlet passage 64 into circular ring segments are formed in that end section of the outlet passage 64 which is on the valve-seat side. The mouth regions of said circular ring segments form an encircling inner sealing edge 68 and an outer sealing edge 70 which are each positioned obliquely with respect to the valve axis and on which, when the outlet valve 22 is closed, encircling sealing surfaces 72 , 74 of the valve disk 48 rest in a sealing manner such that the annular throughflow cross section 44 is blocked.
[0027] According to the illustration in FIG. 1 , the valve disk 48 is of mushroom-shaped design, with the two sealing surfaces 72 , 74 being formed on the rear side which faces away from the working space 8 . In the exemplary embodiment illustrated the valve tappet 46 passes through a rearwardly projecting hub projection 76 of the valve disk 48 where it is held in a rotationally fixed manner. In the exemplary embodiment illustrated, the tappet 46 and the valve disk 48 are axially connected via a tension spring 78 which is held in a spring holder 80 of the spring plate 48 and is supported on the base of the spring holder 80 via a spring plate. That end section of the tension spring 78 which is remote from said base acts on a spring plate 82 which is fastened to the lower end section, in FIG. 2 , of the tappet 46 and runs somewhat spaced apart axially from the adjacent end surface 84 of the spring plate 48 such that the latter is mounted in a spring-elastic manner on the tappet 46 by means of the force of the tension spring 78 .
[0028] That part of the tappet 46 which upwardly adjoins the hub projection 76 in FIG. 1 is held in an axially displaceable manner in a guide bushing 86 of a multi-part coil former 88 which dips by means of radial projections into corresponding recesses of the seat bushing 62 and is secured there via a spring ring 90 . The guide bushing 86 has an axial guide bore 92 for the tappet 46 . In the closed position, the hub projection 76 dips into an end recess 94 of the guide bushing 86 .
[0029] Radially outside the guide bore 92 , an annular recess 96 , into which sections of the secondary coil 52 are inserted, is provided on the guide bushing 86 . The secondary coil 52 is covered toward the top ( FIG. 1 ) by a magnetizable pole ring 98 which is adjoined in the axial direction by a separating ring 100 . Said separating ring 100 is supported on the base of a casing section 102 of the guide bushing 86 , which dips into a corresponding inner recess 104 of the seat bushing 62 . A coil holder 106 which extends downward toward the base of the guide bushing 86 with an axial projection 108 is inserted into said region of the guide bushing 86 which is engaged around by the casing section 102 . Said axial projection 108 is engaged around by the main coil 50 which is therefore inserted into the annular space between the coil holder 106 and the casing section 102 of the guide bushing 86 . That end surface of the main coil 50 which is located at the bottom in FIG. 2 is supported axially on the separating ring 100 via a further pole ring 110 .
[0030] Level with the separating ring 100 , the guide bushing 86 has a disk-shaped section 87 made of a para-magnetic material, for example a stainless steel, which section is connected, for example by welding, to the two other parts of the guide bushing 86 which conduct the magnetic field, and at the same time contributes to the magnetic fields of the two coils 50 and 52 being clearly separated from each other. When the coil is energized, there is therefore no dynamic effect on the valve body 40 in an undesired direction.
[0031] That end section of the tappet 46 which is located at the top in FIG. 1 passes through an inner bore 112 in the coil holder 106 . Said inner bore is widened in the central region thereof to form a spring space 114 for the spring 38 . The latter is supported at one end on an annular shoulder 116 of the spring space 114 and acts at the other end on the main armature 54 which, together with the adjacent end surface of the axial projection 108 of the coil holder 106 , delimits a main working air gap 118 of a main stage of the magnetic actuator 30 . To optimize the characteristic of the magnet, the main armature 54 dips with an armature projection 120 into an end recess 122 of the axial projection 108 .
[0032] That end surface of the main armature 54 which is located at the bottom in FIG. 1 and is remote from the main working air gap 118 bears against a distance washer 124 via which the secondary armature 56 is spaced apart in the axial direction from the main armature 54 . The secondary armature 52 acts by means of its end surface, which is formed with an annular projection 126 , on a radially projecting supporting shoulder 128 of the tappet 46 such that the force of the spring 38 is transmitted via the main armature 54 , the spacer ring 124 and the secondary armature 56 to the tappet 46 and prestresses the latter downward ( FIG. 1 ) such that the spring plate 48 is held by the spring force in its illustrated open position. A secondary working air gap 130 which is minimal in the open position of the outlet valve 22 is formed between that end surface of the secondary armature 52 which is provided with the annular projection 126 and the correspondingly configured end surface of the guide bushing 86 .
[0033] The two coils 50 , 52 are energized via the control electronics 132 fitted on the multi-part coil former 86 .
[0034] When the secondary coil 52 is energized, the valve disk 48 is magnetically locked in the open position thereof. In order to close the valve disk 48 , as already explained above, first of all the two coils 50 , 52 are energized in the illustrated open position of the outlet valve 22 , with the abovementioned secondary working air gap 130 being minimal. In this position, the main working air gap 118 is at maximum, and therefore the magnetic force acting on the main armature 54 is correspondingly small and the valve disk 48 therefore continues to be locked in its open position by the force of the spring 38 and the magnetic field generated by the secondary coil 52 , even when the current strength is low. As can be gathered from the illustration according to FIG. 2 , the separating ring 100 which is produced from para-magnetic material causes the magnetic fields of the two coils 52 , 54 to be separated. Without such a separation of the magnetic fields, the magnetic field generated by the main coil 50 could flow through the secondary working air gap 130 or the magnetic field generated by the secondary coil 52 could flow through the main working air gap 118 , and therefore a magnetic force could be generated in the undesired direction. Accordingly, the components are selected in respect of the material such that there need not be any concern that the two magnetic fields will combine when the coils 50 , 52 are energized simultaneously. For this reason, the seat bushing 62 is also produced from a para-magnetic material. The components of the coil former 88 (guide bushing 86 , coil holder 106 , pole rings 98 , 124 and separating ring 98 ) are preferably connected frictionally to one another and behave as a single component within the valve structure.
[0035] Owing to the already minimal secondary working air gap 130 , even at a low current level, the secondary armature 56 develops a sufficient force in order to keep the outlet valve 22 open. The locking force can be matched to the use conditions by varying the current level. This may be required, for example at higher rotational speeds of the hydraulic machine, if the pistons 6 press high volumetric flows through the outlet valve 22 .
[0036] As soon as the magnetic field of the main coil 50 has been built up, the secondary coil 52 is switched currentlessly to close, and therefore the magnetic force component which is effective in the opening direction is dispensed with, and the main armature 54 carries out a stroke upward counter to the force of the spring 58 and, in the process, closes the main working air gap 118 . The main armature 54 carries along the tappet 46 at the same time here, and therefore the secondary armature 52 is moved upward in the axial direction and the secondary working air gap 130 is enlarged. The valve disk 48 executes a corresponding stroke until the two sealing surfaces 72 , 74 rest on the sealing edges 78 and 70 , respectively, and the throughflow cross section 44 is closed. Said closing force can likewise be adjusted, again by varying the current level in order to energize the main coil 50 .
[0037] An advantage of this concept is that the magnetic field of the main coil 50 is already completely built up before the outlet valve 22 is closed and therefore exerts the maximum possible force on the valve disk 48 . The valve disk 48 is then virtually prestressed. The comparatively small secondary coil 52 converts the activating signal (independently on/off) substantially more rapidly owing to its significantly smaller time constant in comparison to the main coil 50 , thus increasing the dynamics of the valve.
[0038] In order to open the valve, the main coil 50 is switched currentlessly such that the valve disk 48 is moved back into the basic position thereof by the force of the spring 38 . Said opening movement can be assisted by the secondary coil 52 being energized, and therefore the resetting movement of the valve disk 48 is accelerated. This permits higher valve dynamics, both in the closing direction and in the opening direction of the outlet valve 22 , than in conventional solutions.
[0039] A valve according to a first exemplary embodiment of the disclosure is described below with reference to FIGS. 2 and 3 . Only the features which differ from the reference valve according to FIG. 1 are dealt with here, with all of the other structural features and functions being the same as in the reference valve. To this extent, reference is made at this juncture to the description above in respect of the features which are not expressly illustrated and/or described in FIGS. 2 and 3 .
[0040] FIG. 2 is a partial longitudinal sectional view of the low-pressure or outlet valve 22 according to the disclosure, the view showing the valve seat section 42 together with the associated valve body 40 .
[0041] In the first preferred exemplary embodiment of the disclosure according to FIG. 2 too, the valve body 40 is formed as a mushroom-shaped valve disk consisting of an outer sealing ring 1 , an inner valve body hub 2 and a number of radially extending webs/spokes 4 which connect the valve body hub 2 to the outer sealing ring 1 with throughflow openings 6 being formed. The radially outer sealing ring 1 has a planar (flat) contact surface 10 into which an encircling groove 12 is incorporated (milled). By this means, the contact surface 10 is divided into two sealing lips or sealing edges 14 , 16 which are spaced apart radially by the groove 12 .
[0042] On the side of the seat bushing 62 , the valve seat 42 is likewise formed by a planar end surface 18 of the seat bushing 62 , in which end surface the throughflow cross sections 44 which are separated from one another by the webs 66 open out in an encircling axial groove 45 . The sealing edges 14 , 16 which are spaced apart radially from each other are oriented here in such a manner that, when the valve 22 is closed as per FIG. 2 , said sealing edges sit in a sealing manner on the planar end surface 18 of the seat bushing 62 and therefore close the axial groove 45 in the end surface 18 of the seat bushing 62 . Owing to the groove 12 , it is reliably ensured that both the sealing edge 14 and the sealing edge 16 bear against the seat body 62 .
[0043] The inner valve body hub 2 is configured in a similar manner to the valve body hub according to FIG. 1 , i.e. with the hub projection 72 , in which the valve tappet 46 is guided in a sliding manner, and with the spring holder 80 , into which the tension spring 78 is inserted, the tension spring pressing the valve body 40 against the valve seat 42 . However, in contrast to the reference valve, the valve body hub 2 does not protrude axially over the sealing edges 14 , 16 but rather is set back axially behind the sealing edges 14 , 16 . For this reason, the planar end surface 18 of the seat bushing 62 does not have to be formed with any end recess, as in the reference valve, or the end recess 94 can be formed as a flat and optionally planar turned groove such that the guide bore 92 in the seat bushing 62 obtains a maximum length.
[0044] As can furthermore be gathered from FIG. 2 , in the closed state of the valve 22 , the two sealing edges 14 , 16 protrude radially in the region of the valve seat 42 into the mouth openings of the passages 64 such that only a radially outer or inner part of each sealing edge 14 , 16 is in contact with the end surface 18 of the seat bushing 62 . By this means, the mouth opening edges press slightly into the flat sides of each sealing edge 14 , 16 , thus resulting in a fluidtight closure of the mouth openings.
[0045] FIG. 3 shows the connecting region between the valve tappet 46 and valve body hub 2 on an enlarged scale.
[0046] According thereto, the valve tappet 46 penetrates the valve body hub 2 with an annular gap 20 (illustrated exaggerated in FIG. 3 ) of preferably approx. 0.1 mm width being formed. By this means, the mushroom-shaped valve body 40 can not only be displaced axially in relation to the valve tappet 46 within the scope of the maximum adjustment distance of the tension spring 78 in order to compensate for an excessive stroke of the valve tappet 46 and in order to achieve a sufficiently high contact pressure of the valve body 40 against the valve seat 42 but can also tilt slightly with respect to the valve tappet 46 . By means of this tilting movement which is permitted to a limited extent, the valve body 40 , upon coming into contact with the valve seat 42 , is matched virtually automatically to deviations in the orientation of the end surface 18 of the seat bushing 62 and therefore ensures a secure sealing seat on the seat bushing 62 . This is also assisted by the relatively short guidance of the valve body 40 on the valve tappet 46 (owing to the axially retracted hub projection 76 ). Therefore, tolerances, for example involving perpendicularity to the valve seat 42 and valve body 40 , do not have to be selected to be as exacting as in the reference valve according to FIG. 1 , which simplifies the manufacturing of the components and therefore also improves the functionality.
[0047] Furthermore, the inner section of the spring holder 80 is formed with a radial constriction 24 which serves to guide the tension spring 78 and therefore replaces or renders superfluous the additional spring plate (shown in FIG. 1 ) on the inner spring seat.
[0048] The manner of operation of the valve 22 according to the first preferred exemplary embodiment of the disclosure is the same as for the reference valve according to FIG. 1 , and therefore reference can be made at this juncture to the corresponding passages in the description. A further crucial factor in the first exemplary embodiment according to the disclosure is the double flow around the valve body 40 in the region of the outer sealing ring or closing member 1 which, in the open state of the valve 22 , opens up two throughflow cross sections (circulating flow profiles) between itself and the valve housing or the valve bushing 58 .
[0049] FIG. 4 shows a second exemplary embodiment of a valve 22 according to the disclosure. In this case too, only those technical features which differ from the first preferred exemplary embodiment of the disclosure will be described in more detail below. Otherwise, reference is made to the above passages in the description which also apply to the second exemplary embodiment.
[0050] In the valve according to the disclosure according to FIG. 2 , as in the reference valve according to FIG. 1 , the magnet armature consists of a total of four individual components, namely
the guide rod or valve tappet 46 , the main armature 54 , the secondary armature 56 and the distance washer or spacer ring 124 .
[0055] The valve tappet 46 here is guided in two further components, namely
the coil former 88 and the cover or coil holder 106 .
[0058] This arrangement is disadvantageous in so far as, firstly, the outlay on manufacturing to produce the four abovementioned components with extremely exacting tolerances is very high and, secondly, the installation has to be carried out with great care in order to achieve exact axial orientation of the components for clamping-free movement of the valve tappet. In addition, the guides in the coil former 88 and in the coil holder 106 have to be manufactured with a relatively large amount of play in order to avoid jamming of the magnet armature or valve tappet 46 .
[0059] In the valve 22 according to FIG. 4 , the magnet armature 134 is manufactured from a single component. Put in other words, the valve 22 according to FIG. 4 has the valve seat bushing 62 , on the planar seat bushing end surface 18 of which the valve seat 42 is formed (as in FIGS. 2 and 3 ). A guide bore 36 (in contrast to FIGS. 2 and 3 ) is formed in the valve seat bushing 62 for the direct, displaceable mounting of the valve tappet 46 in the valve seat bushing 62 . Main and secondary armatures according to the first exemplary embodiment of the disclosure and also the reference valve are replaced by the single/individual magnet armature 134 which is either placed onto the valve tappet 46 or is formed integrally therewith.
[0060] Furthermore, the valve tappet 46 ends below the coil holder 106 which, in the present exemplary embodiment, is screwed onto the end sides of the webs 66 . In contrast to the previous exemplary embodiment according to FIG. 2 , the coil holder 106 therefore does not have any guiding function. The fit between the valve tappet 46 and valve seat bushing 62 is selected here to be highly exacting (substantially free from play) in order, inter alia, to keep tilting of the valve tappet 46 to a minimum. Should slight tilting nevertheless occur, the further pole ring 110 takes on the function of a second guide.
[0061] Another advantage of this arrangement according to the second preferred exemplary embodiment of the disclosure resides in simpler manufacturing and a reduction in the tolerance chains. In addition, the friction of the magnet armature/valve tappet 46 is reduced, which further increases the valve dynamics.
[0062] Finally, FIG. 5 illustrates a modification of the second exemplary embodiment of the disclosure.
[0063] This involves an individual magnet armature construction, as has been previously described with reference to FIG. 4 but, in contrast to the exemplary embodiment according to FIG. 4 , a valve bushing/valve housing is not provided. That is to say, the valve 22 consists exclusively of the valve seat bushing 62 which is screwed directly into the housing of the hydraulic machine. In this case, the fluid passages formed in the valve seat bushing 62 in the first and second exemplary embodiments are formed directly in the housing of the hydraulic machine. The working space 8 receiving the valve body 40 is also located in the housing of the hydraulic machine.
[0064] All of the further structural features are identical to the second exemplary embodiment of the disclosure according to FIG. 4 . As an alternative thereto, however, the valve according to the first preferred exemplary embodiment of the disclosure could also be formed without the valve bushing/valve housing in order to be screwed directly into the housing of the hydraulic machine.
[0065] The concept according to the disclosure can be used in valves both on the low-pressure side and high-pressure side, which valves may be closed or open when not energized.
LIST OF REFERENCE NUMBERS
[0000]
1 Outer sealing ring
2 Inner valve body hub
4 Radial webs
6 Throughflow openings
8 Working space
10 Planar contact surface
12 Encircling groove
14 Radially outer sealing edge
16 Radially inner sealing edge
18 Seat bushing end surface
20 Annular gap
22 Outlet valve
24 Constriction in the spring holder
26 Magnetic actuator
30 Magnetic actuator
34 Control unit
36 Guide bore
38 Spring
40 Valve body
42 Valve seat
44 Throughflow cross section
45 Axial groove
46 Tappet
48 Valve disk
50 Main coil
52 Secondary coil
54 Main armature
56 Secondary armature
58 Valve bushing
60 Star-shaped radial bore
62 Seat bushing
64 Outlet passage
66 Web
68 Sealing edge
70 Sealing edge
72 Sealing surface
74 Sealing surface
76 Hub projection
78 Tension spring
80 Spring holder
82 Spring plate
84 End surface
86 Guide bushing
87 Disk-shaped section
88 Coil former
90 Spring ring
92 Guide bore
94 End recess
96 Recess
98 Pole ring
100 Separating ring
102 Casing section
104 Inner recess
106 Coil holder
108 Axial projection
110 Further pole ring
112 Inner bore
114 Spring space
116 Annular shoulder
118 Main working air gap
120 Armature projection
122 End recess
124 Spacer ring
126 Annular projection
128 Radial shoulder
130 Secondary working air gap
132 Control electronics
134 Individual magnet armature
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An electromagnetically actuated valve with a valve body which is assigned to a valve seat, is mechanically prestressed in a first direction toward a first switching position and can be adjusted by means of a magnetic actuator in a second, opposite direction into a second switching position is disclosed. The valve body has a planar contact surface which can be brought into sealing contact with a surface of the valve seat, which surface is planar at least in sections.
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CLAIM OF PRIORITY
This application is a continuation of U.S. application Ser. No. 10/687,267, filed Oct. 15, 2003 now U.S. Pat. No. 7,191,683, which application claims the benefit of U.S. Provisional Application No. 60/418,774 filed Oct. 15, 2002, both of which are incorporated herein by reference and made a part hereof.
FIELD OF INVENTION
The present invention relates to a retractor blade which is adjustably connected to a retractor shaft, and more particularly to a retractor blade connected to a retractor shaft with a ball socket connection allowing free movement while limiting the range of motion of the retractor blade relative to the retractor shaft.
DETAILED DESCRIPTION OF RELATED ART
Co-pending and co-owned patent application Ser. No. 10/113,663 shows a multi-position ratchet mechanism for connecting a retractor blade to a ring, which is incorporated by reference. The 10/113,663 application is not prior art, but the development of the technology disclosed in that application assisted the applicant in determining that a need existed for the invention disclosed herein.
The new clamp allows for a retractor blade to be connected by a retractor shaft to the clamp when the clamp is connected to a ring, when the clamp is pivoted downwardly into the wound or from left to right relative to the ring, a fixably mounted retractor blade connected to the retractor shaft as has been traditionally done in the prior art and shown in U.S. Pat. No. 4,354,763, does not maintain the retractor blade in a substantially perpendicular alignment relative to the direction of retraction. The retractor blade is most effective when the majority of the surface area is against tissue (i.e., perpendicular to the direction of retraction) so that proper retraction can occur.
Accordingly, with the development of the multi-positioning clamp as described in U.S. patent application Ser. No. 10/113,663, a need has arisen for improved connection intermediate the retractor blade and the retractor shaft so that the intimate contact with the retractor blade against the tissue may be maintained in spite of the angular relationship of the retractor shaft relative to the multi-position ratchet mechanism, or other angularly adjustable clamp.
SUMMARY OF THE INVENTION
A need exists for an improved connector intermediate a retractor blade and retractor shaft so that an optimal amount of retractor blade may be maintained against tissue in spite of the angular position of the retractor shaft relative to a clamp connecting the retractor shaft to a ring.
A need also exists for an improved retractor blade assembly which is free to rotate to an optimal retraction position when the retractor shaft is not necessarily oriented along a vector oriented in the direction of retraction.
Another need exists for the ability to maintain the retractor blade perpendicular to the direction of retraction when the retractor shaft is not optimally oriented for such retraction.
Accordingly, a retractor assembly is comprised of a retractor blade connected by a stem to a connector and the retractor shaft. The retractor shaft is preferably connected to a ring, which is not necessarily circular, by a rotatable and/or pivoting clamp. The connector allows for the self adjustability of the angle of the retractor blade relative to the retractor shaft as the angle of the retractor shaft relative to the ring is adjusted at the clamp. The connector is preferably a pivoting type connector, but others could also be employed.
Since rings are typically located proximate an elevation of the incision, in the preferred embodiment a limited travel is allowed in the up and down direction. The side to side, or lateral travel, of the retractor shaft relative to the stem connected to the retractor blade in the preferred embodiment is about 120° range of motion so the connector allows for the pivoting of the retractor blade relative to the retractor shaft sufficient to account for an offset of the retractor blade relative to the ring in the direction of the retraction.
It is preferred that the type connection connect the retractor blade to the retractor shaft while allowing the desired range of motion of the ball retractor blade relative to the retractor shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a top perspective view of a retractor blade assembly having a retractor blade connected to a retractor shaft with a connector in accordance with the preferred embodiment of the present invention;
FIG. 2 is a side perspective view of the shaft portion of the retractor blade assembly shown in FIG. 1 ;
FIG. 3 is a top perspective view of a flange clevis of the retractor blade assembly shown in FIG. 1 ;
FIG. 4 is a top perspective view of a pivot flange of the retractor blade assembly shown in FIG. 1 ;
FIG. 5 is a side perspective view of a blade attachment boss of the retractor blade assembly shown in FIG. 1 ; and
FIG. 6 is a practical application of the use of the retractor blade in conjunction with the retractor shaft and connected in accordance with the present invention with one location option shown in phantom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Accordingly, FIG. 1 shows an assembly 10 of the preferred embodiment. The assembly 10 is comprised of a retractor blade 12 having a stem or shoulder 14 . The assembly 10 also has a retractor shaft 16 . The retractor shaft 16 and the retractor blade 12 are joined at connector 18 which is preferably a pivoting type connection. Other connectors like a ball and socket type connection could also be utilized.
A description of the component parts is helpful to understand the anticipated positioning in order to show the capabilities of the assembly 10 shown in FIG. 1 and FIG. 6 . The retractor shaft 16 is preferably equipped with a plurality of angled cuts 34 which allow for a clamp 48 as shown in FIG. 6 to ratchetly or otherwise retain the retractor shaft 16 at a desired position relative to a ring 46 or other appropriate structure. The shaft 16 preferably has a substantially square cross section along a majority of its length with a connection 36 at a distal end 38 .
The pivoting connection is preferably constructed having a flange clevis 20 which connects to the retractor shaft 16 with a pin 22 . The flange clevis 20 connects to a pivot flange 24 which pivots about pin 26 as shown in FIG. 1 . Preferably the flange clevis 20 can pivot at least 60 degrees, if not 90 degrees to either side of shaft axis 17 . In other embodiments, ranges of +/−30 degrees or +/−45 degrees may also be utilized.
FIG. 4 shows the pivot flange 24 apart from the assembly 10 shown in FIG. 1 . The pivot flange 24 has an extension 28 which is received in bore 30 of blade attachment boss 32 which connects with the pivot flange 24 as well as with a shoulder 14 of a retractor blade 12 as shown in FIG. 1 .
The connection 36 is in the form of a post with a bore 40 extending therethrough as shown in FIG. 1 .
The distal end 38 of the shaft 16 is illustrated in FIG. 1 is inserted into receiver 42 shown in phantom in FIG. 3 . Pin 22 shown in FIG. 1 extends through a hole 44 and bore 40 of the connector 36 to retain the shaft 16 relative to the flange clevis 20 as shown in FIG. 1 . It is anticipated that this will be a rigid and non-moveable connection, however, in alternative embodiments, this may not necessarily be the case.
FIG. 3 shows the flange clevis 20 having a slot 50 which receives hub 56 of pivot flange 24 shown in FIG. 4 . The hub may have a circular circumference or, as illustrated in FIG. 4 , may be configured with stops 60 , 62 which when installed in the slot 50 as shown in FIG. 1 , cooperate with the slot 50 to prevent rotation of the hub 56 of more than about 60 degrees to the left or right of shaft axis 17 about rotation axis 60 . In other embodiments, the slot 50 may work to restrict the angular movement of the hub 56 independent of stops 60 , 62 on a hub or other structure. In other embodiments, the hub 56 may be constructed so that 90 degrees or more to the left and right of the shaft axis 17 may be allowed. Pin 26 retains the hub 56 in the slot 50 as shown in FIG. 1 while allowing the hub 56 to pivot. Other connections like a ball and socket joint may be utilized to accomplish this retention and movement capability. It should be understood that the term “pin” is a generic term and can be utilized to mean screw, post or other connection device.
The extension 28 of the pivot flange 24 is received within the bore 30 of the blade attachment boss 32 as shown in FIG. 1 . A pin 68 extends through bore 64 in the extension as well as through side slots 66 which not only accommodates the pin 68 , but also allows for pivoting about tilting axis 70 , at least to a limited degree such as less than about plus or minus twenty degrees relative to shaft axis 17 . Tilting axis 70 is preferably perpendicular to as well as spaced from rotation axis 60 .
The shoulder 14 of the blade 12 is captured within the mouth 72 of the balde attachment boss 32 and, depending on the tolerances of the shoulder 14 relative to the mouth 72 , a connector pin 74 may assist in retaining the shoulder 74 in the mouth 72 .
While the clamp 48 is substantially illustrated as a box in FIG. 6 , it could have sufficient more structure as shown in co-pending U.S. patent application Ser. No. 10/133,663 or other clamp configurations which show how the retractor shaft 16 can be configured to rotate relative to ring 46 about axes 52 , 54 . The pivoting of a retractor shaft 16 into an incision to direct a retractor blade 12 into a wound has been done, however, the retractor blade has been traditionally rigidly connected to the retractor shaft 16 in the prior art.
Accordingly, as the clamp 48 rotates the retractor shaft 16 downwardly, the tissue contact surface 76 shown in FIG. 1 would be angled at a similar angle as the downward tilt of the retractor shaft 16 relative to the ring 16 at the clamp about the axis 52 in a prior art retractor. Accordingly, the connector 18 allows for the tissue contact surface 76 to be maintained adjacent to tissue 58 (and perpendicular to the direction of retraction) as shown in FIG. 6 , even when the retractor shaft 16 is downwardly rotated about axis 52 .
Additionally, when the clamp 48 rotates about axis 54 relative to the ring 46 and/or the clamp 48 is positioned so that the plane extending through axis 54 and retractor shaft 16 does not intersect a plane perpendicular to the tissue contact surface 76 extending through stem 14 , the tissue contact surface 76 may be still maintained contact with the tissue 58 since the slot 50 allows for the side to side rotation, pivoting or swiveling of the hub 56 about the rotation axis 60 , and thus the stem 14 and tissue contact surface 56 of the retractor blade 12 so that it maintains optimal contact with tissue 58 as shown in FIG. 5 .
In the preferred embodiment, the hub 56 is free to pivot about rotation axis 60 as necessary within slot 50 , however in other embodiments, the slot 50 may be configured to lock the hub 56 in a desired position, if necessary. The pin 68 is also free to move within side slots 66 in the preferred embodiment to allow up and down movement about tilting axis.
Rings 46 known in the art are not necessarily circular in their circumference, and some rings may then be substantially linear. Furthermore, there are a plurality of different kinds of clamps 48 apart from those described and illustrated in co-pending application Ser. No. 10/113,663 which could utilize the assembly 10 shown and described herein.
Although most retractor shafts 16 have a square cross section along a linear length, other cross sectional shapes could also be utilized in accordance with the present invention. Furthermore, depending on a particular anticipated uses and angular relationship of the shoulder 14 relative to retractor shaft 16 , the angular travel both laterally (i.e., from side to side as well as top to bottom) may be adjusted. This is believed to assist in maintaining the tissue contact surface 56 in an incision against tissue 58 . While the preferred top to bottom range of motion is less than +/−30° and more particularly about +/−20 degrees, and the preferred range of side to side motion is about 120°, these angles may be restricted and/or expanded depending on the particular needs of the retractor system and assembly 10 utilized.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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A retractor clamp assembly includes a clamp positionable about a support ring. A retractor shaft extends from the clamp and has a connector at the end with a retractor blade connected thereto by a stem. The connector is preferably equipped with a first slot limiting the side to side angular range of motion of the retractor blade stem relative to the retractor shaft, and a second slot limiting the top to bottom range of motion of the retractor blade stem relative to the retractor shaft. This allows the retractor blade to be maintained and/or positioned in an optimum position relative to retracted tissue while allowing the retractor shaft to be selectively positioned by a user.
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BACKGROUND OF THE INVENTION
The invention pertains to a blind-stitch sewing machine including a fabric bending arrangement which makes the fabric to be sewn bulge as it advances.
Blind-stitching machines are known as represented in German Patent No. 11 02 535. In this patent, the fabric bender is axially displaceable in a bearing sleeve against the opposing force of a helical compression spring mounted in this sleeve. The bias of the spring can be changed without thereby affecting the position of the fabric bender relative to the sleeve. The sleeve extends perpendicular to a throat plate mounted on the head of the blind-stitching machine and is axially displaceable to-and-fro on a fabric support arm of the machine by means of a drive shaft supported in said arm. The sleeve is connected to the drive shaft such that the minimum distance by which the sleeve may approach the throat plate when the machine is in operation can be changed. A stop, against which the fabric bender curves or bulges the material to be sewn, is pivotably supported by the throat plate on the side away from the fabric bender so as to pivot about an axis transverse to the direction of advance of the material being sewn or stitched. The stop can be adjusted by a setting screw engaging to stop and threaded into the throat plate in order to assure that the depth of stitching into the material being stitched by the arc needle pivoting to-and-fro on the side of the throat plate away from the fabric bender, which stitch depth is defined by means of the particular setting of the minimum distance between the driven sleeve and the throat plate, is maintained even when said material becomes transiently thicker. For the same purpose also, the bias of the helical compression spring loading the fabric bender can be set correspondingly.
Known blind-stitch sewing machines are not immediately suitable for the sewing of labels having an unevenly thick rim onto the inside of finished garments. There is no assurance that when sewing such a label along its rim, the arc-needle of the blind-stitching machine will always penetrate equally deep into the garment, such as, for example, when sewing a tetragonal label having two parallel edges folded over so that the label includes both single-ply label edges and the double-ply ones. This is, however, required to affix a label in a problem-free manner. If, for instance, the label is to be sewed onto a garment having a thin lining, the arc-needle may not penetrate the fabric layer covered by the thin lining, and on the other hand the arc-needle may not avoid stitching the lining.
Using straight needles, it is known to sew labels, cut from a band and of which both cut edges were folded, to the inside of finished garments, at all four label edges. In such arrangements, the needle perpendicularly and totally pierces both the label edges and the garment. As a drawback, the stitchings at the label edges are visible both on the label and also on the garment outside. Examples of such arrangements are represented by U.S. Pat. No. 2,560,186 and German Auslegeschrift 1,660,818. Moreover it is known, as disclosed in German Patent Nos. 3,515,189 and 3,519,849, to stitch labels spot-wise to garments by means of special blind-stitch sewing machines producing so-called point locks. These stitches are not visible on the garment outside.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a blind-stitch sewing machine capable of sewing various polygon shaped labels of unevenly thick rims, especially rectangular or tetragonal labels with two folded parallel edges, in a problem-free manner to finished garments along the peripheral label edge or along all label edges.
The invention provides a blind-stitch sewing machine having an elastic fabric bender to bulge the material to be sewed following each step of advance through an aperture of a throat plate into the arcuate path of motion of an arc needle pivoting to-and-fro transversely to the direction of advance of the material being sewed, and a stop for the bulged material mounted on the throat plate. The stop of the throat plate is designed for the purpose of sewing labels having unevenly thick rims onto the inside of finished garments along the label rim so that the arc needle pierces the edge of the label laid on the garment and emerges from the garment and the label rim is lifted off the garment at the stop so that only the garment is forced by the fabric bender against the stop.
The invention will now be described with respect to a preferred embodiment of the blind-stitch sewing machine of the invention as illustrated in the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a label sewed by the blind-stitching machine of the present invention to an inside surface portion of a finished garment;
FIG. 2 is the section of the blind-stitching machine along line II--II of FIG. 3 with the item to be sewed inserted during sewing;
FIG. 3 is the section of the blind-stitching machine along line III--III of FIG. 2, but without the item to be sewed; and
FIG. 4 is the elevation of the blind-stitching machine in the direction of the arrow IV in FIG. 3 but with the item to be sewed inserted during sewing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The blind-stitching machine arrangement illustratively shown in FIGS. 2 through 4 is employed to sew a rectangular label 1 as shown in FIG. 1 along all four label edges 6, 7, 8 and 9 by stitching 10 along each edge extending into the lining 2 of a coat 3 in the vicinity of the center back seam 4 of the outer coat fabric 5. The two long label edges 7 and 9 are single ply; the two cross-edges 6 and 8 are double-ply because the label is cut off a band and the two cut label edges 11 are folded. The sewn label 1 is transverse to the back seam 4 of the outer coat fabric 5.
With reference to FIGS. 2 and 3, the blind-stitching machine comprises a throat plate 12 and an arc-needle 13 pivoting to-and-fro above the throat plate 12 along an arcuate path in the direction of the arrows 14 and 15 when the machine is operating. The throat plate 12 and the arc-needle 13 are mounted on the head of the sewing machine.
The blind-stitching machine also comprises a fabric presser plate 17 loaded by a helical compression spring 16 toward the throat plate 12 and a fabric bender 18 extending perpendicular to throat plate 12. Fabric bender 18 moves rectilinearly to-and-fro in the direction of the arrows 19 and 20 when the machine is operating. The fabric presser plate 17 and the fabric bender 18 are present at the free end of a machine fabric support arm 21 which end provides a rest for the helical compression spring 16 of the fabric presser plate 17. Both the fabric presser plate 17 and the free end of the fabric support arm 21 project underneath the head of the blind-stitching machine.
The fabric bender 18 is axially displaceble against the force of a helical compression spring 25 located inside a bearing sleeve 24. Sleeve 24 is axially displaceable relative to fabric support arm 21 by rotation of a drive shaft 23 having an integrally formed drive lever (not labeled) connected to an extension of sleeve 24 through a drive link 22. Fabric bender 18 cooperates with a stop 26 on the throat plate 12 as clearly shown in FIG. 2. The bias of the helical compression spring 25 mounted in the sleeve 24 can be changed by means of an adjustment nut 29 present on a threaded end of shank 28 of the fabric bender 18 which projects from base 27 of sleeve 24. A locking nut 30 is also threaded on the end of the shank 28 in order to lock nut 29 at the desired biasing position.
As shown in FIGS. 3 and 4, stop 26 is L-shaped and comprises a first arm 31 and a second arm 32 positioned orthogonal to each other. The throat plate 12 comprises a projection 33 on the side away from the fabric bender 18 and projection 33 provides a pivot axis 34 for stop 26. Stop 26 is arranged such that first arm 31 enters a slot 35 of the throat plate 12 in the direction of the fabric bender 18 with the second arm 32 of the stop 26 being approximately parallel to the throat plate 12 and resting, by means of an adjustment screw 36, against the throat plate 12. Adjustment screw 36 is screwed into a threaded borehole (not labeled) located at the free end of second arm 32. In order to permit pivoting, stop 26 is provided with a bolt 37 having a head 39 and received in a corresponding borehole 38 at the free end of the projection 33. The throat plate 12 further comprises a bridge 40 spanning, at the end away from the adjustment screw 36, the slot 35 of the throat plate 12 which is transverse to the pivot axis 34 of the stop 26.
As best shown in FIG. 2, the free end of the fabric bender 18 is designed conically to taper transversely to the slot 35 of throat plate 12. First arm 31 of the stop 26 comprises a groove 41 at the free end facing the top of fabric bender 18. Groove 41 extends parallel to slot 35 and is bounded on the right side of FIG. 2 by a beak 42 slanting from the right downward and being part of first arm 31. Stop 26 comprises a guide strip 43, as shown on the right side of FIG. 2, which extends parallel to its second arm 32 (FIG. 3). The spacing of guide strip 43 from the lateral beak 42 of first arm 31 is adjustable by means of two screws 44 which affix guide strip 43 to stop 26. Each screw 44 passes through an elongated slot 45 located in the guide strip 43 parallel to first arm 31.
In addition to the fabric presser plate 17 and the fabric bender 18, the fabric support arm 21 of the blind-stitching machine comprises a fixing needle 46 extending parallel to fabric bender 18 and on the right side thereof, as shown in FIG. 3. Fixing needle 46 can be moved by means of a compressed-air actuator 47 toward slot 35 of throat plate 12, the compressed-air actuator 47 being arranged to displace a support 48 comprising an arm 49 supporting fixing needle 46 and bent-off at a right angle to fabric bender 18 and resting by its end face 50 transverse to the fabric bender 18 against an upright side surface 51 of fabric bender 18. Arm 49 abutting side surface 51 of fabric bender 18 prevents rotation of fabric bender 18 in bush or sleeve 24.
When the label 1 is affixed to the coat 3, first the label edge 6, then the label edge 7, next the label edge 8 and lastly the label edge 9 are sewed onto the lining 2 of the coat 3, each by a stitching 10. The coat 3 and the label 1 are placed into the blind-stitching machine and are rotated by a right angle at the end of each of the first three stitchings 10 so that the four label edges 6, 7, 8 and 9 consecutively move past the stop 26 of throat plate 12 on the right side of stop 26 as shown in FIG. 2.
In the course of each stitching 10, the coat 3 and the label 1 are advanced in conventional stepwise manner in the direction of the arrow 52 (FIGS. 3 and 4). Following each step of advance, the elastic fabric bender 18 makes the coat 3 bulge through the aperture of the throat plate 12 formed by slot 35 extending in the direction of advance 52. This presses the coat 3 against stop 26 of throat plate 12, namely into groove 41 of first arm 31 of stop 26, while the label edge 6 or 7 or 8 or 9 is separated by beak 42 of first arm 31 of stop 26 from lining 2 of coat 3. Beak 42 enters between lining 2 and label edges 6, 7, 8 and 9 respectively. The spring-loaded fabric-presser plate 17, which comprises an aperture 53 for fabric bender 18 and a foot 54 axially displaceable in fabric support arm 21 of the blind-stitching machine, forces coat 3 and label 1 against throat plate 12 as shown clearly in FIG. 2, wherein the two segments of fabric presser plate 17 on each side of fabric bender 18 are shown to be correspondingly mutually offset in height. Alternatively, fabric presser plate 17 may consist of two parts mounted to the right and left in FIG. 2 of the fabric bender 18 with each being independently displaceable vertically relative to throat plate 12.
The arc-needle 13 pivots to-and-fro transversely to the direction of advance 52. Upon each step of advance, arc-needle 13 pierces label edge 6, 7, 8 or 9 that has been lifted by beak 42 of stop 26 from the coat 3 or its lining 2 and that rests against guide strip 43 of stop 26. Strip 43 is also located on the side of the stop 26 facing the arc-needle 13 when arc-needle 13 pivots into the piercing direction 14. After label edge 6, 7, 8 or 9 has been pierced, the arc-needle 13 pierces lining 2 of coat 3 at the apex of the bulge caused by the fabric bender 18 and emerges from lining 2, as shown in FIG. 2. Then, arc-needle 13 pivots back in the direction of arrow 15 as shown in FIG. 2.
Stop 26 of throat plate 12 is set by means of adjustment screw 36 so that arc-needle 13 reliably dips into only the lining 2 of coat 3, not the outer material 5 of the coat. Guide strip 43 of stop 26 is adjusted so that the desired spacing 55 between each stitching 10 and the pertinent label edge 6, 7, 8 or 9 is obtained (FIG. 1).
Fixing needle 46 is employed when coat 3 and label 1 are rotated about a right angle at the end of each of the three stitchings 10 along the first, second, third label edges 6, 7 and 8 respectively. For example, if edges 6, 7 and 8 of label 1 have been sewn to lining 2 of coat 3, the last stitch 56 has been competed, and coat 3, as well as label 1, have been advanced by one step in the direction of arrow 52, as represented in FIG. 4, said advancing being effected during the pivoting motion of the arc-needle 13 in the direction of arrow 15 after having left label edge 8 and during its ensuing pivoting motion in the direction of arrow 14 in FIG. 2 into the position shown in FIG. 4 which is shortly ahead of the piercing position, the blind-stitch sewing machine is stopped, and the compressed air actuator 47 is actuated in order to move fixing needle 46 so that it enters at least coat 3 or its outer fabric 5 and lining 2 at the site of the last arc-needle piercing point 57. That is, fixing needle 46 enters below the point where the arc-needle 13 last pierced label edge 8. Finally, fabric presser plate 17 is moved away by a compressed-air actuator (not shown) from throat plate 12 in order to release coat 3 and label 1. At this point, the operator(s) can rotate coat 3 and label 1 ninety degrees about fixing needle 46 in the direction of arrow 58 of FIG. 4, and the fourth label edge 9 can be sewed onto lining 2 of coat 3. This stitching will continuously join stitching 10 of the third label edge 8 with the needle thread 59 and the bobbin thread 60 of the double lock stitch-blind-stitch sewing machine passing between these two stitchings in the manner shown in FIG. 4 for the two stitchings 10 of the second and third label edges 7 and 8 respectively.
Although disclosed with respect to a particular embodiment of the invention, it is to be understood that various changes and/or modifications may be made without departing from the spirit of the invention as defined by the following claims.
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A blind-stitch sewing machine has an elastic fabric bender to bulge the material to be sewed following each step of advance through an aperture of a throat plate into the arcuate path of motion of an arc needle pivoting to-and-fro transversely to the direction of advance of the material being sewed, and a stop for the bulged material mounted on the throat plate. The stop of the throat plate is designed for the purpose of sewing labels having unevenly thick rims onto the inside of finished garments along the label rim so that the arc needle pierces the edge of the label laid on the garment and emerges from the garment and the label rim is lifted off the garment at the stop so that only the garment is forced by the fabric bender against the stop.
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BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
This invention relates to the manufacture of alcohols. More particularly, this invention relates to a method for the preparation of primary branched alcohols from certain normal hydrocarbons and formaldehyde in the presence of free radical initiators. The product alcohols are obtained as a mixture of species which can have one more carbon atom than the starting material. These alcohols may be used as intermediates for the production of detergents and plasticizers and as solvents.
2. Information Disclosure Statement
Among the many alcohols of commercial significance, fatty alcohols and their derivatives are of great importance as surfactants, plasticizers and as intermediates for the production of monomers, polymers, lubricating oils and the like. The most widely used are the fatty alcohols having from 12 to 15 carbon atoms. The "detergent" alcohols are defined by the Chemical Economics Handbook, Alcohols, 609.5021G (SRI Intl.1987) as alcohols having twelve or more carbon atoms and having a carbon backbone with a "high degree of linearity". This is a convenient category for such alcohols, since they are used primarily in detergent applications (although also used in a number of diverse applications) and alcohols having less than twelve carbons are used to a greater extent in other products and are often referred to as "plasticizer" alcohols. Highly branched alcohols having more than twelve carbons are also excluded. Alcohols derived from animal fats and vegetable oils have carbon backbones that are completely linear, but those derived from ethylene and n-paraffins may range from 35 to 99 percent linear. However, the types and levels of branching still permit the use of such alcohols in most detergent applications. Plasticizer alcohols, i.e. the primary aliphatic alcohols having from 4 to 13 carbons (excluding the linear versions with 12 or 13 carbons) are discussed in the Chemical Economics Handbook, Id. at 609.4021C.
There are many methods known in the art for the preparation of alcohols. See Buehler and Pearson, Survey of Organic Synthesis Wiley Interscience, New York, 174, (1970). For example, solvolysis of esters, halides, xanthates, amines, cyclic ethers etc. produce a variety of alcohols. These alcohols always contain the same number of carbon atoms as the starting material. This can be represented by the following equation: ##STR1##
Paraffinic hydrocarbons such as n-dodecane can be converted to corresponding straight-chain alcohols by direct oxidation, as described by I]am et al. in "Liquid-Phase Oxidation of n-Dodecane in the Presence of Boron Compounds", Ind. Eng. Chem. Prod. Res. Dev.", Vol. 20, pp. 315-19 (1981).
It is known to prepare alcohols which contain one carbon more than the starting material by hydroformylation (the oxo process) of olefins. This process is not new in the art and can be represented as follows: ##STR2##
Formaldehyde may be added to olefins to form alcohols with one more carbon than the starting olefin (Arundale and Mikeska, Chem. Rev., Vol. 51, pp. 505, 506 and 528-39, (1952). ##STR3##
Oyama discloses the reaction of primary and secondary alcohols with formaldehyde in the presence of free radical generators to produce glycols in J. Orq. Chem., Vol. 30, pp. 2429-32 (1965). Kollar in U.S. Pat. No. 4,337,371 disclosed a method for the preparation of ethylene glycol wherein methanol and formaldehyde are reacted in the presence of an organic peroxide and water to form ethylene glycol. Yeakey and Applicant Sanderson disclose in coassigned U.S. Pat. No. 4,550,184 a method for the preparation of 2-hydroxymethyl-l,3-dioxolane from 1,3-dioxolane and formaldehyde in the presence of an organic peroxide. See also coassigned U.S. Pat. No. 4,628,108, in which an ionizable metal salt is used in conjunction with the organic peroxide. An article by Sanderson et al., "Free Radicals in Organic Synthesis. A Novel Synthesis of Ethylene Glycol Based on Formaldehyde," J. Org. Chem., Vol. 52, pp. 3243-46 (1987), discloses the reaction of 1,3-dioxolane with formaldehyde in the presence of free radical initiators to form an intermediate which can be catalytically hydrogenated to ethylene glycol.
U.S. Pat. No. 2,818,440 discloses processes for additions of methylol groups to saturated hydrocarbons, including linear paraffins and cycloparaffins, which employ formaldehyde and organic peroxides. The methylol group can be added to an internal carbon of a linear paraffin. In the preferred mode, a saturated organic compound such as a paraffin or cycloparaffin is in a liquid phase in which the peroxide is dissolved, while the formaldehyde is present in a separate, generally aqueous, liquid phase. Alternatively, gaseous formaldehyde can be added to such a liquid organic phase in the reactor. See Rust et al., "Free Radical Addition of Cyclopentane and Cyclohexane to Formaldehyde", J. American Chem. Soc. Vol. 80, pp. 6148-49 (1958).
Despite the various routes described and the ones which have been devised, there is still a need for a method for producing primary branched alcohols from readily available but non-reactive normal hydrocarbons such as n-alkanes.
Additionally, it would be an advance in the art to prepare branched alcohols from normal hydrocarbons.
SUMMARY OF THE INVENTION
An object of the present invention is an improved process for the production of primary branched alcohols from normal alkanes, especially for the production of branched alcohols in the detergent range of carbon numbers. Other objects and advantages of the invention will be apparent from the following detailed description, including the appended claims.
It has been surprisingly discovered in accordance with the present invention that when certain normal saturated hydrocarbons are reacted with formaldehyde in the presence of a free radical initiator the reaction preferentially involves the addition of the formaldehyde to an intermediate carbon of the hydrocarbon to form primary branched alcohols. The formaldehyde is preferably introduced in the form of paraformaldehyde or trioxane, and the reaction is preferably carried out in non-aqueous or anhydrous media. These conditions are believed to increase the yield of the desired primary branched alcohols relative to byproducts such as n-alkanols and diols. The products obtained are mixtures of such primary branched alcohols having a methylol group bonded to one of various internal carbon positions in the alkane substrate. The reaction products formed contain significant quantities of primary branched alcohols which contain one more carbon than the starting material. The relationship between the reactants and products can be expressed by the equatron below: ##STR4## where x and y can be 0, 1, 2, 3, . . . up to about 15 and x + y = from 0 to 15, preferably 6 to 14. Thus, the normal alkane starting materials can have from about 3 to about 18 carbon atoms, while the corresponding product alcohols will have from about 4 to about 19 carbon atoms. Mixtures of suitable alkanes such as commercially available fractions of petroleum oils can be employed as reactants, resulting in product mixtures varying in molecular weight as well as methylol group position. Although products based upon substantially linear alkanes are preferred, the invention can be practiced with starting materials which are lightly branched, i.e., containing no more than two methyl or ethyl side chains per molecule.
DETAILED DESCRIPTION OF THE INVENTION
Starting Materials
The starting materials for the instant invention are certain normal hydrocarbons, formaldehyde and a free radical initiator.
In the instant invention where normal alkanes are reacted with formaldehyde in the presence of a free radical initiator to produce primary branched alcohols the reaction can be represented by the equation above. The product branched primary alcohols are obtained as mixtures of positional isomers.
The starting materials for the present invention comprise normal hydrocarbons, having from 3 to about 18 carbon atoms, preferably normal alkanes having from about 8 to about 18 carbon atoms. The normal alkanes which can be used in the process of the invention most preferably include those containing about 10 to 14 carbons, which include n-decane, n-undecane, n-dodecane, n-tridecane and n-tetradecane. These materials produce alcohol products in the detergent range. Mixtures of alkanes can be employed. The detergent range alcohols (having about 6 to about 14 carbon atoms) can be reacted with ethylene oxide to produce nonionic detergents; see e.g. Kirk-Othmer's Encyclopedia of Chemical Technology, Third Edition, Vol. 22, page 360 (New York 1980). The lighter alcohols can be employed as additives or blending agents for motor fuels and as intermediates for the production of ethers which are also useful as additives and blending agents for fuels.
Formaldehyde may be employed in its conventional monomeric form as an aqueous formalin solution (37 percent formaldehyde), in "inhibited" methanol solution, as gaseous formaldehyde, as paraformaldehyde, or as trioxane. Paraformaldehyde or trioxane are the preferred starting materials. Gaseous formaldehyde can also be employed.
The free-radical initiator employed in the process of the present invention is preferably selected from the organic peroxides, organic hydroperoxides or certain azo compounds.
Suitable organic peroxides have the following formulas: ##STR5##
In the organic peroxide R and R' are each an alkyl or aralkyl group having 1 to 20 carbon atoms. Organic peroxides which may be used include di-tert-butyl peroxide, methyl-tert-butyl peroxide, di-cumyl peroxide, tert-butyl cumyl peroxide, tert-butyl perbenzoate etc. The preferred organic peroxide is di-tert-butyl peroxide.
Hydroperoxides which are substantially oil-soluble, such as tert-butyl hydroperoxide, tert-amyl hydroperoxide and triphenylmethyl hydroperoxide, can be used, but product yields would be expected to be lower.
Suitable azo compounds can have structures represented by the following formula: ##STR6## wherein R, R', R", R'" may be alike or different and may be alkyl as well as aralkyl. R, R', R", R'" can contain from 1 to 12 carbon atoms. Representative compounds include 2,2'-azobis(2-methylpropionitrile).
Reaction Conditions
In the reactions of the present invention the desired product of the invention is an equimolar addition product of the normal alkane hydrocarbon and formaldehyde. A molar excess of either reactant may be used, but it is preferred to use the normal alkane in excess, since it also serves as the solvent for the reaction and the product yield has been found to vary with the ratio of alkane to formaldehyde. While the ratios of the reactants are conveniently expressed in terms of moles per mole or in terms of weight (as in the examples herein), the number of available methylene groups in the hydrocarbon per mole of formaldehyde must be considered in selecting ratios from the above ranges. In addition, the selection of molar ratios which provide a high ratio of such available methylene groups to formaldehyde tends to favor high yields of the desired products in which a single methylol group is added to a methylene group. Generally the molar ratio of alkane to formaldehyde should be in the range of from about 0.3 to about 5, preferably from about 0.7 to about 4, most preferably from about 1 to about 3, or say about 2:1. Within these preferred ranges, adjustments should be made for different reaction temperatures and proportions of the initiator to the alkane.
The organic peroxide, hydroperoxide or azo compound is suitably used in an amount ranging from about 0.2 to 25 wt percent based o the branched hydrocarbon. Preferably, from about 2 to 15 wt percent of the organic peroxide is used.
If organic peroxides or hydroperoxides are used as the free radical initiator, the reaction is suitably conducted at a temperature within the range of about 80° C. to 280° C. and more preferably within the range of about 80° C. to about 180° C. With azo compounds, the temperature should be within the range of from about 40° C. to about 120° C.
The reaction can be conducted at any suitable pressure of atmospheric or above, but is preferably conducted at superatmospheric pressure. The preferred pressure is between atmospheric and about 100 psi.
In all embodiments, reaction times of from about 0.10 to about 10 hours may be employed with satisfactory results. Preferably, the reaction time will be in the range of about 1 to about 5 hours.
In all embodiments the reaction may be conducted in inert solvents such as chlorobenzene, bromobenzene, nitrobenzene, benzene, acetonitrile, tert-butyl alcohol, etc. but there is no advantage in doing so. The normal alkane starting material is a satisfactory solvent and reaction medium. The reaction can be carried out in the liquid state, in the gaseous state or in mixed states wherein the reactants are at least partially in the vapor state. Paraformaldehyde and trioxane are generally introduced as solids, but produce formaldehyde in solution or gaseous form at elevated temperatures.
At the end of the reaction, the reaction mixture may be separated into components to recover the product by any suitable technique such as distillation, filtration, solvent extraction, etc.
As indicated earlier, the alcohol products of this invention may be useful as intermediates for the production of detergents, plasticizers, monomers and polymers, lubricating oils and the like, and directly as solvents and fuel additives. A preferred application is the production of nonionic detergents.
EXAMPLES
The present invention is further illustrated by the following non-limiting examples.
EXAMPLE 1
First Reduction to Practice
n-Dodecane (99 percent +, 50.0 g), paraformaldehyde (10.0 g), and di-tert-butyl peroxide (5.0 g) were charged to a 300 cc stainless steel autoclave equipped with a glass liner and magnedrive stirrer. The autoclave was sealed and the mixture heated slowly (ca. 1 hr.) to 150° C. and held at 150° C. for four hours. The mixture was then cooled to ambient temperature, vented and decanted from a small amount of solid. The liquid products were analyzed by GC. The products included 2.48 weight percent tridecanols (primary branched alcohols) and a small viscous lower layer which was rich in tert-butyl alcohol, acetone and tridecanols.
EXAMPLE 2
n-Dodecane (99 percent +, 80 ml), paraformaldehyde (5.0 g), and tert-butyl peroxybenzoate were charged to a 200 ml round-bottomed flask, equipped with water-cooled condenser, heating mantle, and magnetic stirrer. The mixture was heated for 4.0 hours at 135° C. GC analysis indicated the presence of 1.36 wt. percent tridecanols.
EXAMPLE 3
n-DodeCane (100.0 g), paraformaldehyde (10.0 g), and di-tert butyl peroxide (6.0 g) were charged to a 500 cc stainless-steel "zipper" autoclave. This mixture was heated at 150° C. for 6.0 hours. The reaction mixture was then cooled to ambient temperature, vented, and a liquid product (112.7 g) obtained. A lower viscous phase (15 g) was also obtained. Analysis of the upper layer by GC/FTIR indicated the presence of 3.52 area percent tridecanols and 0.87 area percent tridecanol formate ester. Analysis of the lower layer indicated the presence of 13.5 area percent tridecanols.
EXAMPLE 4
n-Dodecane (100.0 g), paraformaldehyde (12.0 g), di-tert-butyl peroxide (10.0 g) and tert-butyl alcohol (25.0 g) were charged to a 500 cc stainless-steel "zipper" autoclave equipped with stirrer, heating means, etc. The mixture was heated at 150° C. for 5.0 hours. The reaction mixture was then cooled to ambient temperature, vented and 130.0 g of homogeneous solution obtained. Analysis of the reactor effluent by GC/FTIR indicated the presence of 2.55 area percent tridecanols. There was only 0.08 area percent tridecanol formate present.
EXAMPLE 5
n-Decane (100.0 g), paraformaldehyde (17.0 g) and di-tert-butyl peroxide (13.0 g) were charged to a 500 cc stainless-steel "zipper" autoclave equipped with stirrer, heating mantle, etc. The reaction mixture was then heated to 150° C. and held at 150° C. for 6.0 hours. The mixture was then cooled to ambient temperature, vented and 126.4 g liquid obtained. Analysis by GC/FTIR indicated the presence of 3.2 area percent undecanols. There was 0.4 area percent undecanol formates also present.
EXAMPLE 6
n-Dodecane was reacted with paraformaldehyde in the presence of di-tert-butyl peroxide (DTBP) under the conditions indicated in Table 1.
A variable study was conducted and the reaction mixtures analyzed using GC. analysis. Representative results are shown in Table 1.
TABLE 1______________________________________Reaction of n-Dodecane with Formaldehyde Under VariousConditions Alkane.sup.1 /Example Formal- Alkane.sup.1 / Time Temp. ProductNo. dehyde M/R.sup.4 DTBP (HR) (°C.) (wt %)______________________________________ 6.sup.2 20.0 3.5 20.0 4.0 150.0 3.14 7.sup.2 10.0 1.8 20.0 4.0 150.0 3.58 8.sup.2 5.0 0.9 20.0 4.0 150.0 4.19 9.sup.3 20.0 3.5 10.0 4.0 150.0 8.0810.sup.3 20.0 3.5 10.0 4.0 150.0 7.1911.sup.3 10.0 1.8 10.0 4.0 150.0 7.4512.sup.3 10.0 1.8 10.0 4.0 150.0 5.5113.sup.3 5.0 0.9 10.0 4.0 150.0 5.1114.sup.3 5.0 0.9 10.0 4.0 150.0 2.7215.sup.3 10.0 1.8 6.67 4.0 150.0 8.4916.sup.3 10.0 1.8 6.67 4.0 150.0 6.8117.sup.3 10.0 1.8 6.67 6.0 140.0 5.918.sup.3 5.0 0.9 10.0 6.0 140.0 3.6019.sup.3 6.67 1.33 6.67 4.0 150.0 6.5120.sup.3 20.0 3.5 6.67 4.0 150.0 7.3821.sup.3 5.0 0.9 25.0 4.0 150.0 2.8______________________________________ .sup.1 Weight Ratios. .sup.2 Conducted in 500 cc stainless steel "zipper" autoclave. .sup.3 Conducted in 300 cc autoclave equipped with glass liner. .sup.4 Molar Ratios.
EXAMPLE 14
The reaction of 50 g n-dodecane with 12 g paraformaldehyde as in Examples 9-13 using 10 g of di-tert-butyl peroxide (DTBP) as initiator was found to produce a concentration of tridecanols of about 3.5 percent. These alcohols were easily separated from unreacted hydrocarbon and other impurities by vacuum distillation through a small Vigreux column (108-125° C. at 0.6-0.7 mm Hg°). The positional isomers were not separated but proton and 13 C nuclear magnetic resonance spectroscopy indicated that most of the addition reactions took place in the 2-position of n-dodecane. Only a small amount of addition took place in the 1-position. The relative mole ratios of the positional isomers obtained are shown below. ##STR7##
______________________________________Addition in Position Relative Mole Ratio______________________________________1- small2- 5.03- 3.04- 2.05- 3.56- 3.5______________________________________
GLOSSARY
GC/FTIR: Gas Chromatography/Fourier Transform Infrared Spectroscopy
Di-tert-butyl peroxide
Area percent: Area of gas chromatography peak as a percent of the total area of all peaks.
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A method for the preparation of branched primary alcohols comprises reacting a normal alkane with formaldehyde in non-aqueous media in the presence of a free radical initiator. The reaction involves the preferential addition of formaldeyhde to internal carbon atoms of the normal alkane, resulting in a branched primary alcohol containing one carbon more than the alkane reactant. The product alcohols are obtained as mixtures of positional isomers.
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RELATED APPLICATION
[0001] The present application is a continuation patent application that claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 12/358,110, entitled “Pants with V-Shaped Waistband,” which was filed on Jan. 22, 2009, and the complete disclosure of which is hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention relates generally to apparel. More particularly, this invention relates to pants with a v-shaped waistband for a closer fit to a waist, particularly in the center back region.
BACKGROUND OF THE INVENTION
[0003] FIG. 1 illustrates a typical prior art waistband formed from a single rectangular strip of material 100 . FIG. 2 illustrates pants 200 with the strip 100 sewn to a pant leg 202 , which includes a pocket 204 . This prior art pant configuration frequently results in a “back gap”, shown by arrow 206 . The back gap is the region between the waistband and the back of the individual (not shown) wearing the pants 200 . This back gap is particularly apparent when the individual wearing the pants 200 is in a sitting position.
[0004] Some pants utilize an elastic waistband to address the back gap problem. Many individuals find elastic waistbands aesthetically unpleasant.
[0005] Therefore, it would be desirable to provide a new pant configuration that minimizes back gap, while maintaining aesthetically desirable qualities.
SUMMARY OF THE INVENTION
[0006] Pants include a waistband shaped to descend from the hip region to a rear center region, thereby resembling a shallow v-shape. The rear center region is configured to reach toward the back of the individual wearing the pants. In one embodiment, a reinforcement patch is used to provide foundation to connect a belt loop to the waistband.
BRIEF DESCRIPTION OF THE FIGURES
[0007] The invention is more fully appreciated in connection with the following detailed description taken in conjunction with the accompanying drawings, in which:
[0008] FIG. 1 illustrates a rectangular waistband utilized in the prior art.
[0009] FIG. 2 illustrates prior art pants formed with a rectangular waistband.
[0010] FIG. 3 illustrates two strips of material used to form a v-shaped waistband in accordance with an embodiment of the invention.
[0011] FIG. 4 illustrates the two strips of material from FIG. 3 sewn together; the figure also illustrates a fold line utilized in accordance with an embodiment of the invention.
[0012] FIG. 5 illustrates the waistband of FIG. 4 after sewing and folding.
[0013] FIG. 6 illustrates a v-shaped waistband formed from a single piece of material in accordance with an embodiment of the invention.
[0014] FIG. 7 is a side view of pants with a v-shaped waistband in accordance with an embodiment of the invention.
[0015] FIG. 8 is a rear view of pants with a v-shaped waistband in accordance with an embodiment of the invention.
[0016] Like reference numerals refer to corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIG. 3 illustrates a first material segment 300 and a second material segment 302 . Each material segment has a v-shaped cut-out 304 at a terminal end. The v-shaped cut-out of the first material segment 300 is folded back to form a first v-fold 306 . Similarly, the v-shaped cut-out of the second material segment 302 is folded back to form a second v-fold 308 .
[0018] The first v-fold 306 and the second v-fold 308 are placed in a face-to-face configuration, which is sewn to form a seam 400 , as shown in FIG. 4 . FIG. 4 also illustrates a longitudinal axis 402 of the resultant waistband. The waistband is folded along the longitudinal axis 402 to form the waistband of FIG. 5 . In particular, FIG. 5 is a rear view of the waistband. Observe that the waistband resembles a shallow v-shape.
[0019] FIG. 6 illustrates an alternate embodiment of the v-shaped waistband. In this embodiment, the material 600 is cut from a single piece of material. The single piece of material may be initially cut to form a shallow v-shape. Alternately, a rectangular strip of material may be used. In this instance, material at the center of the strip is folded and sewn to form the shallow v-shape. The two strip embodiment of FIG. 3 has the advantage of using smaller pieces of material, which may be cut from a base material in a more efficient manner to reduce material waste.
[0020] FIG. 7 is a side view of pants 700 formed in accordance with an embodiment of the invention. The figure illustrates a waistband 702 , such as the waistband of FIG. 5 or FIG. 6 , attached to a pant leg 704 , which includes a pocket 706 . Arrow 708 indicates an eliminated or reduced back gap region. In particular, the rear center region reaches toward the back of the individual (not shown) wearing the pants. The disclosed waistband results in a configuration where the top of the waistband has a slightly smaller circumference than the remainder of the waistband, thereby promoting closer engagement with the back of the individual at the top of the waistband.
[0021] FIG. 8 is a rear view of pants 700 . Observe that the waistband 702 has a subtle v-shape descending from the hip region to the rear center region. When the pants are worn by an individual, the natural shape of the body tends to diminish the observable nature of the v-shape. Thus, an individual enjoys a reduced back gap with a contoured fit. At that same time, when worn on a body, the v-shape is barely observable, thereby creating the aesthetic appeal of a straight waistband. Another benefit of the waistband 702 is that the shape tends to align the grains of the fabric (e.g., denim) in a vertical manner.
[0022] FIG. 8 also illustrates a set of belt loops 800 . In one embodiment, one or more belt loops 800 includes a reinforcement patch 802 . The reinforcement patch is a piece of fabric that is attached to the front and/or back of the waistband. The top and/or bottom of the belt loop 800 is sewn to the reinforcement patch 802 . The reinforcement patch provides more foundation for stitching and thereby anchors the belt loop 800 in a more secure manner. Accordingly, the belt loop 800 is harder to tear away This embodiment is particularly useful for rodeo ropers. The reinforcement patch reduces wear, tear and ripping of a belt loop when a rope is pulled in and out of the loop.
[0023] The reinforcement patch may be formed of leather, faux leather, suede or denim. The pants may also be formed from one or more of the same materials.
[0024] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that specific details are not required in order to practice the invention. Thus, the foregoing descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed; obviously, many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, they thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the following claims and their equivalents define the scope of the invention.
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Pants include a waistband shaped to descend from the hip region to a rear center region, thereby resembling a shallow v-shape. The rear center region is configured to reach toward the back of the individual wearing the pants. A reinforcement patch is used to provide foundation to connect a belt loop to the waistband.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage filing under 35 U.S.C. §371 based upon international application no. PCT/CA2009/001539, filed 26 Oct. 2009 and published in English on 6 May 2010 under international publication no. WO2010/048709, which claims priority to U.S. provisional application Nos. 61/108,619, filed 27 Oct. 2008 and 61/152,420, filed 13 Feb. 2009. All of the foregoing are hereby incorporated by reference as though fully set forth herein.
FIELD
[0002] The specification relates to pleatable materials, or fabrics, for use in filtration, and more particularly for use as pleated “filter bags” in baghouse-type dust collectors, for example.
BACKGROUND
[0003] A dust collector is an equipment to remove particles in an industrial fume. Typically the collector contains between hundreds to thousands of cylindrical elements referred to as bags. The bags are made of a filtration fabric that is porous. As the gas flows through, the porous filtration fabric collects particles. The particles can form a cake on the surface after minutes of operation, and the bags are typically cleaned by a reversed jet.
[0004] One of the important parameters of the filtration fabric is the filtration efficiency. The efficiency of filtration of bags is related to the total surface area. Typically, if the surface area is increased, then the velocity of gas and particles going through the fabric will be reduced, which decreases the probability of undesired particles going through the fabric and can consequently reduces the particle emissions. Moreover, a higher surface area can reduce the probability of particles getting embedded into the fabric in a manner where they resist the reversed jet, thereby increasing the lifespan of the filter. It is also possible, by increasing the surface area, to increase the capacity of a dust collector. It is thus generally sought to increase the surface area of the bags in dust collectors, where possible.
[0005] Typically, pleated bags have a greater surface area than non-pleated bags (i.e. simply cylindrical bags). Using pleated bags instead of non-pleated bags is thus one way of increasing the surface area without necessarily increasing the overall size of the dust collector system. In many cases, replacement of non-pleated bags by pleated bags can increase the surface area by two to three times.
[0006] Pleated bags can be made using a pleatable material which keeps its shape after pleating. The pleating can be done with a pleating machine. Some pleating machines operate at room temperature.
[0007] Alternately, for some materials which require thermosetting to retain their pleats, pleating machines having heating blades are used to fold the fabric and keep pressure on the pleats until the fabric is cooled back to room temperature. Heretofore, such processes have been used with polymers that can be thermally formed and have a relatively small density.
[0008] Some materials that are not thermally formable per se can be made so by adding a thermo-setting resin. An example of this is fiberglass felt impregnated with phenolic resin. The temperature of blades allow setting of the phenolic resin which subsequently acts to maintain the shape of the pleats. The reaction being irreversible, the pleats subsequently keep their shape even at high temperature.
[0009] However, even given the state of the art, some filtration materials could not be pleated by the known means and therefore remained known as being unpleatable. Nevertheless, given some desired characteristics, at least one of these unpleatable filtration materials remained a popular choice for some specific applications despite the fact that it was not available in pleated form. There thus remained a strong need for an equivalent to such ‘unpleatable’ materials in pleated form due to the many advantages of pleats in filtration. This called for improvement.
SUMMARY
[0010] As it will appear from the description below, a filtration material such as a PTFE felt covered by an E-PTFE membrane, which was traditionally known as unpleatable, can now be made pleatable by felting with a pleatable scrim, more particularly a pleatable metallic scrim. There are many metals which are pleatable when provided in apertured sheets, and the pleatability of a metallic scrim can take precedence on the pleatability of both the felted PTFE and the E-PTFE membrane. Felting by hydro-entanglement (spunlacing) can be better suited than needle-felting when using a metallic scrim.
[0011] In accordance with one aspect, there is provided a pleatable filtration material comprising a felt having PTFE fibers felted onto a pleatable metallic scrim, a permeability of at least 20 l/dm 2 /minute at 12 mm of water gauge and a weight between 100 and 1000 g/m 2 , the felt having a density between 150 and 1000 g/m 2 and a permeability greater than that of the scrim and between 20 and 250 l/dm 2 /minute at 12 mm of water gauge; and a membrane laminated onto the felt, made of E-PTFE and having a permeability of between 3 and 75 l/dm 2 /minute at 12 mm of water gauge, preferably between 12 and 50 l/dm 2 /minute at 12 mm of water gauge; wherein the filtration material can be pleated using a traditional pleater at room temperature and thenceforth retain its pleats.
[0012] In accordance with one aspect, there is provided a process of making a pleatable filtration material comprising felting PTFE fibers onto a pleatable metallic scrim having resistance characteristics at least comparable to that of the PTFE fibers, a permeability of at least 20 l/dm 2 /minute at 12 mm of water gauge and a weight between 100 and 1000 g/m 2 , until a felt density between 150 and 1000 g/m 2 in addition to the density of the scrim and a permeability greater than that of the scrim and between 20 and 250 l/dm 2 /minute at 12 mm of water gauge are reached; and laminating an E-PTFE membrane having a permeability of between 3 and 75 l/dm 2 /minute at 12 mm of water gauge, preferably between 12 and 50 l/dm 2 /minute at 12 mm of water gauge onto a face of the felted PTFE fibers.
[0013] In accordance with one aspect, there is provided a pleated filter bag for use in a bag house dust collector, the filter bag being elongated and comprising a longitudinal hollow center with an open end, and a pleated filter wall transversally circumscribing the hollow center, the pleated filter wall having a felt felted onto an apertured and pleatable scrim and having a permeability lower than a permeability of the scrim and appropriate for filtration applications, and a membrane having a permeability substantially lower than the permeability of the felt and covering the felt on the outer side thereof facing the hollow center, wherein all of the scrim, the felt, and the membrane are resistant to a harsh filtration environment of the dust collector.
[0014] In accordance with another aspect, there is provided a filter fabric construction which incorporates a pleatable scrim to the base felt. The pleatability of the scrim takes precedence on the pleatability of the remaining components of the filter fabric, thereby rendering the filter fabric pleatable. This construction, or associated production method, can make pleatable a material such as PTFE, which was traditionally known as non-pleatable.
[0015] In accordance with another aspect, there is provided a pleatable filtration fabric having an E-PTFE laminated PTFE felt. This filtration fabric is made pleatable while at least substantially maintaining the thermal and chemical resistance characteristics of the PTFE by making the PTFE felt with a pleatable, heat-resistant and chemical-resistant scrim. The pleatability of the metallic scrim takes precedence in the combination and makes the entire material pleatable.
[0016] It will be understood that in the instant specification, the expression “pleatable” is to be understood in the context of operability in filtration. A pleatable filtration element will retain its pleats for a reasonable lifespan in the context of a normal or recommended use. For instance, a felt of polyester with a polyester scrim can be viewed as a non-pleatable fabric, whereas spunbounded polyester, which is denser and stiffer, can be viewed as pleatable.
DESCRIPTION OF THE FIGURES
[0017] In the appended figures,
[0018] FIG. 1 is a perspective view, fragmented, showing an example of a felt having a pleatable scrim.
DETAILED DESCRIPTION
[0019] One example of a material which was still used in unpleated form is polytetrafluoroethylene (PTFE), at least partly because of its exceptional thermal and chemical resistance characteristics which made the only viable choice for some harsh environments. An example of an application where unpleated PTFE-based bags were still used is dust collectors of waste incineration facilities. Incinerated wastes typically contain plastics which emit aggressive chemicals such as HCl, H 2 SO 4 , and HF during combustion. PTFE was appreciated for resisting to the combination of high temperatures (.about. 150 to 260° C.) and aggressive chemicals present in such waste incineration gaseous by-products. In applications such as waste incineration where tolerated emission levels were quite low, the PTFE fabric can be covered by a membrane to get a more efficient degree of filtration. A porous expanded PTFE membrane (E-PTFE) can be used to this end, laminated on the PTFE felt.
[0020] Tests attempting to pleat a PTFE felt (with or without catalyst) with a PTFE scrim failed. After pleating, the shape was not kept in a satisfactory way. Further, adding resins to the PTFE was found inefficient, at least partly due to the lack of adhesion and wetting by many of the tested resins on PTFE fibers.
[0021] The mere continued use of non-pleated PTFE filtration bags in dust collectors of applications such as waste incineration facilities, in itself demonstrates the former unavailability of this material in pleated form, considering the strong incentives for using pleated bags instead of cylindrical bags.
[0022] As will be detailed below, it will be understood how such materials and others can now be pleatable by felting the fabric onto a pleatable scrim. A type of pleatable scrim which can be used in making a PTFE felt pleatable is a metallic scrim.
[0023] FIG. 1 shows an exemplary sample of a PTFE felt spunlaced onto a metallic scrim. In this example, the metallic scrim is a square steel screen. As shown in the cut-out portion on the bottom and left-hand side corner of the sample, the metallic scrim is sandwiched between two layers of PTFE felt. In fact, during hydro-entanglement of the PTFE fibers, the fibers are placed on one side of the scrim, and partially pass through it, to the other side. The right-hand side of the sample is shown pleated. The E-PTFE membrane (not shown in the illustration), can later be laminated onto one face of the PTFE felt with metallic scrim. The PTFE felt can act as a support layer for the E-PTFE membrane which has a permeability substantially lower than the permeability of the felt. In use, the E-PTFE membrane faces the outside of the filtration bag and determines the relatively low permeability of the filtration material. The felt can thus be used to provide a cushioned support to the membrane, and, in combination with the metallic scrim, gives mechanical resistance to the membrane which acts as the actual “filter” during use but which is not practically usable alone. In fact, in many applications, the stresses which would be imparted to the E-PTFE membrane by the scrim during use if it was adhered directly thereto instead of being supported via felt, would result in an E-PTFE membrane having a very short useful life. The metallic scrim additionally provides pleatability to the filtration material because its higher pleatability takes precedence in the assembly.
[0024] The felt can be made of expanded porous or non-expanded PTFE fibers. The felt can be made by spunlacing the fibers onto the metallic scrim by a water jet—a process commonly referred to as hydro-entanglement. Hydro-entanglement can allow to avoid or reduce damage to the metallic scrim which could result if using conventional needle felting instead. The felt can have a density between 150 and 1000 g/m 2 , preferably between 250 and 700 g/m 2 , and a permeability between 20 and 250 l/dm 2 /minute at 12 mm of water gauge, preferably above 100 l/dm 2 /minute, for example.
[0025] The metallic scrim can be made of galvanized steel, stainless steel, aluminum, aluminum alloy, bronze, brass, copper, copper-based alloy, nickel, nickel-based alloy, or any suitable metal or alloy, provided it has suitable pleatability and resistance, and that it is ductile enough to be pleated without breaking. The metal can be a woven mesh, a punched metal sheet or any method that will create a metal sheet with suitable apertures in it. The permeability of the material should be greater than the permeability which is desired of the felt, preferably at least 20 l/dm 2 /minute at 12 mm of water gauge. The weight of the metal scrim can be between 100 and 1000 g/m 2 , preferably between 300 and 700 g/m 2 for example. Metallic scrims of various known types of metals can have chemical and temperature resistance characteristics suitable for harsh applications.
[0026] The felted support layer can be treated with a binder prior to lamination of the membrane, or the binder can be omitted. The fibers of the felt can act in a binding manner in certain applications. If used, the binder can be a fluorinated ethylene propylene copolymer (FEP) or a hexafluoropropylene-tetrafluorethylene copolymer, for example, or any other suitable binder. The binder can be provided at a concentration of between 25-50% by weight in a liquid suspension, and be either sprayed on a selected side of the support layer or transferred thereon using a roll. The material can then be heated in an oven at ˜120 to 240° C., to evaporate the solvent. After evaporation, the weight of transferred solid binder can represent a relative weight of between 1% and 10% (relative to the weight of the fabric).
[0027] The membrane, which can be made of commercially available E-PTFE, preferably has a permeability between 3 and 75 l/dm 2 /minute at 12 mm of water gauge, more preferably between 12 and 50 l/dm 2 /minute at 12 mm of water gauge. The membrane can be laminated on the side having the binder at a temperature of 270° C.
[0028] It will be noted that in some instances, PTFE felt for use in applications such as incinerators can have particles of catalyst deposited on the surface or embedded into the PTFE fibers. This can be desirable in a pleatable fabric and typically does not affect pleatability. For example, some catalysts help reducing emissions of dioxin, furan or nitrous oxide from waste incineration. The catalyst typically is typically provided a volume less than 20% of the volume of the PTFE fibers. Examples of catalysts include titanium dioxide (TiO 2 ), iron and cobalt (provided in the form of oxides), nickel, platinum and palladium. Other examples of catalysts include zeolith, copper oxide, tungsten oxide, aluminum oxide, chromium oxide, gold, silver, rhodium etc. If used, the catalyst should be provided in a particles size of less than 10 microns, but can be of any suitable shape, such as spheres, whiskers, plates, flakes, etc.
[0029] A resulting pleatable filtration material, or fabric, can include PTFE fibers spunlaced to a steel scrim, covered by a membrane. Such a fabric can be pleated using a traditional pleater operating at room temperature. The use of a pleatable metallic scrim can render the use of heated pleater blades unnecessary. An exemplary embodiment thereof is provided below:
Example 1
[0030] PTFE fibers are spunlaced onto a 400 g/m 2 stainless steel scrim by hydro-entanglement. After entangling the total weight is 800 g/m 2 . The permeability of the material at this step is about 200 l/dm 2 /minute. The resulting felted support material is then sprayed with a suspension of FEP particles to add about 25 g/m of FEP particles after drying at 150° C. Then, an E-PTFE membrane is laminated thereon with the temperature of the FEP particles raised to 270° C. The resulting filtration material has a weight of 825 g/m 2 , and a permeability between 15 and 30 l/dm 2 /minute at 12 mm of water gauge, and is pleatable at room temperature.
Example 2
[0031] Titanium dioxide particles of less than 10 microns in size are mixed with a PTFE dispersion. The titanium dioxide can correspond to 1-90% by volume, preferably 25-85% by volume, for example. The paste is extruded and calendered to form a tape. The tape is slitted along the length, expanded and processed over a rotating pinwheel to form fibers. These fibers with catalyst on the surface are spunlaced onto a 500 g/m 2 stainless steel 316 scrim by hydroentanglement. After entangling the total weight is 900 g/m 2 . The E-PTFE membrane is laminated directly on the surface of the catalytic felt, the fibers acting as the binding agent. The resulting material has a weight of 900 g/m 2 , a permeability between 15 and 30 l/dm 2 /min at 12 mm of water gauge and is pleatable at room temperature.
[0032] It is to be understood that above example is given for illustrative purposes only. Alternate embodiments can be realized. For instance, thicker or thinner fabrics can be realized using more or less spunlaced PTFE, and different E-PTFE membranes. The pleatable metallic scrim can be applied to materials other than PTFE. Further, other scrim materials than metals can have similar pleatability and resistance characteristics. The use of a catalyst is optional. Given the above, the scope is indicated by the appended claims.
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The pleated filter bag, which can be used in a bag-house type dust collector, is elongated and has a longitudinal hollow center with an open end, and a pleated filter wall circumscribing the hollow center. The pleated filter wall has a felt such as PTFE fibers felted onto an apertured and pleatable scrim which can be made of metal, and having a permeability lower than a permeability of the scrim. A membrane of lower-permeability material, such as an E-PTFE membrane, covers the support felt on the outer side of the bag.
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BACKGROUND OF THE INVENTION
This invention relates to tufting machines and more particularly to apparatus for shifting the needles transversely relatively to the backing material between the longitudinal rows of tufted pile formed by the machine.
The art of tufting incorporates a plurality of yarn carrying space needles extending transversely across the machine and reciprocated cyclically to penetrate and insert pile into a backing material fed longitudinally beneath the needles. During each penetration of the backing material a row of pile is produced transversely across the backing. Successive penetrations result in a longitudinal row of pile produced by each needle. This basic method of tufting limits the aesthetic appearance of tufted carpet so produced.
Consequently, methods have been devised which effect relative shifting between the needles and the backing material that provide patterning effects and that break up the noticable alignment of the longitudinal rows which detract from the appearance of the product. Such patterning means generally referred to as needle shifting or stitch placement drives generally are either driven by a rotating cam, a programmable fluid driven device, or a programmable indexing apparatus for drivingly engaging the needle bar to effect displacement thereof. Because the cam driven type is simple, inexpensive and reliable, it has been and remains the most popular drive system.
A drive rod connects the pattern cam drive system to a mounting plate for transversely driving the needle bar. Heretofore, as illustrated in my co-pending U.S. application Ser. No. 253,800 filed Apr. 13, 1981, and assigned to the same Assignee as the present invention, the drive rod was directly connected to a cam follower mounting rod journalled in bearing blocks and extending across and in front of the face of the pattern cam. With this construction, the mounting rod is driven by the followers as determined by the information on the periphery of the cam. However, one disadvantage of this system is that when a pattern change is desired, the follower mounting rod together with the follower must be removed to permit exchange of pattern cams. Consequently, the time required for making a pattern change is substantial.
Moreover, each time a change in cam was effected the needle bar would move slightly so that the relationship of the needles to the hooks and loopers was changed, thereby requiring additional time to effect a pattern change.
Recognizing the need for rapid change of the pattern cam, recent developments have devised various cam mounting systems permitting the cam to be readily replaced. No such developments, however, have been directed toward locking the needle bar during such cam changes to maintain the needle to hook relationship.
SUMMARY OF THE INVENTION
Consequently, it is a primary object of the present invention to provide a tufting machine having a cam driven needle bar shifting apparatus in which the cam may be rapidly replaced to change patterns and having means for locking the apparatus to prevent change in the relationship between the needles and hooks when a cam change is made.
It is another object of the present invention to provide a cam driven needle bar shifting apparatus for a tufting machine in which a pattern cam is mounted on a drive shaft in front of a pair of spaced rods journalled for lateral shifting and driven by cam followers adjustably secured to the rods, the cams being secured on the drive shaft by a clamping member which may be readily released to permit changing of the cam.
It is a further object of the present invention to provide a cam driven needle bar shifting apparatus for a tufting machine in which a pattern cam is mounted on a drive shaft in front of a pair of spaced rods journalled for lateral shifting and driven by cam followers adjustably secured to the rods, and means for clamping the rods against movement when changing the cam.
It is a still further object of the present invention to provide needle bar shifting apparatus for a tufting machine having a pattern cam for driving followers, the cam being mounted for unobstructed replacement thereof, the followers being mounted between a pair of spaced rods journalled for lateral shifting and adjustable laterally relatively to the cam and the rods for accommodating various size cams and followers, and means for clamping the rods when cam replacement is occurring.
Accordingly, the present invention provides a cam actuated shifting apparatus for drivingly shifting the needle bar of a tufting machine, the apparatus comprising a drive shaft journally extending through a frame and having a pattern cam fastened adjacent the end thereof by means of a quick release clamping collar, the periphery of the cam being in engagement with a pair of diametrically opposed followers each being adjustably fastened to a clamping bar and the clamping bar being secured to and spanning a pair of slide rods journalled on the frame intermediate the cam and the front. The slide rods are fastened to means which connect to the needle bar to shift or jog the needle bar laterally in accordance with the information on the periphery of the cam. Since the laterally moving elements are mounted behind the cam, the cam may be removed quickly when pattern changes are desired. The followers are journalled on a block that may be adjustably fastened to the respective clamping block for lateral adjustment, the adjustment means permitting rapid and minute adjustment of the followers relatively to the cam and for changing followers when a cam of a drastically different size is installed. A simple clamping member may lock the slide rods against lateral movement when cam changes or follower adjustment is made thereby preventing a change in the relationship between the needles and the hooks of the tufting machine. When a double or split needle bar is mounted on the tufting machine the apparatus may be fastened to each needle bar at opposite ends of the machine as conventionally known in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which;
FIG. 1 is a fragmentary front elevational view of a tufting machine incorporating a needle bar shifting apparatus constructed in accordance with the principles of the present invention;
FIG. 2 is an enlarged view of the shifting apparatus illustrated in FIG. 1;
FIG. 3 is a rear elevational view of a portion of the shifting apparatus;
FIG. 4 is an enlarged cross-sectional view taken substantially along line 4--4 of FIG. 1;
FIG. 5 is an enlarged cross-sectional view taken substantially along line 5--5 of FIG. 1 illustrating the pattern cam mounting construction; and
FIG. 6 is a fragmentary front elevational view illustrating the pattern cam securing means, as viewed along line 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIG. 1 generally illustrates a portion of a tufting machine 10 having a frame comprising a base 12 and a head 14 disposed above the base. The base 12 includes a needle plate 16 over which backing material (not illustrated) is adapted to be fed by conventional means.
Mounted in the head 14 for vertical reciprocation within one of a plurality of bushing assemblies 18 is a respective push rod 20 to the lower end of which a needle bar support foot 22 is carried. The support foot 22 has a slideway within which a slide plate 24 is slidably received. A needle bar 26 is secured to the plate 24 and slidable laterally relative to the slideway and reciprocably driven vertically by the action of the push rod. The needle bar 26 carries a plurality of needles 28 adapted to penetrate the base material upon reciprocation of the needle bar to project loops of yarn therethrough as the push rods are reciprocated by conventional means. The needles cooperate with loopers (not illustrated) mounted beneath the needle plate for seizing the loops of yarn presented by the needles and for releasing the loops to form loop pile or for holding the loops until cut by a knife cooperating with the loopers or hooks as is notoriously well known in the tufting art.
In order to drive the needle bar 26 selectively with controlled lateral movement, the needle bar 26 is provided with a number of upstanding plate members 30 which are straddled by a pair of rollers 32 pivotably mounted on mounting plates 34 secured to brackets (not illustrated) clamped to a pair of laterally extending slide rods 36. The slide rods are journalled in brackets 38 fixed to the head 14 of the machine above the needle bar. At the end of the machine adjacent the needle bar shifting apparatus, generally illustrated at 40, the slide rods 36 are fastened to a clamping block 42 above the bed. A drive rod 44 is secured to the clamping block 42 and extends through the end housing 46 of the tufting machine head 14 toward the shifting apparatus 40 and journalled in the end wall 48 for lateral movement.
The shifting apparatus 40, as best illustrated in FIG. 2, is mounted on a frame comprising an end plate 50 secured to the end wall 48, a bottom plate member 52 and a vertically upstanding plate member 54 laterally extending relative to the tufting machine and secured to the plates 50 and 52. The drive rod 44 journally extends through the end plate 50 and is fastened to a two piece clamping block 56 by collar means 58 entrapped between the elements of the clamping block 56 and to which the rod 44 is threadily fastened. Also clamped between the elements of the clamping block 56 in vertically spaced relationship are a pair of slide rods 60 and 62 similar to the rods 36. The rods 60, 62 extend laterally and are journalled within bearings in laterally spaced bearing blocks 64, 66, 68 the block 68 being intermediate the blocks 64 and 66. Another bearing block 70 intermediate blocks 66 and 68 has one bearing which, as illustrated, journally supports the slide rod 72, and which has a rod receiving arcuate upper end for receiving a circumferential portion of the other slide rod 60. Each of the bearing blocks 64-70 is secured by conventional means to the vertical plate member 54 so that the slide rods 60, 62 may accurately slide relatively to a rigid frame, the sliding being effected by means hereinafter described.
At the upper end of the bracket 70, a clamping member 72 is disposed having an arcuate cut-out conforming to that of the slide rod 60 for receiving the remainder of the circumference of the slide rod 60, i.e., the portion not received within the top of the block 70. The clamping member 72 is tapped so as to threadily receive two bolts or the like 74 (only one of which is illustrated) which normally are disposed so that the member 72 is above the top of the bearing blocks 70 to permit the rod 60 to slide. However, when a cam change is desired to be made as hereinafter described, the bolts 74 are threaded further into the top of the bearing block 70 and the member 72 is forced into engagment with the rod 60 and the top of the block 70 to lock the slide rod 60 thereto. Because the rods 60 and 62 are tied together by clamping block 56, and by two additional clamping blocks 76 and 78, locking of the rod 60 also locks the rod 62 against lateral movement. Consequently, when a cam change is being made the needle bar 26 is locked and its relationship to the loopers or hooks remains unchanged. This ensures that when the tufting machine is again operated the needles and loopers or hooks cooperate properly and repositioning of the needle bar 26 is not necessary.
As best illustrated in FIG. 5, mounted intermediate the bearing blocks 68 and 70 on the plate 54 but on the reverse side of that from which the bearing blocks 64-70 extend, is a speed reducer 80 having an input shaft 82 and as illustrated in FIG. 5, an output shaft 84. The input shaft 82 is coupled through means 86 to a shaft 88 journalled in at least one bracket 89 and on which a drive sprocket 90 or the like is fastened. Input motion is imparted in timed relationship with the vertical reciprocation of the needle bar by means of a chain or the like 92 which is connected to a similar sprocket (not illustrated) mounted on the main shaft (also not illustrated) of the tufting machine, as is well known in the art. The output shaft 84 of the reducer 80 extends through and is journalled in bearing means 94 supported on the plate 54. The shaft projects intermediate and forwardly of the slide rods 60, 62 and has a collar 96 keyed thereto. An interchangeable pattern cam 98 is disposed in front of the collar 96 in a plane intermediate a plane passing through the rods 60, 62 and the free end of the slot 84. The cam 98 includes a bore for receiving the exterior of an axially extending hub 100 of an adapter plate 102 which abuts the collar 96. The face of the plate 102 adjacent the hub 100 is positioned in abutting relationship with the cam 98 and keyed to the shaft 84. Each of the cam 98 and the adapter 102 have cooperating holes such as illustrated at 104 for receiving bolts 106 which secure the cam 98 to the adapter 102 and thus to the shaft.
Disposed in abutment with the free surface of the plate 102 is a split collet 108 which is also keyed to the shaft 84. Preferably the adapter 102 and the collet 108 may be a single member. Positioned about the circumference of the split collet 108 is a split clamping collar 110 having a pair of offset legs 112 which are tapped to receive a clamping bolt 114 which when tightly threaded into the legs 112 secures the collet 108, adapter blade 102 and cam 98 against axial movement relative to the shaft 84. A single key 116 may secure these members to the shaft 84 against relative rotational movement, and thus when the single clamping bolt 114 is released, the cam 98 together with its adapter 102, the collet 108 and the clamping collar 110 may be readily removed and replaced with a new cam.
Each of the clamping blocks 76, 78 is a two piece member like the block 56 having two members clamped together about the rods 60, 62. However, the blocks 76, 78 also have a respective follower carrier 118, 120 clamped between the members and secured thereto by bolts 122 acting against respective bearing plates 124, 126. At the end of the respective carrier 118, 120 adjacent the follower, the carriers have a respective block 128, 130 on which are mounted respective bearing members 132, 134 which journally carry respective followers 136, 138, the followers 136 acting against the periphery of the cam 98 at substantially diametrically opposed locations. At the other end of each carrier 118, 120 a respective flange 140, 142 extends from the surface of the carriers 118, 120 and receives respective bolts 144, 146. The bolts 144, 146 each extend through the respective flange and at one end abut the adjacent end of the respective clamping block 76, 78. Stop nuts 148 threaded on the bolts 144, 146 straddle the respective flange 140, 142 and secure the roller carrier against lateral movement relative to the followers.
To accurately adjust the rollers 136, 138 against the follower 98, the bolts 122 are loosened to release the respective plates 124, 126 and the respective front half of the clamping blocks 76, 78 from the respective carrier 118, 120. The adjusting stop nuts 148 are thereafter loosened so that the carrier may be moved laterally until the respective follower engages the periphery of the cam. Consequently, when a cam change is made, the followers can be accurately positioned against the periphery of the new cam. Similarly, smaller or larger followers may be readily installed when a different size pattern cam is installed on the apparatus.
During operation of the shifting apparatus, as the cam 98 rotates it drives the followers 136, 138 in accordance with the information on its periphery. As the followers move laterally, they drive the blocks 76, 78 to which they are fastened, which in turn drives the rods 60, 62 and thus the needle bar 26 through the drive rod 44.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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A cam actuated shifting apparatus for drivingly shifting the needle bar of a tufting machine has a pair of spaced rods journally mounted in a frame. A plate cam having pattern information on the periphery thereof is mounted on a drive shaft in a plane substantially parallel to a plane passing through the axes of the rods. A pair of followers are adjustably mounted at opposed dispositions across the cam for driving the rods in accordance with the information on the periphery of the cam. The cam is fastened to the shaft by means of an adapter secured to the cam and keyed to the shaft. A radially split collet abuts the adapter and has a split clamping collar disposed thereabout. A single bolt compresses the collar about the collet to secure the cam axially on the shaft, and upon release of the bolt readily permits the cam to be moved axially.
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BACKGROUND OF THE INVENTION
The invention relates to a method for separating products mounted on a common substrate from each other along (a) cutting line(s), which products each comprise one or more chips present on said substrate and connecting means connected thereto, the connecting ends remote from the chip of which are intended for connecting purposes.
A method for manufacturing such products is for example disclosed in European patent application EP-A-0 885 683. A large number of chips and associated connecting means, such as connection wires and solder balls which may be bonded to the connecting ends, are thereby present on a substrate. The products, which each comprise one or more chips and connection wires or the like connected thereto as well as solder balls which may be bonded to the connecting ends of said wires, must be separated from each other. In the case of larger products, the associated chip(s) may each be separately encapsulated, whilst in the case of smaller products a large number of chips associated with several products may be jointly encapsulated.
The substrate and, if present, possibly also the layer of material encapsulating the chips must be cut or sawn through for separating the products from each other.
With conventional methods, the joined products are mounted to a substrate and subsequently said substrate and possibly the layer of material encapsulating the chips are cut through. One drawback of the method that has been used so far is the fact that it is difficult to cool the saw blade or the like, since access to the saw blade is only possible from one side of the products. Another drawback is the fact that contamination with saw-dust of the products occurs, which makes it necessary to subject the products to a time-consuming and expensive cleaning treatment after they have been separated from each other.
SUMMARY OF THE INVENTION
According to the invention, the products are clamped down on a supporting element by using a vacume, and said supporting element and a rotating cutting blade are moved relative to each other along the intended cutting line so as to cut through the substrate, whilst a liquid is being supplied at the cutting line on either side of the substrate.
By using the method according to the invention, an effective cooling of the cutting blade on either side of the substrate can be effected, which has a positive influence on the working life of the cutting blade. In addition, the supply of a sufficient amount of liquid makes it possible for saving dust and any other fouling material to be washed off while the products are being separated from each other, so that it will not be necessary to clean the products after they have been separated from each other.
A method for clamping down products on a supporting element by using a sub-atmospheric pressure with a view to cutting the substrate through so as to separate the products from each other is known per se. The connecting ends face towards the substrate thereby. The construction must be such that each product to be cut out is supported all around by an edge portion which is present between the cut to be formed and the connecting ends.
According to another aspect of the invention, the products are clamped down on the supporting element on the side of the products remote from the connecting ends, so that the connecting ends can remain in sight, whilst the products can be clamped down on the at least substantially flat surface of the chip-loaded substrate. An advantage of this is the fact that it is possible to move the cutting blade closely past the connecting ends of a product, as a result of which the spacing between the products can be reduced.
A simple and efficient device for carrying out the above method is obtained when the device comprises a cutting blade to be rotated about an axis of rotation and a supporting element which is provided with spaced-apart suction cups and lines connected thereto for generating a sub-atmospheric pressure on the side of the suction cups remote from said supporting element and with lines for supplying a liquid between said suction cups.
Preferably, said supporting element is thereby fixed to a manipulator, by means of which said supporting element can be moved in desired directions relative to the cutting blade.
The invention will be explained in more detail hereafter with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a possible embodiment of a substrate on which three product fields are present, each field comprising thirty-six products in the illustrated embodiment.
FIG. 2 is a plan view of a separate field of thirty-six products to be separated from each other.
FIG. 3 is a side view of FIG. 2 .
FIG. 4 is a larger-scale view of a single product.
FIG. 5 is a side view of FIG. 4 .
FIG. 6 is a schematic plan view of an embodiment of a device according to the invention.
FIG. 7 is a larger-scale sectional view of a part of a carrier with a few products attached thereto.
FIG. 8 is a larger-scale view of the encircled portion VIII in FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a substrate 1 on which three fields 2 of products 3 arranged in rows and columns, thirty-six products 3 per field 2 in the illustrated embodiment, are present.
As is shown in FIGS. 4 and 5, each product within the scope of the present application comprises a substrate portion 1 ′, on one side of which a coating 4 is present, in which one or more chips (not shown) is (are) encapsulated. Connected to said chip(s) are connecting means, to the connecting ends of which remote from said coating 4 solder balls 5 are bonded in certain cases. As those skilled in the art will know, however, also other embodiments of such products comprising one or more chips are conceivable.
A product assembly as shown in FIG. 1 may for example be manufactured in a device as disclosed in the aforesaid European patent application No. 0 885 683. Of course also other devices for manufacturing such products are conceivable, however, whilst also the shapes and the numbers of initially joined fields and products may differ from those which are shown in FIGS. 1 and 2.
In order to separate the products 3 from each other, the substrate 1 comprising three fields which is shown by way of example in FIG. 1 will preferably be cut or sawn into three parts so as to obtain separate fields 2 as shown in FIGS. 2 and 3. Then, in order to obtain the separate products 3 , the fields 2 will be cut or sawn through according to cutting lines 6 and 7 intersecting each other perpendicularly in the illustrated embodiment (FIG. 2 ), which are located in the spaces between products 3 in the aforesaid columns and rows of products 3 .
A device as schematically indicated in FIG. 6 may be used for separating the joined products, Said device comprises a frame 8 , in which a motor 9 is mounted, by means of which a cutting disc 10 which is rotatable about a horizontal axis of rotation can be driven. Cutting disc 10 is covered by means of a cover 11 , preferably of a transparent material, which is movably supported on frame 8 in a direction parallel to the axis of rotation of cutting disc 10 . A slotted hole 12 , which is open at one end thereof, is provided in cover 11 , which slotted hole extends perpendicularly to the axis of rotation of cutting disc 10 .
The device further comprises a manipulator 13 , which is provided with a support 14 fixed to frame 8 . Support 14 supports a first arm 15 , which is capable of pivoting movement about a vertical axis with respect to support 14 .
Mounted on the end of first arm 15 remote from support 14 is a second arm 16 , which is capable of pivoting movement about a vertical axis with respect to first arm 15 .
Mounted on the free end of arm 16 is a shaft (not shown) extending downwards from arm 16 , which is rotatable about a vertical axis of rotation, to the lower end of which a supporting element 17 for picking up an assembly of products can be detachably attached. Said supporting element can also be reciprocated in vertical direction with respect to arm 16 . Also other embodiments of a manipulator by means of which the supporting element 17 can be moved as desired are conceivable, of course.
FIGS. 7 and 8 show a part of a possible embodiment of such a supporting element 17 for picking up the field 2 of products 3 as shown in FIG. 2 .
Such a supporting element 17 comprises a supporting plate 18 , on which a number of suction cups 19 are mounted in a pattern which corresponds to the pattern of the products 3 in the field to be picked up. As will be apparent from FIGS. 7 and 8, the cross-sectional area of suction cups 19 is slightly smaller than that of products 3 . A recess 20 is formed in each suction cup on the side of the suction cups remote from supporting plate 18 , so that the suction cups only come into contact with the flat side of coating 4 remote from the solder balls 5 along their closed outer circumference. Each recess 20 is in communication with a bore 22 provided in supporting plate 18 via a bore 21 provided in suction cup 19 . The bores 22 provided in supporting element 17 are in communication, in a manner which is not shown, to a device for generating a sub-atmospheric pressure.
It will be apparent that grooves 23 are present between the suction cups 19 on supporting plate 18 in a pattern which corresponds to the pattern of the cutting lines 6 , 7 or of the spaces present between the products 3 in a field 2 . Bores 24 formed in supporting plate 18 open into said grooves. Said bores 24 are in communication, in a manner which is not shown, to a source for supplying a cooling liquid, such as water.
A supporting element 17 can be used for picking up the substrate comprising three fields as shown in FIG. 1, which supporting element is provided with a supporting plate 18 comprising three suction cups 19 mounted thereon, wherein the size of each suction cup 19 is adapted to conform to the size of a field 2 , and wherein slots 23 , which are also in communication with liquid supply channels, will be present between said suction cups 19 .
The device further comprises a camera 25 , which is connected to a computer (not shown), by means of which the device, in particular manipulator 13 , is controlled.
A test piece is picked up by means of a supporting element and a saw cut is made in said test piece for the purpose of inputting the correct position of the cutting blade 10 with respect to manipulator 13 into the computer. Then the object in which a saw cut has thus been made is positioned in front of camera 25 , and data relating to the position of the saw blade relative to supporting element 17 are fed into the computer on the basis of the position and the length of the saw cut as detected by the camera.
Then one or more substrates 1 with products 3 , for example as shown in FIG. 1, can be supplied to the device 8 , as is indicated in the left-hand top corner of FIG. 6 . Said substrates can be picked up one by one by means of the manipulator and be moved past the cutting blade 10 so as to separate fields 2 from each other. Substrate 1 is first positioned in front of camera 25 by means of manipulator 13 for the purpose of determining the position of fields 2 and in particular the position of the connecting ends, the solder balls or the like relative to supporting element 17 , in such a manner that supporting element 17 will be so controlled that substrate 1 will be cut through correctly between fields 2 . The manipulator shaft, to which supporting element 17 is attached, will be led through slot 12 in cover 11 during the cutting operation, and since cover 11 is movable in a direction parallel to the axis of rotation of cutting disc 10 , cover 11 can be moved by manipulator 13 in order to move the substrate to be cut through, on which products are present, to the correct position relative to cutting blade 10 .
During the cutting operation, cutting blade 10 will penetrate through the substrate 1 to be cut, and possibly through coating 4 , into the slot 23 present between suction cups 19 . The cutting blade will thereby be cooled during said cutting by means of a cooling liquid which is supplied via bores 24 , as well as by a cooling liquid which is sprayed against the cutting blade under the object to be cut through, that is, on the side of solder balls 5 , by means of spraying elements 50 or the like during cutting.
By using a sufficient amount of cooling liquid, the cutting dust or chips being released when the objects are being cut will be washed away by the liquid flows, so that clean products will be obtained. By positioning the cutting blade under the products being cut by the cutting blade, the waste that is produced can easily fall down and be discharged.
The separated fields 2 can be placed at a depositing station 26 . When a plurality of separated fields 2 have been obtained in this manner, the supporting element coupled to the manipulator for picking up the objects shown in FIG. 1 can be exchanged for a supporting element 17 which is suitable for picking up a field as shown in FIG. 2, wherein each product 3 is held by its own suction cup 19 . Following the determination of the position by means of camera 25 and the movement of supporting element 17 derived therefrom, the products present in such a field can be separated from each other, for example by cutting through said field according to cutting lines 6 first, after which the field can be cut through according to cutting lines 7 once the supporting element 17 supporting the products has been rotated through 90°. Also in this case, water or a similar cooling liquid will be supplied to a sufficient degree during cutting, of course, for cooling the cutting blade and washing away the dust and the like that is being released during cutting.
After the products 3 have thus been separated from each other, they may be led, still connected to supporting element 17 , past blowing nozzles (not shown), via which air, which may or may not be heated, is blown past the products so as to remove adherent water. Then the products can be deposited at a depositing station 27 , for example, from where they can be supplied to further processing devices or the like.
Of course it is also conceivable not to separate fields 2 from each other before the products 3 are separated from each other, but rather separate the products 3 present in a number of joined fields 2 directly from each other.
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The invention relates to a method and a device for separating products mounted on a common substrate, from each other, along (a) cutting line(s). The products each comprise one or more chips present on said substrate and connecting means connected thereto, the connecting ends remote from the chip of which are provided with solder balls bonded thereto. The products are clamped down on a supporting element by using a sub-atmospheric pressure, and the supporting element and a rotary cutting blade are moved relative to each other along the intended cutting line so as to cut through the substrate. A liquid is supplied at the location of said cutting line on either side of the substrate.
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This is a continuation in part (CIP) of U.S. patent application Ser. No. 08/659,403 filed on Jun. 6, 1996.
FIELD OF THE INVENTION
The present invention generally relates to a portable sewing machine and more particularly to a sewing machine for providing an upper and a lower thread to perform a lock stitch to the fabrics.
BACKGROUND OF THE INVENTION
This invention has a particular application to a portable sewing machine which comprises a driving means, a transmitting means and a plurality of guiding means. The portable sewing machine constructed in accordance with the present invention is a compact, hand held sewing machine. The transmitting means mounted within the apparatus drives a shuttle and a bobbin to move and thus creates an excellent sewing performance.
Prior hand held sewing machine, when sewing, provides only upper thread to a knitted material, thus the sewing machine can only form a loop upon every stitch, instead of a knot, which makes the knitted material very easy to be torn apart once a knitted thread is broken.
Although another kind of hand held, compact sewing machine having both the upper and the lower thread has been provided to the market, however, it still uses a user's holding strength as the power of the apparatus. Using the holding strength of a user as the power of the apparatus is very inefficient when sewing, and the user is very easy to feel exhausted, especially when the to-be knitted area is quite big.
The present invention provides an improved portable sewing machine using battery and/or AC adaptor as the power and providing functions other than sewing to mitigate and/or obviate the aforementioned problems.
SUMMARY OF THE INVENTION
The main objective of the invention is to provide a portable sewing machine comprising a driving means, a transmitting means, and a plurality of guiding means. The driving means uses batteries and/or AC adaptor as the only source of power, the transmitting means includes a plurality of gears, and rods which are pivotally connected to one another and the guiding means has a plurality of guiding elements to guide both the upper and the lower threads to a proper position.
Another objective of the invention is to provide a portable sewing machine which is compact and easy to use.
Still another objective of the invention is to provide a portable sewing machine which uses detachable gears to function as a bobbin winder in order to save a lot of effort winding thread onto a bobbin.
Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be better understood with the reference of the accompanying drawings wherein;
FIG. 1 is a schematic view of one preferred embodiment of the present invention;
FIG. 2 is a side view of the invention;
FIG. 3 is a bottom schematic view of the invention;
FIG. 4 is a plan view showing the internal mechanism of the invention;
FIG. 5 is a schematic view showing the operation of the internal mechanism of FIG. 4;
FIGS. 6 and 7 are schematic views of the structure and the operation of a pressing plate constructed in accordance with the present invention;
FIG. 8 is an exploded view of a sectorial gear, a feeding dog and a resilient member;
FIG. 9 is a perspective view of the sectorial gear, a feeding dog and a resilient member, when in combination;
FIGS. 10 and 11 are top views of horizontal movement of a feeding dog because of a sectorial gear and multiple pushing rods;
FIGS. 12 and 13 are side views of vertical movement of the feeding dog because of the sectorial gear and a top plate;
FIG. 14 is a schematic view of the related position of a detachable gear and a driving gear;
FIGS. 15 and 16 are schematic views of the movement of the detachable gear and the separation of the detachable gear and the driving gear;
FIG. 17 is an exploded view of the lower thread mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and particularly FIG. 1, a portable lock stitch sewing machine is provided.
A handle 11 is mounted at a rear upper part of a main housing 10, and a power switch 12 is mounted in front of the handle 11. A needle arm cover 13 is pivotally connected to the main main housing 10 at both sides of the power switch 12 with holes 131. A manual adjusting wheel 14 and a spool stand 15 having a spool pin 16 are mounted on one side of the main housing 10 for receiving a spool thread 17. A first guider 161 is mounted on top of the spool stand 15 and the bed 18 extended integrally with the main housing 10 extends axially. A shuttle cover 181 is provided on top of the bed 18 so that a lower thread mechanism is received therein. The needle arm 40 able to move vertically is mounted on top of the bed 18. A spool thread tension dial 42 and a second guider 43, a third guider 44 and a forth guider 45 are provided along on the needle arm 40 for respectively adjusting the tension of the upper thread and guiding the upper thread to a proper position. A presser foot 50 is provided below the needle needle arm 40 and on the bed 18.
Referring to FIG. 2 of a side view of the present invention taken in another direction, wherein a bobbin winder switch 19 and a presser foot lifter 51 are provided on the other side of the main housing 10, a fifth guider 162 is thus mounted on top of the presser foot lifter 51. A battery compartment cover 101 mounted at a rear part of the main housing 10 is shown in FIG. 3. A user may open the battery compartment cover 101 to replace the battery received therein.
From FIG. 4, it is noted that a deceleration-gear-set 20 powered by a motor 22 is provided within the main housing 10 for decelerating the power of the motor 22. The power of the motor 22 drives a detachable gear 23 having a winding axis 233 inseted therein to turn and consequently rotates a driving gear 26 through a series of mated gears (not numbered). A driving rod 30 is pivotally and peripherally connected with the driving gear 26, therefore, the driving rod 30 will have horizontal movement when the driving gear 26 is turned by the power of the motor 22.
A front end of the driving rod 30 is pivotally connected with a front rod 311 which is integrally formed with a rear rod 312 of a transmitting shaft 31 and an elevation rod 313 is pivotally connected with the rear rod 312 at its lower end (not labeled). An upper end of the elevation rod 313 is also pivotally connected to a plate 46 to a bottom face of the needle arm 40 positioned at a plate 46. Incorporated with FIG. 5, it is noted that when the driving rod 30 is forced to move horizontally by the driving gear 26, the front rod 311 will turn, and thus the transmitting shaft 31 turns clockwise, which the elevation rod 313 will be lifted upward because of the rear rod 312 integrally formed with the transmitting shaft 31. Due to the horizontal movement of the driving rod 30 and the upward and downward movement of the elevation rod 313, the needle arm 40 is able to move up and down to fulfill the movement needed for a sewing operation.
As discussed before, the manual adjusting wheel 14 is used to adjust various positions of the needle arm 40, so that a user is easier to have a thread inserted into the needle and an easier access to load and unload the fabric.
A driven rod 32 extended toward the bed 18 is also pivotally connected at the place where the driving rod 30 is pivotally connected with the front rod 311, thus the power of the motor 22 is transmitted toward the bed 18. An assembling plate 39 having mechanism (not shown) to drive a shuttle and a feed dog 35 (not shown in this Figure) is provided with a pivotally connected sectorial gear 33. A front end of the driven rod 32 is pivotally connected with the sectorial gear 33 and a gyration gear 34 mated with the sectorial gear 33 is pivotally connected in front of the sectorial gear 33 and onto the assembling plate 39. Therefore, the gyration gear 34 will turn back and forth when the turning of the sectorial gear 33 is activated by the horizontal movement of the driven rod 32.
It is well known to the people that before sewing is started, it is necessary to first insert a fabric to be knitted under a needle and use a device to hold the fabric in steady position, such that the sewing operation may be regularly done. Referring to FIG. 6 and FIG. 7, they show the upward movement of a presser foot 50 permitting said fabric to be inserted. It is again noted that the presser foot 50 is pivotally connected with the needle arm 40 at the same axis 54 having a resilient member 53 mounted therewith. One end of the resilient member 53 abuts against an inner face of the bed 18, the other end of the resilient member 53 is then abutting against a flange 501 of the presser foot 50, so that the resilient member 53 is able to provide a downward resilient force to the presser foot 50 to allow said fabric to be inserted thereunder. A presser foot lifter 51 having an integrated-formed adjusting protrusion 521 is pivotally connected with the bed 18 at an axis 52, and one end of the adjusting protrusion 521 abuts against a bottom face of the presser foot 50, so that the presser foot 50 will be lifted upward when the presser foot lifter 51 is manually adjusted to the right as shown in FIG. 7.
Referring to FIGS. 8 and 9 wherein, on the sectorial gear 33, a central tube (not numbered) is provided on the upper face (not labeled) thereof, at least two lugs 331 are provided and spaced apart. One of the lugs 331 is provided between the sectorial gear 33 and a top plate 332 formed integrally with the central tube and having an inclined top surface. The upper part of a feed dog 35 is formed with wavy form and the lower rear part extends outward a projection 351 configured to mate the lug 331, such that the feed dog 35 is driven by the lugs 331 to swing left and right. A recess 352 formed integrally with the feed dog 35 for receiving a resilient member 36. Therefore, it is apparent to be noted that a free end (not shown) of the resilient member 36 is inserted into the recess 352 of the feed dog 35 for providing a recoil force to the feed dog 35.
Referring to FIGS. 10 and 11, a plurality of lugs 331 are formed integrally with the sectorial gear 33 and the lugs 331 are able to move the feed dog 35 received within a slot 183 of a shuttle housing 182 and having smaller size comparing to the size of the slot 183 to move from the left to the right and vice versa by a projection 351 formed on a bottom face of the feeding dog 34 when the sectorial gear 33 is turned.
It is also well known in the art that the knitted fabric has to be gradually pushed forward in order that the knitted apparatus is able to continue to perform the next sewing procedure. A top plate 332 integrally formed and co-axial with the sectorial gear 33 is provided on top of one of the lugs 331. One end of a resilient element 36 is securely fixed on a bottom face of the board 18 and the other end of the resilient member 36 is inserted into a recess 352 defined within the feed dog 35. The position shown in FIG. 10 is corresponding to the position of FIG. 10 where a top face of the feed dog 35 is aligned with the surface of the board 18. The top plate 332 will make the resilient member 36 moving upward and so as to the feed dog 35, when the sectorial gear 33 is turned due to the power transmitted by the driven rod 32, as shown in FIG. 11. The feed dog 35 will resume to its original position due to the resilient force of the resilient member 36 when the sectorial gear 33 turns to the other direction.
Another advantage of the invention is that the detachable gear 23 may be used as a thread winding element.
Referring to FIG. 14 and taking FIG. 15 and FIG. 16 as reference, the motor 22 is mounted on a gear seat 21, the detachable gear 23 is mated with the driving gear 26 and the driving rod 30 is peripherally and pivotally connected with the driving gear 26. A bobbin winder shaft 231 having the detachable gear 23 received thereon has a coil spring 24 situated between the detachable gear 23 and a stop 232 provided on a free end of the bobbin winder shaft 231. A smaller and thinner winding axis 233 having the detachable gear 23 inserted therein is received within the bobbin winder shaft 231. A hook 25 received within a slot 211 has a through hole 251 on one end and a head 252 securely connected with an inner side of the detachable gear 23 on the other end. The through hole 251 of the hook 25 is pivotally connected with the bobbin winder switch 19 at a point 191 and the stop 232 is received within a hole (not numbered) of the bobbin winder switch 19. Therefore, when the bobbin winder switch 19 is opened, the hook 25 will be pulled outward, and because the head 252 is securely connected with the detachable gear 23, thus the detachable gear 23 will no longer be mated with the driving gear 26, and the winding axis 233 will extend outward from the surface of the main housing 10 as a thread winding device. The coil spring 24 will be compressed when the bobbin winder switch 19 is opened, thus the detachable gear 23 will be pushed back to a position where the detachable gear 23 and the driving gear 26 are mated with each other.
Referring to FIG. 17, the lower thread mechanism, as we described before, comprises a lower thread bobbin 38, a shuttle 37, a shuttle housing 341 situated within the board 18 and providing space to the shuttle 37 to move back and forth due to the rotation of the gyration gear 34 which is mated with the shuttle housing 341. Since the operation principle of the lower thread mechanism is well known in the art, it is not necessary to further describe the operation and the related members of the lower thread mechanism.
From the foregoing, it is seen that the objects hereinbefore set forth may readily and efficiently be attained, and since certain changes may be made in the above construction and different embodiments of the invention without departing from the scope thereof, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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A portable lock stitch sewing machine includs a driving mechanism, a transmitting mechanism and a number of guiding mechanisms. The function of the driving mechanism is to transfer a battery power to pivotally connected members to make them move as required by a user. The transmitting mechanism then transmits the power of the battery to related members to fulfill the sewing performance and the number of guiding mechanism are used to ensure the tension on threads.
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FIELD OF THE INVENTION
This invention relates to a method of diagnosing or controlling a grinding mill for paper pulp, wood chips, or other fibrous materials, by measuring the incremental change in power related to an incremental change in the gap, and using the ratio of the two differences, together with the measure of applied power, as the diagnostic or control parameter.
BACKGROUND OF THE INVENTION
In the manufacture of paper or paperboard, it is common to employ large attrition mills to grind wood chips or other fibrous raw materials to produce pulp, or to grind chemically produced wood pulp to enhance its papermaking properties. In both cases, the process is referred to as refining. These attrition mills are normally of the disk type or the conical type (or sometimes a combination of the two), where a rotor surface acts against a stator surface (or in some instances a counter-rotating surface) and causes a reduction in the size or a change in some other desirable physical properties of the material being processed. The working surfaces of these mills usually consist of a stator plate with more or less radial bars and grooves, and a rotor plate of similar form. The material being processed, often fibrous in nature, is captured between a rotor bar edge and the opposing stator or counter-rotating bar edge. It is the compression loading of the fibrous particles which acts to cause a change in the physical properties of the material being processed.
The wear surfaces of these grinding mills (called refiner plates or refiner fillings) are replaceable and may be require replacement at intervals between a few weeks and several months or more. They are usually made of cast steel but may also be fabricated or machined from solid steel blanks. During the normal course of refining of the wood chips or the pulp, it is the wearing down of the bars on the opposing surfaces which eventually leads to the need for replacement.
The most common control parameter in the refining of wood chips or pulp is the applied power. More precisely it is the net applied power that is of significance, since a certain amount of the input shaft horsepower is consumed by viscous frictional losses in the fluid which suspends the process particles (either a vapor or liquid phase). The net applied power is a measure of the amount of energy that is being applied to a given flow of process material and is referred to as the specific energy consumption (often expressed as kilowatt-hours per ton of moisture free material processed).
It is well known in the pulp and paper industry, that specific energy consumption (SEC) is not the only significant parameter that influences the quality characteristics of the material being processed. A second parameter, which reflects the magnitude of the compressive loads applied to the fibrous particles, should also be significant. This second parameter is called refining intensity. There has not previously been any means to directly measure refining intensity, and it is usually inferred by a parameter called specific edge load (SEL). SEL is usually computed by carefully measuring the total length of the stator and rotor bar edges that will cross in a single revolution. The net applied power divided by the product of the total edge length and the rotational speed yields a value for the specific edge load (usually expressed as watt-seconds per meter).
The two-parameter concept of refining has been viewed in a variety of ways. One such view identifies a first parameter as a measure of the number of impacts that act on an average particle, and a second measure as the intensity of the impact that acts on the average particle. However, all such views depend on the measurement of the edge length of the working surface of the filling and take no account of the extent to which material is in fact captured on the available edge length. Other process variables including the condition of the process material, the condition of the bar edge, the angle of intersection of rotor and stator bars and the flow velocity in the filling, all may have significant effects on the amount of process material actually captured on the edges. Indeed, there are many instances in both pilot plant and commercial experience, where a particular pulp processed under identical conditions of SEC and SEL has exhibited significantly different measured physical characteristics.
Refining intensity has long been considered a parameter of interest in low consistency refining of paper pulps using bar equipped beating devices. It is now generally accepted that the refining effect on pulp in any given refiner is largely determined by the amount of refining (the specific energy consumption, or SEC) and the intensity of refining (the specific edge load, or SEL). Even in comparing the effects of different refiners of different size and process flow, these two parameters have proven to be reasonably predictive of pulp characteristics and the resulting paper properties—at least qualitatively if not quantitatively. They are often described as the “amount” and the ‘severity” of refining, respectively.
The calculation methods for the two parameters are simple and they will not be presented here. SEC is arguably a fundamental process variable (energy input per unit mass of moisture free substance). While the energy may be applied more or less efficiently in terms of producing some desired effect, it is conceptually easy to appreciate its potential impact on the refining result. SEL, on the other hand, represents a machine parameter (a function of edge length available and rotational speed rather than a process condition. It is generally presumed to be indicative, at least on a relative basis, of the severity of the stress acting on the fibers in the process. However, it does not account for what may be very large variations in the collection of pulp fibers on bar edges due to such factors as pulp consistency, flow velocities, bar edge sharpness, or degree of refining. In attempting to optimize refiner fillings and operating conditions, it is often not sufficiently predictive to meet the needs of some modern papermaking operations, and it offers no diagnostic help when an unexpected result is realized.
In general, while SEC and SEL are somewhat predictive of the product quality characteristics, a more direct measure of the actual strains applied to the process material would be very useful. It could be used in the diagnosis and control of disk mills, in particular with regard to the design and development of more energy efficient refiner fillings, and with regard to optimizing the operating conditions of the process so as to produce higher quality products.
It has long been recognized that the operating clearance between the rotor and stator will be of significant importance in a disk mill. It is not uncommon in modern commercial chip refining systems to have several refiners equipped with clearance measuring devices. However, the difficulty in maintaining the precision and reliability of the devices, particularly with regard to the zero reference, has made them of limited value in routine diagnosis and control of refiners. Because the bars of the working surface wear continuously and in a very irregular way, and because of the very hostile environment in which they operate, delicate gap measuring instruments are often not reliable.
Nonetheless, operating clearance or gap remains an important operational factor and the present invention takes into account a “delta g” or the change in gap (instead an absolute value for gap) in providing a direct measure for refining intensity.
SUMMARY OF THE INVENTION
We propose a qualitative conceptual model of the microscopic process of fiber cell wall strain occurring in the pulp refining process. Based on the assumptions of this conceptual model, an analysis of the mechanics of the physical model are presented, together with a proposed method for measuring, on a relative basis, the degree of fiber strain that is occurring in a commercial refiner under any given set of operating conditions. This method involves the accurate measurement of operating plate gap and net applied power at the refiner. In addition to facilitating the design and application of plate patterns, this type of measurement could provide valuable real-lime indications of changing pulp characteristics that would allow immediate corrective action to be taken and offset process adjustments to be made downstream.
The unique method of this invention includes a precise measure of the incremental change in the gap of a refiner and a simultaneous precise measure of the related incremental change in the net applied power (or more precisely, in the incremental change in the normal force acting to close the gap). Because it is the incremental change in gap that is of consequence, it is not necessary to have a zero reference. And, since a zero reference is not required, the wear of the fillings is of little consequence. In fact, precise incremental changes in gap can be determined by making precise measurements of the movement of external supporting machine elements thus avoiding any complications due to either filling wear or the hostile process environment.
Specific examples are included in the following description for purposes of clarity, but various details can be changed within the scope of the present invention.
OBJECTS OF THE INVENTION
An object of the invention is to provide a method for diagnosis of a pulp refining mill.
Another object of the invention is to provide a diagnostic parameter for refining intensity in a pulp mill.
Another object of the invention is to provide a direct measure of severity of the stress acting on fibers or refining intensity under any given set of operating conditions in a pulp refining process.
Other and further objects of the invention will become apparent with an understanding of the following detailed description of the invention or upon employment of the invention in practice.
BRIEF DESCRIPTION OF THE DRAWING
A preferred embodiment of the invention has been chosen for detailed description to enable those having ordinary skill in the art to which the invention appertains to readily understand how to practice the invention and is shown in the accompanying drawing in which:
FIG. 1 presents Table 1 detailing load-compression test results of an experiment with reinforced plastic tubing sections to demonstrate that in principle, when compressing bundles of such tubular elements, applied load is approximately proportional to the inverse of displacement. While the scale of length is much smaller for pulp fibers, the general characteristics of load response can be reasonably assumed to be similar.
FIG. 2 is a graph of the test results of FIG. 1 .
FIG. 3 presents Table II which records data comparing different refiner fillings at different conditions of plate position and applied power.
FIG. 4 is a graph of the data of FIG. 3 .
FIG. 5 is a graph of Specific Edge Load (SEL) for two different refiner fillings.
FIG. 6 is a graph of relative stress vs power of the fillings of FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Conceptual Model
A conceptual model has been established for the method of the present invention based on four underlying assumptions. These assumptions and arguments supporting them follow.
1. All of the observed effects on the constituent fibers of refined pulps occur as a result of the peak compressive load acting on fiber accumulations—just as two opposing bars begin to overlap. The refining process begins with random accumulations of fibers gathering between approaching rotor and stator bar edges, and the consolidation and compression of these fiber accumulations between those edges as they pass each other (these fiber accumulations are commonly referred to as flocs, although the formation and composition of these accumulations is quite different from freely formed flocs in a suspension). It has often been suggested that a significant shear effect may occur between the surfaces of opposing bars in a pulp refiner, but it seems more likely that the great majority of the refining action occurs at the leading bar edges as the plates cross each other and a sudden compression of the floc occurs. Even if the consistency of the fiber flocs being sheared is very high, it is the nature of a compressible material acting under a normal load to further compress under an additional shear load, thus relaxing the normal force component if the compressing surface does not further displace. This is because the plane of principal stress is shifted by the application of shear and the resulting increase in the principal stress causes further deformation. In our opinion, the significance of the bar surfaces is much more likely related to their role as a bearing surface. When the peak compressive load applied at the edge substantially exceeds the capacity of the fully compressed fibrage, then the bar surfaces may act to resist an immediate collapse of the operating gap. Thus, the occasionally observed benefit of wider bars may be explained. There is some evidence to suggest that pulp cannot be refined by the application of shear loads alone. On the other hand, there is considerable evidence to suggest that sufficiently high compressive loads always produce a refining effect on pulp. Finally, if we are interested in peak stresses, it is of course necessary to divide the measured load by the area over which it acts. It seems almost certain that the load bearing area at a bar surface is at least an order of magnitude more than that of the bar edge, and so the stress level on the surface should be very small by comparison.
2. The quality of the refining effect for any single fiber is determined largely by the magnitude of the peak compressive stress occurring in the cell wall, and this is proportional to the average magnitude of the peak compressive stress acting on the accumulation of fibers. Because fibers vary widely in both diameter and cell wall thickness, stress levels will vary widely. Only in those cases where the cross section of a constituent fiber has been strained to cause failure—presumably at the outermost element of the section—will a refining effect occur, However, the higher the peak stress on the accumulation, the higher will be the peak stresses on each of the constituent fibers, and so the peak load on the accumulation can be presumed to be reasonably indicative of relative fiber stress.
3. The magnitude of the peak compressive stress in a fiber floc or accumulation of fibers is proportional to the peak degree of compression of the accumulation during a bar edge crossing event. There is no rigorous argument to support this assumption. Although it is true that certain compressible materials behave according to this relationship, the fiber accumulation is a complex and very heterogeneous structure and its strain behavior is difficult to model. In addition, the strain rate in a refiner bar edge interaction is extremely high. Dynamic effects may predominate. Nevertheless, the inventors have performed a crude experiment with a collection of reinforced plastic tubing sections arranged to simulate a collection of fibers draped over a bar edge. The tubing dimensions reflected a scale factor of about 2500 for the fibers and bar geometry, and the simulated bar edge reflected a radius of about 60 μm. The tubing sections were arranged more or less parallel, about three deep, and spread along a bar length of about 10 tubing diameters. The load-compression results of this very simple test are shown in Table I appearing in FIG. 1 . If the zero reference is adjusted by an amount equal to the fully compressed collection, then the applied load is approximately proportional to the inverse of the displacement. See FIG. 2 . An additional piece of empirical evidence supporting this assumption is our repeated observation (different refiners, fillings and pulp types) that a linear regression of net power on 1/gap (with an appropriate selection of the zero reference) yields a very high degree of correlation. The degree of floc compression can be expressed as the ratio of the uncompressed to the compressed dimension of the accumulation (measured in the direction of compression). As with the simple tubing experiment, it may be that the inferred gap based on our measurements is less than the actual gap by an amount equal to the height of the fully compressed fiber accumulation.
4. The magnitude of the peak compressive stress in an accumulation of fibers is proportional to the magnitude of the peak compressive load acting on that accumulation divided by the effective load bearing area. This area is assumed to be proportional to the product of the bar edge radius and some relative measure of the uncompressed accumulation. Although the relationship between load and stress is obvious, the assumption regarding area may not be. Since we are interested in the component of load which acts along a vector between the two opposing bar edges as they approach and cross, we must make a reasonable assumption regarding those variables which determine the area over which that load is distributed. It seems reasonable to assume that if the load is applied at the edge, the radius of curvature of the edge will determine one linear component of the area calculation, reflecting the extent to which the load is “spread” over the edge. The other linear component should reflect the extent to which the load is “spread” along the edge on either side of the line of action of the load. It is easy to imagine that the extent of spreading may depend very much on the intersecting angle. However, for a given geometry at the vertex, the extent of load distribution along the edge should be largely determined by the amount of fiber collected on the edge, and this can be expressed by a measure of the average size of the floc that gets caught at the vertex.
Mathematical Model
Assumptions 1 and 2 above define the overall physical arrangement of load application to the constituent fibers of a pulp as it is processed in a typical commercial refiner. Assumption 3 allows us to express the stress in a fiber accumulation, and in its constituent fibers, as a function of the floc strain as follows:
σ a =c 1 ( h o /h )
where σ a represents the stress in a fiber accumulation at a bar crossing point, h 0 and h represent the uncompressed and compressed heights respectively of the fiber accumulation at that crossing point, and c 1 is a constant of proportionality. This constant of proportionality should be dependent only on material properties, reflecting a relative stiffness of the fiber accumulation (such as fiber species, pulping process and degree of refining).
Assumption 4 allows us to express the relationship between the applied load and the stress by the equation:
σ a =c 2 f nc /( h o /r e )
where f nc is the net compressive force acting on the accumulation, along the vector described previously and r e is the effective radius of the bar edge. Again, h o is a measure of the size of the floc at the crossing point and therefore reflects the extent to which the load f nc is distributed along the edge while r e reflects the extent to which it is distributed over the edge.
These two equations can be combined to define the load acting at each bar edge crossing point:
f nc =c 1 c 2 r e ( h o 2 /h )
According to this expression, the load acting on the fiber accumulation at the crossing point of a rotor bar edge and a stator bar edge (for a given edge radius condition) depends only on the uncompressed and compressed heights of the accumulation. Only those process variables affecting the accumulation of fiber on edges (such as consistency or flow velocity) will change the crossing point load if the value of h is not changed.
While it may not be possible to measure individual loads at individual crossing points in a refiner, the cumulative effect of the individual loads are the resultant axial and torsional loads, and those can be measured. The force f nc can be resolved into its axial and tangential components. If we are correct in our assumption that the refining effect occurs predominantly at bar edges, then the axial and tangential components should be about equal. Nevertheless, without knowing the precise geometry of the force resolution, we can say:
f net =c 3 f nc
where f net is the tangential component and c 3 is the resolving coefficient which may depend mostly on the radial angles of the rotor and stator bars at the crossing point.
If each tangential load component is multiplied by the radius at that particular crossing point, and if these values are summed, the resultant sum is the total torque applied to the refiner shaft:
T=Σ (n=1,x) f net r n
where X is the total number of crossing points for the particular refiner filling being used. An approximate value for X for any combination of rotor and stator plates can be obtained with the following equam (.U 0.45
cos α+β)( D 2 −d 2 )/( s 1 s 2 )
where α is the average radial angle of the stator bars, β is the average radial angle of the rotor bars, d and D are the inside and outside diameters of the active surface, and s 1 and s 2 are the edge to edge distances for the stator and rotor bar patterns respectively.
If we further assume:
a) that f net is not radially varying (it probably does vary slightly due to the uniform wear constraint imposed by the mechanics of a disk refiner—but this fact does not materially affect the outcome of our analysis); b) that the number of crossing points at any radius is proportional to the radius for constant edge-to-edge distance between bars; and c) that the bars extend from an inside diameter of d to an outside diameter of D, then the resultant torque is expressed as follows:
T=c 3 ×f nc ( D+d )/4
And the resultant power P, is defined as:
P=k 1 RPM T
where RPM is the shall speed of the refiner and k 1 is the appropriate constant for the units of measure.
According to the above equations, the power applied to a disk refiner can be related to the uncompressed height of the fiber accumulation and the height to which it has been reduced by the compressive load of refining:
P=k 1 RPM [( D+d )/4]× c 1 c 2 c 3 r e ( h o /h )
If we now assume now that the operating plate gap, g, in a refiner is proportional to the value of h (with C 4 as the constant of proportionality), then the power can be expressed in terms of the gap as follows:
P=k 1 RPM [( D+d )/4]× c 1 c 2 c 3 c 4 r e ( g o 2 /g)
Then, dP/dg=−k 1 RPM [( D+d )/4]× c 1 c 2 c 3 c 4 r e ( g o 2 /g ).
Of particular interest is the fact that, according to the assumptions and development of the model:
P /( dP/dg )=− g
It should be remembered that c 1 c 2 c 3 c 4 are constant only for certain conditions, c 1 being dependent on the compressibility characteristics of the fiber accumulation, c 2 relating edge radius and floc size to load bearing area, c 3 being mostly a function of the rotor bar angle, and c 4 depending on specific geometry at the intersecting points.
Model Application
According to the relationship implied by this model, the power applied to a disk refiner will vary with the inverse of plate gap. There is growing empirical evidence to support the fact that this is so. We have measured the relative changes in plate gap and applied power in several tests with different pulps in refiners of differing size and different process conditions. In all these cases, it has been possible to accurately determine the absolute value of net applied power by very carefully measuring no-load power. No attempt has been made to measure absolute gap, but gap changes during a loading cycle have been carefully measured.
In fact, it is very difficult to precisely measure absolute operating gaps in a low consistency, double disk pulp refiner. First, the gaps are exceedingly small—in the order of 0.01-0.02 mm for hardwood pulps. This is much smaller than the variations due to run-out and out-of-tram misalignments in a refiner with a new set of plates. Therefore, accurate gap measurements can only be made after plates are well worn in. But by the time the plates are worn in, a reliable zero gap reference is usually not possible.
Short-term gap changes, however, are quite easy to measure and with a high degree of precision, (in a double disk, floating rotor machine, operating conditions must favor a hydraulically balanced rotor). It is only necessary to precisely measure the displacement of the sliding head and to divide by the number of gaps represented (two in the case of a double disk refiner). For For tment of gap changes, a precision of 0.005 mm is possible, and it can be done at any point in the wear cycle of a set of refiner plates after initial wear-in.
The experimental determination of the power-gap curve for a given set of process conditions is quite simple. One of the most reliable methods of determining gap changes is to count the degrees of revolution of the input worm gear on the refiner actuating mechanism. So long as the motion is in only one direction to avoid backlash error, and the threads of the main thrust screw are not excessively worn, this is a precise indicator of gap changes. A precise value of the no-load power at the existing wear condition of the refiner plates must be known and a precise value of the motor load must be recorded after each measured incremental gap change.
Once the power and corresponding gap measurements have been made, a regression analysis is used to “smooth” the data and generate an equation of power as a function of gap. This equation can then be differentiated to determine the slope at any power level. At each recorded power level, the actual operating gap g (according to the above model) can be determined by dividing the power reading by the calculated slope. And, since all the coefficients remain constant in the power equation, go can be calculated from that equation.
If our assumptions are correct, the average stress level in the fibers is reflected by the average stress level in the accumulations, and is proportional to g o /g.
We would propose that the calculated value of g o /g is very good indication of the relative refining intensity in any operating refiner given a particular type of pulp and degree of refining. It remains to be seen, for this particular ratio, what is the sensitivity to degree of refining and to what extent can we include degree of refining in the expression for actual refining intensity.
Experimental Results
Attached Attached 3 is a Table II that lists the data recorded and the subsequent calculations for a recent experiment with two side-by-side 38″ double disk refiners, comparing two sets of refiner fillings with very different edge lengths and SEL values. The “MD Filling” was a Multi-Disk refiner filling with a 1.0-2.0 bar pattern. The “FB Filling” was a fine Double Disk refiner filling with a 1.0-1.3 bar pattern. The regression show in FIG. 4 was done using the presumed 1/g relationship. The zero reference was varied in an iteration to force the exponent of the power transform to a value of −1 in the linear regression. However, it is not necessary to do this. Any transformation may be used so long as it results in a high R 2 value and results in an equation that is mathematically differentiable.
The throughput rate of hardwood kraft was identical for both refiners. As seen in FIG. 5 , the SEL values for the two fillings were appreciably different for any net applied power level. However, the calculated relative stress based on measured power and gap changes ( FIG. 6 ) are nearly identical. In fact the results of pulp tests (TABLE III and FIGS. 5-12 ) could not distinguish between the two refiners despite the fact that the difference in SEL should have caused significant and measurable difference in pulp properties.
Referring to FIG. 3 (the spreadsheet Table II) which shows the recorded power and handwheel rotations for each of two side-by-side 38″ disk refiners in a papermill producing copy paper. One machine had a filling referred to as an FB filling which had a full filling edge length of about 133 km per revolution, and was a double disk type with a refining zone on each side of a single rotor turning at 510 RPM. The second machine, otherwise identical to the first, had a filling referred to as an MD filling which had a full filling edge length of about 191 km. It was a three-rotor filling with a total of six refining zones, also operating at 510 RPM. The FB filling had a no-load power of 150 kw and the MD filling a no-load power of 300 kw. The test was performed primarily to ascertain the extent to which the paper quality would be diminished by refining at the higher specific edge load of the FB filling. A significant reduction in the quality was expected by the relative difference in SEL, assuming that SEL is a satisfactory measure of refining intensity. Subsequent testing of pulp samples taken at each recorded power level indicated little if any difference between the two fillings, and as will be seen below, this may be explained by the use of the new measure of refining intensity which is the subject of this invention.
For each filling, there is a listing above each table showing the no-load power, the total filling edge length, the rotor outside and inside diameters, the RPM, the total crossing point value X, and the assumed values for the several earlier described constants K 1 , c 1 , c 2 , c 3 , and the edge radius r e . The constants and the edge radius were assumed identical for both fillings given that the bar material was the same in both cases, and the pulp being processed was identical.
The main body of the data tabulations for each filling contains several columns. The first column is the recorded motor load in kilowatts. The second column is the cumulative degrees of handwheel rotation which, in the spreadsheet, is automatically adjusted by the addition of an “assumed zero” value above the column. This assumed zero is manipulated so that regression equation of an assumed form, P=b*1/g n , produces a fit line for a value of n=1. This then defines the appropriate gap-power relationship. It infers that the power approaches an infinite value as the gap approaches zero, although in reality the pulp flocs become increasingly “sheared off” rather than compressed as the load gets excessive, and this becomes obvious by the well-known drop in measured power as the gap gets too small.
The third column is the calculated gap based on the handwheel revolution (adjusted for the assumed zero value), and is the value of gap used in the trial regressions. The fourth column is the net power consumed by a single disk pair (one refining zone), and is calculated from the measured gross power, first by subtracting the no-load power for that filling, and then dividing the result by the number of disk pairs (or refining zones). This is the value of power used in the trial regressions.
The fifth column is a calculated value of power based on the gap the of column three, using the general form of the gap power equation described above, and using a value for b derived from the regression iteration.
Column six is the result of the mathematical integration of the power equation resulting from the regression, showing the dP/dg value for each value of gap in column three.
The seventh column is a gap value which is calculated by dividing the single pair power of column four by the dP/dg value of column six. As can be seen it conforms closely to the measured gap (adjusted for the assumed zero) except at the extremes.
Column eight is the calculated value for g o based on the equations of the proposed model, using the assumed values for the constants.
The relative stress shown in column eight is calculated from the ratio of go/g according to the equations of the model and the assumed constants. While the true absolute value of average stress in the fiber wall is highly dependent on the assumed values of certain constants, the relative comparison for two fillings acting on the same pulp, is according to this invention, a much more valid indicator of relative refining intensity compared with SEL.
Columns nine and ten show the net value of applied power (being the measured total power less the no-load power), and the Specific Edge Load (SEL, in watt seconds per meter), for each power point, for each filling.
As indicated in FIGS. 4 and 5 , and with the knowledge that the pulp properties were essentially identical for both fillings, the Relative Stress was a much better predictor of pulp properties than was the calculated SEL.
A succinct statement of a method according to the invention is that of indirectly determining the operating gap of a disk mill by performing a series of measurements of the incremental displacement of the stator element (or elements) of the mill and the resulting incremental change in motor load, then performing an iteration by regression to arrive at a solution for the constant b o , and a zero reference position, that causes a high degree of fit of the measured data to the equation power=b o ×1/gap n , describing the general form of the inverse relationship between operating gap and applied power for a known value of the exponent n. The value for n is a direct inverse of the relationship of Δp/Δg. For pulp refining, n can be reasonably valued at 1.
An instrument (patent rights reserved) is currently being constructed which will facilitate monitoring of power and plate gap changes in mill operating refiners. It is expected that, over a period of time, a large database of power-gap relationships will be generated. To the extent possible, information regarding pulp type and condition, average flow velocities, intersecting angles, edge radii, and bar patterns will be included. This should lead to improved methods for designing and applying plate patterns in stock prep applications. It is also possible that permanently installed power-gap measuring devices could provide valuable real time indications of changing pulp characteristics which would allow immediate corrective action to be taken, and offsetting process adjustments to be made downstream.
Thus it is possible in many pulp and paper mill installations to quite simply retrofit the appropriate sensing devices to determine changes in refiner filling gap. And, many such mills have relatively precise measure of refiner motor load available within the existing mill DCS system. All that is required to implement this method is to add a rotation counting device to the refiner, and to generate the table of power and position values recorded during a single loading cycle. It is possible to automatically program such cycles so as to repeat at regular time intervals, thus providing a semi-continuous indication of real refining intensity.
Various changes may be made to the method embodying the principles of the invention. The foregoing embodiments are set forth in an illustrative and not in a limiting sense. The scope of the invention is defined by the claims appended hereto.
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This invention relates to a method of diagnosing or controlling a grinding mill for paper pulp, wood chips, or other fibrous materials, by measuring the incremental change in power related to an incremental change in the gap, and using the ratio of the two differences, together with the measure of applied power, as the diagnostic or control parameter.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of priority under 35 U.S.C. 119 to Korean Patent Application No. 10-2011-0077069 filed on Aug. 2, 2011 which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] The present disclosure relates to an antenna and a mobile terminal including the same, and more particularly, to an antenna including a solenoid disposed inside a square pattern to receive power, thereby improving a magnetic field and the degree of freedom of an antenna shape.
[0003] As mobile terminals are developed, they have various functions such as voice calls, video calls, capturing of a moving image, playing of a file and a game, and receiving of broadcasting. Accordingly, mobile terminals are complicated and miniaturized.
[0004] Such a mobile terminal is provided not only with an antenna for voice or video calls, but also with a device such as Wi-Fi, Bluetooth, or a near field communication (NFC) antenna to receive and transmit signals of different frequency bands.
[0005] FIG. 1 is a cut-away perspective view illustrating an inner structure of a mobile terminal including an NFC antenna installed on a battery pack of the mobile terminal. Referring to FIG. 1 , a mobile terminal 5 includes an NFC antenna 5 - 2 , which a square type one, and is used for communications at a frequency of about 13.56 Mhz. Noises transferred by the mobile terminal 5 , and eddy currents induced in a conductor decrease an NFC recognition distance. Ferrite sheets may be used to address this issue. A ferrite sheet 5 - 1 may be disposed between the NFC antenna 5 - 2 and an outer surface (not shown) of a battery cell.
[0006] Parallel-fed double loop antennas may be used to ensure a stable recognition distance for improving a magnetic field. NFC antennas may be square type antennas to vary in shape and size, so that an antenna for a voice and video call, or a GPS or Wi-Fi antenna can transmit and receive signals of a different frequency band, without interference with an NFC antenna.
SUMMARY
[0007] In one embodiment, an antenna includes: a loop antenna installed on a mobile terminal; a solenoid connected in parallel to the loop antenna, and receiving power; and a plurality of connections connecting the loop antenna to the solenoid.
[0008] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a cut-away perspective view illustrating an inner structure of a mobile terminal including an NFC antenna installed on a battery pack of the mobile terminal.
[0010] FIG. 2 is a plan view illustrating an antenna according to an embodiment.
[0011] FIG. 3 is a plan view illustrating an antenna according to another embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0012] In the description of embodiments, it will be understood that when a layer (or film), region, pattern or structure is referred to as being ‘on/over’ or ‘under’ another layer (or film), region, pattern or structure, the terminology of ‘on/over’ and ‘under’ includes both the meanings of ‘directly’ and ‘indirectly’. Further, the reference about ‘on/over’ and ‘under’ each layer will be made on the basis of drawings.
[0013] In the drawings, the thickness or size of each layer is exaggerated, omitted, or schematically illustrated for convenience in description and clarity. Also, the size of each element does not entirely reflect an actual size.
[0014] Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings.
[0015] FIG. 2 is a plan view illustrating an antenna according to an embodiment. Referring to FIG. 2 , an antenna 10 according to the current embodiment may include: a loop antenna installed on a mobile terminal; a solenoid 13 connected in parallel to the loop antenna 11 and receiving power; and a connection 12 connecting the loop antenna 11 to the solenoid 13 . Further, the antenna 10 may include a power source 15 providing electricity to a square pattern.
[0016] The loop antenna 11 may be constituted by at least one square pattern. In FIG. 2 , the loop antenna 11 is constituted by three square patterns.
[0017] The solenoid 13 may be disposed inside of the loop antenna 11 constituted by the square patterns.
[0018] The connection 12 may connect the outermost one of the square patterns to a terminal of the solenoid 13 .
[0019] The connection 12 may include contacts 12 - 1 and 12 - 2 to the square patterns to the solenoid 13 . The contact 12 - 1 connects the outermost square pattern to one(upper) terminal of the solenoid 13 . A contact 14 - 1 connects the outermost square pattern to the other(lower) terminal of the solenoid 13 . The contacts 12 - 1 and 14 - 1 may be formed symmetrically to each other with respect to the inner center of the loop antenna 11 .
[0020] The connection 12 and a connection 14 may include not only the contacts 12 - 1 and 14 - 1 disposed on the outermost pattern, but also a plurality of contacts disposed on the other patterns. The plurality of contacts may connect the square pattern to a portion of the solenoid 13 . For example, the one (upper) terminal of the solenoid 13 is connected to the outermost pattern through the contact 12 - 1 . When the outermost pattern is disposed over the one(upper) terminal of the solenoid 13 at the contact 12 - 1 , the one(upper) terminal of the solenoid 13 may be disposed over another pattern at another contact. The innermost pattern may be disposed over the upper terminal of the solenoid 13 at the contact 12 - 2 , like at the contact 12 - 1 . That is, according to the current embodiment, when a terminal of a solenoid contacts a plurality of patterns, the relative positions between the terminals and the patterns may be reversed at neighboring contacts.
[0021] As described above, the contacts 12 - 1 , 12 - 2 , 14 - 1 , and 14 - 2 , connecting the terminals of the solenoid 13 to the plurality of patterns, may function as feed points for the solenoid 13 , and constitute a portion of the loop antenna 11 or the a portion of solenoid 13 .
[0022] Since the solenoid 13 is connected to a portion of the outermost pattern in a square shape, the antenna 10 can amplify a magnetic field. For example, when a magnetic field is formed in a direction perpendicular to a square surface, the solenoid 13 forms a magnetic field in a direction to reinforce the magnetic field formed in the perpendicular direction, thereby increasing the intensity of the electric field on the whole.
[0023] In addition, since the antenna 10 has a square shape, the shape thereof can be easily changed. Even though the antenna includes the solenoid 13 , the shape thereof can be easily changed. Thus, the antenna 10 is adapted to a small device such as a mobile terminal.
[0024] FIG. 3 is a plan view illustrating an antenna according to another embodiment. Referring to FIG. 3 , an antenna 20 according to the current embodiment may include a loop antenna 21 , a solenoid 23 , a connection 22 , and a power source 25 . The antenna 20 is the same in configuration and operation as the antenna 10 except for the shape of the loop antenna 21 .
[0025] Also in FIG. 3 , terminals of the solenoid 23 contact the outermost one of patterns of the loop antenna 22 in positions symmetrical to each other.
[0026] As described above, according to an embodiment, the intensity of a magnetic field can be improved without increasing the size of an antenna. In addition, the antenna can be applied to a mobile terminal.
[0027] Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
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Provided are an antenna and a mobile terminal including the antenna. The antenna includes a loop antenna, a solenoid, and a plurality of connections. The loop antenna is installed on a mobile terminal. The solenoid is connected in parallel to the loop antenna, and receives power. The connections connect the loop antenna to the solenoid. Accordingly, the degree of freedom of an antenna shape and a recognition distance of the antenna are improved.
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CROSS REFERENCE TO RELATED APPLICATION
This disclosure is a continuation-in-part of a co-pending disclosure of the same title by the same inventor, filed Feb. 20, 2002, bearing Ser. No. 60/358,143.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates, generally, to the fabrication of microlenses attached to the end of optical fibers or small cylindrical rods in general. The purpose of the microlens is to focus light entering or leaving the fiber or mini-rod.
2. Description of the Prior Art
Lenses are used in fiber optics for coupling a signal propagating through an optical fiber into preselected photonic components. An optical beam exiting a fiber must be focused or collimated to facilitate its coupling to a preselected photonic component.
External lenses, one of which is known as the GRIN lens, are in current use.
Attempts, with varying degrees of success, have been made to improve upon such external lenses by positioning a lensing element at the distal end of the fiber, in the near field of the fiber aperture. However such a lens, at best, can only focus the output beam. Moreover, such lenses would be expensive to produce on a commercial scale.
One prior art lens provides a non-focusing lens in the far field; the divergence of the beam is merely reduced.
What is needed, then, is an inexpensive means for better focusing or collimating a light beam exiting an optical fiber. More particularly, a focusing lenslet is needed at the distal end of an optical fiber in the far field of the fiber aperture.
However, in view of the prior art considered as a whole at the time the present invention was made, it was not obvious to those of ordinary skill in the pertinent art how the identified need could be fulfilled.
SUMMARY OF THE INVENTION
The long-standing but heretofore unfulfilled need for a method for fabricating lenses at the end of optical fibers in the far field of the fiber aperture is now met by a new, useful, and nonobvious method that includes the steps of selecting a lens material from a group of lens materials having a large refractive index, high transparency, low shrinkage upon curing, good thermal stability, and ease of curing while centrifuged. A droplet of said lens material is applied to a preselected end of the optical fiber, followed by application of a predetermined artificial gravitational acceleration by spinning the optical fiber and droplet in a centrifuge. The lens material is cured by a suitable means as the optical fiber is spinning.
In a second embodiment, nanoparticles of a preselected transparent material having a high refractive index are incorporated into the lens material, thereby creating a composite lens material having an increased refractive index and providing a gradient in the refractive index to enhance the focusing capability of the composite lens material. The nanoparticles are incorporated into the lens material prior to the application of artificial gravity.
In a third embodiment, a microsphere is introduced into the lens material prior to application of the artificial gravitational acceleration.
The novel method of attaching a microsphere to a preselected end of an optical fiber at a preselected distance from said preselected end includes the steps of selecting an optical cement having a preselected surface tension and a preselected density. A microsphere having a density greater than the preselected density of the optical cement is then selected. A droplet of the optical cement is applied to the preselected end of the optical fiber and the optical fiber is positioned in a vertical plane so that the optical cement depends from a lowermost end of the optical fiber and a microsphere is introduced into the optical cement. At least a portion of the microsphere but less than a hemisphere of the microsphere protrudes from the optical cement. The optical fiber and droplet are then mounted on a rotatable disc and an artificial gravitational acceleration is applied to the optical fiber and droplet along a longitudinal axis of symmetry of the optical fiber by spinning the disc about its rotational axis with the droplet positioned radially outward of the optical fiber. The optical cement is cured while the disc is spinning. In this way, the microsphere is attached to the preselected end of the optical fiber at a preselected distance from said preselected end.
A top wall of the disc has a predetermined slope so that a center of the disc is elevated with respect to the peripheral edge of the disc. The predetermined slope is an angle equal to the arctan of the ratio of the gravitational acceleration of earth to the artificial gravitational acceleration produced by the spinning.
In a fourth embodiment, the surface of the microsphere is chemically treated to produce a preselected contact angle with respect to the optical cement so that the step of applying the artificial gravitational acceleration is eliminated.
A fifth embodiment includes a method for fabrication of lenslets in artificial gravity under nonequilibrium conditions. A droplet is deposited on an optical fiber and may be partially cured prior to spinning said droplet to increase the starting viscosity of the droplet to a predetermined high value.
More particularly, the droplet is spun for a predetermined amount of time with a predetermined time profile of the rotational speed. The time required for the droplet to change its shape noticeably at any moment during its evolution history from rest to a predetermined terminal rotational speed is long compared to its curing time. Moreover, the shape of the droplet is determined by the predetermined amount of time and the predetermined time profile of the rotational speed.
In a first example of the fifth embodiment, a weak UV curing source is employed so that the curing time of the droplet is comparable to the total spin time. The viscosity and surface tension coefficient of the droplet varies with time as curing proceeds. The evolution of the droplet ceases when a sufficiently high viscosity is reached. The use of a weak UV curing source provides lenslet shapes that are different from those obtainable with a strong UV curing source.
In a second example of the fifth embodiment, the intensity of the weak UV curing source is varied with time. In a third example, the weak radiation is followed by a short intense pulse to instantaneously solidify the photopolymer at a preselected droplet shape. This provides still further lenslet shapes not otherwise obtainable.
Microlens arrays are fabricated in a sixth embodiment. A previously-treated substrate is selected to produce an array of circular mesas and a plurality of photopolymer droplets is applied to the top of each circular mesa. The droplets are subjected to artificial gravity and cured by UV radiation under equilibrium or non-equilibrium conditions.
A novel method for forming an array of microlenses under artificial gravity includes the steps of providing a substrate having a plurality of circular mesas formed therein and depositing a photopolymer droplet upon each of the mesas. A rotationally-mounted disc is adapted for rotation about a central axis of rotation. The disc includes a top wall having a first predetermined diameter, a bottom wall having a second predetermined diameter less than the first predetermined diameter, and a sidewall interconnecting the top and bottom walls to one another. The sidewall presents a wedge-shaped profile when viewed in side elevation. An angle α is defined as the angle between the plane of the top wall and the plane of the sidewall.
A substrate is attached to the sidewall and each substrate is covered with a housing that includes a UV-transparent window means formed therein. The disc is positioned within a rotor housing that is concentrically mounted with respect to the central axis of rotation of the disc. A plurality of UV light sources is positioned in circumferential spacing around an inside wall of the rotor housing so that a uniform light intensity impinges upon each photopolymer droplet regardless of its instantaneous position. The disc is rotated about the central axis with a predetermined time profile of the rotational speed for a predetermined amount of time.
When the photopolymer droplet is subjected to equilibrium curing, the sidewall is angled relative to a plane perpendicular to the central axis of rotation at an angle the tangent of which is determined by the ratio of the artificial gravitational acceleration created by the rotation of the disc at the terminal rotational speed of the disc to the earth's gravitational acceleration.
When the photopolymer droplet is subjected to non-equilibrium curing, the sidewall is angled relative to a plane perpendicular to the central axis of rotation at an angle the tangent of which is determined by the ratio of the artificial gravitational acceleration created by said rotation of the disc at the terminal rotational speed of the disc, the artificial gravitational acceleration corresponding to a rotational speed at which curing is essentially complete, to the earth's gravitational acceleration.
The novel apparatus for forming an array of microlenses under artificial gravity includes a substrate having a plurality of circular mesas formed therein. A photopolymer droplet is deposited atop each of said circular mesas. The novel apparatus further includes a rotatably mounted disc adapted for rotation about a central axis of rotation. The disc has a top wall of first predetermined diameter, a bottom wall of second predetermined diameter less than the first predetermined diameter, and a sidewall interconnecting the top and bottom walls to one another. The sidewall presents a wedge-shaped profile when viewed in side elevation. A substrate is attached to the sidewall. A rotor housing is mounted concentrically with respect to the central axis of rotation of the disc. A plurality of UV light sources are positioned in circumferential spacing around an inside wall of the rotor housing so that a uniform light intensity impinges upon each photopolymer droplet regardless of its instantaneous position.
No housing and hence no window means formed therein is required when a vacuum is provided between the inside wall of the rotor housing and the sidewall of the disc. The disc is rotated about the central axis with a predetermined time profile of the rotational speed for a predetermined amount of time.
An important object of this invention is to provide reliable methods for attaching a microlens to an optical fiber in the far field of the optical fiber.
A more specific object is to advance the art of optical fiber microlenses by disclosing a method for forming a microlens by attaching a droplet of a suitable lens material to an optical fiber and spinning the optical fiber and droplet in a centrifuge.
Additional important object includes advancing the art by incorporating nanoparticles into the lens material prior to the application of artificial gravity.
Still another object is to provide a method for incorporating a microsphere into the lens material at a distance from the optical fiber with the application of artificial gravity.
Yet another object is to provide a method for incorporating a microsphere into the lens material and forming a microlens without subjecting the optical fiber and lens material to artificial gravity.
Another object is to provide a method for fabrication of lenslets in artificial gravity under nonequilibrium conditions.
Another object is to provide a method for forming an array of microlenses under artificial gravity.
These and other important objects, advantages, and features of the invention will become clear as this description proceeds.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the description set forth hereinafter and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a diagrammatic view of a drop of liquid depending from an optical fiber;
FIG. 2 is a diagrammatic view depicting the focusing of a thick lens;
FIG. 3 is a side elevational, diagrammatic view of a spinning platform;
FIG. 4 is a diagrammatic view of a microlens with a graded refractive index;
FIG. 5 is a diagrammatic view of a liquid droplet containing a microsphere depending from a fiber;
FIG. 6A is diagrammatic view of a liquid cement droplet containing a microsphere depending from a fiber;
FIG. 6B is an enlarged view of the microsphere depicted in FIG. 6A ;
FIG. 7A is a top plan view of a substrate having an array of circular mesas;
FIG. 7B is a side elevational view thereof;
FIG. 7C is a side elevational view of said substrate after droplets of a photopolymer are applied to the top of said mesas;
FIG. 8 is a top plan view of an apparatus for forming a microlens array;
FIG. 8A is an enlarged, detailed view of the circled area denoted 8 A in FIG. 8 ;
FIG. 9 is a side elevational view of a spinning disc that forms a part of the apparatus for making a microlens array; and
FIG. 9A is an enlarged, detailed view of the circled area denoted 9 A in FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In a first embodiment, the lens material is a droplet of photopolymer, thermoplastic, sol-gel, or the like and is applied to a preselected end of a rod or fiber. The lens material is selected from the group of suitable lens materials having a large refractive index, high transparency, low shrinkage upon curing, good thermal stability, and ease of curing while centrifuged. The optical fiber is cleaved at a preselected end and the coating of optical fiber is removed with a stripping agent. The droplet is applied at the cleaved end and the optical fiber and droplet are placed in an artificial gravitational acceleration.
The shape of the liquid drop is found from Laplace's formula:
1
R
1
+
1
R
2
+
g
ρ
y
α
=
const
.
(
equation
1
)
where R 1 and R 2 are the principal radii of curvature, g is gravitational acceleration, ρ is the density of the liquid, and α is the surface tension coefficient for the liquid. When the capillary constant
a = 2 a g ρ
is much larger than the dimensions of the drop, the last term on the left may be ignored. This holds for rods having a diameter of about 100μ at the surface of the earth. The shape of the solid lens will be the same as that of the liquid if negligible shrinkage occurs upon solidification.
With the coordinates as depicted in FIG. 1 , equation (1) becomes
y
″
(
1
+
(
y
′
)
2
)
3
2
+
y
′
x
(
1
+
(
y
′
)
2
)
1
2
=
2
R
0
(
equation
2
)
Where R 0 is the radius of curvature at x=0.
The solution to equation 2 is
y=R 0 −√{square root over (R 0 2 −x 2 )} (equation 3)
It is seen that when gravity is ignored, the drop is a sphere having a flattened top.
The focusing by a thick lens as shown in FIG. 2 is given by:
1
S
+
n
S
′
=
n
-
1
R
(
equation
4
)
To achieve large focusing power (for a given n), R must be made small and S′ large. The largest S′/S is achieved for S′>>r, in which case:
S′/S≅n− 2 (equation 5)
For a given S′, R can be made smaller by applying an artificial gravitational acceleration, (through spinning, e.g.) to increase g and hence decrease a. For a comparable to r, the shapes of the droplets have been given by Freud & Hawkins in the Journal of Physical Chemistry, volume 33, page 1217 (1929). For r/a=0.6 and S′/a=1.6, e.g., R/a=0.6. From equation (4), S=S′ for n=2.2. In contrast, the best focusing power without artificial gravity would be S′/S=0.2 for the same n from equation (5). For r=120μ, a=0.2 mm. This corresponds to g=200 g 0 , and can readily be achieved by spinning.
As depicted in FIG. 3 , a platform is mounted for rotation about a vertical axis. The optical fiber is aligned in radial relation to the axis of rotation with the droplet positioned radially outwardly of the optical fiber. The optical fiber is positioned so that the droplet and a predetermined extent of the optical fiber overhang a peripheral edge of the platform. A top wall of the platform is sloped at a predetermined slope so that a center of the platform is elevated with respect to the peripheral edge of the platform. The predetermined slope is an angle equal to the arctan of the ratio of the gravitational acceleration of earth to the artificial gravitational acceleration produced by the spinning. More precisely, the angle θ should be made to be equal to tan
- 1 ( g o g s )
where g s is the artificial gravitational acceleration produced by spinning.
The polymer-tipped rod or fiber is placed inside a small glass tube to shield the droplet from the deleterious effects of air currents as the platform is spun about its axis of rotation. When the droplet has reached equilibrium, a curing/drying source such as a UV lamp is turned on. To achieve uniformity of curing, a polished aluminum platform is used to reflect the UV radiation so that the top and bottom sides of the droplet receive approximately equal irradiation. This prevents hardening of one part of the lenslet prior to hardening of another part and thus reduces unwanted distortion.
The spinning has the effect of elongating the droplet and making it more pointed. The result is a microlens in the far field that overcomes the limitations of microlenses heretofore known.
In a second embodiment of the invention, the refractive index of the polymer or sol-gel is increased by mixing in high refractive index nanoparticles formed of a transparent material such as Ti 2 O 3 . This also enables producing a microlens with a graded refractive index along the optical axis through centrifugation as depicted in FIG. 4 .
Solid line AB indicates a bent ray as a result of the graded index, and dashed line AC is a straight line the ray would follow without the gradient.
Positioning of Microsphere at End of Optical Fiber by Artificial Gravity
In a third embodiment, a microsphere is attached to the end of an optical fiber by using an optical cement for the purpose of focusing the light coming out of the fiber. The focusing properties of the microsphere depend on the thickness of the cement in between. The novel technique of this invention allows the controlled positioning of the microsphere by applying an artificial gravitational acceleration to the fiber/microsphere assembly before the cement is cured.
When a fiber tipped with a liquid containing a microsphere is held vertically with the droplet hanging at the bottom, the microsphere protrudes out of the liquid if it has a density greater than that of the liquid, as depicted in FIG. 5 . The extent of protrusion depends upon its size and its surface interaction with the liquid, the radius of the fiber, the surface tension of the liquid, etc.
By balancing the “weight” of the microsphere with the buoyant force of the liquid and the atmosphere outside, to have the solid/liquid/gas intersection make an angle α with the “horizontal” ( FIG. 5 ), the artificial gravitational acceleration needed is given by:
g
=
6
γ
cos
α
cos
(
α
+
θ
c
)
-
3
r
Δ
P
(
1
-
sin
2
α
)
4
r
2
ρ
′
-
r
2
ρ
(
2
+
3
sin
α
-
sin
3
α
)
where γ is the surface tension of the liquid. θ c is the contact angle of the liquid on the microsphere, r is the radius of the microsphere, ρ and ρ′ are the densities of the liquid and the microsphere, and Δp is the difference in pressure between the liquid at the bottom and the outside atmosphere (p−p in FIG. 5 ).
For
α=0, γ=40 dynes/cm, θ c =30°, r=30μ, ΔP=γ/r, ρ=1.2 g/cm 3 , and ρ′=4 g/cm 3 , g=700 g o where g o is the earth's gravitational acceleration. The volume of the liquid determines the gap between the microsphere and the end of the fiber.
The artificial gravity is created by placing the fiber on a rotating disk, with the fiber end pointing outwards. The microsphere is fixed in place by applying UV/heat to cure the optical cement while the fiber is spun at the desired rotational speed. To correct for earth's gravity which will introduce some amount of asymmetry, the disc can be made to have a slightly conical cross-sectional profile with a cone angle of tan −1 (g/g o ).
Distancing Microsphere from End of Optical Fiber by Controlling Contact Angle
In a fourth embodiment, a microsphere is attached to the end of an optical fiber at a distance from the fiber end if a suitable contact angle between the optical cement and the microsphere is selected as depicted in FIGS. 6A and 6B .
For a cement drop >100 μm, forces due to liquid and air pressure can be ignored. Accordingly,
2
π
rγcos
α
cos
(
α
+
θ
c
)
≅
4
3
π
r
3
ρg
where γ is the surface tension of the cement and θ c the contact angle between the cement and the microsphere. For r<50μ and typical values of γ and ρ, the equation is satisfied for
α + θ c ≅ π 2 .
For small α, θ c must be close to ninety degrees (90°), i.e., the cement must wet the microsphere only slightly. When the microsphere is captured by the cement by contact, the fiber is held vertically as shown and cement UV/heat cured. If the contact angle between the selected cement and the native surface of the sphere is not close to 90° to begin with, the latter can be treated chemically to produce decreased wetting. This method can either reduce or eliminate the need to apply artificial gravity.
Fabrication of Lenslets in Artificial Gravity Under Nonequilibrium Conditions
In the above embodiments, curing of the droplet which is to become the lenslet is initiated when the artificial gravity generated by spinning has reached a constant value and the droplet has had time to adjust to an equilibrium shape. Under these conditions the shape of the lenslet for a given base diameter and volume is completely determined by its density, surface tension, and the magnitude of the artificial gravitational field. More precisely, where:
ρ=density of the liquid;
α=surface tension coefficient of liquid; and g=artificial gravitational acceleration;
then the crucial parameter is the capillary constant defined by
a
=
2
α
g
ρ
When equilibrium has been reached at a given artificial gravitational acceleration, i.e., when all flowing of the droplet has ceased, the final shape of the droplet is uniquely determined by its base diameter, its volume (or height), and the capillary constant α.
In this fifth embodiment the droplet is cured under nonequilibrium conditions to obtain different final shapes for the lenslet. A hyperbolic shape is especially desirable because it provides distortionless focusing for a collimated incident beam. In the following examples, the starting liquid is a photopolymer and the curing agent is ultraviolet light, although other possibilities also exist (e.g., thermoplastic with heat curing).
In a first example of the fifth embodiment, a droplet is deposited on an optical fiber and may be partially cured before it is spun. This increases the starting viscosity of the droplet to a sufficiently high value so that the time required for the droplet to change its shape noticeably at any moment during its evolution history from rest to a predetermined terminal rotational speed is long compared to its curing time. Accordingly, it becomes possible to obtain any of the intermediate shapes between the two times. The sequence of intermediate shapes itself depends on the predetermined time profile of the rotational speed.
In a second example of the fifth embodiment, a weak UV curing source is used so that the curing time is comparable to the total spin time. Thus, the viscosity and surface tension coefficient of the photopolymer varies with time in addition to the rotational speed. The evolution of the droplet ceases when a sufficiently high viscosity is reached. Lenslet shapes different from those obtainable with the first example of this fifth embodiment can be provided when the steps of this second example are followed.
In a third example of the fifth embodiment, the second method is modified by programming the intensity of the weak UV curing source to vary with time. In particular, the weak radiation may be followed at the end by a short intense pulse to instantaneously solidify the photopolymer at some desired droplet shape. This third example of the fifth embodiment thus produces lenslet shapes not possible with the first examples.
In view of this disclosure, it is now obvious to those of ordinary skill in this art that other variations are possible to produce lens-tipped optical fibers in artificial gravity under nonequilibrium conditions.
In a sixth embodiment, the same basic principles are applied to the fabrication of microlens arrays. The process begins by selecting a substrate that has been treated previously (e.g., lithographically) to produce an array of circular mesas. FIGS. 7A and 7B provide top and side views, respectively, of such a substrate, denoted 10 as a whole. Droplets of photopolymer 12 ( FIG. 7C ) are applied to the top of mesas 14 by microjetting or other suitable means.
The shape of each droplet 12 will always be spherical in normal gravity for mesa diameters of less than approximately one millimeter (1 mm), regardless of the orientation of substrate 10 . When used to focus a beam of light, such a shape will lead to spherical aberration, especially when the thickness of the lens is a substantial fraction of its diameter at the base and the light beam fills a large portion of the available aperture. This aberration is reduced by subjecting droplets 12 to artificial gravity prior to curing by UV radiation under either equilibrium or non-equilibrium conditions.
A preferred embodiment of an apparatus that forms an array of microlenses under artificial gravity is depicted in FIGS. 8 , 8 A, 9 , and 9 A. Substrates 10 with photopolymer droplets 12 are attached to spinning disk 16 which is mounted for rotation as indicated by directional arrow 15 about axis 17 . Disc 16 is a many sided polygon with a wedged side as seen in side elevation or cross section, as shown in FIG. 9 .
More particularly, disc 16 includes top wall 16 a of first predetermined diameter, bottom wall 16 b of second predetermined diameter less than said first predetermined diameter, and sidewall 16 c interconnecting said top and bottom walls to one another, said sidewall presenting a wedge-shaped profile when viewed in side elevation.
The wedge-shaped side eliminates the effect of the earth's gravitational field. As indicated in the detailed views of FIGS. 8A and 9A , each substrate 10 is covered by a housing 20 which is fitted with a window 22 transparent to the UV radiation required for curing. Housing 20 eliminates any deleterious effect that might be caused by air turbulence during spinning. As depicted in FIG. 8 , a plurality of UV light sources 24 are circumferentially arranged around the inside of rotor housing 26 in such a way that each array sees essentially a uniform light intensity regardless of its instantaneous position. Array housings 20 can be eliminated if a vacuum is provided in the space in which the arrays are spun.
In the case of equilibrium curing, wedge angle α ( FIG. 9 ) should be made
α
=
tan
-
1
(
g
g
0
)
where g o is Earth's gravitational acceleration and g is the artificial gravitational acceleration at the terminal rotational speed. In the case of non-equilibrium curing, g should correspond to the rotational speed at which curing is essentially complete.
It will thus be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained. Since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.
Now that the invention has been described.
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A microlens is affixed in the far field of an optical fiber to spatially transform a beam either entering or exiting the fiber. In a first embodiment, a droplet of photo polymer is placed on the end of an optical fiber and the fiber is spun to create an artificial gravity. The droplet is cured by UV radiation during the spinning. In a second embodiment, nanoparticles are mixed into the droplet to increase the refractive index of the photo polymer. A third embodiment employs artificial gravity to attach a microsphere to the end of the optical fiber. A fourth embodiment chemically treats the surface of the microsphere so that the requirement of artificial gravity is either reduced or eliminated. In a fifth embodiment the droplet is cured under equlibrium or nonequilibrium conditions to obtain different final shapes for the lenslet. A sixth embodiment discloses fabrication of microlens arrays.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 12/567,468, filed Sep. 25, 2009, which is a continuation of U.S. patent application Ser. No. 11/345,817, entitled “Versatile Lighting Device”, filed Feb. 2, 2006, which claims the benefit of prior provisional application Ser. No. 60/650,536, entitled “Versatile Lighting Device”, filed Feb. 8, 2005. The disclosures of the foregoing applications are incorporated herein in their entirety.
BACKGROUND
The present invention relates to lighting devices, particularly to a versatile lighting device, and more particularly to a versatile lighting device for art gallery, display and decorative lighting applications.
Picture lights and display lights have been widely used in public establishments (e.g., galleries and museums) to illuminate paintings, artifacts and architectural details for enhanced visual effects. Recently, these lighting devices are slowly making their way into private homes. Many people attempt to make their homes appear warmer and more attractive by installing what used to be considered professional lighting fixtures. Private individuals may also have the need to showcase a wide range of possessions, such as paintings, prints, photographs, awards, artifacts, plants, flowers, and aquariums. A variety of decorative lighting devices have been designed and marketed for these purposes. The known types of decorative lighting devices have at least the following drawbacks.
A major portion of known lighting devices are powered by so-called household or conventional electric grid power sources. They are either required to be hard-wired to household electric lines or include power cords to be plugged into electric sockets. It is usually costly or at least troublesome to route and conceal the unsightly electric wires or power cords. Although a few battery-powered lighting devices have been proposed, they have not been commercially successful due to poor light quality (often linked to power constraints), short battery life, and the inconvenience of battery replacement or recharge.
Existing decorative lighting devices typically tend to be obtrusive and lack flexibility or versatility. Once installed in a ceiling or on a wall, they cannot easily be moved to a different location without extensive reinstallation or rewiring. The light intensities are usually fixed or not easily adjustable. Typically, the light beams, with respect to focus and direction, can only be adjusted manually, which may be cumbersome and even unsafe, since many decorative lighting devices are installed in hard-to-reach places.
Still further, many decorative lighting devices are designed and/or installed in an obtrusive fashion. When a picture light or display light is implemented, it is desirable to draw attention to the painting or artifact that is on display, not the light source. Preferably, the light itself should be hidden or invisible, or at least unobtrusive and unnoticed. Currently, very few ceiling-mountable or wall-mountable decorative lights meet this requirement. Recessed lighting may partially solve this problem, but the installation involves creating openings in a wall or ceiling, which is not always feasible.
In view of the foregoing, it is desirable to provide a more efficient solution for decorative lighting.
BRIEF SUMMARY
The present invention provides a versatile lighting device that overcomes deficiencies of known lighting devices and systems.
According to one embodiment of the invention, a versatile lighting device is provided which is operable to produce appealing and pleasing illumination. The lighting device may not require any connection to an electric grid power source or outlet. One or more batteries that power the lighting device may be charged without removal from the installed lighting device. The batteries may have relatively long run-time and short charge time. Alternatively, the lighting device may be powered by a low-profile power unit which is wired to an AC power source. The lighting device may comprise a low-power consuming light source, such as one or more light emitting diodes (LEDs), to provide bright and warm illumination that is comparable to natural light. The lighting device may be provided in various configurations, including wall sconces, picture lights and various forms of decorative lighting, and may be remotely controlled to achieve desired lighting effects, including position, intensity and focus.
The present invention still further provides a versatile lighting device which may be mounted in a wide variety of locations, and powered by an onboard battery power source. The battery source may be conveniently recharged without removal from the lighting device by a charging apparatus which includes an elongated wand, rod or pole for connecting a source of recharging power to the battery. The battery charging apparatus may be easily connected to the lighting device and easily removed therefrom using a variety of connection means known in the art. The charging apparatus may be stored in a closet or other storage space when not needed and may include a telescoping type rod or pole to facilitate access between a source of charging power and the lighting device itself.
The present invention will now be described in more detail with reference to embodiments thereof as shown in the accompanying drawings. While the present invention is described with reference to preferred embodiments, it should be understood that the invention is not limited thereto. Those of ordinarily skill in the art having access to the teachings herein will recognize additional implementations, modifications, and embodiments, which are within the scope of the present invention, and with respect to which the present invention may be of significant utility.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified side elevation view in somewhat schematic form of a lighting device according to one preferred embodiment of the invention;
FIG. 2 is a diagram illustrating components of a lighting device according to the invention;
FIG. 3 is a perspective view of a remote control unit for a lighting device according to the invention;
FIG. 4 is an exploded perspective view of the remote control unit shown in FIG. 3 ;
FIG. 5 is a table showing certain performance parameters of a selected type of battery which may be suitable for use with the lighting device of the invention;
FIG. 6 is a perspective view of another preferred embodiment of a lighting device in accordance with the invention;
FIG. 7 is a perspective view of still another preferred embodiment of a lighting device of the invention;
FIG. 8 is a perspective view of yet another preferred embodiment of a lighting device in accordance with the invention;
FIG. 9 is a perspective view of still another preferred embodiment of a lighting device in accordance with the invention;
FIG. 10 is an exploded perspective view of the lighting device shown in FIG. 9 and taken from a different perspective;
FIG. 11 is a perspective view of the embodiment of the lighting device shown in FIGS. 9 and 10 and illustrating the connection between a charging apparatus for charging the battery of the lighting device;
FIG. 12 is a detail perspective view of an embodiment of a battery charging apparatus;
FIGS. 13 and 14 are detail side elevation views of parts of another embodiment of a charging apparatus;
FIG. 15 is a perspective view of a power supply unit for supplying power to and through the charging apparatus for charging the battery or batteries of the lighting device of the invention;
FIG. 16 is a schematic diagram of a portion of the control circuitry onboard the lighting device shown in FIGS. 9 and 10 ;
FIG. 17 is a schematic diagram of a further portion of control circuitry for the lighting device of the invention;
FIG. 18 is a schematic diagram of control circuitry for a remote control unit for the lighting device of the invention;
FIG. 19 is a perspective view of another embodiment of a charging apparatus for the lighting device of the invention; and
FIG. 20 is a perspective view of a wall sconce embodiment of the invention.
DETAILED DESCRIPTION
Reference will now be made in detail to the embodiments of the invention which are illustrated in the accompanying drawings. The drawings are not necessarily to scale and certain components may be shown in schematic form in the interest of clarity and conciseness.
Referring to FIG. 1 , there is shown an exemplary lighting device 100 according to one embodiment of the invention. The lighting device 100 may comprise two main components: a base 102 and a pan-tilt assembly 104 . The base 102 may house electronics and one or more batteries. The pan-tilt assembly 104 may house a lens, one or more LEDs, and a heat sink.
The base 102 may be mounted to a surface 10 or a recess opening therein. The base 102 may be mounted via a number of mechanisms. For example, the base 102 may be screw-mounted via a ceiling mount or a wall mount, or the base 102 may include a hook and loop patch-type fastening means, an adhesive pad or other detachable mounting devices. Since the lighting device 100 is battery-powered, it may be installed in various rooms and in various configurations based on specific decorative needs. For example, the lighting device 100 may be mounted on a wall above a painting, poster or mirror. The lighting device 100 may be attached to a ceiling with its light beam directed to and/or focused on a painting on a nearby wall. Alternatively, the lighting device 100 may be positioned above a shelf to highlight artifacts displayed thereon. The lighting device 100 may be hidden under a mantle to illuminate fireplace displays, for example. According to other embodiments of the invention, the base 102 or the entire lighting device 100 may be recessed in a wall or ceiling opening, for example, to make the fixture appear even less intrusive.
Referring further to FIG. 1 , the base 102 may comprise battery charge pins or contact elements 106 , one shown, to which a charging apparatus (not shown in FIG. 1 ) may be temporarily coupled to charge the batteries. Though the charge pins 106 are shown as protruding out of the base 102 , they are preferably recessed (e.g., in a socket). One or more batteries, preferably rechargeable, may be provided in a modular battery pack so that the batteries may be easily replaced at the end of their lives. The batteries may occupy the greatest amount of space and contribute the most to the overall weight of the lighting device 100 . In one embodiment, a battery component may measure no more than 2.5 inches by 2.3 inches by 1.50 inches and weigh as little as 0.5 lbs. Electronic control circuitry may occupy a 2.25 inch by 4.0 inch printed circuit board (PCB) in the same package as the battery. In another embodiment, the battery component may be optionally replaced with a transformer in the same modular enclosure, which transformer may be connected to an AC grid electric line or plugged into a suitable outlet.
The pan-tilt assembly 104 may rotate around a pan axis 110 and/or tilt a light beam to a desired angle around a tilt axis 112 . Tilting and panning adjustments of the pan-tilt assembly 104 may be remotely controlled. Although conceptually illustrated in FIG. 1 as a separate component, the pan-tilt assembly 104 may be housed in substantially the same enclosure as the base 102 . The overall enclosure may present an aesthetic yet functional appearance. In order for the lighting device 100 to be unobtrusive, its enclosure may, preferably, have the same color as the surface 10 and/or the surrounding environment. Therefore, enclosures with a wide range of colors may be provided. Alternatively, the enclosure may be made of a paintable material, such as a white plastic with a paintable surface, so that the lighting device 100 may be easily adapted to a desired color.
FIG. 2 comprises a block diagram illustrating functional components of an exemplary lighting device 200 according to another preferred embodiment of the invention. The lighting device 200 may comprise a base 22 , a light emitter and lens support assembly 24 and a suitable beam focus adjusting mechanism 25 . A pan-tilt mechanism 104 interconnects assembly 24 with base 22 . The assembly 24 may comprise a set of LEDs 218 and a lens 220 . Developments in LED technology have enabled the creation of a warm spot light with minimal power consumption so that the lighting device 200 can be battery powered. According to one embodiment, the LEDs 218 may include Luxeon™ brand Warm White Emitters from Lumileds Lighting, U.S., LLC of San Jose, Calif. The Luxeon™ brand Warm White LEDs provide a light that closely resembles that emitted by the desired warm yellow-white halogen/incandescent light. The Luxeon™ brand Warm White LEDs have a nominal correlated color temperature (CCT) of 3200K, describing the warmth or coolness appearance of a light, and a typical color rendering index (CRI) of 90, describing the effectiveness of a light source on color appearance (CRI of 100 represents the maximum most “natural” looking reference condition). Compared with incandescent bulbs, which generally have a low CCT around 2700-3000K and a high CRI, the Luxeon™ brand Warm White LED is a good low-power alternative. Other colors may be provided using paintable LEDs and/or lenses.
The LEDs 218 may be connected either in series or in parallel. The number of LEDs 218 may be determined based on a total required number of lumens desired. Depending on the desired light intensity, the LEDs 218 may be customized together with the associated electronics and battery component. The LED light emitting intensity may also be controlled to conserve battery power.
The lens 220 may be an FT3 Tri Lens Module from Fraen Corporation of Reading, Mass. The FT3 Tri Lens Module, is an off-the-shelf product specially designed for the Luxeon™ brand LEDs. The high collection efficiency reaches 85% of the total flux and provides a clear, focused beam with minimal hotspots. This means that the lens preserves 85% of the light quality characteristics after filtering the light beam. Though this is a tri-lens module, it functions very well when using only one or two LEDs. The lens focuses all LED configurations similarly without creating hotspots. According to preferred embodiments of the invention, it may be beneficial to attach one or more color filters to the lens 220 in order to obtain a desired color of illumination that is different from the original color of the LEDs 218 . Other filters, such as ultraviolet (UV) filters and dispersion filters, may also be attached to the lens 220 . As mentioned above, the LEDs may be modified to provide different color light.
The LEDs 218 may be powered by a LED drive circuit 202 suitably disposed on the base 22 . The Luxeon™ brand LEDs are characterized at 350 mA. The cut-in voltage required to run each LED is approximately 3.6 volts. If three LEDs are placed in series, the LED drive circuit 202 must supply 10.8 volts. Given this voltage, the power dissipation is expected to be approximately 3.78 watts for the LEDs 218 . The LED drive circuit 202 may employ a DC to DC voltage converter to boost the voltage output of a battery 204 . For example, a six-volt output from a battery may be boosted to twelve volts in order to run the three LEDs 218 in series. This DC to DC voltage converter may allow the use of a smaller battery to produce the same voltage as a larger battery. The LED drive circuit 202 may also be compatible with one or more LEDs in series. The more LEDs, the shorter time they may be run on a single charge of the battery 204 .
Referring briefly to FIG. 5 , there is shown a table of battery life for certain battery capacity and operating conditions of a versatile lighting device in accordance with the invention. The data for FIG. 5 is determined using a preferred embodiment of a battery which is a lithium ion type battery which is of a type that is lightweight and offers a particularly long runtime or life. Still further, by dimming the output light emitted by a lighting device using batteries of the type mentioned, battery life may be extended substantially, as indicated. For example, using pulse width modulation (PWM) where in the LEDs of the lighting device are energized twenty percent of the time, a high capacity six cell battery package might provide as many as forty-three hours of operation while a three cell battery operating on a duty cycle of eighty percent illumination by pulse width modulation (PWM) the runtime for the lighting device may be as low as about nine hours. It should be noted that other chargeable and rechargeable batteries may also be implemented with varying costs and recharging times including, but not limited to, lead-acid, nickel hydride and nickel cadmium batteries, for example.
In accordance with an important aspect of the invention, the battery 204 may be charged without being removed from the base 22 . A charge apparatus or so-called probe 210 , including an elongated rod or wand 208 , may charge the battery 204 through a charge control module 206 . The wand 208 may be either foldable or telescopic with an adjustable length to accommodate different ceiling heights or other difficult to access locations of the device 200 . The wand 208 include a coaxial pin type connector 208 a which may be inserted in a cooperating socket 208 b and partially secured to a pair of recessed conductor pins 205 in the base 22 . As a result, the wand 208 is prevented from disconnecting during a battery charging operation. However, a quick release mechanism or breakaway connection may be implemented in case the wand 208 is accidentally pulled, so that the lighting device 200 will not be unintentionally damaged or detached from its mounted position. The distal end of the wand 208 may also include two metal hooks, not shown, to provide a mate to recessed charge connector pins on the battery pack, not shown. A nonconductive cap, not shown, may be used to prevent the circuit from being shorted if the wand 208 is misplaced or inadvertently touched.
According to one embodiment, charging a three cell lithium ion battery from a discharged state may require 1.20 amps DC current for approximately two hours. At floor level, a transformer in the charge apparatus or probe 210 may convert 115 volts AC power from a wall outlet to a suitable battery charging voltage which goes through the wand 208 . The wand 208 may have a receptacle to accept a plug from the transformer. The charge control module 206 may automatically shut off when the battery 204 is fully charged.
Referring further to FIG. 2 , power for charging the battery 204 for the lighting device 200 may also be obtained from a photovoltaic power source, such as that indicated by numeral 240 in FIG. 2 . The photovoltaic power source 240 includes a suitable adapter 242 to be connected to the charge control circuit 206 in place of the wand 208 . Accordingly, electromagnetic radiation may be focused on or applied to the power source 240 which may then transfer the power to the battery 204 by way of the charging control circuit 206 . Such an arrangement would be particularly useful for applications of the lighting device 200 which are substantially inaccessible by electrical wiring or by other means of connecting the charging control circuit to a power source, such as the wand 208 and the charge probe circuit 210 . Yet further methods for charging the battery 204 can include removing the battery and/or battery unit from the lighting device and using the charging methods described herein or by providing the battery unit with its own adapter for charging by placement in communication with the electric grid at a convenient interior wall outlet, for example. The battery unit or the entire lighting device might be adapted for connection to the electric grid through a wall outlet or into a recharging base, depending on the economics of providing this additional structure and the convenience of using it or not.
The lighting device 200 may be remotely controlled via remote control unit 212 , FIGS. 3 and 4 also. A control receiver 214 , FIG. 2 , in the base 22 may receive and decode infrared (IR) signals transmitted from the remote control unit 212 . A dimmer control module 216 may cause the illumination intensity of the LEDs 218 to be incrementally or continuously adjusted. A pulse width modulation (PWM) circuit may be used to dim the LEDs 218 . This circuit may modulate a DC signal to create a flickering power source that provides power to the LEDs 218 . The flicker may be undetectable to the human eye. The ratio of time the light is turned on versus turned off per cycle, or so-called duty factor, of 60% means the LEDs 218 will illuminate for 60% of the time in each cycle. Manipulating the duty factor controls the light intensity and can cause the light to be dim or bright. This circuitry may also provide a simple and inexpensive way to increase the battery life because the LEDs 218 are flickering instead of constantly draining the battery 204 . For example, a lighting device according to the invention would be operable for a longer period of time using the same battery if the PWM was set to 85% duty factor instead of 100%.
Although only the dimmer control module 216 is shown coupling the control receiver 214 and the LED drive circuit 202 , a number of functions associated with the lighting device 200 may be controlled in a similar manner. For example, the beam focus may also be remotely controlled by way of suitable control circuitry connected to the mechanism or apparatus 25 . In addition, the panning and tilting movements of the pan-tilt assembly 104 may be remotely controlled so that the light beam may be positioned as desired. If a timer is, implemented for the lighting device 200 , the timer may also be remotely set or adjusted.
According to other embodiments of the present invention, it may sometimes be desirable to power the lighting device through an AC grid. In this case, a low-profile AC power unit may be wired to the AC grid and convert a standard AC supply voltage (e.g., 120V or 220V) to a desired DC voltage (e.g., 10V or 12V). According to one particular embodiment, a Model PSA-15LN power supply unit manufactured by Phihong USA, Inc. of Fremont, Calif. may be a suitable choice. The PSA-15LN power supply unit is a compact AC-to-DC converter that can take a S-wire or 2-wire 90-264VAC input and generate a DC output which can be a preset value between 3.3V and 24V. Further, the lighting device of the invention may be designed to operate on battery only, on AC power only, or interchangeably on either battery or AC power. In a lighting device with interchangeable power supply capability, the AC power unit may have physical dimensions substantially similar to those of the battery component so that either power supply may fit into the same lighting device.
Referring further to FIGS. 3 and 4 , the remote control unit 212 includes a two-part housing comprising opposed shell-like housing members 252 and 254 which are suitably secured together in a conventional manner. The remote control unit 212 includes a radiation beam emitter, preferably emitting infrared radiation, and designated by numeral 256 . Emitter 256 is suitably connected to a control circuit 258 including a three position slide switch 548 the purpose of which will be described later herein. Control circuit 258 is supplied with power by suitable batteries 260 disposed within the housing 252 , 254 , FIG. 4 . The control circuit 258 will be explained in further detail herein. As shown in FIG. 3 , the control unit 212 includes a pushbutton momentary type switch including a switch actuator 262 for controlling the energization of the lighting device 200 . Still further, the control unit 212 includes suitable pushbutton type switch actuators 264 and 266 for controlling the intensity of the light emitted by the device 200 . Thus, remote control of a lighting device in accordance with the invention may be easily carried out by the use of an aesthetically pleasing hand-held remote control unit which includes its own source of electric power and which may be used to control energization of the lighting device 200 , as well as other embodiments of the lighting device described herein. An additional control switch, not shown, may be included in the remote control unit 212 for controlling a panning and tilting drive mechanism and a focusing mechanism, such as previously described.
Referring now to FIGS. 6 , 7 and 8 , for example, there is illustrated a versatile lighting device generally designated by the numeral 300 including a housing 302 for supporting a movable head or housing member 304 including a lens 306 and one or more LED light sources, not shown in detail in FIGS. 6 , 7 and 8 . Housing 302 is adapted to removably support a rechargeable battery unit 308 suitably connected to the housing 302 for removal therefrom or for connection to a charging apparatus of a type generally as described herein. As shown in FIG. 8 , additional battery units 310 may be connected to the housing 302 or to the battery unit 308 to extend the life and, perhaps, the power output of the lighting device 300 . Alternatively, as shown in FIG. 7 , the battery unit 308 may be replaced by a self-contained AC power conversion unit 312 whereby the lighting device 300 may be “hard wired” to an AC power source and the power converter unit 312 is operable to convert the power required by the lighting device 300 to the appropriate, DC voltage desired.
The battery units 308 and 310 may, for example, be of modular construction and be adapted to receive shrink-wrapped packs of one or more individual battery “cells” which could be added to the units 308 and 310 to increase operating life of the lighting device 300 between battery charging operations. Alternatively, the battery units 308 and 310 could be of different capacities. One problem associated with multiple battery cells and one or more battery units is to properly charge and discharge the batteries. Providing contacts for connection of the battery units to a charging apparatus can be difficult to accomplish in a way which will provide the ability to connect all the batteries to the charging or discharging conductors in parallel. Moreover, if battery units or individual batteries of differing ages are used, charging without systemized control may not be proper. One solution to this problem would be to devise a raceway of pass-through conductor housings or casings enabling independent conductors to be connected to the lighting device control circuit and to a charging unit or apparatus. The pass-through arrangement could be controlled by DIP switches, to provide a modular unit so that any battery would be operable in any position. Such an arrangement would also be required for charging the battery units with a charging module located on a master circuit board. Such an arrangement might require extensive software written into a microprocessor controller for discharging one battery at a time and then charging the batteries, also one battery at a time.
Referring now to FIGS. 9 and 10 , still another preferred embodiment of a versatile lighting device in accordance with the invention is illustrated and generally designated by the numeral 400 . The lighting device 400 is characterized by a generally planar oval-shaped base 402 which may be adapted for mounting on a ceiling surface or any surface operable to accommodate the base. The base 402 is provided with a pedestal type support member 404 for supporting a light emitter and lens support housing 406 which is operable to support plural LED light emitters 408 and a suitable collimating lens 410 , FIG. 9 . Housing 406 is mounted on suitable trunnions connected to the pedestal 404 whereby the housing 406 and the light emitters may be positioned in a predetermined direction with respect to the base 402 . Base 402 also supports a control circuit board 412 , as shown in FIG. 10 .
Referring further to FIGS. 9 and 10 , the lighting device 400 further includes a support bracket 414 , FIG. 10 , for supporting a removable battery unit 416 . A removable cover comprising a somewhat arcuate shell-like member 418 is adapted to be removably connected to the base 402 . The base 402 , housing 406 , cover 418 and a housing 420 for the battery unit 416 may all be made of a suitable thermoplastic or polymer, such as ABS or a polycarbonate. Battery unit 416 may be suitably connected to control circuitry mounted on board 412 by way of suitable contacts 415 and 417 mounted on bracket 414 , FIG. 10 , and cooperating contacts 415 a and 417 a on battery unit 416 . Battery unit 416 includes plural battery “cells” 417 b , FIG. 10 . As shown in FIGS. 9 and 10 , the cover 418 is provided with suitable openings 418 a , FIG. 9 and 418 b to accommodate the movable housing 406 , and the battery unit 416 . Cover 418 also supports a radiation sensor 424 , an LED indicator 426 and a pushbutton momentary type switch actuator 428 for energizing or extinguishing the LED light sources 408 . Sensor 424 is operable to receive radiation signals from emitter 256 of the remote control unit 212 and indicator 426 is operable to indicate the charge status of the battery unit 416 . Lighting device 400 may also be adapted to be a hanging or clip-on type device for illuminating works of art and the like.
One significant advantage of the lighting device 400 , as well as the other lighting devices disclosed herein, is the provision of means on or associated with the battery unit 416 for supporting an apparatus for supplying battery charging power to the battery unit. Housing 420 includes spaced apart laterally and upwardly extending fingers 430 and 432 , FIGS. 9 and 10 , and defining a slot 434 therebetween. Fingers 430 and 432 are depicted as being somewhat arcuate but can have any desired shape as long as they can facilitate selective engagement with and disengagement from a charging apparatus. It will be appreciated that housing 420 can include any structure capable of selectively mating with corresponding structure of a charging apparatus, including but not limited to, one or more magnets or piece of metal that can engage a magnet or piece of metal on the charging apparatus, one or more protrusions that engage one or more corresponding recesses or other mechanical features of the charging apparatus, and one or more recesses that engage one or more corresponding protrusions or other mechanical features of the charging apparatus. One wall 421 of housing 420 , FIG. 10 , supports spaced apart battery charging contacts 421 a and 421 b , which contacts face toward the fingers 432 and 430 , respectively.
Referring now to FIGS. 11 and 12 , the lighting device 400 is particularly adapted for charging of the battery unit 416 utilizing a charging apparatus or so-called probe similar to the wand 208 . The battery charging apparatus or probe shown in FIGS. 11 and 12 is generally designated by the numeral 440 and includes a transverse head part 442 having suitable electrical contact members 443 and 444 mounted thereon for engagement with the contact members 421 a and 421 b . The battery charging probe 440 is characterized by a suitable telescoping or detachable pole assembly 446 having telescoping pole sections 448 , 450 and 452 with the latter pole member being directly connected to the head 442 . Fewer or greater numbers of pole sections may be utilized in the apparatus or probe 440 . Moreover, the pole sections may be releasably connected to each other to extend the working length of the probe 440 as compared with being a telescoping type probe assembly as shown in FIGS. 11 and 12 .
For example, viewing FIGS. 13 and 14 , the head 442 is shown connected to a fixed length pole or tube 456 having a receptacle 458 at its lower end for connection to an extension pole member 460 having a grip 461 formed thereon, FIG. 14 . A suitable breakaway coupling 462 is formed on the distal end of pole member 460 for engagement in the receptacle 458 for normally maintaining the pole sections 456 and 460 connected to each other, but allowing breakaway in the event that, while a charging operation is in process, a person inadvertently substantially deflects the pole assembly. In such an event, pole member 460 may detach from pole member 456 . As shown in FIGS. 11 and 13 , the head 442 is provided with a boss defining receptacle 442 a for receiving a coaxial pin type electrical connector of a power source 470 , see FIG. 15 . Power source or power supply unit 470 is of a type which may be directly connected to an electrical grid and includes a transformer and rectifier unit 472 for reducing AC voltage to a suitable DC voltage for charging the batteries of battery unit 416 . Power supply unit 470 includes elongated, flexible conductor means 474 connected to a coaxial pin-type connector 472 a for connection to the head 442 via the receptacle 442 a whereby the contacts 443 and 444 are then in electrically conductive communication with the power supply unit 470 . Alternatively, suitable conductors, not shown, may be extended through the pole assembly of the apparatus 440 internally to eliminate the separate flexible conductor means 474 and the pin-type connector 472 a.
Accordingly, when it is desired to charge the battery unit 416 of lighting device 400 , such as would be indicated by the color of the visual indicator 426 turning from green to red, for example, the battery charging apparatus or probe assembly 440 would be connected to a source of power by way of the power supply unit 470 and placed in electrically conductive contact with the battery unit 416 by hanging the head 442 in the position shown in FIG. 11 in engagement with the fingers 430 and 432 or other connection means disclosed herein or known in the art for connecting two parts together. Thanks to the sloping bottom wall 442 b , FIG. 13 , of the head 442 and the arcuate shape of the fingers 430 and 432 , the head of the charging apparatus or probe assembly 440 is biased into engagement with the wall 421 of battery unit housing 420 and the electrical contacts on the head 442 and those supported on the wall 421 , respectively, are forced into engagement. Once charging is completed, the probe assembly 440 , including the modification illustrated in FIGS. 13 and 14 , may be removed from the lighting device 400 until battery charging is again required.
Referring briefly to FIG. 19 , another embodiment of a charging apparatus for the lighting device of the invention is illustrated and designated by the numeral 440 a . The charging apparatus 440 a includes an elongated pole or rod 446 a which may be telescoping or made up of interconnected sections and includes a boss 447 formed on a distal end thereof, which boss may be provided with opposed hemispherical projections 447 a , one shown, and a tubular or so-called barrel magnet 447 b supported thereon. The pole 446 a of the charging apparatus 440 a is provided with a detachable head member 442 c similar in some respects to the head member 442 but modified to be detachably connected to the pole 446 a . Head member 442 c includes a receptacle 442 a for receiving the axial pin-type connector 472 a and a recess 445 formed therein for receiving the boss 447 of the pole 446 a . Opposed slots 445 a may receive the projections 447 a of the boss 447 whereby the pole 446 a may be detachably connected to the head 442 c for “hooking” the head 442 c onto the battery unit 416 , for example. The pole 446 a may be further secured to the head 442 c by cooperation between the magnet 447 b and a suitable magnet or plug of magnetic material 449 disposed in the recess 445 as illustrated. Accordingly, the charging apparatus 440 a is advantageous in that, during a charging operation, the pole 446 a is not required to remain connected to the lighting device during a battery charging operation.
Referring briefly to FIGS. 16 and 17 , there is illustrated control circuitry for a preferred embodiment of a controller for the lighting device 400 . Certain elements, including connectors and voltage regulators are eliminated from the control circuitry shown in the interest of clarity and conciseness. As shown in FIG. 16 , a portion of the control circuitry for the controller for the lighting device 400 is illustrated which is characterized by radiation sensor 424 which is operably connected to a decoder circuit 500 , the output signal from which may be modified by a set of DIP switches 502 mounted on controller circuit board 412 , for example. In this way the control unit 212 , which may also have a set of switches or a multiposition switch mounted thereon, may be adapted to control only a particular lighting device in an array of such devices or a selected number of lighting devices in an array.
Referring to FIG. 17 , the controller for the lighting device 400 further includes the momentary off/on switch 428 and the battery charge level visual indicator 426 , as illustrated. The aforementioned components are operably connected to a microcontroller 506 which is connected to the light emitting diodes 408 by way of a circuit including a transistor 508 controlled by the microcontroller 506 through a control circuit 510 and a smoothing inductor 512 . Thus, the microcontroller 506 may, upon receipt of instructions from a remote control unit for the lighting device 400 , such as unit 212 , control the energization of the LEDs 408 by imposing a signal on the LEDs whose width in time is modified via pulse width modulation (PWM) to vary the light intensity emitted by the lighting device 400 . The microcontroller 506 may be suitably programmed to operate in accordance with desired operating characteristics of the lighting device 400 by temporary connection to a programming computer, not shown, via a connector 501 , FIG. 17 .
Referring briefly to FIG. 18 , there is illustrated a schematic diagram for the control circuitry for the remote control unit 212 . Remote control unit 212 is operable to transmit a coded signal to the controller for the lighting device of the invention by way of, for example, an infrared emitter, such as the emitter 256 . Emitter 256 is driven by a transistor 540 which is connected to an AND gate 542 , the inputs for which comprise the output from an encoder circuit 544 and a modulation circuit 546 , both operably connected to the battery source 260 , not shown in FIG. 18 . The encoder circuit 544 is also connected to a three position slide switch 548 which establishes, in combination with the DIP switches 502 FIG. 17 , a predetermined code specific to controlling a particular one of a lighting device of the invention, such as the device 400 , without inadvertently controlling similar lighting devices in the vicinity of the lighting device 400 . Remote control unit 212 is operable to be in an off, non-power consuming condition, until any one of the pushbutton switches 262 , 264 or 266 is actuated to control an output signal to be provided by the encoder circuit 544 . The control circuitry for the remote control unit 212 may be constructed using commercially available circuit components as indicated in the diagram of FIG. 18 .
Those skilled in the art will appreciate from the foregoing description that the lighting device of the present invention is indeed versatile and may be utilized in many applications. For example, viewing FIG. 20 , there is illustrated a further embodiment of a lighting device in accordance with the invention and generally designated by the numeral 600 . The lighting device 600 may include a single LED 602 disposed in a movable housing 604 and operable to emit light through a suitable lens 606 . Housing 604 is mounted for limited movement on a second housing 608 which includes control circuitry 613 and a battery power source 615 , essentially like that of the embodiments of FIG. 2 , FIG. 6 or FIGS. 9 and 10 . Single LED lighting device 600 is further characterized by a control switch 610 for energizing or deenergizing the single LED 602 as well as a second switch 612 for controlling the light intensity. Lighting device 600 is particularly adapted for disposition and operation as a sconce, which sconce includes a suitable wall bracket 614 and a pedestal 616 connected thereto and supporting an upward facing light shielding or light disseminating shade 618 . Light disseminating shade 618 is shown as a translucent member, by way of example. Lighting device 600 may be integral with the wall bracket and shade 618 or may be adapted to be placed in and supported by the shade, as illustrated. A battery recharging connector is not shown in the embodiment of FIG. 20 but may be provided on the housing 608 in the same manner as is provided for the embodiments of FIG. 2 and FIGS. 9 and 10 , for example. In all events, those skilled in the art will recognize that the lighting device 600 is versatile in the sense that it may be an integral part of a wall sconce or may be easily removed from the supporting shade member 618 for replacement or battery recharging, as needed.
The construction and use of the versatile lighting device embodiments of the invention, as described hereinabove, is believed to be readily understandable to those of ordinary skill in the art. Conventional engineering materials and components may be used to construct the embodiments of the lighting devices described herein. Although preferred embodiments of a lighting device in accordance with the invention have been described above, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.
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A charging system for use in charging a battery includes an elongate handle with a working length sufficient to reach a battery that is out of reach of a user. The charging system includes a charging apparatus coupled to the elongate handle. A head member is configured to mechanically engage with and electrically connect to a battery unit and also mechanically disengage and electrically disconnect from the battery unit by manually grasping and applying mechanical force to the elongate handle. The charging system also includes a power supply configured to provide electrical power to the charging apparatus. The charging system can be used to recharge the battery of a wall or ceiling mounted device (e.g., a battery powered lighting device) that is out of reach of the user without having to remove the device or use a ladder to reach the device.
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This application is a divisional application of application Ser. No. 12/023,692 filed Jan. 31, 2008 and now issued as U.S. Pat. No. 8,098,163 on Jan. 17, 2012.
This invention relates to a method for detecting the onset of birth of piglets. This can be used for example to communicate to an operator when birth is occurring to allow operator intervention to reduce piglet loss at birth and to control a heating system to attract the piglets away from the sow to prevent crushing and so that the heating system is actuated only when required to reduce heating costs.
BACKGROUND OF THE INVENTION
It is known in regard to the raising of animals, particularly cows and dogs, that a device may be provided to detect the onset of the birthing process commonly by attaching the device to the vagina or vulva of the animal so that a signal can be generated and communicated to the operator. Examples are shown in European Application 108,330 (Weiland) published 16 May 1984, in U.S. Pat. No. 4,264,900 (Charlier) issued 28 Apr. 1981 and in U.S. Pat. No. 4,319,583 (Ingle) issued 16 Mar. 1982.
Also in U.S. Pat. No. 4,651,677 (de Wit) issued Mar. 24, 1987 is shown an arrangement in which a microphone detects sounds emitted by a sow and/or the piglets and analyzes the sounds to determine the condition of birthing or crushing of the piglets to summon the operator. This arrangement is apparently not currently available in the market place.
The problem of monitoring the onset of birth can of course be resolved by providing enough work people to ensure that sows are closely visually monitored to ensure that the person is available as soon as possible after the onset so that all viable piglets are extracted and protected. However many such hog facilities are located in areas where labor costs are such that close monitoring of this nature is not economically feasible.
However despite the proposal of the above techniques for detecting the onset of birth of the piglets, in practice this remains a problem and no effective economic systems are available for this purpose.
Another aspect of protecting piglets after birth is that of providing a suitable location within the farrowing pen for receiving and containing the piglets while keeping them away from the sow where they can be crushed.
In U.S. Pat. No. 4,478,175 (Fisher) issued Oct. 3, 1984 is disclosed a temperature controlled heated nest box for the piglets after birth.
In a brochure by Veng Systems is disclosed a heating lamp and cover panel arranged to be located in the farrowing pen with a temperature sensor to maintain the covered area of the pen at a predetermined temperature for the piglets. No patent or published patent application describing this machine has been found.
Other patents and published documents in this general field are as follows:
PCT/DK2001/000812, WO2002/046850, Inventor: Niels Skov Veng which discloses a control system.
French Patent: FR2579452A1, Inventor: Guy Houssin, registered 29 Mar. 1985 which discloses a device including a contact which is displaced by an arriving piglet for detecting birth;
French Patent: FR2582507A1, Inventor: Paul Fuseau, registered 4 Jun. 1985 which discloses a device mounted in the uterus for detecting the onset of birth;
PCT Published Patent Application WO03/056907A1, Inventor: Jan Tambo, published the 17 Jul. 2003 which discloses a heating control system for piglets.
US Published Patent Application 2007/0262859 Inventor: Marjolaine Henry, published the 15 Nov. 2007 which discloses detection of the birthing process either by a motion sensor or by a weight sensor at the piglet area and the transmission of a signal to the worker in the barn.
SUMMARY OF THE INVENTION
It is one object of the invention to provide a method for detecting the onset of birth of piglets for example so that birthing is detected in time to provide a signal to an operator to attend the birthing with the opportunity to reduce deaths of the piglets at birth.
Such deaths can occur for many reasons notably the following:
crushing Trauma risks Death by inanition Splay leg, disability, congenital abnormality Stillborn Infection, diarrhea
According to one aspect of the invention there is provided an apparatus for use in a farrowing crate having a sow containing area and at least one piglet area into which the piglets can move, the apparatus comprising:
a control unit;
a temperature sensor for communicating temperature data to the control unit;
a mounting assembly for the temperature sensor for mounting the sensor at the farrowing crate;
a system for communication to a worker of commencement of birth of the piglets;
wherein the control unit and the temperature sensor are arranged so as to detect an increase in temperature in the pen at a sensing position in the pen arranged so as to detect the presence in the pen of a piglet after birth.
Preferably the sensor is a sensor for location in the pen at a position spaced from its sensing position. Such sensors can be of the type which receives radiation, generally in the infra-red range, from the body or area to be sensed. Thus the sensor is located at a position spaced from the area which it is sensing and has an angle of observation of the radiation emitted which can be very narrow or can be larger to detect the temperature of a larger part of the piglet area. The directional or laser type infra red type sensor is particularly effective in that it can be located away from the area to be monitored where it is protected from contact and potential damage and yet can readily detect the increase of temperature which occurs when the body of the newly born piglet enters the area of detection. This temperature increase occurs because the pen itself and the area to be detected is maintained at a temperature below body temperature in order to maintain the sows in the most comfortable environment without overheating.
However other types of sensor can be used with measure directly at the location to be sensed.
Preferably the sensor is an infrared heat sensor. However other types of sensor can be used.
Preferably the communication system of the control unit communicates wirelessly with the worker. However other types of communication can be used.
Preferably the sensor is mounted on a cover at the piglet area. However the sensor can be located and mounted at other positions including on the crate itself.
Preferably there is provided a heating device or more than one heating device in the piglet area and the sensor is mounted adjacent the heating device for example on a cover.
Preferably the control unit also actuates and controls the output of the heat lamp or lamps.
Preferably the heat lamp or lamps and the sensor or sensors are mounted on a cover at the piglet area. In this case the cover may be movable at the piglet area. Thus the cover may be movable for example by sliding along a guide arrangement at the piglet area to cover different parts of the piglet area In addition or alternatively, the cover may be mounted so as to be movable to a raised position exposing the piglet area.
According to a second aspect of the invention there is provided an apparatus for use in a farrowing crate having a sow containing area and at least one piglet area into which the piglets can move, the apparatus comprising:
a combination of a birth sensing system and a piglet heating system comprising:
a control unit;
a temperature sensor for communicating temperature data to the control unit;
a mounting assembly for the temperature sensor for mounting the sensor at a piglet area in the farrowing crate;
and a heating lamp; wherein the control unit and the temperature sensor are arranged so as to detect an increase in temperature in the pen at a sensing position in the pen arranged so as to detect the presence in the pen of a piglet after birth;
wherein the control unit is arranged to actuate the heating lamp on detection of the presence in the pen of one or some piglets at birth;
and wherein the control unit is arranged to control heat output from the lamp to regulate the temperature in the piglet area at a predetermined curve level.
According to a third aspect of the invention there is provided an apparatus for use in a farrowing crate having a sow containing area and at least one piglet area into which the piglets can move, the apparatus comprising:
a heating lamp;
wherein the heat lamp is mounted on a cover arranged for covering the piglet area;
and wherein the cover is movable along the piglet area to cover different parts of the piglet area.
Other types of sensor can be used in some cases which include notably the following:
Movement detector
Camera
“Micro switch” (used by the operator, turns on and off manually)
Mat that detects movement by sensing the piglets
Preferably there is also provided in the farrowing pen an area for receiving the piglets at a position in the pen spaced from the sow to protect the piglets from crushing. The area includes a heating system for maintaining the piglets at a desired temperature for encouraging them to remain in the area, bearing in mind that the farrowing pen itself is preferably maintained at the above lower temperature more suitable for the sows. The system control provides a signal which is sent to the heat control system to set the heating system in operation automatically causing the heat lamp to be turned on. This allows the heating system to remain off until it is required and also creates a warm location to attract the piglets immediately after they are born thus attracting them away from the area of the sow where they can be crushed. In another arrangement the sensing system and the heating system operate as a combined system where a single sensor is provided which is moved from detecting at the sensing position to detecting at the area after the onset of birth is detected and is arranged to provide a control signal to a heat control system for controlling the heating system.
The birth detector system may be an entirely separate system from the heating system and cover system, so that it is not considered as one whole integral system. It is one option that the systems be combined but also it may be an important factor for the commercialization of the product to be able to separate the three systems.
Preferably the farrowing crate is located in a farrowing room which includes a series of such crates and the signal contains information identifying the crate concerned.
Preferably the farrowing crate is located in a farrowing room which includes a series of such crates and each crate contains at least one separate sensor.
Preferably at least some of the sensors are connected to a common central unit or circuit board arranged to generate and communicate the signal to the operator in response to a signal from one of the sensors connected thereto.
In the system installed in each pen there are algorithms that permit the detection of the births and control the temperature. The temperature variation is realized by receiving temperature signals that increase or decrease the power transmitted to the heating element such as a heat lamp, radiator or a heating mat. In this regard, the system must receive, on constant intervals, the temperature signals.
The cover can also be provided to cover substantially the whole of the piglet area and can just be lifted to expose the area. However this Is not preferred as the intention is that the cover be located at the front end during all times with the exception of the actual birthing time when the cover is moved to the rear end to immediately attract, detect and warm and dry up the piglets after birth. Thus as soon as the birthing process is over, the worker moves the cover to the forward end of the crate.
The sensor can be used with or without a cover. The heating system can also be used with or without a cover. The movable cover can be equally used with or without the sensing system and or the heating system.
A single temperature sensor having sufficient area of sensing can be used centrally between two crates to detect in both adjacent crates.
The cover can use a shock absorber in the hinging movement to assist in lifting forces and to slow any downward or upward movement in the event the cover is dropped or lifted with force to avoid damage to the heating element which can be damaged on impact.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic plan view of a series of farrowing crates including one example of a birth monitoring system according to the present invention.
FIG. 2 is a schematic plan view of one of the farrowing crates including a heating and cover arrangement for the piglets and a monitoring system according to the present invention.
FIG. 3 is an isometric view of one of the farrowing crates including a movable cover and heating arrangement for the piglets in the front position together with the birth monitoring apparatus.
FIG. 4 is an isometric view of the farrowing crate of FIG. 3 with the movable cover in a raised position.
FIG. 5 is a rear elevational view of the farrowing crate of FIG. 3 with the movable cover in a raised position.
FIG. 6 is an isometric view of the farrowing crate of FIG. 3 with the movable cover in a rear position together with the birth monitoring apparatus.
DETAILED DESCRIPTION
In FIG. 1 is shown a row of farrowing crates where the row is generally indicated at 10 and includes a series of farrowing crates indicated at 11 , 12 , 13 etc. Each farrowing crate is identical to the others so that one is shown particularly at 11 and includes a sow containing area 14 with a floor 15 on which the sow can stand and lie defined by side edges 16 and 17 . The sow containing area extends forwardly to a front wall 18 and rearwardly to a rear wall 19 . On one side or as shown on each side of the sow containing area 14 is defined a piglet receiving area 20 and 21 . In most cases there is provided a piglet receiving area on each side of the sow containing area so that the piglets can move to either side of the sow depending upon the direction to which the sow is lying. However in some cases there may be only a single area on one side.
The crate is closed at the sides by walls 22 and 23 . All of the walls 18 , 19 , 22 and 23 can be formed from posts and rails or may be sheet metal to prevent air penetration and there may be provided a gate at the front and/or rear.
In many cases the sow area 15 includes a feeder 24 at the front wall 18 from which the sow can take feed. The piglet containing areas 20 and 21 as shown each include a heating system 25 for applying heat to the areas to keep the piglets at the required temperature. In the embodiment shown in FIG. 1 the heating system 25 comprises an overhead lamp or other heating element mounted in each area. It will be appreciated that the temperature of the barn must be controlled to maintain the sow at a suitable temperature and this is often too cold for the piglets so that they must be heated by a supplementary heat source. It is also desirable to keep the piglets away from the sow as much as possible so as to reduce the possibility of crushing when the sow stands and lies. Suitable anti-crushing methods are well known to persons skilled in the art and include anti-crush bars at the side edges 16 and 17 and other systems of a more complex nature.
A monitoring system is provided generally indicated at 30 which includes a temperature sensor 31 , a control unit 32 and a pager 33 or other communication device such as a cell phone. The temperature sensors 31 of the system are preferably conventional temperature sensors of the remote infra-red type which detects temperature along a directional line 31 A. Such systems are generally infra-red detectors but other sensors may also be used. Examples of such sensors are readily available.
Each sensor 31 is mounted so that its direction sensing line can be moved within the pen to detect at required locations as shown at 31 A and 31 B. For this purpose the sensor includes a bracket 31 C shown schematically in FIG. 2 so that the sensor can be rotated and tilted downwardly to take up a required direction. As an alternative, the bracket may be fixed to the sensor and the sensor moved from one location to another to take up the required directions. Thus the bracket may be a simple strap which wraps around a bar of the farrowing pen with the location of the sensor on the bar defining the required direction.
Each sensor is connected to a central control unit 32 as shown in FIG. 1 by a respective wire 34 so as to provide to the control unit an indication of which sensor has been activated by motion within the respective piglet area.
In FIG. 2 each pen can include its own control unit forming part of an assembly of parts including the sensor 31 , a control 32 A and a heating system 25 A. These elements can form a common assembly which can be connected to an electrical supply and can be disconnected to be moved from crate to crate as required.
The control unit includes an antenna 36 which transmits a signal 37 to the antenna 38 of a pager or similar device 39 . The control unit is arranged such that the signal 37 includes information identifying the particular stall involved. The pager includes a screen 39 which indicates to the operator of the hog facility that a motion event has occurred and indicates the stall at which the motion has taken place. The system can be installed relatively inexpensively at the crates of the farrowing area. Thus when each sow is pregnant and ready to give birth, the sow is moved from an initial containment area into a respective one of the crates for the birthing process.
Up till now it has been necessary for the operator to maintain a watch over the sows and to use skills obtained from experience to know approximately when the sow will give birth. Even despite such experienced operators, it is possible for the sow to give birth without any attention and this can lead to the loss of piglets either by crushing or by still births. It is well known that early intervention during the birthing process can reduce the number of losses by an average of one or two piglets per sow per gestation. Such average losses provide thus a significant loss of income. A typical sow facility of this type may contain one thousand sows and an operator is present at all times but is involved in many functions during the working day. In individual cases, early intervention may prevent the loss of the whole litter or a significant part of the litter, which would otherwise dramatically increase average or cumulative losses.
The present system therefore provides an indication to the operator as to the presence of a piglet at a crate so that the operator may immediately move to the crate concerned and intervene in any problems that are arising. Stillbirths can be reduced by reducing difficulties in the birthing process by assisting where necessary. Crushing can be reduced by ensuring that the piglets are moved to the required area. The heating system can be turned on only when the birthing is actually occurring so as to reduce cost and to ensure the heating system is available as soon as the piglets are expelled thus increasing their tendency to move away from the sow to the heated areas within the corners of the crate.
Even though the birthing process is detected by the temperature change caused by the arrival of the first or one of the first piglets, rather than by detecting the actual ejection of the first piglet, it has been found that this indication can be effected simply and effectively and yet provides a signal to the operator allowing intervention at a sufficiently early stage to provide the reduction in losses which can otherwise occur.
The sensor 31 in the arrangement of FIG. 2 is thus initially directed at the area behind the birth canal of the sow so that the arrival of the first piglet in that area is detected by the change in temperature. This detection by the sensor 31 is communicated to the control unit 32 A for generation of an alarm signal to the responsible worker. The alarm signal can be generated by a central control unit using wireless communication or can be a simple alarm signal such as a sound and light generating system generated at the control unit 32 A. After the worker is summoned and attends the birth for protection of the remaining piglets, the sensor can be moved to a position to detect temperature in a piglet area 25 B adjacent the heating system 25 .
The control unit at the same time as sending the alarm signal also acts to start the heating action of the heating system 25 to heat the piglets in the area 25 B. The control unit can be set to maintain a required suitable temperature for the piglets in the area 25 B bearing in mind that the piglets prefer to be maintained in a temperature higher than the surrounding farrowing pen for the sow and bearing in mind that the piglets generate several watts of heat themselves so that the area needs to be topped up with heat to maintain the required temperature. Thus the smart controller for the heating device uses a pre-set curve for the temperature to be maintained for the piglets so that the temperature declines as the piglets get older from a maximum when they are first born to a minimum at the weaning stage. The sensor detects the actual temperature under the cover and the control unit on the lamp controls the time period of operation of the lamp or controls the power output of the lamp to maintain the temperature at the required level based on the set curve.
In the embodiment shown, the area 25 B includes a cover 25 C having a front edge 25 D over the piglet area and rear edges at the side and front wall of the pen. In this way the piglets are maintained in a covered area or nest area where they can be kept warmed and protected causing all of the piglets to congregate in this area under the heat lamp.
This use of a covered area and temperature control can avoid the use of a heat pad on the floor of the pen which pads are inconvenient and tend to be wasteful as they add heat to the environment and thus heat the sow.
The heating system thus comprises a single heat lamp mounted in the cover and projecting downwardly toward the piglets and the floor. This area thus causes the piglets to congregate away from the area under the sow thus tending to reduce the risk of crushing.
While there are two piglet areas one on each side of the sow for free movement of the piglets, it is preferred that only one includes the cover and heating to reduce complexity and cost. However each side may include a covered heated area if preferred.
It is preferred that a single sensor be used which can serve both functions of birth detection and temperature control. However two separate sensors can be provided as part of two separate systems with the sensor for the detection being associated with the central control system of FIG. 1 and the heating systems being independent of the birth detection system.
The sensor can be placed in many different locations such as suspended above the area, attached to the lamp, etc.
Also, the piglet area may not always be covered since many arrangements simply using the heating system without a cover are possible.
One possibility is that each pen is equipped with an individual control system. As an alternative, there is the possibility that the sensor of a pen is connected wirelessly or by wire to the control system of a zone, which is connected wirelessly or by wire to a network.
One important feature of the invention is the automatic actuation of the heating system causing the heat lamp to be turned on, which feature is not limited to a particular form or arrangement of sensing system such as the infra red sensor described above.
The actuation of the heating system acts to attract the piglets away from the sow to prevent crushing and so that the heating system is actuated only when required to reduce heating costs. In this way the heating system comes into effect only when the piglets are being born to avoid unnecessary use prior to this time, bearing in mind that the cost of such heating is significant and the use of the heating is undesirable to keep the sow cool. Also the sensor actuation is preferably used with the sensor temperature monitoring to further ensure cost savings by using minimum energy to keep the piglets at the required temperature, again bearing in mind that the heat generated by the piglets themselves increases as they become larger thus reducing heat requirements.
Other types of sensors can be used.
Where the system states that wireless communication can be used it will be appreciated that communication with wires is also possible.
Thus the circuit board can be connected to the sensors by wires or by sound, which alarms the operator who can notice clearly which pen is concerned.
Turning now to FIGS. 3 to 6 there is shown a heating and cover system for the piglet area which can be used with the birth monitoring apparatus or can be used without the apparatus.
Thus the crate 54 includes a front wall 50 , a rear wall 51 and two side walls 52 and 53 all of which are formed of closed sheet material such as plastics, fibreglass or metal to contain the piglets and to keep drafts from them. Two upstanding panels 55 and 56 formed by horizontal and vertical rails act to confine the sow from respective sides leaving space between the panels and the sides of the crate for the piglets to be contained.
A cover 60 is located between the panel 56 and the side wall 52 and is dimensioned to have a width filling the space between the panel and the side wall and a length approximately equal to one third to one half of the length of the crate. The cover is mounted on one of the rails 61 of the panel 56 by brackets 62 which allow the cover to slide between the position shown in FIG. 2 at the front end and the position shown in FIG. 6 at the rear end. This sliding action is effected simply by the sliding of the brackets on the rail 61 .
The brackets are arranged such that the cover can be lifted on the rail 61 by rotation of the cover around the axis defined by the rail to a position where the cover is moved away from the piglet area and inverted over the sow containment area. In this position the operator has access to the piglet area for accessing the piglets and for cleaning the piglet area.
The cover when supported in the lowered operating position is at the top of the side wall 52 so as to enclose the piglets within the crate underneath the cover to prevent cool air penetration or heated air escape.
The cover has a pair of mounting holes 65 and 66 each of which, or both of which, can receive a heating lamp 67 which is carried in the cover so as to shine heat downwardly into the area underneath the cover. One hole is located at one end of the cover and the other at the other end of the cover. Alongside each lamp mounting hole is located a sensor mounting hole on the side of the lamp adjacent the end of the cover. Thus in the position of FIG. 3 the lamp is in the hole at the front end of the cover with the temperature sensor between it and the front wall. Thus in the position of FIG. 6 the lamp is in the hole 66 at the rear end of the cover with the temperature sensor between it and the rear wall.
In operation, when the sow is about to give birth, the cover is moved to the position of FIG. 6 with the sensor adjacent the rear end of the sow. As soon as the first piglet is expelled it moves away toward the piglet area and enters the zone of detection of the sensor 70 where the temperature rise relative to the bare area is detected and communicated to the control unit 80 . The control unit can be located at any suitable position for example on the cover. However preferably it is formed as part of the lamp control circuitry and mounted on the heating device housing. The control unit then detects from this temperature rise the presence of the piglet and actuates both the signal to the worker and the power to the lamp 67 immediately. The worker is thus summoned to deal with the birth. The worker can slide the cover away from the rear end either partly or wholly toward the front end to allow access to the piglets.
At the same time as sending the alarm signal, the lamp is actuated which acts to immediately heat the piglets while they are most vulnerable and also acts to draw them away from the sow toward the heat lamp which reduces the likelihood of crushing.
After the birth and during the suckling stage, the piglets are protected under the cover which is located in the front end of the crate, encouraging the piglets to locate at the front end and thus tending to prevent the piglets from being crushed or hurt under the sow. Also the lamp heat output is controlled by the control unit based upon the sensed temperature underneath cover in the area of the piglets so that their temperature is maintained at the best level while allowing the heat output to decline depending upon the amount of heat emanating from the piglets, thus reducing energy requirements.
Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
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The number of piglets dying at birth is reduced by providing a temperature sensor in a farrowing crate at the piglet area thereof on a movable cover so that, when the sow is expected to give birth, the sensor is located in the crate at a location to detect the presence of one or more piglets after birth. On detection by a control unit using the sensor signal of the one or more piglets, the sensor communicates a signal to a pager carried by an operator indicating to the operator that birth of piglets is in progress and activates a heating lamp for the piglets in the pen to attract them away from the area of the sow to reduce crushing. The control unit and the sensor also control the heat output. The cover can slide along the piglet area and can lift to expose the piglet area.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a ferroelectric liquid crystal composition. More particularly it relates to a ferroelectric liquid crystal composition having a negative dielectric anisotropy comprising an achiral compound having a negative dielectric anisotropy and a light switching element using the same.
2. Description of the Related Art
In recent years, liquid crystal display has come to be broadly employed for display elements, utilizing the specific features thereof, such as light weight, small power consumption, etc. However, most of these display elements utilize TN display mode using liquid crystal materials having a nematic phase; hence in the application fields where high multiplexity is required, the response time is still slow so that there has been a need for improving the elements.
In such present status, a display mode which has recently been noted is the one proposed by N. A. Clark and S. T. Lagerwall, i.e. a display mode utilizing a light switching phenomenon of ferroelectric liquid crystals (see Applied Physics, Letters, Vol. 36, p. 899 (1980)). The presence of ferroelectric liquid crystals has been stated by R. B. Meyer for the first time (see Journal de Physique, vol. 36, p. 69 (1975)), and from the viewpoint of classification of liquid crystals, the ferroelectric liquid crystals belong to chiral smectic C phase, chiral smectic I phase, chiral smectic F phase, chiral smectic G phase, chiral smectic H phase, chiral smectic J phase and chiral smectic K phase (hereinafter abbreviated to SC* phase, SI* phase, SF* phase, SG* phase, SH* phase, SJ* phase and SK* phase, respectively).
When the light switching effect of ferroelectric liquid crystals is applied to display elements, there are two superior specific features as compared with TN display mode. The first specific feature is that the response is made at a very high rate and the response time is 1/100 or less that of TN display mode elements. The second specific feature is that there is a memory effect, which makes multiplex drive easy coupled with the above-mentioned high-speed properties.
In order for display elements using ferroelectric liquid crystals to have memory properties, two methods are considered. One of these is a method proposed by N. A. Clark et al wherein memory properties are developed by reducing the cell thickness (d) down to a thickness of the helical pitch (p) or less to thereby undo the helix (Applied Physics, Letters, vol. 36, p. 899 (1980)) and the other is a method found by Le Piesant wherein memory properties are developed by utilizing AC stabilizing effect (Paris Liquid Crystal Conference, p. 217 (1984)). The word AC means alternate current hereinafter.
Most current ferroelectric liquid crystal materials have short helical pitches (1 to 3 μm); hence in order to develop memory properties by reduction in the thickness of the cell, proposed by N. A. Clark et al, it is necessary to retain the cell thickness at about 1 to 3 μm, but from the viewpoint of the current cell preparation technique, there is a problem that the retention is difficult in the aspects of cost and yield. On the other hand, the method found by Le Piesant wherein memory properties are developed utilizing AC stabilizing effect is effective only for ferroelectric liquid crystal materials having a negative dielectric anisotropy (Δε), but even in the case of thick cells (5 to 7 μm), it is possible to develop memory properties; thus the current cell preparation technique is utilizable and hence the method is very practical.
The AC stabilizing effect is due to a mode utilizing the following fact:
Spontaneous polarization (Ps) results from an impressed electric field in the case where low frequency is applied to ferroelectric liquid crystals, whereas spontaneous polarization does not follow in the case of high frequency; as a result, normal dielectric anisotropy becomes effective and hence if the dielectric anisotropy value is negative (Δε<0) liquid crystal molecules are compelled to be in a parallel state to the substrate. Thus, memory properties are developed even in the case of a thick cell. A matrix display utilizing this AC stabilizing effect has been actually reported by Jeary in 1985 for the first time (SID'85, Digest, p. 128 (1985)), but thereafter almost no report has been issued. The main reason for so few reported examples is that there are so few ferroelectric liquid crystal materials having a negative dielectric anisotropy value. Further, according to Jeary's report, a voltage of about 40 V is required for developing memory properties by utilizing AC stabilizing effect, but when usual IC drive voltage range is taken into account, it is desired that AC stabilizing effect be developed at a far lower voltage (25 V or less). As to AC stabilizing effect, the more the negative dielectric anisotropy value, the lower the voltage of the effect developed; hence appearance of ferroelectric liquid crystal materials having a negative larger dielectric anisotropy value has been earnestly desired. Further, the response time of ferroelectric liquid crystal materials reported by Jeary et al is several msecs, that is, the response time is still slow in the aspect of practical use; hence appearance of ferroelectric liquid crystals having a negative dielectric anisotropy value and also high-speed response properties has been desired.
SUMMARY OF THE INVENTION
A first object of the present invention is to provide a ferroelectric liquid crystal composition having a negative large dielectric anisotropy value, an AC stabilizing effect at lower voltages and yet high-speed response properties.
A second object of the present invention is to provide a light switching element using the abovementioned liquid crystal composition.
The present inventors have conducted extensive research in order to solve the above-mentioned problems, and as a result, have found that when certain liquid crystal compounds are combined together as shown below, a ferroelectric liquid crystal composition having a negative large dielectric anisotropy value and yet high-speed response properties is obtained, and have achieved the present invention.
The present invention in a first aspect resides in
a ferroelectric liquid crystal composition having a negative dielectric anisotropy value and comprising at least two components at least one of which is a compound expressed by the formula ##STR2## wherein R 3 and R 4 each represent the same or different linear or branched chain alkyl group each of 1 to 18 carbon atoms and l represents 1 or 2,
having a negative dielectric anisotropy value and
being contained in the composition in an amount of 5% by weight or more. As a preferable embodiment of the above-mentioned liquid crystal composition, there is provided
a ferroelectric liquid crystal composition having a negative dielectric anisotropy value and comprising at least the following three components A, B and C in proportions of 5 to 40% by weight of component A, 20 to 70% by weight of component B and 5 to 40% by weight of component C:
component A being a compound expressed by the above-mentioned formula (A);
component B being at least one member of a compound expressed by the formula ##STR3## wherein R 5 and R 6 each represent the same or different linear or branched chain alkyl group or alkoxy group each of 1 to 18 carbon atoms,
a compound expressed by the formula ##STR4## wherein R 7 and R 8 each represent the same or different linear or branched chain alkyl group or alkoxy group each of 1 to 18 carbon atoms,
a compound expressed by the formula ##STR5## wherein R 9 and R 10 each represent the same or different linear or branched chain alkyl group or alkoxy group each of 1 to 18 carbon atoms, or
a compound expressed by the formula ##STR6## wherein R 11 represents a linear or branched chain alkyl group or alkoxy group each of 1 to 18 carbon atoms, Z represents a direct bond or --O--, k represents 0 to 10 and (±) indicates racemic compounds; and
component C being at least one member of a compound expressed by the formula ##STR7## wherein R 12 represents a linear or branched chain alkyl group or alkoxy group each of 1 to 18 carbon atoms, R 13 represents a linear or branched chain alkyl group of 2 to 18 carbon atoms, W represents --H, --F or --CN and * indicates an asymmetric carbon atom,
a compound expressed by the formula ##STR8## wherein R 14 represents a linear or branched chain alkyl group or alkoxy group each of 1 to 18 carbon atoms, R 15 represents a linear or branched chain alkyl group of 2 to 18 carbon atoms, V represents --H, --F or --CN and * indicates an asymmetric carbon atom,
a compound expressed by the formula ##STR9## wherein R 16 represents a linear or branched chain alkyl group or alkoxy group each of 1 to 18 carbon atoms, R 17 represents an alkyl group of 1 to 18 carbon atoms and * indicates an asymmetric carbon atom, or
a compound expressed by the formula ##STR10## wherein R 18 represents a linear or branched chain alkyl group or alkoxy group each of 1 to 18 carbon atoms, R 19 represents a linear or branched chain alkyl group of 2 to 18 carbon atoms or an alkoxy group of 1 to 18 carbon atoms and * indicates an asymmetric carbon atom.
The present invention in a second aspect resides in
a light switching element comprising the above-mentioned ferroelectric liquid crystal composition having a negative dielectric anisotropy value, and utilizing AC stabilizing effect.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows graphs illustrating AC stabilizing effect of the ferroelectric liquid crystal composition of the present invention wherein 1(a) shows a graph illustrating the wave of impressed voltage, 1(b) shows a graph illustrating the memory properties of a ferroelectric liquid crystal composition composed mainly of components B and C but containing no component A; and 1(c) shows a graph illustrating memory properties of a ferroelectric liquid crystal composition having component A added to the above-mentioned composition.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Since the compound expressed by the formula (A) in the present invention has a large dipole moment (represented by CN) in the perpendicular direction to the molecules, it has a very notable characteristic. A patent application for this compound, which has been laid open, has previously been applied for by the present applicants (e.g. Japanese patent application laid-open Nos. Sho 55-66556/1980, Sho 55-102550/1980 and Sho 59-10557/1984).
The compound expressed by the formula (A) exhibits a nematic phase or smectic A phase and exhibits no SC phase, but it has a negative dielectric anisotropy value as very large as -20 to -25; hence it plays an important role of causing AC stabilizing effect to develop at low voltages in the ferroelectric liquid crystal composition of the present invention. Representative examples of the compound expressed by the formula (A) are shown in the following Tables 1 and 2, Table 1 showing compounds of the formula (A) wherein l=1 and expressed by the formula ##STR11## and Table 2 showing those wherein l=2 and expressed by the formula
TABLE 1______________________________________R.sup.3 R.sup.4 R.sup.3 R.sup.4______________________________________C.sub.3 H.sub.7 -- --C.sub.5 H.sub.11 C.sub.5 H.sub.11 -- --C.sub.6 H.sub.13" --C.sub.6 H.sub.13 " --C.sub.7 H.sub.15C.sub.4 H.sub.9 -- --C.sub.3 H.sub.7 C.sub.6 H.sub.13 -- --C.sub.4 H.sub.9" --C.sub.4 H.sub.9 " --C.sub.5 H.sub.11" --C.sub.5 H.sub.11 " --C.sub.6 H.sub.13" --C.sub.6 H.sub.13 " --C.sub.7 H.sub.15" --C.sub.7 H.sub.15 C.sub.7 H.sub.15 -- --C.sub.3 H.sub.7.sup. C.sub.5 H.sub.11 -- --C.sub.3 H.sub.7 " --C.sub.4 H.sub.9" --C.sub.4 H.sub.9 " --C.sub.5 H.sub.11" --C.sub.5 H.sub.11 " --C.sub.6 H.sub.13______________________________________
TABLE 2______________________________________R.sup.3 R.sup.4 R.sup.3 R.sup.4______________________________________C.sub.3 H.sub.7 -- --C.sub.2 H.sub.5 C.sub.5 H.sub.11 -- --C.sub.5 H.sub.11" --C.sub.3 H.sub.7 " --C.sub.6 H.sub.13" --C.sub.4 H.sub.9 " --C.sub.7 H.sub.15" .sup. --C.sub.5 H.sub.11 C.sub.7 H.sub.15 -- --C.sub.2 H.sub.5" .sup. --C.sub.6 H.sub.13 " --C.sub.3 H.sub.7" .sup. --C.sub.7 H.sub.15 " --C.sub.4 H.sub.9.sup. C.sub.5 H.sub.11 -- --C.sub.2 H.sub.5 " --C.sub.5 H.sub.11" --C.sub.3 H.sub.7 " --C.sub.6 H.sub.13" --C.sub.4 H.sub.9 " --C.sub.7 H.sub.15______________________________________
As described above, the present invention consists in that the compound expressed by the formula (A) and having a negative dielectric anisotropy value is contained in ferroelectric liquid crystal compositions, and particularly when component A expressed by the general formula (A), component B expressed by the formulas (B-1) to (B-4) and component C expressed by the formulas (C-1) to (C-4) are combined together, then a ferroelectric liquid crystal composition having an even larger negative dielectric anisotropy value larger and yet having high-speed response properties is obtained.
As described above, the achiral compound as component A has a negative dielectric anisotropy value as large as -20 to -25 and plays an important role in the ferroelectric liquid crystal composition of the present invention in that it develops a negative large dielectric anisotropy value and exhibits AC stabilizing effect and as a result, generates good memory properties. Component A exhibits no SC phase and when it is used in a too high concentration, the upper limit temperature of SC* phase in the ferroelectric liquid crystal composition is lowered; hence too high a concentration is undesirable. Thus, when the use object of component A is taken into consideration, the concentration of component A used in the present invention is preferably 40% by weight or less.
Compounds expressed by the formulas (B-1), (B-2), (B-3) and (B-4) as component B are achiral compounds and play a role of basic SC compound in the present invention.
Phenylpyrimidine compounds expressed by the formula (B-1) have SC phase within a low temperature region. For example, in the case of a compound of R 5 =C 6 H 13 O- and R 6 =C 8 H 7 - , the phase transition points of the compound are as follows: ##STR12##
On the other hand, biphenylpyrimidine compounds expressed by the formula (B-2) have SC phase within a high temperature region. For example, in the case of a compound of R 7 =C 7 H 15 - and R 8 =C 8 H 17 - , the phase transition points are as follows: ##STR13##
In the above phase transition temperature, Cr, N and Iso represent crystal, nematic phase and isotropic liquid, respectively.
Thus, when a compound expressed by the formula (B-1) is combined with a compound expressed by the formula (B-2), there is obtained a basic SC mixture having SC phase over a range from a low temperature region to a high temperature region.
The compounds having a core of (B-1) or that of (B-2) have a superior specific feature of a very low viscosity as already described in Japanese patent application laid-open No. Sho 61-291,679/1986 filed by the present inventors; hence the compounds also each play an important role as a basic SC compound in the ferroelectric liquid crystal composition of the present invention.
As the compound expressed by the formula (B-1), those wherein R 5 represents a linear alkoxy group of 6 to 12 carbon atoms and R 6 represents a linear alkyl of 8 to 11 carbon atoms and have SC phase are particularly preferred.
On the other hand, phenylpyridine compounds expressed by the formula (B-3) have SC phase and the like over a broad temperature range from a low temperature region to high temperature region and, e.g. in the case of a compound of R 9 =C 7 H 15 - and R 10 =C 7 H 15 - , the phase transition points are as follows: ##STR14##
Further, biphenyl compounds expressed by the formula (B-4) have SC phase and the like within a low temperature region and e.g. a compound of R 11 =C 7 H 15 - , Z=single bond and k=3 has the following phase transition points: ##STR15##
Compounds having a core of the general formula (B-3) or that of the formula (B-4) have a superior specific feature as already described in EP 86108267 by the present inventors and also have a very low viscosity similar to those of the above-mentioned pyrimidine compounds; hence the compounds also play a role as a basic SC compound in the ferroelectric liquid crystal composition of the present invention and are used for adjusting tee SC phase temperature range, if necessary.
As the phenylpyridine compounds expressed by the formula (B-3), those wherein R 9 represents an alkyl group of 4 to 10 carbon atoms and R 10 represents an alkoxy group of 4 to 12 carbon atoms are particularly preferred. Further, as the biphenyl compounds expressed by the formula (B-4), those wherein R 11 represents an alkoxy group of 7 to 10 carbon atoms, Z represents a single bond and k represents 3 and having SC phase are particularly preferred.
As the pyrimidine compounds of the formula (B-1) or (B-2) used as a component of the ferroelectric liquid crystal composition of the present invention, those having SC phase are preferred as described, but even those exhibiting no SC phase may also be used if the quantity thereof is within a range where the SC phase temperature range of smectic compositions to be obtained is not notably narrowed.
This applies to phenylpyridine compounds expressed by the formula (B-3) or biphenyl compounds expressed by the formula (B-4), each exhibiting no SC phase, and these compounds may be used for viscosity reduction or adjustment of SC phase temperature range.
When it is taken into consideration that the use object of the compound of component B is to use it as a base SC compound, the concentration of component B used in the present invention is preferably 70% by weight or less.
Compounds of component C expressed by the formulas (C-1), (C-2), (C-3) or (C-4) are chiral compounds, and a patent application for compounds expressed by the formulas (C-1) or (C-2), which has been laid open, has already been applied for by the present applicants and (e.g. Japanese patent application laid-open Nos. Sho 61-43/1986, Sho 61-210056/1986 and Sho 63-48254/1988). The compounds exhibit SC* phase within a high temperature region, have a large tilt angle and a very large spontaneous polarization value. For example, a compound of the formula (C-1) wherein R 12 =C 8 H 17 O- , R 13 =-C 6 H 13 and W=-F has the following phase transition points: ##STR16## and a tilt angle of 34.5° and a Ps of
132 nC/cm.sup.2 (T-Tc=-30° C.).
A compound of the formula (C-1) wherein R 12 =C 6 H 13 O- , R 13 =-C 6 H 13 and W=-H has the following phase transition temperatures: ##STR17## and a tilt angle of 38.1° and a Ps of
110 nC/cm.sup.2 (T-Tc=-30° C.).
A compound of the formula (C-1) wherein R 12 =C 8 H 17 O-R 13 =C 6 H 13 and W=-CN has the following phase transition points: ##STR18## and a tilt angle of 25° and a Ps of
240 nC/cm .sup.2 (T-Tc=-30° C.).
Further a compound of the formula (C-2) wherein R 14 =C 8 H 17 O- , R 15 =-C 6 H 13 and V=-F has the following phase transition points: ##STR19## and a tilt angle of 36.5° and a Ps of
109 nC/cm.sup.2 (T-Tc=-30° C.).
A compound of the formula (C-2) wherein R 14 =C 8 H 17 O- , R 15 =-C 6 H 13 and V=-H has the following phase transition points: ##STR20## and a tilt angle of 45° and a Ps of
39 nC/cm.sup.2 (T-Tc=-30° C.).
A compound of the formula (C-2) wherein R 14 =C 8 H 17 - , R 15 =-C 6 H 13 and V=-CN have the following phase transition points: ##STR21## and a tilt angle of 22° and a Ps of
137 nC/cm.sup.2 (T-Tc=-15° C.).
Thus, the compounds of the formulas (C-1) or (C-2) play important roles of development of high-speed response properties, improvement in the tilt angle and improvement in the upper limit temperature of SC* phase in the ferroelectric liquid crystal composition of in the present invention.
On the other hand, a patent application, not yet laid open, for the compounds expressed by the formulas (C-3) or (C-4) has already been applied for by the present inventors and (e.g. Japanese patent application Nos. Sho 61-133269/1986, Sho 62-049796/1987, etc.). The compounds have a very large spontaneous polarization value (extrapolated value: about 100 nC/cm 2 ) and far superior response properties. Thus, the compounds play an important role of development of high-speed response properties in the ferroelectric liquid crystal composition of the present invention. When the concentration of components A and B used and also the utility of component C are taken into consideration, the concentration of component C used in the present invention is preferably 40% by weight or less.
The respective proportions of components A, B and C having made use of the above-mentioned specific features of these components to obtain the objective liquid crystal composition having superior specific features have been variously examined, and as a result, it has been found that a concentration of component A in the range of 5 to 40% by weight, that of component B in the range of 20 to 70% by weight and that of component C in the range of 5 to 40% by weight as described above are preferred.
The present invention will be described in more detail by way of Examples, but it should not be construed to be limited thereto.
In the Examples, the spontaneous polarization value (Ps) was measured according to Sawyer-Tower method; the helical pitch (P) was sought by directly measuring the distance between the dechiralization lines corresponding to the helical pitch under a polarizing microscope; and the tilt angle (θ) was sought from the moved angle (corresponding to 2θ) of the extinction site under crossed nicols by impressing an electric field sufficiently higher than the critical one upon the homogeneously aligned cell to extinguish the helical structure and further inverting the polarity.
The response time was measured from the change in the intensity of transmitted light observed when the respective compositions were filled in a cell subjected to an aligning treatment and having a distance between the electrodes of 2 μm and a square wave having a V pp (Voltage of peak to peak) of 20 V and 100 Hz was impressed.
The dielectric anisotropy value was calculated by using a cell subjected to a parallel aligning treatment and a vertical aligning treatment and measuring the dielectric constant from the capacity of the empty cell and the capacity in the case where a liquid crystal was filled therein.
EXAMPLE 1
A ferroelectric liquid crystal composition D composed mainly of components B and C used in the present invention and having the following proportions of the components was prepared:
__________________________________________________________________________Composition D__________________________________________________________________________ ##STR22## 17.5 wt. % ##STR23## 5 wt. % ##STR24## 10 wt. % ##STR25## 10 wt. % ##STR26## 7.5 wt. % ##STR27## 20 wt. % ##STR28## 15 wt. % ##STR29## 10 wt. % ##STR30## 5 wt. %__________________________________________________________________________
This ferroelectric liquid crystal composition D exhibited SC* phase within a temperature region of -21° to +56° C., exhibited SA phase on the higher temperature side thereof, formed N* phase at 68° C. and formed isotropic liquid at 73° C. At 25° C., it had a spontaneous polarization value of 8.5 nC/cm 2 , a tilt angle of 25° and a response time of 15 μsec (electrolytic intensity: E=±0.5 V/μm). Further, its dielectric anisotropy value was +0.5. This composition D was filled in a cell provided with two substrates having transparent electrodes each surface of which was subjected to rubbing treatment and having a cell thickness of 5 μm to prepare an electrooptical element. This element was placed between two crossed polarizers and a pulse wave (pulse width: 600 μsec and wave height value: 25 V) as shown in FIG. 1(a) was impressed. As a result, no memory properties were observed (see FIG. 1(b)). Thus, an AC wave of 20 KHz and 25 V was overlapped with the above pulse wave to observe change in the level of transmitted light. As a result, no memory properties were similarly observed and change in the intensity of transmitted light as shown in FIG. 1(b) was observed. Thus, to the composition D was added the following achiral compound as component D of the present invention having a negative dielectric anisotropy value to prepare a ferroelectric liquid crystal composition E: ##STR31##
This ferroelectric liquid crystal composition E exhibited SC* phase within a temperature region of -22° to +53° C., exhibited SA phase on the higher temperature side, formed N* phase at 60° C. and formed isotropic liquid at 69° C. At 25° C., it had a spontaneous polarization value of 7.5 nC/cm 2 , a tilt angle of 22° and a response time of 230 μsec (E=±5 V/μm). Further, its dielectric anisotropy value was -2.
This composition E was filled in a cell similar to that in the case of the composition D, followed by impressing a pulse wave shown in FIG. 1(a). As a result, no memory properties were observed as in the case of composition D (see FIG. 1(b)). Whereas, when an AC wave of 20 KHz and 25 V was overlapped with the wave shown in FIG. 1(a), good memory properties as shown in FIG. 1(c) were observed. This fact may be interpreted as follows:
when the compound having a negative dielectric anisotropy value as component A of the present invention was added, the resulting ferroelectric liquid crystal composition had a negative larger dielectric anisotropy value, and as a result, AC stabilizing effect was notably developed to afford superior memory properties. The response time was shorter (about 1/4 ) and yet AC voltage was lower (about 1/2) as compared with the results of the report of Jeary; hence it has been found that the ferroelectric liquid crystal composition of the present invention is very practical.
EXAMPLES 2-7
The proportions of the ferroelectric liquid crystal compositions Nos. 1-6 of the present invention are shown in Table 3 and the specific features thereof are shown in Table 4. In addition, the respective proportions in Table 3 all refer to percentage by weight.
TABLE 3__________________________________________________________________________ Composition No. and proportions (% by weight)Component Formula Compounds 1 2 3 4 5 6__________________________________________________________________________A A ##STR32## 5 5 5 A ##STR33## 5 5 5 A ##STR34## 5 A ##STR35## 5 A ##STR36## 5 5 A ##STR37## 5 5 5 5 5 5 A ##STR38## 5 5 5 5 5B B-1 ##STR39## 12.4 12.2 5 4.4 4.1 3.6 B-1 ##STR40## 8.6 8 B-1 ##STR41## 4.3 4.1 B-1 ##STR42## 4.3 4.1 B-2 ##STR43## 8.6 8 B-2 ##STR44## 4.3 4.1 B-2 ##STR45## 5 4.4 4.1 3.6 B-2 ##STR46## 5 4.4 4.1 3.6 B-2 ##STR47## 5 4.4 4.1 3.6 B-2 ##STR48## 5 4.4 4.1 3.6 B-3 ##STR49## 5 4.4 4.1 3.6 B-3 ##STR50## 5 4.4 4.1 3.6 B-3 ##STR51## 5 4.4 4.1 3.6 B-3 ##STR52## 5 4.4 4.1 3.6 B-3 ##STR53## 5 4.4 4.1 3.6 B-4 ##STR54## 14.3 13.5C C-1 ##STR55## 14.3 13.5 4.5 4 3.8 3.3 C-1 ##STR56## 9 8 7.5 6.5 C-1 ##STR57## 4.5 4 3.8 3.1 C-3 ##STR58## 9 4 7.5 6.5 C-4 ##STR59## 4Others ##STR60## 4.8 4.5 ##STR61## 4.8 4.5 ##STR62## 4.8 4.5 ##STR63## 9.5 9 ##STR64## 9 8 7.5 6.5 ##STR65## 4 4 3.9 3.1__________________________________________________________________________
TABLE 4__________________________________________________________________________ Composition No.Characteristics 1 2 3 4 5 6__________________________________________________________________________Phase transitionpoint (°C.)Cr → SC* -18 -19 -24 -36 -35 -28SC* → SA 63 66 65 59 62 49SA → N* 68 68 74 69 68 64N* → Iso 81 84 81 80 82 77Spontaneous (nC/cm)* 6 6 15 16 16 7polarization valueTilt angle (°)* 22 21 21 23 23 17Helical (μm)* 2 2 4 3 3 2pitchResponse (μsec)* 275 563 130 400 430 675timeDielectric* -2 -3 -4 -5 -7 -9anisotropy__________________________________________________________________________ *Values at 25° C.
In addition, Table 3 also includes compositions containing chiral compounds having the objective of elongating the helical pitch of SC* phase or broadening the temperature region of SC* phase, but it does not damage the specific features of the ferroelectric liquid crystal composition of the present invention to contain such chiral substances in the composition, which therefore raise no problem.
A ferroelectric liquid crystsl composition No. 3 of the present invention was filled in a cell provided with transparent electrodes each obtained by coating PVA as an aligning agent and rubbing the resulting surface to subject it to a parallel aligning treatment and having a cell gap of 5 μm, followed by placing the resulting liquid crystal cell between two polarizers arranged at crossed nicol state and causing a pulse wave having a pulse width of 400 μsec and a wave height value of 25 V to overlap with an AC wave of 20 KHz and 20 V. As a result, a good AS stabilizing effect was observed to obtain a liquid crystal display element having good memory properties and also a contrast ratio as very good as 1:20.
According to the present invention, a ferroelectric liquid crystal composition which makes the negative spontaneous polarization value larger, has AC stabilizing effect and yet has high-speed response properties, and a light switching element using the above composition are obtained. As the use applications of the ferroelectric liquid crystal composition of the present invention, a high-speed shutter, a high-multiplex liquid crystal display, etc. are exemplified.
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A ferroelectric liquid crystal composition having a negative large dielectric anisotropy value, AC stabilizing effect at low voltages and yet high-speed response properties, and a light switching element using the composition are provided, which composition comprises at least two components at least one of which is a compound expressed by the formula ##STR1## wherein R 3 and R 4 each represent the same or different linear or branched alkyl group of 1-18C and l is 1 or 2, and having a negative dielectric anisotropy value.
A preferred embodiment of the above composition contains at least three components A, B and C, one of which is the above compound of the formula (A) and components B and C of which are each selected from a group of specified compounds, and the respective proportions of components A, B and C being 5-50 weight %, 20-70 weight % and 5-40 weight % based on the total weight of the three, respectively.
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FIELD OF THE INVENTION
[0001] The present invention relates to the detection of ice or other foreign matter on wind turbine blades.
BACKGROUND OF THE INVENTION
[0002] FIG. 1 illustrates a wind turbine 1 . The wind turbine comprises a wind turbine tower 2 on which a wind turbine nacelle 3 is mounted. A wind turbine rotor 4 comprising at least one wind turbine blade 5 is mounted on a hub 6 . The hub 6 is connected to nacelle 3 through a low speed shaft (not shown) extending from the nacelle front. The wind turbine illustrated in FIG. 1 may be a small model intended for domestic or light utility usage, or may be a large model, such as those that are used in large scale electricity generation or on a wind farm for example. In the latter case, the diameter of the rotor could be as large as 100 metres or more.
[0003] Ice formation on wind turbine blades is a well known problem, as wind turbines are frequently installed in cold and stormy environments. The accrual of ice or other matter, such as dirt, is a hazard and leads to reduced wind turbine performance. It is a hazard because ice or other matter on the turbine blades may fall from the blades at any time, and in large amounts. It reduces wind turbine performance because it affects the aerodynamic behaviour of the blades and because the turbine may need to be stopped to remove hazardous ice or dirt.
[0004] The detection of ice on wind turbine blades has been achieved in a number of ways. One method that has been proposed is to monitor the bending loads on wind turbine blades.
[0005] It is known to provide the blades of a wind turbine with strain gauges in order to monitor the bending moment on the blades. This can be used in order to monitor the loads applied to the blades. Optical strain sensors, such as Fibre Bragg Grating strain sensors, are known for monitoring strain in wind turbine blades. Optical strain sensors for measuring the strain in wind turbine blades, and in particular for measuring the flapwise bending strain, are typically positioned at the root of the turbine blade. Measurement of flapwise bending strain of a wind turbine blade requires a measurement technique capable of distinguishing between strain on a strain sensor as a result of bending forces and strain resulting from other forces such as centripetal force. In order to do this, strain sensors are arranged pairwise around the root of the turbine blade, with the sensors in each pair arranged diametrically opposite each other. The strain due to bending detected by the sensors in each pair should be is approximately equal but of opposite sign, as one sensors will be under tension and one under compression. Strain due to centripetal force should be the same for both sensors. Using two pairs of sensors allows a bending strain to be determined in two dimensions, i.e. edgewise and flapwise. From changes in these bending strains, the build up of ice can be detected.
[0006] Although this method of measuring bending strain gives good results in theory, in practice it is not as precise as some applications need. This is the result of several factors. First, the material used to form the turbine blades is not absolutely homogenous. Second, the thickness of the material forming the turbine blades is not absolutely uniform. Third, the temperature of the wind turbine blade may vary slightly from one spot to another. Fourth, the sensors may not be mounted absolutely accurately. Fifth, in practice, sensors often fail or give erroneous results during their service lifetime.
[0007] We have recognised that there is a need for a more sensitive way of detecting the build up of ice or other matter on wind turbine blades.
SUMMARY OF THE INVENTION
[0008] In a first aspect of the invention, there is provided a method of detecting ice or other foreign matter on a wind turbine blade or damage to a wind turbine blade, the wind turbine blade mounted to a hub and having a longitudinal axis extending away from the hub, comprising:
measuring twisting torque on the blade about its longitudinal axis to provide a detected torque signal; comparing a value based on the detected torque signal with a comparison value, the comparison value derived from one or more measured parameters having a predetermined relationship with the twisting torque about the longitudinal axis of the blade when the blade is operating under normal operating conditions; and determining that ice or other foreign matter is on the blade or that the is blade is damaged if the value based on the detected torque signal differs from the comparison value by more than a predetermined amount.
[0012] Wind turbine blades are designed such that any change in the shape of the blade reduces twisting torque on the blades significantly. Torque about the longitudinal axis of the blade can therefore be used as a sensitive indicator of ice on the blade and of damage to the blade.
[0013] The term “twisting torque” is intended to mean the twisting forces on the blade as distinguished from any bending forces on the blade.
[0014] The value based on the detected torque signal may simply be the detected torque signal. The comparison value is calculated from one or more measured parameters having a predetermined relationship with the twisting torque about the longitudinal axis of the blade when the blade is operating under normal operating conditions. In this context, normal operating conditions mean conditions in which it is known that there is no significant ice or other matter on the blade and no damage to the blade.
[0015] Preferably, the one or more measured parameters comprise bending moments on the blade. By comparing the bending moments with the twisting torque about the longitudinal axis of the blade an accurate evaluation of the aerodynamic performance of the blade can be made.
[0016] Preferably, the method further comprises establishing a relationship between the bending moments on the blade and the twisting torque about the longitudinal axis of the blade under normal operating conditions. The relationship may depend on the structure of the blade, the wind speed, air density, temperature, and angle of attack of the blade.
[0017] The twisting torque may be measured by one sensor or by a plurality of sensors. The detected torque may be an average of twisting torque measurements from a plurality of sensors.
[0018] Preferably, the method further comprises measuring the bending moments on the blade.
[0019] Preferably, the step of measuring the bending moments on a wind turbine blade, comprises:
locating at least three strain sensors on the turbine blade, in use each strain sensor providing a strain measurement, the strain sensors located such that edgewise and flapwise bending can be determined from the strain measurements; calculating a plurality of resultant bending strains using the strain measurements; calculating an average resultant bending strain from the plurality of resultant bending strains.
[0023] The individual strain measurements may be converted into bending moments before calculating resultant bending moments and average resultant bending moment. This is useful if the relationship between bending strain and bending moment is not the same for all of the sensors. This might be the case if the blade cross-section at the position of the sensors is not symmetrical and homogenous. Accordingly, the terms “resultant bending strain” and “average resultant bending strain” as used herein should be interpreted to include “resultant bending moment” and “average resultant bending moment” respectively.
[0024] Preferably, the method further comprises calculating a confidence value for the average resultant bending strain. Preferably, the confidence value for the average resultant bending strain is based on a comparison of the plurality of resultant bending strains with each other, or with the average resultant bending strain. The confidence value for the average resultant bending strain may, for example, be based on the value of a standard deviation of a normal distribution fitted to the plurality of resultant bending strains.
[0025] A confidence value in the bending strain measurement is useful because it provides a measure of confidence of whether there is ice on the blade or whether an anomaly in the measurements might simply be an error within the measurement resolution of the sensor arrangement.
[0026] The strain sensors are preferably arranged such that they are all substantially equidistant from the root end of the blade. However, if the sensors are all located in a portion of the blade that is symmetrical and homogenous in cross-section this is not always necessary.
[0027] Preferably, the step of measuring the bending strain further comprises the step of calculating a confidence value for a first sensor based on a comparison of resultant bending strains derived from the strain measurement from the first sensor with the average resultant bending strain. This allows faulty, badly installed or broken sensors to be identified and ignored in strain calculations.
[0028] Each resultant bending strain is preferably calculated from bending strain measurements taken from a different pair of strain sensors, where the strain sensors in each pair provide bending strain measurements in directions non-parallel to one another. Depending on the type and orientation of the strain sensors, each bending strain measurement may be a simple strain measurement output from a strain sensor or may be a strain measurement from a strain sensor processed to remove non-bending components from the strain measurement.
[0029] The confidence value for the first sensor may be calculated in a number of ways. For example the confidence value may be based on an absolute difference between the resultant bending strains derived from measurement from the first sensor with the average resultant bending strain. Alternatively, the confidence value may be based on a number of standard deviations that the bending strain measurement from the first sensor is from the average resultant bending strain.
[0030] Preferably, the method further comprises locating at least four strain sensors on the turbine blade, and further comprises comparing the confidence value with a confidence threshold, and if the confidence value is less than the confidence threshold, re-calculating an average resultant bending strain without using the strain measurement from the first strain sensor.
[0031] Preferably, the strain sensors are located to provide bending strain measurements in at least three non-parallel directions.
[0032] Preferably, each of the strain sensors is an optical strain sensor, such as a Fibre Bragg Grating sensor.
[0033] Preferably, the method further comprises locating at least five strain sensors on the turbine blade. Preferably, the strain sensors are located symmetrically around the longitudinal axis of the blade. This allows for a simple calculation of bending strain for each strain sensor and the ability to recalculate the average bending strain based on measurements from only three or four of the strain sensors if one or two strain sensors give erroneous measurements. To provide for greater redundancy and greater resolution, precision and confidence, a greater number of strain sensors may be used.
[0034] Alternatively, or in addition to bending moments, the one or more measured parameters having a predetermined relationship with the twisting torque about the longitudinal axis of the blade may include wind speed and power output from the wind turbine. The method may further include the step of establishing a relationship between twisting torque about the longitudinal axis of the blade and the wind speed and power output from the wind turbine under normal operating conditions.
[0035] Preferably the step of measuring twisting torque on the blade about its longitudinal axis comprises locating strain sensors on the blade. Preferably, the strain sensors are located such that twisting torque and the bending moment can be derived from outputs of the strain sensors.
[0036] Bending moments are typically measured by mounting strain sensors parallel with the longitudinal axis of the blade. Preferably, a method in accordance with the invention comprises the step of locating at least one pair of adjacent strain sensors on the blade such that their sensitive axes are non-parallel with the longitudinal axis of the blade. Preferably, the sensitive axes of each pair of sensors are disposed symmetrically about a line parallel with the longitudinal axis of the blade, but are not perpendicular to it. The strain measurements from each pair of sensors can then be simply combined to resolve bending strain and torque strain. For example, each pair of sensors may be arranged in a “V” shape or an “X” shape.
[0037] In a second aspect of the invention, there is provided a system for detecting ice or other foreign matter on a wind turbine blade or damage to a wind turbine blade, the wind turbine blade mounted to a hub and having a longitudinal axis extending away from the hub, comprising:
one or more sensors mounted on the turbine blade and configured to provide a measure of the twisting torque on the blade about its longitudinal axis; and a processor configured to compare a value based on the measure of the torque with a comparison value, the comparison value derived from one or more measured parameters having a predetermined relationship with the twisting torque about the longitudinal axis of the blade when the blade is operating under normal operating conditions, and determine that ice or other foreign matter is on the blade, or that the blade is damaged if the value based on the measure of the twisting torque differs from the comparison value by more than a predetermined amount.
[0040] Preferably, the processor is configured to calculate the comparison value based on one or more measured parameters having a predetermined relationship with the twisting torque about the longitudinal axis of the blade when operating under normal operating conditions.
[0041] Preferably, the one or more measured parameters comprise a bending moment on the blade.
[0042] Preferably, the system comprises a plurality of sensors mounted on the turbine blade. Preferably, the sensors are all positioned substantially equidistant from the root end of the blade.
[0043] Preferably, the plurality of sensors are configured to allow both twisting torque about the longitudinal axis of the blade and bending moments to be derived from their outputs. Preferably the plurality of sensors comprise at least one pair of adjacent strain sensors positioned on the blade such that their sensitive axes are non-parallel with the longitudinal axis of the blade. Preferably, the sensitive axes of each pair of sensors are disposed symmetrically about a line parallel with the longitudinal axis of the blade but are not perpendicular to it. The strain measurements from each pair of sensors can then be simply combined to resolve bending strain and torque strain. For example, each pair of sensors may be arranged in a “V” shape or an “X” shape.
[0044] Preferably, the strain sensors comprise at least three strain sensors located on the turbine blade, in use, each strain sensor providing a strain measurement, the strain sensors located such that edgewise and flapwise bending can be determined from the strain measurements; and
the processor is connected to each of the strain sensors, and configured to: calculate a plurality of resultant bending strains using the strain measurements; calculate an average resultant bending strain from the plurality of resultant bending strains.
[0048] Preferably, the processor is configured to calculate a confidence value for the average resultant bending strain. Preferably, the signal processor is configured to calculate the confidence value for the average resultant bending strain based on a comparison of the plurality of resultant bending strains with each other, or with the average resultant bending strain. The confidence value for the average resultant bending strain may, for example, be based on the value of a standard deviation of a normal distribution fitted to the plurality of resultant bending strains.
[0049] Preferably, the processor is configured to calculate a confidence value for a first sensor based on a comparison of resultant bending strains derived from the strain measurement from the first sensor with the average resultant bending strain.
[0050] Preferably, the strain sensors are located to provide bending strain measurements in at least three non-parallel directions.
[0051] Preferably, each of the strain sensors is an optical strain sensor, such as a Fibre Bragg Grating sensor.
[0052] Preferably, the system comprises at least four strain sensors on the turbine blade; and the signal processor is further configured to compare the confidence value with a confidence threshold, and if the confidence value is less than the confidence threshold, re-calculate an average resultant bending strain without using the strain measurement from the first strain sensor.
[0053] Preferably, the system comprises at least five strain sensors on the turbine blade. Preferably, the strain sensors are located symmetrically around the longitudinal axis of the blade.
[0054] In a third aspect of the invention, there is provided a method of monitoring bending strain on a wind turbine blade, comprising:
locating at least three strain sensors on the turbine blade, in use each strain sensor providing a strain measurement, the strain sensors located such that edgewise and flapwise bending can be determined from the strain measurements; calculating a plurality of resultant bending strains using the strain measurements; calculating an average resultant bending strain from the plurality of resultant bending strains; and calculating a confidence value for a first sensor based on a comparison of resultant bending strains derived from the strain measurement from the first sensor with the average resultant bending strain.
[0059] The individual strain measurements may be converted into bending moments before calculating resultant bending moments and average resultant bending moment. This is useful if the relationship between bending strain and bending moment is not the same for all of the sensors. This might be the case if the blade cross-section at the position of the sensors is not symmetrical and homogenous. Accordingly, the terms “resultant bending strain” and “average resultant bending strain” as used herein should be interpreted to include “resultant bending moment” and average resultant bending moment” respectively.
[0060] Each resultant bending strain is preferably calculated from bending strain measurements taken from a different pair of strain sensors, where the strain sensors in each pair provide bending strain measurements in directions non-parallel to one another. Depending on the type and orientation of the strain sensors, each bending strain measurement may be a simple strain measurement output from a strain sensor or may be a strain measurement from a strain sensor processed to remove non-bending components from the is strain measurement.
[0061] The confidence value may be calculated in a number of ways. For example, the confidence value may be based on an absolute difference between the resultant bending strains derived from measurement from the first sensor with the average resultant bending strain. Alternatively, the confidence value may be based on a number of standard deviations that the bending strain measurement from the first sensor is from the average resultant bending strain.
[0062] Preferably, the method further comprises locating at least four strain sensors on the turbine blade; and further comprises the step of comparing the confidence value with a confidence threshold, and if the confidence value is less than the confidence threshold, re-calculating an average resultant bending strain without using the strain measurement from the first strain sensor.
[0063] Preferably, the method further comprises the step of calculating a confidence value for the average resultant bending strain. Preferably, the confidence value for the average resultant bending strain is based on a comparison of the plurality of resultant bending strains with each other, or with the average resultant bending strain. The confidence value for the average resultant bending strain may, for example, be based on the value of a standard deviation of a normal distribution fitted to the plurality of resultant bending strains.
[0064] Preferably, the strain sensors are located to provide bending strain measurements in at least three non-parallel directions. Preferably, the sensors are all positioned substantially equidistant from the root end of the blade.
[0065] Preferably, each of the strain sensors is an optical strain sensor, such as a Fibre Bragg Grating sensor.
[0066] Preferably, the method further comprises locating at least five strain sensors on the turbine blade. Preferably, the strain sensors are located symmetrically around the longitudinal axis of the blade. This allows for a simple calculation of bending strain for each strain sensor and the ability to recalculate the average bending strain based on measurements from only three or four of the strain sensors if one or two strain sensors give erroneous measurements. To provide for greater redundancy and greater resolution precision and confidence, a greater number of strain sensors may be used.
[0067] Preferably, the method further comprises calculating non-bending components of the strain measurements from the strain sensors. Preferably, the method further comprises calculating twisting torque about the longitudinal axis of the blade from the strain measurements from the strain sensors. The twisting torque may be calculated as an average from a plurality of measurements.
[0068] In a fourth aspect of the invention, there is provided a method of monitoring bending strain on a wind turbine blade, comprising:
[0000] locating at least three strain sensors on the turbine blade, in use, each strain sensor providing a strain measurement, the strain sensors located such that edgewise and flapwise bending can be determined from the strain measurements;
calculating a plurality of resultant bending strains using the strain measurements; calculating an average resultant bending strain from the plurality of resultant bending strains; and calculating a confidence value for the average resultant bending strain based on a comparison of the plurality of resultant bending strains with each other or with the average resultant bending strain. The confidence value for the average resultant bending strain may, for example, be based on the value of a standard deviation of a normal distribution fitted to the plurality of resultant bending strains.
[0072] Each resultant bending strain is preferably calculated from bending strain measurements taken from a different pair of strain sensors, where the strain sensors in each pair provide bending strain measurements in directions non-parallel to one another. Depending on the type and orientation of the strain sensors, each bending strain measurement may be a simple strain measurement output from a strain sensor or may be a strain measurement from a strain sensor processed to remove non-bending components from the strain measurement. Preferably, the sensors are all positioned substantially equidistant from the root end of the blade.
[0073] In a fifth aspect, the invention is a system for monitoring bending strain on a wind turbine blade, comprising:
[0000] at least three strain sensors located on the turbine blade, in use, each strain sensor providing a strain measurement, the strain sensors located such that edgewise and flapwise bending can be determined from the strain measurements; and
a signal processor connected to each of the strain sensors, the signal processor configured to: calculate a plurality of resultant bending strains using the strain measurements; calculate an average resultant bending strain from the plurality of resultant bending strains; and calculate a confidence value for a first sensor based on a comparison of resultant bending strains derived from the strain measurement from the first sensor with the average resultant bending strain.
[0078] Preferably, the strain sensors are located to provide bending strain measurements in at least three non-parallel directions.
[0079] Preferably, each of the strain sensors is an optical strain sensor, such as a Fibre Bragg Grating sensor.
[0080] Preferably, the system comprises at least four strain sensors on the turbine blade, and the signal processor is further configured to compare the confidence value with a confidence threshold, and if the confidence value is less than the confidence threshold, re-calculate an average resultant bending strain without using the strain measurement from the first strain sensor.
[0081] Preferably, the signal processor is further configured to calculate a confidence value for the average resultant bending strain. Preferably, the signal processor is configured to calculate the confidence value for the average resultant bending strain based on a comparison of the plurality of resultant bending strains with each other, or with the average resultant bending strain. The confidence value for the average resultant bending strain may, for example, be based on the value of a standard deviation of a normal distribution fitted to the plurality of resultant bending strains.
[0082] Preferably, the system comprises at least five strain sensors on the turbine blade. Preferably, the strain sensors are located symmetrically around the longitudinal axis of the blade.
[0083] In a sixth aspect, the invention is a system for monitoring bending strain on a wind turbine blade, comprising:
at least three strain sensors located on the turbine blade, in use, each strain sensor providing a strain measurement, the strain sensors located such that edgewise and flapwise bending can be determined from the strain measurements; and a signal processor connected to each of the strain sensors, the signal processor configured to: calculate a plurality of resultant bending strains using the strain measurements; calculate an average resultant bending strain from the plurality of resultant bending strains; and calculate a confidence value for the average resultant bending strain based on a comparison of the plurality of resultant bending strains with each other or with the average resultant bending strain. The confidence value for the average resultant bending strain may, for example, be based on the value of a standard deviation of a normal distribution fitted to the plurality of resultant bending strains.
[0089] Preferably, the strain sensors are configured to allow both twisting torque about the longitudinal axis of the blade and bending moments to be derived from their outputs. Preferably, the plurality of strain sensors comprise at least one pair of adjacent strain sensors positioned on the blade such that their sensitive axes are non-parallel with the longitudinal axis of the blade. Preferably, the sensitive axes of each pair of sensors are disposed symmetrically about a line parallel with the longitudinal axis of the blade but are not perpendicular to it. The strain measurements from each pair of sensors can then be simply combined to resolve bending strain and torque strain. For example, each pair of sensors may be arranged in a “V” shape or an “X” shape.
[0090] It should be clear that when reference is made to a confidence value or error threshold, such a value may equally be expressed as an error value or error threshold. Confidence values can be compared with a threshold confidence determine if the confidence value is less than the confidence threshold. To provide the same information, a corresponding error value can be compared with an error threshold to determine if the error value is greater than the error threshold. Accordingly, the term “confidence value” should be understood to encompass “error value” and the term “confidence threshold” should be understood to encompass “error threshold”.
[0091] In a seventh aspect, the invention is a system for monitoring a wind turbine blade comprising a pair of strain sensors located on the wind turbine blade positioned on the blade such that their sensitive axes are non-parallel with a longitudinal axis of the blade, the sensitive axes being disposed symmetrically about a line parallel with the longitudinal axis of the blade but not perpendicular to it.
BRIEF DESCRIPTION OF THE DRAWINGS
[0092] Embodiments of the present invention will now be described in detail, by way of example only, with reference to the accompanying drawings, in which:
[0093] FIG. 1 is a schematic illustration of a wind turbine;
[0094] FIG. 2 is a schematic illustration of a monitoring system in accordance with the present invention;
[0095] FIG. 3 is a schematic cross section showing the position of the strain sensors of FIG. 2 ;
[0096] FIG. 4 a is a schematic illustration of a first configuration of pairs of strain sensors for resolving bending and twisting strain;
[0097] FIG. 4 b is a schematic illustration of a second configuration of pairs of strain sensors for resolving bending and twisting strain;
[0098] FIG. 4 c is a schematic illustration of a third configuration of pairs of strain sensors for resolving bending and twisting strain;
[0099] FIG. 5 a is a graphical illustration of the calculation of bending strain using the sensors of FIGS. 2 and 3 , in accordance with a first example;
[0100] FIG. 5 b is a detailed view of the crossing points of lines P 1 to P 5 in FIG. 4 a;
[0101] is FIG. 6 a is graphical illustration of the calculation of the bending strain using sensors shown in FIGS. 2 and 3 , in a second example; and
[0102] FIG. 6 b is a detailed view of the crossing points of lines P 1 to P 5 in FIG. 5 a.
DETAILED DESCRIPTION
[0103] FIG. 2 shows a wind turbine blade 5 with five pairs of strain sensors 20 positioned around a root end of the turbine blade, in accordance with an embodiment of the present invention. The pairs of strain sensors 20 are Fibre Bragg Grating (FBG) sensors within optical fibres, arranged in a “V” configuration. Each of the optical fibres 22 in which the FBGs are formed is connected to a signal processor 24 . The signal processor 24 has an output 26 , for providing strain measurements for use in diagnostics and/or control of the wind turbine.
[0104] FIG. 3 is a schematic cross section of the root of the blade shown in FIG. 2 . It can be seen from FIG. 3 that the FBGs 20 are disposed symmetrically around the longitudinal axis of the blade 5 . The sensors are also positioned equidistant from the root end of the blade in the longitudinal direction.
[0105] Other forms of optical strain sensor may alternatively be used, such as long Period Gratings. Piezoelectric or semiconductor strain sensors may also be used, but for wind turbines it is preferable to use sensors that do not contain electrically conductive components, as electrically conductive components significantly increase the chances of lightening strikes on the wind turbine.
[0106] The strain sensors are configured to allow for a determination of twisting torque about the longitudinal axis 26 of the blade 5 . The signal processor 24 is configured to determine the twisting torque and to compare the twisting torque with a comparison value or predicted value for the torque based on one or more other measured parameters that correlate with twisting torque when the blade is operating under normal operating conditions.
[0107] In this embodiment, the bending moment on the blade is used as the parameter that correlates with the torque on the blade under normal operating conditions. Other parameters may be used, in addition, to improve correlation, or as an alternative to bending moment. For example measurement of wind speed, angle of attack of the blades and air temperature may be used as measured parameters.
[0108] The comparison may be made with the measured torque or with a value derived from it. So, in this example, the comparison may be made between the measured torque and a predicted torque derived from the amount of bending moment on the blade, or it may be made between the bending moment (the comparison value) and value derived from the measured torque, or it may be made between a value derived from the measured torque and an expected value derived from the bending moment. In other words, the measured torque may be mathematically manipulated in some way before the comparison is made without affecting the ability to detect the presence of ice on the blade or damage to the blade.
[0109] The comparison values with which comparison is made may be stored in a look-up table in a memory connected to the processor or may be calculated continually from the measured parameter or parameters. Typically in the design of a wind turbine blade complex computer models of the mechanical properties of the blade are used. These models may be based on finite element analysis, for example. These computer models can be used to provide the relationship between measured strains and the bending moment and twisting torque. They can also be used to provide the relationship between bending moment and twisting torque. Alternatively, values for populating a look-up table may be derived by operating the wind turbine under conditions in which it is known that no ice is present (herein referred to as normal operating conditions), or based on empirical data obtained from wind turbine blades of identical design. For example, the look-up table may comprise torque values for a range of measured bending moments.
[0110] If the torque about the longitudinal axis of the blade falls below the comparison value by more than a predetermined amount, then it can be inferred that ice or some other matter that disrupts the flow of air across the blade is present. If the torque is higher than expected under normal operating conditions then some kind of structural damage to the blade may have occurred.
[0111] The predetermined amount of difference used as the threshold for the determination of ice build-up can be based on the known resolution of the sensors used and/or a confidence value associated with the measurements used. There may also be an amount of ice or debris on the blade that can be safely tolerated. The predetermined amount may also be based on known variations in the relationship between the torque and the measured parameter due to environmental changes, such as air density or pressure, that typically remain within known limits.
[0112] In order to measure the bending moment and the twisting torque on the blade, strain sensors 20 are placed round the root of the blade 5 . In the embodiment shown in FIGS. 2 and 3 , the same sensors 20 are used to determine bending moment and torque. However, separate sets of sensors, of the same or different types may be used.
[0113] In the example shown in FIG. 2 , the strain sensors 20 are positioned symmetrically around the longitudinal axis of the turbine blade 5 , and are equidistant from the root end of the blade. Positioning the sensors symmetrically i.e. angularly equally spaced with respect to the longitudinal axis 26 of the blade, has advantages in the processing of strain measurements from the strain sensors. However, it should be clear that symmetrical disposition of the sensors is not essential for operation of the system in accordance with the present invention. Furthermore, if the strain sensors are all placed in the round, homogenous part of a turbine blade close to the hub it is not necessary for all of the sensors to be equally spaced from the root end of the blade, as the measured strains will be the same irrespective of the longitudinal position of the sensors within that round cross-section portion of the blade. However, if the blade cross-section at the position of the sensors is not symmetrical in any way, then the sensors should be arranged to be equidistant from the root and of the blade.
[0114] Twisting torque and bending moments can be derived from the measured twisting and bending strains using the computer models described above, which are typically based on finite element analysis, or based on empirical data.
[0115] In order to measure both the bending strain and the twisting strain on the root of the blade, the strain sensors are arranged in pairs. Each sensor in a pair is arranged to be sensitive to strain in a direction non-parallel to the longitudinal axis 26 of the blade. For ease of signal processing the sensors 20 in each pair are best arranged so that they are symmetrically disposed about a line parallel to the longitudinal axis of the blade. FIGS. 4 a , 4 b and 4 c show possible configurations of the sensor pairs.
[0116] FIG. 4 a shows “V” shaped pairs of sensors arranged on the root of the blade. Each pair of sensors may be FBGs, embedded in the same or different optical fibres. By comparing the strain measured by each sensor with the strain measured by the other sensor in the pair, both torque and longitudinal strain (from which bending moments may be derived) can be determined. FIG. 4 b shows “X” shaped pairs of sensors and FIG. 4 c shows “V” shaped pairs of sensors with greater spacing between the sensors in each pair. All of these arrangements operate on the same principle.
[0117] The bending strain measured by each pair of sensors 20 is determined by its position. The bending strain measured by each pair of FBG is the strain in a radial direction, i.e. in a direction towards the centre of the root of the turbine blade 5 , although it is derived from a measure of strain in a direction parallel to the longitudinal axis of the blade. This is clearly illustrated in FIG. 3 by the dotted lines extending from each sensor.
[0118] FIG. 5 a is a graphical illustration of how the bending strain measurements from the sensors are used to provide a resultant bending strain measurement.
[0119] The FBG strain sensors shown in FIGS. 2 , and 3 are affected not only by bending strain but also by strain parallel to the longitudinal axis of the blade, by twisting strain and by temperature changes. Before calculating a resultant bending strain or bending moment, the strain measurements from each sensor are added together and then divided by the number of sensors to provide an average strain. Contributions to the strain resulting from strain in a longitudinal direction of a turbine blade e.g. those due to centripetal force, will be the same for all of the sensors. The contribution to the strain measurements from bending forces acting in the plane defined by the sensors, will add up to zero if the sensors are symmetrically disposed. Accordingly, subtraction of the average strain measurement from the strain measurement taken by each of the sensors will result in removal longitudinal strain from the strain measurement. Twisting strain is removed from the strain measurements by adding the strain measurements within each pair of sensors together. The resulting strain measurement for each pair of sensors is referred to herein as a bending strain measurement. Temperature compensation may still be required, and one or more temperature sensors may be provided on the blade for that purpose. Temperature sensors may also be provided to determine if conditions are such that ice formation is a possibility.
[0120] In FIG. 5 a the bending strain measurement from each of the sensors, labelled S 1 , S 2 , S 3 , S 4 and S 5 , is illustrated as vector F 1 , F 2 , F 3 , F 4 and F 5 respectively. The bending strain measured by each of the sensors can be understood as a force that points in the radial direction defined by the mounting position of the sensor. The bending strains are illustrated in FIG. 5 a as emanating from a single point, the centre of the root of the blade. The actual or resultant bending strain is illustrated by vector R which comprises both edgewise and flapwise components, and from which the edgewise and flapwise components can be simply derived. The resultant strain R can be determined from the five bending strain measurements F 1 to F 5 . The bending strain measured by each strain sensor is the component of the resultant bending strain in the radial direction defined by the position of the sensor. This is clearly shown in FIG. 4 a where lines P 1 to P 5 are drawn from the resultant bending strain R to each of the measured bending strains F 1 to F 5 , at right angles to each of the measured bending strains. So one way to calculate the resultant bending strain from the measured bending strain is to simply determine where the lines P 1 to P 5 cross. This can be understood algebraically as solving simultaneous equations for two variables, i.e. the magnitude and direction of the resultant bending strain, from five simultaneous equations.
[0121] The individual strain measurements may be converted into bending moments before calculating resultant bending moments and average resultant bending moment, rather than calculating resultant bending strains and an average resultant bending strain directly from the strain measurements. This is useful if the relationship between bending strain and bending moment is not the same for all of the sensors. This might be the case if the blade cross-section at the position of the sensors is not symmetrical and homogenous.
[0122] In the examples shown in FIG. 5 a, θ N is the angle between the bending strain F N measured by sensor N (N=1, 2, 3, 4, 5) and the resultant strain R measured in a clockwise direction from R (only θ 2 is shown). |F N | is the magnitude of the strain F N detected by each strain sensor.
[0123] The simultaneous equations for the resultant strain are then:
[0000] | R″=|F 1 |/cos θ 1 =|F 2 |/cos θ 2 =|F 3 |/cos θ 3 =|F 4 |/cos θ 4 =|F 5 |/cos θ 5 .
[0124] There is known relationship between θ 1 , θ 2 , θ 3 , θ 4 and θ 5 so long as the position of the sensors is known, so there are only two unknowns to solve for. In the examples shown in FIG. 5 a there are five sensors equally spaced so that θ 1 =θ 2 −2π/5=θ 3 −4π/5=θ 4 −6π/5=θ 5 −8π/5. Where the measured strain is compressive i.e. negative, the magnitude |F| should be negative.
[0125] Only two equations are needed to provide a solution for the two unknowns, |R| and θ. But with N sensors, there are N simultaneous equations. There are therefore ½N(N−1) pairs of equations that can be used to provide a solution for R. With N=5 there are 10 possible solutions, corresponding to the 10 crossing points of lines P 1 to P 5 .
[0126] In theory each of these solutions for |R| and θ should be identical. This corresponds to the situation in which each of the lines P 1 to P 5 in FIG. 5 cross at exactly the same point. In reality, not all of the solutions for |R| and θ will be the same. This is illustrated in FIG. 5 b which shows that each of the lines P 1 to P 5 do not cross at the same point. The different solutions are due to several kinds of problems, including sensor similarity, variations in the material properties of the blade, measurement resolutions and alignment of the sensors. It may also be the case that one or more of the sensors is faulty or broken.
[0127] Rather than selecting simply one solution as the resultant bending strain the resultant bending strain can be calculated as an average of all of the possible solutions i.e. an average of all of the crossing points of lines P 1 to P 5 in FIG. 5 b . The average can be a simple mean for the magnitude and direction, calculated by summing and dividing all of the possible solutions. Alternatively, a two-dimensional normal distribution can be fitted to the results, which provides not only a convenient average but also a convenient measure of confidence in the result, based on the standard deviation from the mean. Other measures of confidence or accuracy in the resultant bending strain are also possible, such a simple average of the deviation of each result from the mean.
[0128] Providing a measure of confidence in the average resultant bending strain can be extremely useful. It allows the basis for a decision on whether to stop the turbine to remove ice or clean the blades to factor in how accurate the measurements are. If the confidence value is high that there is a tolerable amount of ice on the turbine blade then the turbine blade can continue to operate. If the confidence value is low, a greater margin of error can be used and any amount of ice close to the maximum tolerable level may require the turbine to be stopped.
[0129] A system in accordance with the present invention can also allow faulty, badly installed or broken sensors to be detected and their measurements discounted from the strain calculations. FIG. 6 a is a similar diagram to that of FIG. 5 a , but for a different set of example measurements. Again the bending strain measurements (from which non bending strain contributions have been subtracted) are represented by lines F 1 to F 5 . Perpendicular lines P 1 to P 5 have been drawn from the ends of each of F 1 to F 5 , and the crossing points of lines P 1 to P 5 represent possible solutions for the resultant bending strain R. It can be seen in FIG. 5 a that the result obtained from sensor 1 i.e. bending strain F 1 , provides very different solutions from the results obtained using combinations of the other sensors. The line P 1 does not cross the lines P 2 , P 3 , P 4 or P 5 near the area in which lines P 2 to P 5 cross each other. FIG. 6 b is a detailed view of the crossing points of the lines P 1 to P 5 in FIG. 6 a . In this example, the strain measurement F 1 is clearly erroneous and should be ignored. The resultant bending strain can be better calculated using only the measurements from sensors 2 to 5 i.e. bending strains F 2 to F 5 as illustrated.
[0130] In order to determine whether or not a particular strain measurement is faulty, the solutions for resultant bending strain R provided using that strain measurement are compared to the average solution for R. If the difference between the results using one of the strain sensors are all (or alternatively on average) greater than a threshold difference value, then measurements from that strain sensor can be discarded and the calculations (including those calculations removing non-bending strain contributions from the strain measurements) are repeated without input from the faulty sensor. The threshold value can be set as an absolute value or as a number of standard deviations away from the mean value or any other suitable method, such as a proportion of the average resultant bending strain. This process of comparing each result with an average result can be fully automated within the signal processor and may provide a confidence value for each sensor and provide an alert when a faulty sensor is detected i.e. when the threshold level is exceeded. This allows the system to provide more accurate results and provide automated diagnostics.
[0131] Even if no sensor is found to be faulty, a confidence value for each strain sensor can be provided to an external diagnostics unit for subsequent analysis.
[0132] Although specific methods for calculating average strain and strain confidence values have been described, any suitable analysis methods may be used to give a resultant bending strain and confidence values both in the average bending strain and in the measurement from each individual sensor.
[0133] In order to provide the capability to calculate resultant bending strain accurately while discarding measurements from one or more of the available strain sensors, sufficient strain sensors need to be provided. The minimum number of FBG strain sensors needed to provide a resultant bending strain measurement in two dimensions is three FBG sensors. In order to provide redundancy, more than three strain sensors need to be provided. In a preferred embodiment five or more sensors are provided. The more sensors that are provided the greater the resolution, precision and confidence of measurement that can be obtained and the lower the threshold for discarding erroneous measurements can be set.
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The invention provides a method and system of detecting ice or other foreign matter on a wind turbine blade or damage to a wind turbine blade. The method in one aspect comprises: measuring twisting torque on the blade about its longitudinal axis to provide a detected torque signal; comparing a value based on the detected torque signal with a comparison value, the comparison value derived from one or more measured parameters having a predetermined relationship with the twisting torque about the longitudinal axis of the blade when the blade is operating under normal operating conditions; and determining that ice or other foreign matter is on the blade or that the blade is damaged if the value based on the detected torque signal differs from the comparison value by more than a predetermined amount. Wind turbine blades are designed such that any change in the shape of the blade reduces twisting torque on the blades significantly. Torque about the longitudinal axis of the blade can therefore be used as a sensitive indicator of ice on the blade and of damage to the blade.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for finally shaping an air bearing surface (ABS) of a magnetic head slider and a manufacturing method of a magnetic head slider using this shaping method.
DESCRIPTION OF THE RELATED ART
[0002] A flying magnetic head slider with a thin-film magnetic head is required to have a slightly convex shape such as convex crown and/or camber in an ABS of each rail in order to obtain an excellent flying performance. The “crown” represents a deformation in shape along fore-and-aft directions of the magnetic head slider or directions in parallel with an air-flowing direction, and the “camber” represents a deformation in shape along lateral directions of the magnetic head slider or directions perpendicular to the air-flowing direction. In some cases, the crown and the camber may be generically called as the crown.
[0003] The ABS with such convex shape is formed in a final shaping work after various works for a row bar provided with a plurality of aligned magnetic head sliders. Namely, in this final work, the ABS is shaped in convex by radiating a laser beam to a surface opposite to the ABS of the row bar so as to intentionally deform this row bar (U.S. Pat. No. 5,266,769).
[0004] However, in the conventional final shaping work, since the row bar is caught by a jig for holding, chipping of the row bar or contamination thereof may be occurred.
[0005] Also, if the row bar is cut and separated into individual magnetic head sliders after the shaping of the ABS into convex, the convex ABS may be deformed due to a distortion produced during the cutting. Thus, a desired flying performance cannot be expected.
[0006] If the shaping of the ABS into convex is executed after the cutting of the row bar into individual magnetic head sliders, the latter problem will not occur. However, in this case, a positioning of each magnetic head slider for the shaping in convex and a measurement of a crown amount or a height of the crest from the root of the convex shape are very difficult. Particularly, in case of a downsized magnetic head slider called as a 30% slider with a size of 1.0 mm×1.235 mm×0.3 mm or 20% slider with a size of 0.7 mm×0.85 mm×0.23 mm, it is quite difficult to easily and accurately execute the positioning of each magnetic head slider and the measurement of a crown amount. As will be noted, during or after the shaping of the ABS into convex, it is required to measure the crown amount to control a shaping amount.
SUMMARY OF THE INVENTION
[0007] It is therefore an object of the present invention to provide a method for finally shaping an ABS of a magnetic head slider and a manufacturing method of a magnetic head slider using this shaping method, whereby occurrence of chipping and contamination of the magnetic head slider can be reduced.
[0008] Another object of the present invention is to provide a method for finally shaping an ABS of a magnetic head slider and a manufacturing method of a magnetic head slider using this shaping method, whereby an ABS of the magnetic head slider can be easily and accurately shaped into a desired convex shape.
[0009] According to the present invention, a method for shaping an ABS of a magnetic head slider includes a step of holding at least one row bar with a plurality of aligned thin-film magnetic head elements by adhering a first surface of the at least one row bar to an adhesive tape capable of passing a laser beam there through, the first surface being opposite to an ABS of the at least one row bar, a step of shaping the ABS of the at least one row bar in a convex shape by radiating a laser beam to the first surface of the at least one row bar through the adhesive tape, a step of cutting the at least one row bar into individual magnetic head sliders, and a step of then, removing the magnetic head sliders from the adhesive tape after weakening adhesion properties of the adhesive tape by for example heating the tape.
[0010] Since the shaping of the ABS of the row bars are executed while the row bars are adhered and held by the adhesive tape, no chipping of the row bars nor contamination thereof are occurred.
[0011] It is preferred that the cutting step includes cutting at least one row bar into individual magnetic head sliders so that the adhesive tape holds all of the individual magnetic head sliders. It is also preferred that the method includes a step of measuring a crown amount of each magnetic head slider after the cutting step but before the removing step. Since a crown amount of the magnetic head slider is measured under the state where all the sliders are held by the adhesive tape, a precise measurement can be extremely easily performed.
[0012] It is further preferred that the holding step includes holding a single row bar with a plurality of aligned thin-film magnetic head elements by adhering the first surface of the row bar to the adhesive tape, or holding a plurality of row bars, each having a plurality of aligned thin-film magnetic head elements, by adhering the first surface of each of the row bars to the adhesive tape.
[0013] Also, according to the present invention, a method for shaping an air bearing surface of a magnetic head slider includes a step of holding at least one row bar with a plurality of aligned thin-film magnetic head elements by adhering a first surface of the at least one row bar to an adhesive tape capable of passing a laser beam there through, the first surface being opposite to an ABS of the at least one row bar, a step of cutting the at least one row bar into individual magnetic head sliders so that the adhesive tape holds all of the individual magnetic head sliders, a step of shaping an ABS of the individual magnetic head slider in a convex shape by radiating a laser beam to the first surface of the magnetic head slider through the adhesive tape, and a step of then, removing the magnetic head sliders from the adhesive tape after weakening adhesion properties of the adhesive tape.
[0014] Since the shaping of the ABS of the row bars are executed while the row bars are adhered and held by the adhesive tape, no chipping of the row bars nor contamination thereof are occurred. In addition, since the convex shape is formed after cutting into the individual magnetic head sliders, no deformation in crown due to a distortion that may occur during the dicing process of the row bar into the individual magnetic head sliders will be produced. Also, as all the magnetic head sliders are held in the fixing state to the adhesive tape, the positioning of each magnetic head slider for the shaping in convex can be precisely and easily performed.
[0015] It is preferred that the method includes a step of measuring a crown amount of each magnetic head slider after the cutting step but before the removing step. Since a crown amount of the magnetic head slider is measured under the state where all the sliders are held by the adhesive tape, a precise measurement can be extremely easily performed.
[0016] It is further preferred that the holding step includes holding a single row bar with a plurality of aligned thin-film magnetic head elements by adhering the first surface of the row bar to the adhesive tape, or holding a plurality of row bars, each having a plurality of aligned thin-film magnetic head elements, by adhering the first surface of each of the row bars to the adhesive tape.
[0017] According to the present invention, further, a method for shaping an ABS of a magnetic head slider includes a step of holding at least one row bar with a plurality of aligned thin-film magnetic head elements by adhering a first surface of the at least one row bar to a UV tape capable of passing a laser beam there through, the first surface being opposite to an ABS of the at least one row bar, a step of shaping the ABS of the at least one row bar in a convex shape by radiating a laser beam to the first surface of the at least one row bar through the UV tape, a step of cutting the at least one row bar into individual magnetic head sliders, and a step of then, removing the magnetic head sliders from the UV tape after radiating an ultra violet light to the UV tape so as to weaken its adhesion properties.
[0018] Since the shaping of the ABS of the row bars are executed while the row bars are adhered and held by the UV tape, no chipping of the row bars nor contamination thereof are occurred.
[0019] It is preferred that the cutting step includes cutting at least one row bar into individual magnetic head sliders so that the UV tape holds all of the individual magnetic head sliders. It is also preferred that the method includes a step of measuring a crown amount of each magnetic head slider after the cutting step but before the removing step. Since a crown amount of the magnetic head slider is measured under the state where all the sliders are held by the UV tape, a precise measurement can be extremely easily performed.
[0020] It is further preferred that the holding step includes holding a single row bar with a plurality of aligned thin-film magnetic head elements by adhering the first surface of the row bar to the UV tape, or holding a plurality of row bars, each having a plurality of aligned thin-film magnetic head elements, by adhering the first surface of each of the row bars to the UV tape.
[0021] Also, according to the present invention, a method for shaping an ABS of a magnetic head slider includes a step of holding at least one row bar with a plurality of aligned thin-film magnetic head elements by adhering a first surface of the at least one row bar to a UV tape capable of passing a laser beam there through, the first surface being opposite to an ABS of the at least one row bar, a step of cutting the at least one row bar into individual magnetic head sliders so that the UV tape holds all of the individual magnetic head sliders, a step of shaping an ABS of the individual magnetic head slider in a convex shape by radiating a laser beam to the first surface of the magnetic head slider through the UV tape, and a step of then, removing the magnetic head sliders from the UV tape after radiating an ultra violet light to the UV tape so as to weaken its adhesion properties.
[0022] Since the shaping of the ABS of the row bars are executed while the row bars are adhered and held by the UV tape, no chipping of the row bars nor contamination thereof are occurred. In addition, since the convex shape is formed after cutting into the individual magnetic head sliders, no deformation in crown due to a distortion that may occur during the dicing process of the row bar into the individual magnetic head sliders will be produced. Also, as all the magnetic head sliders are held in the fixing state to the UV tape, the positioning of each magnetic head slider for the shaping in convex can be precisely and easily performed.
[0023] It is preferred that the method includes a step of measuring a crown amount of each magnetic head slider after the cutting step but before the removing step. Since a crown amount of the magnetic head slider is measured under the state where all the sliders are held by the UV tape, a precise measurement can be extremely easily performed.
[0024] It is further preferred that the holding step includes holding a single row bar with a plurality of aligned thin-film magnetic head elements by adhering the first surface of the row bar to the UV tape, or holding a plurality of row bars, each having a plurality of aligned thin-film magnetic head elements, by adhering the first surface of each of the row bars to the UV tape.
[0025] Further, according to the present invention, a manufacturing method of a magnetic head slider includes a step of dicing an wafer on which many of thin-film magnetic head elements are fabricated to obtain a plurality of row bars each having a plurality of aligned thin-film magnetic head elements, a step of forming ABSs of magnetic head sliders on one surface of the each row bar, and the above-mentioned steps for shaping the ABS of each magnetic head slider.
[0026] Further objects and advantages of the present invention will be apparent from the following description of the preferred embodiments of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows an oblique view schematically illustrating an example of a magnetic head slider fabricated by a manufacturing method according to the present invention;
[0028] FIG. 2 shows a sectional view seen from an A-A line of FIG. 1 ;
[0029] FIG. 3 shows a sectional view seen from a B-B line of FIG. 1 ;
[0030] FIG. 4 shows a flow chart schematically illustrating a manufacturing method of a magnetic head slider as a preferred embodiment according to the present invention;
[0031] FIG. 5 shows an oblique view illustrating an adhering step of a row bar to a UV tape;
[0032] FIG. 6 shows an oblique view illustrating an example of a fixing jig on which a UV tape with a plurality of row bars is attached;
[0033] FIG. 7 shows a sectional view seen from a C-C line of FIG. 6 ;
[0034] FIG. 8 shows a sectional view of the fixing jig mounted on a laser radiation device;
[0035] FIG. 9 shows a sectional view of the fixing jig mounted on a cutter device;
[0036] FIGS. 10 a and 10 b show sectional views illustrating the row bar adhered on the UV tape before cutting and after cutting; and
[0037] FIG. 11 shows a flow chart schematically illustrating a manufacturing method of a magnetic head slider as another embodiment according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] FIG. 1 schematically illustrates an example of a magnetic head slider fabricated by a manufacturing method according to the present invention, FIG. 2 is a sectional view seen from an A-A line of FIG. 1 , and FIG. 3 is a sectional view seen from a B-B line of FIG. 1 .
[0039] In FIG. 1 , reference numerals 11 and 12 denote two side rails of a flying type magnetic head slider 10 , 13 denotes a rear rail of the magnetic head slider 10 , 14 denote slider ABSs formed on surfaces of the side rails 11 and 12 and the rear rail 13 of the slider, 15 denotes a thin-film magnetic head element partially appeared on the ABS of the rear rail 14 , and 16 - 19 denote electrode terminals electrically connected to the magnetic head element 15 , respectively.
[0040] As slightly exaggerated for purposes of illustration in FIGS. 2 and 3 , the magnetic head slider 10 is worked to have a slightly convex shape such as convex crown and/or camber in the ABS 14 of each rail in order to obtain an excellent flying performance.
[0041] FIG. 4 schematically illustrates a manufacturing method of a magnetic head slider as a preferred embodiment according to the present invention. Hereinafter, a method for shaping an ABS of the magnetic head slider into a convex shape and a manufacturing process of the magnetic head slider will be described with reference to the figure.
[0042] First, many magnetic head elements arranged in matrix are fabricated on an wafer by using a thin-film fabrication technique (step S 1 ). This wafer process for fabricating the thin-film magnetic head elements can be performed by using various known methods.
[0043] Then, the wafer is cut into a plurality of row bars each of which has a plurality of aligned thin-film magnetic head elements (step S 2 ).
[0044] Then, the plurality of row bars are adhered and fixed to a UV tape (step S 3 ). This adhesion is performed by adhering a surface opposite to the ABS of the row bar to the UV tape. The UV tape has in general a three-layers structure of a base film, a UV-curing adhesive layer that will be cured by radiation of an ultra violet light and a peel-off film. As shown in FIG. 5 , first, the peel-off film 50 a is removed from the UV tape 50 and then the row bars 51 are stuck to the exposed adhesive layer 50 b. It is important to press the UV tape against the stuck row bars so that no air-bubble is remained between the row bars and the UV tape.
[0045] Next, the UV tape 50 with the stuck row bars 51 is attached to a fixing jig used for a laser radiation process and a cutting or dicing process (step S 4 ).
[0046] FIG. 6 illustrates an example of this fixing jig with the attached UV tape, and FIG. 7 is a sectional view seen from a C-C line of FIG. 6 .
[0047] As shown in these figures, the fixing jig 60 consists of a base frame 61 shaped in a circular loop for example, and a cover frame 62 also shaped in the circular loop and used in contact with the base frame 61 . The fixing jig 60 holds or supports the UV tape 50 with the stuck row bars 51 by pinching the margins of the UV tape 50 between the base frame 61 and the cover frame 62 . Thus, the row bars 51 will be tightly supported by the stretched UV tape 50 .
[0048] Then, the fixing jig 60 is mounted on a laser radiation device and a laser beam is radiated to surfaces opposite to the ABSs of the row bars via the UV tape (step S 5 ).
[0049] FIG. 8 illustrates the fixing jig 60 mounted on a table of the laser radiation device and the row bars 51 to which the laser beam is applied from rear side of the UV tape 50 . Tackiness or adhesion properties of the adhesive layer of the UV tape 50 will not change even if the laser beam is radiated. The UV tape 50 will not absorb the laser beam but pass there through and therefore the radiated laser beam will be applied to the surface of the row bars 51 , which is opposite to the ABS. By applying the laser beam to only the surface opposite to the ABS, this surface is partially and momentarily heated and melted to produce a stress in this surface only. Therefore, there occurs a difference in stresses between the opposite surface and the ABS, and then a convex shape such as convex crown and/or camber shown in FIGS. 2 and 3 is formed in each row bar.
[0050] Any kind of laser source can be used if it is possible to partially heat and melt the rear surface of the row bar. In case that the laser beam is a spot beam with a small diameter, the laser beam will be moved to scan the row bars in longitudinal directions, lateral directions or slanting directions. In case of a relatively large diameter laser beam, these row bars will be radiated at once.
[0051] Thereafter, the fixing jig is detached from the laser radiation device and then mounted on a dicing device, so that each row bar is cut and separated into individual magnetic head sliders (step S 6 ).
[0052] FIG. 9 illustrates the fixing jig 60 mounted on a working table 90 of the dicing device. The working table 90 has a vacuum chuck 93 with a porous chuck 91 and a vacuum chamber 92 . The fixing jig 60 is attached on this working table 90 and the rear surface of the UV tape 50 is sucked through the porous chuck 91 to uniformly support the whole area of the UV tape. Under this state, the row bar 51 is cut and separated into individual magnetic head sliders.
[0053] FIGS. 10 a and 10 b illustrate the row bar 51 adhered on the UV tape 50 . FIG. 10 a indicates the row bar before cutting and FIG. 10 b indicates the row bar after cutting. As shown in FIG. 10 b, when cutting the row bar 51 , the UV tape 50 will not completely cut along its thickness but a part of the UV tape will be remained in connection. Thus, all the magnetic head sliders 101 will be held in a fixing state to the fixing jig 60 through the UV tape 50 .
[0054] Then, if necessary, a crown amount of each magnetic head slider is measured (step S 7 ). The crown amount that corresponds to a height of the crest from the root of the convex shape in the ABS of the magnetic head slider will be optically measured. In order to execute this measurement, it is required that each magnetic head slider is precisely positioned on a measurement stage without inclining. In this embodiment, since all the magnetic head sliders are held in the fixing state to the UV tape, the positioning will be automatically completed and therefore extremely easy and precise measurement of the crown amount can be expected. This is in particular advantageous for a downsized magnetic head slider such as a 20% slider or a 30% slider. Also, since a crown amount of each magnetic head slider not a crown amount of each row bar can be measured, influence of a distortion that might occur during the dicing process of the row bar into the individual magnetic head sliders can be omitted from the measured amount. Furthermore, because of using of a thin UV tape with a thickness of about 100 μm, a distortion that may be produced at adhesion of the row bars to this UV tape will be absorbed by the UV tape itself and the magnetic head slider will be unaffected by the possible distortion. As a result, a flatness of the ABS will not change before and after the adhesion and thus precise crown amount can be measured.
[0055] Thereafter, an ultra violet light is radiated to the rear surface of the UV tape 50 to cure the adhesion layer of this UV tape (step S 8 ).
[0056] Due to curing of the adhesion layer, the adhesion properties of the UV tape will be weakened, and then the magnetic head sliders 101 are detached from the UV tape 50 (step S 9 ).
[0057] As aforementioned, according to this embodiment, since the shaping of the ABS of the row bars are executed while the row bars are adhered and held by the UV tape, no chipping of the row bars nor contamination thereof are occurred. Also, as a crown amount is measured under this state, a precise measurement can be extremely easily performed.
[0058] FIG. 11 schematically illustrates a manufacturing method of a magnetic head slider as another embodiment according to the present invention. In this embodiment, a dicing process of row bars is carried out before a laser radiation process. Hereinafter, a method for shaping an ABS of the magnetic head slider into a convex shape and a manufacturing process of the magnetic head slider will be described with reference to the figure.
[0059] First, many magnetic head elements arranged in matrix are fabricated on an wafer by using a thin-film fabrication technique (step S 11 ).
[0060] Then, the wafer is cut into a plurality of row bars each of which has a plurality of aligned thin-film magnetic head elements (step S 12 ).
[0061] Then, the plurality of row bars are adhered and fixed to a UV tape (step S 13 ).
[0062] Next, the UV tape 50 with the stuck row bars 51 is attached to a fixing jig used for a cutting or dicing process and a laser radiation process (step S 14 ).
[0063] Then, the fixing jig 60 is mounted on a dicing device, so that each row bar is cut and separated into individual magnetic head sliders (step S 15 ).
[0064] Thereafter, the fixing jig is detached from the dicing device, and then mounted on a laser radiation device. A laser beam is radiated to surfaces opposite to the ABSs of the row bars via the UV tape (step S 16 ). By applying the laser beam to only the surface opposite to the ABS, this surface is partially and momentarily heated and melted to produce a stress in this surface only. Therefore, there occurs a difference in stresses between the opposite surface and the ABS, and then a convex shape such as convex crown and/or camber is formed in each row bar. In this embodiment, since the convex shape is formed after cutting into the individual magnetic head sliders, no deformation in crown due to a distortion that may occur during the dicing process of the row bar into the individual magnetic head sliders will be produced.
[0065] Then, if necessary, a crown amount of each magnetic head slider is measured (step S 17 ).
[0066] Thereafter, an ultra violet light is radiated to the rear surface of the UV tape 50 to cure the adhesion layer of this UV tape (step S 18 ).
[0067] Due to curing of the adhesion layer, the adhesion properties of the UV tape will be weakened, and then the magnetic head sliders 101 are detached from the UV tape 50 (step S 19 ).
[0068] Another procedure in each process, operations and advantages in this embodiment are the same as those in the embodiment of FIG. 4 .
[0069] In the aforementioned embodiments, the execution order of the process of step S 3 or S 13 and the process of step S 4 or S 14 may be inversed each other, namely, row bars may be adhered to a UV tape after the UV tape is attached to a fixing jig.
[0070] Also, instead of the UV tape, any adhesive tape that passes a laser beam there through and has adhesion properties weakened by heating may be used. In this case, the similar processes except that a heating process is performed in place of the ultra violet light radiation process will be carried out and the similar advantages will be obtained.
[0071] Many widely different embodiments of the present invention may be constructed without departing from the spirit and scope of the present invention. It should be understood that the present invention is not limited to the specific embodiments described in the specification, except as defined in the appended claims.
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A method for shaping an ABS of a magnetic head slider includes including a step of holding at least one row bar with a plurality of aligned thin-film magnetic head elements by adhering a first surface of the at least one row bar to an adhesive or UV tape capable of passing a laser beam there through, the first surface being opposite an ABS of the at least one row bar, a step of shaping the ABS of the at least one row bar in a convex shape by radiating a laser beam to the first surface of the at least one row bar through the adhesive or UV tape, a step of cutting the at least one row bar into individual magnetic head sliders, and a step of then, removing the magnetic head sliders from the adhesive or UV tape after weakening adhesion properties of the adhesive or UV tape.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to suspended ceilings and, in particular, to improvements in grid runners.
PRIOR ART
[0002] Suspended ceiling grid runners are manufactured in a variety of cross sections to serve different functions and/or afford different appearances. Packaging of these grid runners for distribution may involve nesting them side-by-side with alternate runners being inverted. Such arrangements can minimize the size of a box in which the runners are packaged and the space taken up during transport and storage of the runners. While space may be conserved with a nested group of runners, the geometry of the runner cross section may allow the runner elements, visible in a finished installation, to be marred. Vibration during shipping and/or handling can cause parts of adjacent runners to mar the visible areas of a runner.
[0003] U.S. Pat. No. 4,679,375 shows a grid tee formed with tabs stamped out of a web. The tabs are intended to center tiles or panels in the grid spaces. The tabs reduce the risk that a panel can shift in the suspended grid space and slip off a flange. These prior art tabs, however, may be ineffective to restrain and center relatively thin panels of sheet metal or plastic.
SUMMARY OF THE INVENTION
[0004] The invention relates to a grid runner with an improved indexing tab construction. The inventive indexing tabs stamped from a central web of the grid runners, can protect nested grid runners from damage in transit. Once the grid runners are installed, the tabs, additionally, can restrain and center even relatively thin ceiling tiles in the grid spaces.
[0005] The indexing tab is especially adapted to be incorporated into a double reveal type grid runner. This runner type has a stepped flange which can be especially susceptible to marring when it is compactly nested in a package or box.
[0006] The indexing tab can be more readily implemented in certain types of grid runner constructions where the grid profile is made in two separate roll forming operations and when stamping is performed between these roll forming operations. In such runner constructions, the sheet metal area adjacent the lower margins of the web may not be folded in a preform state so that there is clearance for tooling to conventionally stamp the tabs at a level of the eventual flange. Locating the tabs at the flange level ensures that even thin panels can be restrained in the center of a grid space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a cross-sectional view of a grid runner preform prior to final roll forming;
[0008] FIG. 2 is a fragmentary side elevational view of the grid runner preform of FIG. 1 ;
[0009] FIG. 3 is a sectional view of the grid runner preform taken in the plane of the lines 3 - 3 in FIG. 2 ;
[0010] FIG. 4 is a cross-sectional view of a finish rolled grid runner made in accordance with the invention;
[0011] FIG. 5 is a fragmentary side elevational view of the grid runner of FIG. 4 ;
[0012] FIG. 6 is a diagrammatic end view of a package of grid runners in accordance with the invention; and
[0013] FIG. 7 is an enlarged fragmentary view of the package shown in FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] FIGS. 4 and 5 illustrate an elongated grid runner 10 used to form a grid for a suspended ceiling. The illustrated grid runner 10 is of a style sometimes referred to as a double reveal profile. The profile is characterized with a two-level flange 11 . A central portion 12 of the flange 11 is dropped below laterally outward portions 13 of the flange. The grid runner also includes a central vertically extending web 14 above the flange 11 and a hollow reinforcing bulb 16 at the top of the web. In the illustrated case, the grid runner 10 is made of two roll formed sheet metal, typically steel, strips. A main body strip 17 forms an upper part of the flange 11 , the double walls of the web 14 and the reinforcing bulb 16 . A face sheet 18 , typically of lighter gauge than the main body strip 17 , forms the appearance or face side of the flange 11 . The face strip is retained on the main body strip by marginal longitudinally extending areas 19 folded over longitudinal edges of the main body strip 17 in the manner of a hem. The outer side of the face strip 18 can be pre-painted as is customary.
[0015] The grid runner 10 , as is conventional, can be provided as main runners and cross runners to form a rectangular grid that is suspended by wires. The flanges 11 serve to support ceiling tiles or panels in the grid spaces made by parallel and intersecting grid runners. The panels or tiles are typically carried on the upper sides of the laterally outward portions 13 of the flanges 11 .
[0016] In the illustrated case, the central flange portion 12 is somewhat narrower than the reinforcing bulb 16 . The illustrated grid runner 10 can be roll formed in two stages through a primary roll set and a secondary roll set.
[0017] When the strips 17 , 18 exit the first roll set, they make up a grid runner preform 20 shown in FIGS. 1 and 2 . The preform 20 has a generally conventional grid tee shape although the web 14 has a greater height than is normal. In the preform state, the material ultimately forming the two level flange 11 extends in a flat plane, apart from the marginal hem areas 19 , perpendicular to the web 14 . The grid runner preform 20 is received in a press where various details, including cross tee slots and end connectors are formed or, in the illustrated case, end connector pockets are formed for receiving end connectors. In this intermediate press station, indexing tabs 26 are stamped out of the web 14 by combination punch and die sets diagrammatically illustrated at 27 . The indexing tabs 26 are formed on both sides of the web 14 . Each tab 26 has a generally flat face 28 parallel to the web 14 and a free edge having sections 31 , 32 generally lying in planes perpendicular to the web and to each other. The punch and die sets 27 on opposite sides of the preform 20 are complimentary to each such that the punch of one unit works with the die of the other and vice versa to form a pair of adjacent tabs during a stroke of the press. Alternatively, a simple die punch set can be used to form a single tab at a particular location along the length of the preform 20 . The material remaining at the web 14 where the cut edges 31 , 32 are severed from the web proper are ordinarily supported by a die surface on the side of the web to which a tab is displaced. The spacing of the tab faces 28 from the web 14 or center of the finished grid runner 10 is selected to position a ceiling panel or tile in the center of a grid space. The tabs 26 whether in pairs on opposite sides of the web 14 or standing alone are made adjacent each end of the grid runner 10 . Additionally, main runners and long cross runners are formed with additional tabs on each side of the web along their lengths.
[0018] After the grid runner preform has been stamped with the tabs 26 and other features, it is passed through a secondary roll set. In this subsequent roll forming step, the flange 11 is finally shaped to the stepped configuration illustrated in FIG. 4 . FIGS. 4 and 7 illustrate that the tabs 26 extend vertically upwardly from the level of the outer flange portions 13 . More precisely, the lower edge 31 of a tab 26 is preferably less than about 0.010 in. above the upper surface of a hem 19 and can be at or below this surface. With this geometry, the tabs 26 can center ceiling panels of relatively thin gauge, e.g. 0.020 in. thick, without the risk that the panels can slip under the tabs and not be centered.
[0019] It is customary to nest grid runners side-by-side or laterally to minimize the size of a quantity of grid runners in a package for shipping and storage purposes. FIGS. 6 and 7 illustrate a packaging arrangement for a number of grid runners 10 received in a box 36 , typically a cardboard container. It will be seen that alternate grid runners 10 are arranged with their adjacent upper flange portions 13 overlapped. Intervening grid runners 10 are inverted and their adjacent upper flange portions 13 are similarly overlapped. The tabs 26 of each grid runner abut the reinforcing bulbs 16 of adjacent grid runners. The tabs 26 are advantageously proportioned so that their width or lateral offset, measured from the center of the web 14 , combined with the width of a reinforcing bulb 16 is greater than the width of a flange 11 across its distal edges plus the width of the dropped central or mid-portion 12 of the flange. The foregoing described tab geometry prevents the distal flange edges, designated 34 of either alternate or intervening grid runners from contact with the dropped central flange portions 12 of adjacent runners. This situation is illustrated in FIG. 7 . Contact of these elements during package handling and shipping could result in abrasion and marring of the visible surfaces of the drop central flange portion 12 .
[0020] It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
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A roll formed sheet metal grid runner, and method of its manufacture, for a suspended ceiling grid having indexing tabs stamped from a central web of the runner profile, the tabs being effective to reliably locate ceiling panels and, when the grid runner is nested with other identical runners in a package, avoid marring of visible surfaces.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to softside luggage case construction, specifically luggage cases sized to be carried on into the cabin of a commercial aircraft by the traveler. More specifically, this invention relates to luggage cases sized to fit beneath the aircraft seat directly in front of the passenger. In many instances the traveler has no choice but to place his or her carry-on luggage in the extremely restricted space beneath the passenger seat immediately in front of the traveler. This space must also accommodate the feet of the passenger. For tall passengers, this is a major problem. The passenger must put his or her feet on either side of the carry-on luggage case stowed in this precious space or place his or her feet on the case itself. For shorter passengers, it is often an advantage to have carry-on luggage on which to place ones' feet to create a comfortable position and to rest ones' feet or legs.
[0002] It is an object of this invention to accommodate both or all passengers to optimize the use of the space below the seat immediately forward of the passenger, as well as to accommodate bottles and containers that may otherwise more easily spill by providing a shelf space within this carry-on sized luggage case to position a bottle or container at about 45° from a horizontal plane, whether the case is in the stowed position (that is, lying down) below the mentioned passenger seat or standing erect on its wheels and/or glides as when the case is being towed or wheeled on the provided wheels typical for such luggage cases.
BRIEF DESCRIPTION OF THE FIGURES
[0003] FIG. 1 is a perspective view of the luggage case according to this invention.
[0004] FIG. 2 is right side view thereof.
[0005] FIG. 3 is a front view thereof.
[0006] FIG. 4 is the left side view thereof.
[0007] FIG. 5 is a top view of the luggage case.
[0008] FIG. 6 is a back view thereof.
[0009] FIG. 7 is a view of the carry-on case in its stowed position with the flexible lid portion open to expose the specially slanted shelf arrangement.
[0010] FIG. 8 is a closer view thereof.
[0011] FIG. 9 is a similar view with the self-hinging zip door fully open to expose the entire main packing compartment.
[0012] FIG. 10 shows the case in a similar configuration to FIG. 8 but with the case in a vertical position.
[0013] FIGS. 11 A, B, and C illustrate three conditions of use that take advantage of the innovative features of this preferred embodiment.
[0014] FIG. 12 is a perspective view of a second embodiment of the present invention including a dually accessible compartment that can be opened from a top side or a bottom side.
[0015] FIG. 13 is a right side thereof.
[0016] FIG. 14 is a front view thereof.
[0017] FIG. 15 is the left side view thereof.
[0018] FIG. 16 is a back view thereof.
[0019] FIG. 17 is a top view of the luggage case.
[0020] FIG. 18 is a view of the carry-on case as it would appear in a stowed position either underneath a passenger seat or in an overhead compartment.
[0021] FIG. 19 is a closer view of the dually accessible compartment.
[0022] FIG. 20 shows the luggage case in an upright position with the main packing door open and hinged from the side.
[0023] FIG. 21 is a closer view thereof.
[0024] FIG. 22 is a closer view of the main packing door showing how the main packing compartment can be easily accessed even when the carry-on is in a stowed position.
[0025] FIG. 23 is a close up view of an organizing feature within the main packing compartment.
[0026] FIGS. 24 and 25 show the case in a stowed and upright position respectively.
[0027] FIGS. 26 through 29 illustrate another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] The case 2 is constructed in the known manner using a fabric, preferably textile fabric, outer covering. Plastic sheets 4 stabilize the overall shape of the case 2 and conventional wheels 6 and carry handle 8 and/or towing handle (not shown) permit the case to be towed on a pair of corner mounted wheels 6 as shown in the figures. Wheels 6 could comprise castor wheels. Inside the case 2 there is a specially designed organizing feature 12 , specifically one and preferably two stiffened dividers 14 which are mounted at approximately 45° from the horizontal or stowed position ( FIGS. 11B and C for example) as well as 45° from the vertical position (when the case 2 stands on its wheels 6 and glides 7 as in FIG. 11A for example). These dividers 14 help support and position one or more containers 16 , such as containers 16 used to hold liquid refreshment during a flight, cosmetics, snacks, medication bottles and the like. Of course, it should be understood by one of ordinary skill in the art that case 2 can comprise any type of storage and/or transport vessel, including backpacks, messenger bags, totes, purses, briefcases, or any other type of storage and/or transport device. Case 2 may be manufactured with the exclusion of wheels and can be transported by any other mechanism including shoulder straps, backpack straps, carry-handles, or other transport device.
[0029] The main packing door 18 of the case 2 has a special construction and operation, as can be seen in the figures. This packing door 18 preferably extends the entire front face of the luggage case 2 and is generally constructed in two sections. The first section follows a generally tapering side shape. This tapering portion or surface 22 has a stiffening polyethylene panel to permit it to help resist crushing or permanent bending when the passenger's feet are placed on these surfaces. The packing door 18 also has a flexible hinge portion 24 connecting this tapering portion 22 with the rest of the main packing door 18 . This permits this door 18 to be flipped open as shown in FIG. 8 to permit access to the 45°-mounted slanting shelf area, created by dividers 14 , within the main packing compartment 26 . Thus, access can be had without removing the case 2 from its stowed position beneath the passenger seat 28 immediately in front of the traveler. The rest of the main packing door 18 is constructed of layers of textile fabric on the inside and outside and preferably includes another small compartment 30 with zipper access 32 (see FIG. 2 ). Small compartment 30 includes inner pouches of various materials and sizes. Otherwise the construction of the case 2 is typical and construction techniques are well known throughout the luggage industry, using polyethylene sheet to give resilient stiffness to the overall door 18 . Preferably, at least the tapering portion 22 of the door 18 further includes a layer of foam padding with a pleasing texture or ribs 34 sewn or molded in to permit a comfortable rest for the stocking feet of the traveler.
[0030] The main packing door 18 may also comprise on its inner surface an upper pocket 36 and a lower pocket 38 . Upper and lower pockets 36 and 38 may comprise any shape or depth, and may comprise any material including solid textile or mesh material. Pockets 36 and 38 may be open pockets or they may be closed by zippers 40 . Main packing door 18 defines main packing compartment 26 and is secured by zipper 32 . Referring to FIG. 4 , towing handle is concealed by back pouch 42 . Back pouch 42 is surrounded by zippers 32 and may accommodate packed items of the user. Back pouch 42 may vary in size and shape and may include a multitude of additional inner pouches.
[0031] FIGS. 12 through 25 illustrate a second embodiment of the present invention. An advantage of the present invention is a dually accessible compartment 44 that is shown in closer detail in FIG. 19 . As shown in FIG. 12 , the luggage case 2 can comprise all of the above-mentioned features in a variety of visual manifestations. For example, tapered portion 22 can also be defined by a padded front panel as shown in FIGS. 12 through 25 . Tapered portion 22 is tapered such that not only does case 2 fit comfortably underneath the forward passenger seat 28 , but also neatly resides in the overhead compartment by shoving the case 2 tapered-end first into the overhead bin. The contents of case 2 can be accessed while the case 2 is stowed in the overhead compartment by opening a bottom zipper 46 that defines dually accessible compartment 44 . Thusly, dually accessible compartment 44 can be accessed from the bottom by opening bottom zipper 46 , or accessed from the top when in an upright position, by opening zipper 32 . A securing feature 48 is provided to lock bottom zipper 46 in place, helping to remind the user to secure the contents of dually accessible compartment 44 while the case 2 is being towed or stored upright. In this embodiment of the present invention, securing feature 48 comprises a hook and snap mechanism. Of course, other securing mechanisms may be used to secure the bottom zipper 46 . Such securing mechanisms may include hook and loop fasteners, buttons, slots and straps, or any other securing mechanism. Dually accessible compartment 44 includes additional pouches of various sizes and material.
[0032] FIG. 19 illustrates a close up view of the accessibility of dually accessible compartment 44 . Case 2 can be stored underneath the forward passenger seat 28 with tapered portion 22 facing the passenger, or with the bottom opening of the dually accessible compartment 44 facing the passenger. In either configuration, the contents of the present invention are much more easily accessible than those contents store in a conventional carry-on.
[0033] As shown in FIG. 13 , a second carry handle 8 is provided on the right side of case 2 . In this embodiment of the present invention, the main packing door 18 is self-hinged from the side of case 2 . It should be understood by one of ordinary skill in the art that the length and position of hinge 24 can vary. For example, side hinge 24 could be shorter, so that main packing door 18 could still be easily bent back by a passenger while the case 2 is stored under the forward passenger seat 28 . The passenger would need only slightly open zipper 32 . Of course, the location of the main packing door hinge 24 can be moved any where along case 2 . For example, main packing door 18 can be hinged from the bottom as discussed previously with regard to the descriptions of FIGS. 1 through 12 . Conversely, hinge 24 could be positioned on a corner allowing main packing door 18 to be opened horizontally.
[0034] As shown in FIGS. 20 through 25 , this second embodiment of the present invention incorporates organizing feature 12 . The organizing feature comprises one modular unit that includes a shelf area created by dividers 14 . This unique shelving area allows items such as water bottles 16 to remain slightly upright whether the case itself is laying down or upright. In all embodiments of the present invention, the organizing feature 12 may be removable from case 2 , or it may be fixed permanently within the case 2 . Organizing feature 12 could be sewn into the case 2 , or attached by other means including glue, staples, pins, etc. Additionally, dividers 14 may be individually removed from either a permanent or removable organizing feature 12 . Organizing feature 12 may incorporate a slot (not shown) to accommodate the mechanism of the towing handle (not shown). Organizing feature 12 is attached to the main packing compartment 26 by a system of snaps 50 . Of course, other mechanisms could be used to detachably affix the organizing feature 12 to main packing compartment 26 , including hook and loop fasteners and so on. Snaps 50 are sewn to the sides and/or bottom of organizing feature 12 and attach to mating eyes (not shown) that are sewn onto the material of the main packing compartment 26 . Dividers 14 include elastic strips 52 to further secure personal items in an upright position. Any other securing methods could be incorporated into dividers 14 . Such mechanisms may include basting, pouches, etc.
[0035] FIGS. 26 through 29 illustrate a third embodiment of the present invention. The case shown in FIGS. 26 through 29 incorporates features of both the first and second embodiments. The case 2 in these figures incorporates a tapered portion 22 that also includes ribs 34 . Case 2 further includes an all-sided accessible compartment 60 . Referring to FIG. 28 , all-sided accessible compartment 60 is defined by a self-hinging textile panel 45 that is Approximately 2 inches in length. Self-hinging textile panel 45 is affixed directly to the textile panel that defines all-sided accessible compartment 60 . This minimal hinge connection 45 permits access to the interior of all-sided accessible compartment 60 from all normal sides of the compartment including a top side, both the vertical sides, and from the bottom side as well. This valuable feature permits the traveler to store case 2 in any location on an aircraft, including an overhead compartment, the space below a passenger seat, or other location, while still being able to access the contents of all-sided accessible compartment 60 without having to remove the case 2 from its place. Of course, the sides of all-sided accessible compartment 60 may include a folding gusset panel (not shown). In addition, a mini compartment 54 is included in which a passenger may store essential items.
[0036] The present invention therefore provides a method and system for easily accessing items stored in a stowed case 2 by including a tapered portion 22 , a smartly placed door hinge 24 , and a dually accessible compartment 44 .
[0037] Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example, and changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.
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Luggage cases that are sized and shaped to be carried on to the passenger compartment of a commercial airplane are called carry-on luggage cases. Cases small enough to fit below the passenger seat 28 immediately in front of the traveler must be very small and compact and generally interfere with comfortable placement of the passenger's feet during travel. The disclosed luggage case 2 includes a tapering reinforced portion 22 of the main packing door 18 on which a passenger may wish to place or rest his or her feet during travel. This main packing door 18 is constructed to bend and open to give access to a specially designed slanting shelf area 12 where a bottled drink 16 or cosmetics can be easily accessed without removing the case 2 from its stowed position beneath the front passenger seat 28.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. Provisional Application No. 61/020,592 filed on Jan. 11, 2008, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The field of the invention relates generally to protective shields for isolating selected portions of construction and remodeling projects, and more specifically to a tool, a kit and methods for applying and adhering a protective film to a surface.
[0003] Protective films and covers, sometimes referred to as “shields” are widely utilized in the construction and remodeling industry to isolate, for example, finished elements and features on a job site that are proximate to, or in the midst of, unfinished elements and features on the job site. By virtue of such shields, some elements and features on the job site may be preserved and protected in good condition while work may be conducted in nearby locations. The shields prevent protected surfaces from being soiled, stained, marred, scuffed, scratched or otherwise adversely impacted by construction or remodeling activities. For certain items and surfaces, existing shield materials can be difficult to properly apply and install and improvements are desired.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one embodiment, an applicator tool for applying an elongated protective film material to a surface to be protected is disclosed. The protective film material comprises a sheet of solid film continuously wound upon itself in a roll for a plurality of turns. The protective film material has an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface. The applicator tool comprises a film mounting portion adapted to engage the roll of protective film material and facilitate rotation of the roll of protective film material on the surface to be protected when the exposed tacky surface of the roll is in direct contact with the surface to be protected. A handle portion is coupled to the film mounting portion for moving the film mounting portion relative to the surface to be protected, thereby rotating the film mount and adhering the tacky surface to the surface to be protected when the handle is moved to advance the roll of protective film material in a predetermined direction.
[0005] Optionally, the film mounting portion may engage a central aperture in the roll of material. The film mounting portion may be adapted to support the roll from only one side of the roll. The surface to be protected may be selected from the group of a carpeted floor, a wood floor, a tile floor, a concrete floor, a laminate floor, a vinyl floor, a wall, a window, a step, a piece of furniture, and a countertop. The handle portion may be extendable and retractable to adjust an axial length of the handle.
[0006] In another embodiment, a hand held surface shield applicator tool is disclosed. The applicator tool comprises a handle portion configured to be gripped with a single hand of a user; a film mounting portion rotatably coupled to the handle portion; and an elongated protective film material continuously wound upon itself in a roll for a plurality of turns. The protective film material has an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface. The roll is mounted on the film mounting portion to facilitate rotation of the roll when the exposed tacky surface of the roll is in direct contact with a surface to be protected, and the handle is movable relative to the surface to be protected to simultaneously rotate the roll and adhere the tacky surface to the surface to be protected, thereby providing an elongated shield on the surface to be protected. The shield has at least a length corresponding to a plurality of turns of the roll.
[0007] Optionally, the film mounting portion may be slidable into a central aperture in the roll of material. The film mounting portion may support the roll from only one side of the roll. The surface to be protected may be selected from the group of a carpeted floor, a wood floor, a tile floor, a concrete floor, a laminate floor, a vinyl floor, a wall, a step, a window, a piece of furniture, and a countertop. Only the tacky surface of the roll may engage the surface to be protected as the handle portion is moved. The surface to be protected comprises a substantially planar surface that is one of vertically oriented or horizontally oriented.
[0008] In another embodiment a kit for shielding a substantially planar surface is disclosed. The kit comprises an applicator tool having a handle portion defining a hand grip and a film mounting portion that is rotatable relative to the hand grip. At least one elongated protective material is provided that is continuously wound upon itself in a roll for a plurality of turns. The protective film material has an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface, wherein the roll is removably mountable to the film mounting portion to simultaneously rotate the roll in direct engagement with the substantially planar surface to be protected and adhere the tacky surface to the substantially planar surface to be protected, thereby providing an elongated shield on the surface to be protected having at least a length corresponding to a plurality of turns of the roll.
[0009] Optionally, the film mounting portion may be slidable into a central aperture in the roll of material. The film mounting portion may extend from only one side of the roll. The tacky surface of the roll may engage the substantially planar surface, and the film mounting portion may not engage the substantially planar surface. The substantially planar surface may comprise one of a vertically oriented surface and a horizontally oriented surface. The substantially planar surface may comprise one of a floor, a wall, a step, a window, a countertop and a piece of furniture.
[0010] A method of shielding a surface to be protected on a construction or remodeling job site is also disclosed. The method comprises providing a roll of elongated protective film material continuously wound upon itself for a plurality of turns, the surface shield material having an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface. The method further comprises providing a hand-held applicator tool having a handle portion and a film mounting portion; mounting the roll to the film mounting portion; directly engaging the tacky surface of the roll to the surface to be protected; and guiding, using the handle portion, the tacky surface of the roll over the surface to be protected in a predetermined direction, thereby simultaneously rotating the roll and adhering the tacky surface to the surface to be protected, thereby providing an elongated shield over the surface to be protected.
[0011] Optionally, guiding the tacky surface of the roll comprises guiding the tacky surface of the roll along a substantially planar surface, the planar surface extending in one of a vertically oriented plane and a horizontally oriented plane.
[0012] In another embodiment, a shield for protecting a surface is disclosed. The shield comprises a carrier tube comprising a central aperture and an external surface and an elongate protective film material. The film material is continuously wound upon itself in a roll for a plurality of turns and an inner surface of the roll is coupled to the carrier tube external surface. The protective film material has an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface. The protective film material is less than about 24 inches wide and is configured to separate from the roll and adhere to a surface to be protected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a known adhesive film and applicator for protecting a surface.
[0014] FIG. 2 is a perspective view of another type of protective film for protecting a surface.
[0015] FIG. 3 illustrates an applicator tool for the film shown in FIG. 2 in accordance with an exemplary embodiment of the invention.
[0016] FIG. 4 is a side elevational view of the applicator tool shown in FIG. 3 in use to apply the shield.
[0017] FIG. 5 is a perspective view of another embodiment of an applicator tool in a first operating condition.
[0018] FIG. 6 is an elevational view of the tool shown in FIG. 5 in a second operating position.
[0019] FIG. 7 is an exemplary flowchart of a method of shielding a surface with the applicator tool.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The following detailed description illustrates embodiments of the invention by way of example and not by way of limitation. It is contemplated that the invention has general application to protective shields for isolating selected portions of construction and remodeling projects, and more specifically to a tool, kit and methods for applying and adhering a protective film to a surface.
[0021] Exemplary embodiments of applicator tools, kits and methods for applying adhesive protective films for selected surfaces on construction and remodeling job sites are described in detail below. The applicators, tools, kits and methods facilitate secure and reliable placement and application of the protective films with minimal time and by a single person. The tools, kits and methods are applicable to a variety of different sizes of films for protecting a wide variety of surfaces on a job site.
[0022] A. Introduction
[0023] It is often desirable to shield certain elements and features on a construction or remodeling site from potentially adverse effects while work is being conducted. As one example, it is often desirable to protect an existing floor, or a newly installed one, from construction traffic, dust, tools, paint and other construction materials that may otherwise soil, negatively impact or ruin a carpeted, wood, laminate, vinyl, or tiled surface. As another example, it is often desirable to shield and protect a newly installed countertop, or one in good condition, during construction and remodeling activities in the vicinity of the countertop.
[0024] Some protective films that are suitable to shield such surfaces are available in rolls wherein protective material is wound upon itself for compact storage and transport to a job site. When needed, the rolls may be placed on designated surfaces to be protected by unrolling the material on the designated surfaces to provide a protective barrier shield on the designated surfaces. The shields are removable when work is complete or when the shielding is no longer necessary.
[0025] Certain types of protective films are adhered to the surfaces to be protected on the job site so that their position can be maintained, and also to form a seal between the film and the surface being protected. While such adhesive shields are beneficial to protect such surfaces, they can be inconvenient, and sometimes difficult, to install.
[0026] FIG. 1 is a perspective view of a known adhesive film 100 and applicator 102 for protecting a surface 104 , such as, for example only, a carpeted floor on a job site. The film 100 is generally provided as a single, solid, and continuous sheet of material that is continuously wound upon itself in a roll 106 for a plurality of turns. The roll 106 provides for convenient and compact storage prior to use of the film 100 . When unrolled, the film 100 provides a strip of a thin skin or membrane on the surface to be protected 104 to shield and protect it from adverse effects of surrounding work in the area of the film 100 . Multiple strips of film 100 may be provided side-by-side or overlapping one another to shield larger areas of the surface 104 to be protected on the site. The film 100 may be fabricated from a variety of known materials and is generally available in a variety of sizes, such as 24 inch, 36 inch and even 48 inches in width W measured between lateral side edges 114 , 116 of the film 100 . The length of the film, measured generally perpendicular to the dimension W, may range from, for example, about 30 feet to 200 feet. The film 100 may be cut to any desired length by the user.
[0027] The film 100 is provided with opposing major surfaces 108 and 110 . The major surface 108 is provided with a pressure-sensitive adhesive that renders it tacky and adherent to the surface 104 to form a protective barrier seal with the surface 104 to be protected. The opposing major surface 110 of the film 100 does not include an adhesive and is not tacky. The roll 106 is wound such that the tacky surface 108 faces inwardly and the non-tacky surface 110 faces outwardly. That is, the non-tacky surface 110 is exposed on the outer surface of the roll 106 and the tacky surface 108 is not.
[0028] To assist with installing the film 100 , an applicator 102 has been provided that commonly includes a generally rectangular frame 112 that suspends the roll 106 above the surface 104 to be protected. A handle 120 extends from an upper portion of the applicator frame 112 , and the film 100 is partly unrolled from the roll 106 and drapes around a lower portion of the frame 112 such that the tacky surface 108 of the film passes under the lower portion of the frame 112 to engage it with the surface 104 to be protected. A person gripping the handle 120 may walk behind the frame 112 and push the frame 112 along the surface 104 to adhere the film 100 to the surface 104 . The lower portion of the frame 112 smoothly presses the tacky surface 108 to the surface 104 , and tension in the film 100 causes the suspended roll 106 to rotate in the direction of arrow B and release more of the tacky surface 108 for application to the surface 104 . Thus, the applicator 102 serves both to dispense the film 100 from the roll 106 and apply the film 100 to the surface 104 to be protected.
[0029] The applicator 102 presents a number of difficulties to certain users. The relatively large-sized rolls 106 (24 inch, 36 inch and 48 inch rolls) require a relative large and sturdy applicator 102 that can be costly, cumbersome to use, difficult to transport to a job site, and requires substantial storage space when not in use. The applicator 102 is convenient for large open settings such as industrial, commercial, and institutional facilities, but because of its size it is not well suited for smaller areas and settings, such as residential projects, having smaller areas and corners. The applicator 102 is therefore generally impractical for do-it-yourself projects and for occasional users of protective films.
[0030] The applicator 102 also is not well suited for certain applications. The size, weight, and bulk of the rolls 106 and applicator 102 renders it practically useless to apply film to vertical surface such as walls or windows, and also for some smaller horizontal floor surfaces and elevated horizontal surfaces from a floor, such as a countertop or stair step. It is not well suited for certain floor applications either, such as applying the film 100 to a floor that adjoins a wall that is to be painted, because the lateral edges 114 and 116 of the film 100 are inwardly spaced from the outer lateral edges of the applicator frame 112 , thereby leaving a small, and undesirable gap between one lateral edge 114 or 116 of the film 100 and the wall that is to be painted.
[0031] Still further, because of the size and bulk of the rolls 106 and the applicator frame 112 , it can be difficult for one person to properly install and suspend a roll 106 on the applicator frame 112 and to apply the distal end 118 of the film 100 to the surface 104 to be protected. That is, an assistant is often required to install and suspend a roll 106 of film 100 , drape it over the lower portion of the applicator frame 112 , and properly adhere the distal end 118 of the film 100 to the surface 104 and for an ensuing initial distance in the direction of arrow A until one operator can effectively push the applicator 102 alone to dispense and apply the film 100 for a desired distance. The need for multiple workers to install the film 100 consumes time and labor costs that may be more beneficially spent on other tasks.
[0032] For at least the above reasons, the rolls 106 and the applicator 102 are not very user friendly or practical to many potential users that desire to apply a protective film to surfaces on a job site. It would be desirable to provide an easier to use and more universally applicable applicator for a wider variety of applications of protective films on a job site.
[0033] FIG. 2 illustrates another type of protective film 130 for protecting a surface 132 on a job site. Like the film 100 described in relation to FIG. 1 , the film 130 in FIG. 2 is generally provided as a single, solid, and continuous sheet of material, such as polyethylene, that is continuously wound upon itself in a roll 134 for a plurality of turns for convenient and compact storage prior to use of the film 130 . When unrolled, the film 130 provides a strip of a thin skin or membrane on the surface to be protected 132 to shield and protect it from adverse effects of surrounding work in the area of the film 130 . Multiple strips of film 130 may be provided side-by-side or overlapping one another to shield larger areas of the surface 132 to be protected on the site. The film 130 is also available in a variety of sizes, such as 21 inch, 24 inch, 36 inch and even 48 inches in width W measured between lateral side edges 136 , 138 of the film 130 . The length of the film, measured generally perpendicular to the dimension W may range from, for example, about 30 feet to 200 feet. The film 130 may be cut to any desired length by the user.
[0034] Like the film 100 , the film 130 is provided with opposing major surfaces 140 and 142 . The major surface 140 is provided with a pressure-sensitive adhesive that renders it tacky and adherent to the surface 132 to form a protective barrier seal with the surface 132 to be protected. The opposing major surface 142 of the film 130 does not include an adhesive and is not tacky. Unlike the roll 106 shown in FIG. 1 , the roll 134 is wound such that the tacky surface 140 faces outwardly and the non-tacky surface 142 faces inwardly. That is, the tacky surface 140 is exposed on the outer surface of the roll 134 and the non-tacky surface 142 is not. That is, compared to the roll 106 of FIG. 1 , the roll 134 is reversed or oppositely wound with the tacky surface 140 exposed on the outer exterior surface of the roll 134 .
[0035] The reverse winding of the roll 134 is advantageous over the roll 106 in some aspects. The tacky surface 140 of the roll 134 may be directly engaged to the surface 132 to be protected, and the applicator 102 shown in FIG. 1 and its accompanying drawbacks may be avoided. That is, the roll 134 may be simply placed in surface engagement with the surface 132 to be protected, and rotated by the user about the axis 144 of the roll 134 in the direction of arrow B to unwind or unroll the film 130 on the surface 132 . The roll 134 is much more amenable to application by a single person than the roll 106 .
[0036] The roll 134 is not without drawbacks, however. The exposed tacky surface 140 on the outer surface of the roll 134 can make it somewhat difficult, or unpleasant, to rotate about the axis 144 by hand in an even manner. In floor installations, the roll 134 may be unrolled with a person's feet, but this can be difficult to do in an even manner, often resulting in undesirable voids and incomplete adherence and surface engagement of the film 130 with the surface 132 to be protected. Because of the size of the roll 134 , it may very well require more than one person to reliably and uniformly adhere the film 130 to the surface 132 to be protected, and the roll 134 is not very practical, if at all, for relatively small surfaces. It would be difficult, to say the least, to use the roll 134 on an inclined or vertically oriented surface on a job site.
[0037] B. Inventive Embodiments of Protective Film Applicators, Kits and Methods
[0038] Unique and advantageous embodiments of protective film applicators, tools, and methods of shielding surfaces that may be used more or less universally across a wide variety of different surfaces on a job site are disclosed hereinafter. The applicators and tools may be provided at relatively low cost to users, and the methods may be capably, easily, and quickly performed by a single person. The uniqueness, benefits and advantages of the tools, kits and methods will in part be apparent and in part will be pointed out in the discussion below.
[0039] FIG. 3 illustrates an exemplary applicator tool 150 that overcomes numerous disadvantages in the art, including but not limited to those discussed above. The applicator tool 150 generally includes a handle portion 152 , a film mounting portion 154 , and a roll 156 of protective film 160 that may be unrolled, using the applicator tool 150 as explained below, to cover and shield a substantially planar surface 162 on a construction or remodeling job site.
[0040] The handle portion 152 in the illustrative embodiment depicted in FIG. 3 defines a contoured hand grip 164 that may be conveniently gripped with one hand. The handle portion 152 may extend as shown in FIG. 3 in a generally perpendicular orientation to the longitudinal axis 166 of the roll 156 , although in other embodiments, the handle portion 152 may be oriented differently relative to the roll 156 , such as obliquely to the roll axis 166 or parallel to the axis 166 if desired. A variety of shapes, dimensions, and configurations of the handle portion 152 are possible in further and/or alternative embodiments without departing from the scope and spirit of the invention, and while still obtaining the benefits of the inventive concepts disclosed herein.
[0041] Also, as shown in FIG. 3 , the handle portion 152 is approximately centered along the longitudinal axis 166 of the roll 156 , although in another embodiment the handle could be positioned elsewhere as desired.
[0042] The film mounting portion 154 is rotatably mounted to the handle portion 152 such that the film mounting portion 154 may rotate about the roll axis 166 in the direction of arrow C when the handle portion 152 is moved relative to the surface 162 to be protected in the direction of arrow D. The film mounting portion 154 extends from and is supported by the handle portion 152 on only one lateral end 167 of the roll 156 , leaving the opposing end 168 of the roll 156 generally free and clear of any obstruction. As such, the film 160 can be applied with the applicator tool 150 to, for example, a horizontal surface at a location where it adjoins a vertical surface such as a wall or trim piece, without leaving a gap on the surface to be protected by abutting the free lateral end 168 of the roll 156 immediately proximal to or against the vertical surface.
[0043] The roll 156 , similar to the roll 134 described in relation to FIG. 2 , includes opposing major surfaces 170 and 172 . The surface 170 is provided with a known pressure sensitive adhesive rendering the surface 170 to be tacky, and the tacky surface 170 is exposed on the outer exterior surface of the roll 156 . The tacky surface 170 is appropriately formulated to be easily removed and peeled off the surface 162 to be protected when no longer needed without leaving any residue on the surface 162 . The surface 172 is not tacky and is outward facing and exposed when the film 160 is applied and adhered to the surface 162 to be protected. The non-tacky surface 172 may be finished with non-slip coatings and the like as desired. The film 160 is provided in a solid and substantially continuously extending sheet of material, such as a polyethylene blend or equivalent material that is tear resistant and puncture resistant. The film 160 may be transparent or opaque in different embodiments.
[0044] Like the roll 134 shown in FIG. 2 , the sheet of film material is wound upon itself for a plurality of turns about the roll axis 166 . The roll 156 may be provided on a carrier tube 174 fabricated from cardboard, for example, or another suitable material known in the art. Unlike the roll 134 , the roll 156 is substantially smaller and lighter. As an example, in one embodiment the roll 156 is approximately 9 and ⅛ inches wide and has an axial length of about 50 feet, thereby significantly reducing the size and weight of the roll 156 , and the complexity and difficulties of installing the film. Of course, other widths and lengths of film may be used, whether greater or smaller than those specifically identified above, in other embodiments. For example only, the roll 156 may vary from about one inch wide to about twenty-four inches wide with lengths ranging from about one foot to over fifty feet. Of course, other widths and lengths of film may be used, whether greater or smaller than those specifically identified above, in other embodiments.
[0045] The roll 156 , and more specifically a central aperture of the carrier tube 174 , may be fitted to the film mount portion 154 of the applicator tool 150 with slight interference and slip-fit engagement between the carrier tube 174 of the roll 156 and the film mounting portion 154 . Rotatable elements and mechanisms suitable for use as the film mounting portion 154 are well known and specific discussion thereof will be accordingly omitted. The roll 156 may be slip fit on the film mounting portion 154 with force applied along the roll axis 166 in the direction of arrow E, and removed with force applied along the roll axis 166 in the direction of arrow F opposite to the direction of arrow E.
[0046] Referring now to FIG. 4 , the handle portion 152 may be gripped by a user and the outer tacky surface 170 exposed on the outer exterior surface of the roll 156 may be directly engaged, with surface-to-surface engagement, with the surface 162 to be protected on a job site. With slight pressure to maintain the roll 156 in contact with the surface 162 to be protected, and with slight force applied to the handle portion 152 to move the applicator 150 in a direction parallel to the surface 162 to be protected (the direction of arrow D in FIG. 4 ), the roll 156 may be simultaneously rotated in the direction of arrow C and pressed into firm, substantially even and uniform adherence with the surface 162 to be protected. As such, the thin film 160 is rather easily unrolled into a planar orientation and reliably secured to the surface 162 to be protected.
[0047] The applicator tool 150 , including the roll 156 is lightweight and may be easily gripped and used by one person to apply the film 160 . The applicator tool 150 also is versatile and may be used to apply film 160 to a vertically oriented surface 180 (shown in phantom in FIG. 4 ). The tool 150 is also amenable to use on elevated surfaces such as countertops, table tops, other furniture pieces, and stair steps. The relatively small size of the applicator tool 150 allows for use in a variety of spaces large and small, including corner areas and intersections of vertical and horizontal surfaces.
[0048] Special formulations of film material may be provided in rolls 156 of various sizes in various embodiments for use on surfaces with different properties and textures, including but not limited to carpeted surfaces of varying piles, wood surfaces, laminate surfaces, vinyl surfaces, metallic surfaces, tile surfaces (e.g., glass, ceramic and stone), countertop surfaces (e.g., granite, marble, veneer, laminate), concrete and cement surfaces, painted surfaces, windows and doors of all types, and upholstery and fabrics. Still other surfaces could be protected with specifically formulated film materials optimal for specific attributes of the surfaces. An inventory of film materials may be maintained and universally applied with the same applicator tool 150 . The inventory may be color-coded, for example, to easily distinguish one type of roll for another. Alternatively, special purpose applicator tools having optimized shapes, sizes, and colors, but otherwise comparable functional features, may likewise be developed for use on specific surfaces and specific locations.
[0049] Cutting edges and the like may be provided in further alternative embodiments of the inventions to facilitate the film 160 being cut to length for a specific project. Otherwise, the film 160 may be cut with a utility knife or other tool separate from the applicator tool 150 .
[0050] Applicator tools 150 and protective film rolls 156 may be provided to users as kits in another aspect of the invention. For example, an applicator tool 150 may be packaged and sold together with, say, three film rolls 156 of the same or different types. The user may select a roll 156 for a project and mount it the applicator tool 150 for use, and when the roll is consumed the user may easily replenish the tool 150 with another roll 156 , or exchange one roll with another for protecting different surfaces.
[0051] FIGS. 5 and 6 illustrate another embodiment of an exemplary applicator tool 200 that in some aspects is similar to the applicator tool 150 shown in FIGS. 3 and 4 . Like features in FIGS. 3 and 4 are therefore designated with like reference characters in FIGS. 5 and 6 .
[0052] The applicator tool 200 includes the film mounting portion 154 and roll 156 of adhesive film as described above. Unlike the tool 150 having a relatively short and truncated handle portion 152 , the applicator tool 200 includes an extendible handle portion 202 having a first section 204 defining a hand grip for a user, a second section 206 that telescopes within the first section 204 , and a third section 208 that telescopes within the second section 206 so that the handle portion 202 can be extended ( FIG. 6 ) or retracted ( FIG. 5 ) to different lengths as desired by a user. Twist-type couplers 210 and 212 , familiar to those in the art, may be utilized to secure or release the telescoping sections 206 and 208 to obtain a user-selected length of the handle portion 202 appropriate for a given job. The extendible handle portion 202 may be particularly advantageous for applying the protective films to floor surfaces, wall surfaces, and windows, for example, to reduce the effort required by the user to install the film.
[0053] FIG. 7 is an exemplary flowchart of a method 220 of shielding a surface with an applicator tool, such as the tools 150 and 200 described above. The method includes providing 222 a roll of elongated protective film material, such as a roll 156 described above, that is continuously wound upon itself for a plurality of turns, and having an exposed tacky surface on an exterior of the roll and a non-tacky surface opposite the tacky surface. The method also includes providing 224 a hand-held applicator tool having a handle portion and a film mounting portion. The steps of providing 222 and 224 the roll and the applicator tool may occur at the job site or at another location, may not involve a sale of either the roll or the applicator tool, and need not occur at the same time or in any particular order or sequence to perform the steps 222 and 224 .
[0054] Once provided, the user may mount 226 the roll to the film mounting portion of the applicator tool as previously described, and directly engage 228 the tacky surface of the roll to the surface to be protected. The user then may guide 230 , using the handle portion, the tacky surface of the roll over the surface to be protected in a predetermined direction, thereby simultaneously rotating the roll and adhering the tacky surface to the surface to be protected, and providing an elongated shield over the surface to be protected. After cutting 232 to a desired length to complete the shield, the user may choose another surface to be protected and return to step 228 .
[0055] If desired, the user may remove 234 the roll from the tool, select 236 another roll of film, and return to step 226 .
[0056] A variety of substantially planar surfaces, whether in horizontal planes, vertical planes or sloped planes that are oblique to vertical and horizontal planes, may be preserved and protected using the above-described methodology.
[0057] It is understood that additional steps, and omission and modification of the steps described are contemplated. For example, the tool may be provided with the roll mounted thereon so as to render the steps 222 , 224 , and 226 unnecessary. As another example, additional steps of extending and retracting the tool handle portion may be performed in connection with the method between any of the illustrated steps. Further additional steps that are contemplated include cleaning of the surface to be protected prior to installing the protective film to ensure optimal bonding of the film, and removing the film after construction or remodeling work is completed. If desired, more than one applicator tool may be provided so that more than one person can apply protective film.
[0058] The benefits of the invention are now believed to have been amply demonstrated along with how disadvantages in the art are overcome. The applicator tools, kits, and methodology disclosed may be provided and performed at relatively low cost with much appeal to professional contractors and workers, as well as lay people seeking to undertake home improvements and renovations on their own.
[0059] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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A tool, kit, and method for applying an elongated protective film material to a surface. The tool includes a roll of sticky protective film wound so that the sticky surface is on the outside of the roll, a mounting portion to hold the roll while letting it rotate and a handle for ease of guiding the tool during use.
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BACKGROUND OF THE INVENTION
The present invention relates generally to glue guns, and more particularly, to a gas heated glue gun with self-contained gas chamber.
Hot melt glue guns have been widely used in repairing chairs, restoring furniture, and laying electrical circuits, as well as bonding car carpets, laying tiles and gluing of wire netting, etc. The power supply to such a conventional glue gun is often an electrical current supply which is indeed very convenient in normal working conditions, but not when gluing procedures are to be completed at an isolated locality where power an electrical power supply is not accessible.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a glue gun having its heat supplied by gas combustion.
A further object of the present invention is to provide a glue gun with self-contained gas chamber and ignition system.
Another object of the present invention is to provide a glue gun which is adapted to be used suitably and conveniently at an isolated locality where electricity is not accessible.
These and additional objects, if not set forth specifically herein, will be readily apparent to those skilled in the art from the detailed description provided hereinbelow, with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a glue gun in accordance with the present invention;
FIG. 2 is an enlarged, fragmentary view of the gas control means in accordance with the present invention;
FIG. 3 is an elevational view of the glue gun shown in FIG. 1, the casing having been broken away for clarity, showing the trigger when it is fully extended; and
FIG. 4 is an elevational view of the glue gun, with the casing broken away and with the trigger fully depressed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and initially to FIGS. 1 and 3, the glue gun, generally indicated by reference numeral 11, includes a body portion 12 and a handle portion 13. Projecting from the body portion 12 is a gluing member 14. The gluing member 14 includes a tube 15 having a gluing tip 16 and a leak-proof cone 17. A metal stand 18 is provided on a lower side of the body portion 12 to support the glue gun 11 immediately after use so as to prevent any undesirable contact between the hot gluing member 14 and the bench or floor which might be finely decorated. A window 19 is provided on one side of the body portion 12 for a protruder of a ring for controlling purpose which will be described more fully hereinbelow.
A melt cartridge 21 is provided within the body portion 12 proximate to the gluing member 14. A guiding conduit 22 that is open at both ends thereof is provided within the body portion 12, immediately adjacent to the melt cartridge 21, for receiving a glue stick 23.
A pivot 31 is provided on the interior of the body member 12. Rotatably positioned on the pivot 31 is a trigger 32. The upper end of the trigger 32 has a hole 33 and is in communication with a drawing means, generally indicated by reference numeral 41. The lower portion of the trigger 32 is in communication with a sparking means, generally referred to by reference numeral 51.
Drawing means 41 is activated by the trigger 32. The drawing means 41 is generally a shaft 42 having an end part 43 extending laterally. The laterally extending end part 43 inserts through the hole 33 of the trigger 32 so as to be in engagement therewith and is secured to the body member 12 in any suitable manner, such as securing to a circular socket formed on an inner surface of the body member 12 with the aid of a coil spring to stay in place, as depicted.
The shaft 42 includes a first notch 44 and a second notch 45 along its length, and an integrally perpendicularly formed pulling plate 46 at an end remote from the laterally extending end part 43. The first and second notches 44 and 45 are provided such that the drawing means 41 is held in some particular positions on the body member 12. This can be accomplished in any suitable manner, such as forming a rectangular socket 47 on an inner face of the body member 12, wherein the rectangular socket 47 has a triangular body 48 therein, as depicted. The triangular body 48 is usually spring enforced so as to stay secure. The pulling plate 46 is a flat plate having a hole 49 thereon for encircling a gas control means, generally referred to by reference numeral 71.
Sparking means 51 is also activated by the trigger 32. Sparking means 51 includes a stop plate 52 in contact with the trigger 32, a coil 53, a coil retainer 54 for retaining the coil 53, a crystal 55 encircled by the coil 53, a container 56 for retaining the crystal 55, and two distinct wires 57 and 58 extending from the coil 53. The extending wire 57 extends to a location proximate to an end of a gas control means 71; the extending wire 58 is preferably electrically connected to the gas control means 71 at another end. The gas control means 71 will be described in detail more fully hereinbelow.
The glue gun 11 is provided with a gas supply means, generally indicated by reference numeral 61. The gas supply means 61 is located inside the barrel of the glue gun 11, preferably at the location with respect to the handle portion 13. The gas supply means 61 is generally a gas chamber having an opening 62 at an upper side thereof. The gas supply means 61 further includes a gas nozzle 63 and a gas valve 64 at the bottom side thereof for filling or injecting gas thereinto. The opening 62 is, in turn, connected to the gas control means 71.
The gas control means 71 includes a first hose 72 having an end connected to the opening 62 of the gas chamber 61, as mentioned previously, and a second hose 73 having an end part provided with a nozzle 74. The second hose 73 is provided with a circumferential notch 75 therearound at a position proximate to the nozzle 74 such that the second hose 73 can be firmly fixed in the hole 49 of the pulling plate 46 of the drawing means 41 when the second hose 73 inserts into the hole 49, with the circumferential notch 74 being firmly caught by the pulling plate 46.
The gas control means 71 further includes an adjustable dial 76 covered with a ring 77 having a protruder 78. The protruder 78 projects from the body member 12 through the previously mentioned window 19 after installation of each components in the barrel of the device 11. The adjustable dial 76 is provided at the junction of the first hose 72 and second hose 73.
The way the first hose 72 and the second hose 73 are joined together is depicted most clearly in FIG. 2. The first hose 72 has a larger diameter; the second hose 73 has a smaller diameter. The second hose 73 is provided with an inlet 79 near its interconnection part with the first hose 72. A sleeve 80, substantially covered with the previously mentioned adjustable dial 76 and ring 77, is rotatably mounted on the second hose 73 and covers the inlet 79. The sleeve 80 has a helical flange 81 on its inner wall. The sleeve 80 is further provided with a plug 82 and an aperture 83 on its outer face. The portion of the sleeve 80 not covered by the adjustable dial 76 is covered by the first hose 72. The first hose 72 is internally provided with a plate 84 having an opening 85. The opening 85 is closeable by the plug 82.
Referring again to FIG. 1, a combustion chamber 91 is provided within the body member 12 at a location below the melt cartridge 21. The combustion chamber 91 includes a plurality of vents 92 for the purpose of heat dissipation. The sidewall of the combustion chamber 91 is preferably cushioned with a layer of asbestos (not shown) so as to protect the body portion 12 from being damaged by heat. The end part of the combustion chamber 91 is provided with a bore 93 in which a cylindrical tube 94 can be installed. The cylindrical tube 94 is provided so as to receive the nozzle 74 of the control hose 71.
With particular reference to FIGS. 3 and 4, the manner in which the glue gun 11 is manipulated or operated will now be described in detail.
When the glue gun 11 is not in use, the trigger 32 stays at its fully extended state, as depicted clearly in FIG. 3. The operator may operate the glue gun 11 by moving the trigger 32 to its rearmost position or its fully depressed state, as depicted in FIG. 4.
The stop plate 52 urges the coil retainer 54 in rearward direction and finally abuts against the container 56. This causes mechanical stress on the crystal 55 and produces a piezoelectricity. As previously mentioned, the gas control means 71 is electrically connected with the wire 58 and the terminal of the wire 57 is very close to the end part of the gas control means 71, thereby subatantially forming a "circuit". The small distance between the nozzle 74 and the terminal of the wire 57 acts as a spark gap. Thus, a spark is produced at the position near the combustion chamber 91, due to the polarization of the above-mentioned "circuit", when the trigger 32 is moved rearwardly.
The drawing means 41, which is also activated by the trigger 32, moves forwards. The triangular body 48 initially catching the first notch 44 now catches the second notch 45.
The gas control means 71, as previously mentioned, is in communication with the drawing means 41 which in turn is in communication with the trigger 32. Thus, the gas control means 71 is simultaneously activated by the action of the trigger 32.
The pulling plate 46, being drawn by the trigger 32, draws the second hose 73 forwards. With reference to FIG. 2 again, the plug 82 of the sleeve 80 detaches from the opening 85 of the plate 84 of the first hose 72, thereby forming a passage for the gas. Gas thus flows from the gas chamber 61 through the opening 62, the passage thus formed, the aperture 83, the air inlet 79, and finally, the nozzle 74 and enters the combustion chamber 91 for combustion.
The flow rate of the gas is substantially determined by the size of the inlet 79. The rotatable sleeve 80 is adjustable by fastening the protruder 78 of the ring 77 through the window 19. The helical flange 81 of the sleeve 80, being slidable around the second hose 73, may completely cover the inlet 79, or partially cover the inlet 79, or not cover the inlet 79 at all. When the helical flange 81 does not cover the inlet 7 at all, the flow rate of the gas is the maximum. When the helical flange 81 partially covers the inlet 79, then the flow rate may be determined by the area of exposure of the inlet 79, or the area of the inlet 79 not covered by the helical flange 81.
While the present invention has been explained in relation to its preferred embodiment, it is to be understood that various modifications thereof will be apparent to those skilled in the art upon reading this specification. Therefore, it is to be understood that the invention disclosed herein is intended to cover all such modifications as fall within the scope of the appended claims.
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A glue gun is provided, structured for the reception of a chamber that is a self-contained supply of gas for heating of glue. The operator can operate the glue gun by moving the trigger rearwards to produce a spark and to allow gas to flow from the gas chamber to the combustion chamber. The flow rate of the gas can be controlled by adjusting the protruder that projects from the window of the body portion.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. application Ser. No. 15/075,491, filed Mar. 21, 2016, which is a continuation of U.S. application Ser. No. 14/169,516, filed Jan. 31, 2014, now U.S. Pat. No. 9,293,064, which claims the benefit of U.S. Provisional Application No. 61/810,420, filed Apr. 10, 2013, all of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The present application relates generally to a device for simulating medical values.
[0004] Description of Related Art
[0005] Health care or patient care providers must be trained to use various medical devices and to perform diagnosis and treatment of patients. However, an individual playing the role of a patient in a training scenario cannot actually exhibit the vital signs or symptoms of a medical condition. For example, a patient actor cannot fake a high temperature, high blood pressure, or a blood glucose level. Moreover, the patient actors cannot truly respond to a treatment regimen such that their physical condition or vitals react to the treatment.
[0006] Furthermore, actual medical devices used for treating patients in real medical scenarios are often prohibitively expensive or otherwise unavailable for use in training situations. Moreover, these devices are configured to generate true readings and measurements, not provide readings or measurements for a specific training scenario. Health care or patient care providers, however, must still learn to use these devices to diagnose and treat patients.
SUMMARY OF THE INVENTION
[0007] Generally, provided is a device for simulating a medical value that provides a realistic training environment for health care or patient care providers. In one example, the simulated medical device can be a blood glucose simulator that simulates blood glucose levels, and can be configured to provide readings or measurements for one or more training scenarios. Disclosed is a simulated medical device that is less expensive to produce and/or operate than a corresponding medical device that performs in real medical situations readings or measurements.
[0008] According to a preferred and non-limiting embodiment, disclosed is a simulated medical device for providing a realistic training environment for health care or patient care providers that can include a visual display, a microprocessor connected to the visual display, and a memory connected to the microprocessor. The memory can store non-transitory computer readable program codes for operation of the microprocessor and one or more data values. The simulated medical device can further include a first actuator, connected between a power supply and the microprocessor, where in response to actuation of the first actuator, the microprocessor receives power from the power supply. The simulated medical device can further include a body housing the visual display, the microprocessor, the memory, and the first actuator. The body can further include a slot in the body, a light supported by the body, and a strip insertion sensor can be configured to provide to the microprocessor an indication of the presence of a test strip in the slot.
[0009] In another example, the first actuator can be a mechanical switch or a virtual switch displayed on the visual display by the microprocessor and operating under the control of the non-transitory computer readable program code.
[0010] In another example, the slot can be configured to receive internally at least a portion of the test strip.
[0011] In another example, the light can be positioned at a proximal end of the slot.
[0012] In another example, the simulated medical device can further include a second actuator connected between a power supply and the light. The light can illuminate in response to actuation of the second actuator.
[0013] In another example, the second actuator can be a mechanical switch or a virtual switch displayed on the visual display by the microprocessor operating under the control of the non-transitory computer readable program code.
[0014] In another example, each data value can be a simulated medical value or text. In another example, the microprocessor, running under the control of the non-transitory computer readable program code, can perform the following steps: in response to receiving power from the power supply, the microprocessor can display on the visual display a third actuator; in response to actuation of the third actuator, the microprocessor can display a prompt on the visual display; in response to the strip insertion sensor sensing at least a portion of the test strip internally received in the slot, initiates a pre-set timer countdown; and in response to the pre-set timer countdown completion, the microprocessor can display a first simulated medical value of the plurality of simulated values.
[0015] In another example, the microprocessor, running under the control of the non-transitory computer readable program code, can further perform the following steps: in response to another actuation of the third actuator, the microprocessor can display another prompt on the visual display; in response to the strip insertion sensor sensing at least a portion of the test strip internally received in the slot, initiates a pre-set timer countdown; and in response to the pre-set timer countdown completion, the microprocessor can display a second simulated medical value of the plurality of simulated values.
[0016] In another example, the microprocessor can be configured to store values of the simulated medical values in the memory based at least in part on user input.
[0017] In another example, the simulated medical device can further include an interface. The interface can receive wireless signals including data from an external wireless transmitter, the interface can provide the data included in the received wireless signals to the microprocessor, and the microprocessor can be configured to set the values of the at least one simulated medical value based at least in part on the data included in the received wireless signals.
[0018] In another non-limiting and preferred embodiment, disclosed is a method for providing a realistic training environment for health care and patient care providers using a simulated medical device. The method can include actuating a first actuator of the simulated medical device that turns on the simulated medical device, and following, actuating a second actuator of the simulated medical device. The method can then further include prompting the user to simulate scanning a first bar code in response to the actuation of the second actuator.
[0019] In another example, the method can further include actuating a third actuator in response to prompting the user to simulate scanning a first bar code in response to the actuation of the second actuator, and causing a light of the simulated medical device to illuminate in response to the actuation of the third actuator.
[0020] In another example, the method can further include, inserting a test strip into a slot of the simulated medical device following the step of causing a light of the simulated medical device to illuminate in response to the actuation of the third actuator, and a pre-set timer countdown is initiated in response to the insertion of the test strip into the slot. In response to the completion of the pre-set timer countdown, simulated medical device displaying on a visual display a simulated medical value in response to the insertion of the test strip into the slot.
[0021] Further preferred and non-limiting embodiments or aspects are set forth in the following numbered clauses.
[0022] Clause 1: Disclosed is a simulated medical device for providing a realistic training environment for health care or patient care providers, the device comprising: a visual display; a microprocessor connected to the visual display; a memory connected to the microprocessor and storing non-transitory computer readable program code for operation of the microprocessor and one or more data values; a first actuator connected between a power supply and the microprocessor, wherein in response to actuation of the first actuator the microprocessor receives power from the power supply; and a body housing the visual display, the microprocessor, the memory, and the first actuator, the body further including: a slot in the body; a light supported by the body; and a strip insertion sensor configured to provide to the microprocessor an indication of the presence of a test strip in the slot.
[0023] Clause 2: The simulated medical device of clause 1, wherein the first actuator can be a mechanical switch or a virtual switch displayed on the visual display by the microprocessor operating under the control of the non-transitory computer readable program code.
[0024] Clause 3: The simulated medical device of clause 1 or 2 , wherein the slot can be configured to receive internally at least a portion of the test strip.
[0025] Clause 4: The simulated medical device of any of clauses 1-3, wherein the light can be positioned at a proximal end of the slot.
[0026] Clause 5: The simulated medical device of any of clauses 1-4 can further comprise a second actuator connected between a power supply and the light. The light can illuminate in response to actuation of the second actuator.
[0027] Clause 6: The simulated medical device of any of clauses 1-5, wherein the second actuator can be a mechanical switch or a virtual switch displayed on the visual display by the microprocessor operating under the control of the non-transitory computer readable program code.
[0028] Clause 7: The simulated medical device of any of clauses 1-6, wherein: each data value can be simulated medical values or texts; and the microprocessor, running under the control of the non-transitory computer readable program code, can perform the following steps: in response to receiving power from the power supply, display on the visual display a third actuator; in response to actuation of the third actuator, display a prompt on the visual display; in response to the strip insertion sensor sensing at least a portion of the test strip internally received in the slot, initiates a pre-set timer countdown; and in response to the pre-set timer countdown completion, display a first simulated medical value of the plurality of simulated values.
[0029] Clause 8: The simulated medical device of any of clauses 1-7, wherein the microprocessor, running under the control of the non-transitory computer readable program code, can further perform the following steps: in response to another actuation of the third actuator, display another prompt on the visual display; in response to the strip insertion sensor sensing at least a portion of the test strip internally received in the slot, initiates a pre-set timer countdown; and in response to the pre-set timer countdown completion, display a second simulated medical value of the plurality of simulated values.
[0030] Clause 9: The simulated medical device of any of clauses 1-8, wherein the microprocessor can be configured to set values of the simulated medical values in the memory based at least in part on user input.
[0031] Clause 10: The simulated medical device of any of clauses 1-9 can further comprise: an interface; wherein the interface can receive wireless signals including data from an external wireless transmitter; wherein the interface can provide the data included in the received wireless signals to the microprocessor; and wherein the microprocessor can be configured to set the values of the at least one simulated medical value based at least in part on the data included in the received wireless signals.
[0032] Clause 11: Also disclosed is a method for providing a realistic training environment for health care and patient care providers using a simulated medical device, the method comprising: (a) actuating a first actuator of the simulated medical device that turns on the simulated medical device; (b) following step (a), actuating a second actuator of the simulated medical device; (c) in response to the actuation of the second actuator, prompting the user to simulate scanning a first bar code.
[0033] Clause 12: The method of clause 11, can further comprise: (d) in response to the prompt in step (c), actuating a third actuator; and (e) in response to the actuation of the third actuator, causing a light of the simulated medical device to illuminate.
[0034] Clauses 13. The method of clause 11 or 12, can further comprise: (f) following step (e), inserting a test strip into a slot of the simulated medical device; (g) in response to the insertion of the test strip into the slot, a pre-set timer countdown is initiated; and in response to the completion of the pre-set timer countdown, the simulated medical device can display on a visual display a simulated medical value.
[0035] These and other features and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structures and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Further features and other objects and advantages will become apparent from the following detailed description made with reference to the drawings in which:
[0037] FIG. 1A is a front view of a simulated thermometer according to a preferred and non-limiting embodiment;
[0038] FIG. 1B is a back view of a simulated thermometer according to a preferred and non-limiting embodiment;
[0039] FIG. 1C is an expanded front view of a simulated thermometer according to a preferred and non-limiting embodiment;
[0040] FIG. 2 is a circuit diagram of a simulated thermometer according to a preferred and non-limiting embodiment.
[0041] FIG. 3A is a front view of a simulated glucose strip reader according to a preferred and non-limiting embodiment;
[0042] FIG. 3B is a back view of a simulated glucose strip reader of FIG. 3A ;
[0043] FIG. 4A is a block diagram of the electronics of the simulated glucose strip reader of FIGS. 3A-3B ;
[0044] FIG. 4B is a combined block diagram and circuitry schematic view of the electronics of the simulated glucose strip reader of FIGS. 3A-3B ;
[0045] FIG. 5 is an isolated view of a wireless transmitter and the interface of the simulated glucose strip reader for inputting external values into memory of the simulated glucose strip reader; and
[0046] FIG. 6 is a flow diagram of the operation of the simulated glucose strip reader.
DETAILED DESCRIPTION OF THE INVENTION
[0047] Simulated Thermometer:
[0048] FIGS. 1A and 1B , respectively, show front and back views of a simulated thermometer 2 . Although preferred and non-limiting embodiments are described below with respect to a simulated thermometer for the display of simulated temperatures, disclosed embodiments are not limited thereto, and it is further envisioned that simulated thermometer 2 may be configured to display other simulated values. The simulated thermometer 2 includes a body 4 which houses a printed circuit board (PCB) which supports circuitry including a visual display 6 which is visible through an opening in a front side of body 4 . The PCB further supports a plurality of buttons or switches including a first button 8 , a second button 10 , a third button 12 , and/or a fourth button 14 . The first through fourth buttons 8 - 14 are accessible to a user of the simulated thermometer 2 via one or more openings on a back side of body 4 .
[0049] With reference to FIG. 1C and with continuing reference to FIGS. 1A and 1B , the simulated thermometer 2 further includes a simulated thermometer probe 16 , which is physically coupled to body 4 via a coiled cable 18 . For reasons discussed hereinafter, the probe 16 is not coupled to any signal processing circuitry of the simulated thermometer 2 . For example, the probe 16 is not configured to record or send any signal representative of a reading or measured value to the PCB for processing. The probe 16 has a proximal end 20 adapted to be held by the hand of the user and a distal end 22 that is similar in shape and size to an end of a conventional thermometer used for taking temperatures of patients. Because the probe 16 is not actually used for taking temperatures, the distal end 22 of probe 16 can be made of any suitable and/or desirable material that is, desirably, biocompatible.
[0050] The body 4 may include an optional integral sheath 24 for receiving the distal end 22 of probe 16 with the proximal end 20 supported above a mouth of the sheath 24 . When it is desired to deploy the probe 16 from a position within sheath 24 , a user grasps the proximal end 20 of probe 16 and pulls the distal end 22 out of the sheath 24 .
[0051] Referring now to FIG. 2 and with continuing reference to FIGS. 1A-1C , circuitry 26 housed on the PCB within the body 4 includes an integrated control microprocessor 28 , which is coupled to visual display 6 and the first through fourth buttons 8 - 14 . The microprocessor 28 is connected to a DC power supply 30 via a switch 32 . The circuitry 26 further includes biasing resistors and capacitors which are utilized in a manner known in the art, but which are not specifically described herein for the purpose of simplicity.
[0052] The visual display 6 may be any suitable and/or desirable form of display including an LED display, an LCD display, an OLED display, etc. In a preferred and non-limiting embodiment illustrated in FIG. 2 , the visual display 6 comprises five 7-segment LEDs; however, preferred embodiments are not to be construed as limited thereto.
[0053] A switch 32 is positioned within sheath 24 , such that when the distal end 22 of probe 16 is inserted into sheath 24 , the distal end 22 of probe 16 causes the switch 32 to be in an open state. Upon removal of distal end 22 of probe 16 from the sheath 24 , the switch 32 assumes a closed state completing an electrical path between the DC power supply 30 and the microprocessor 28 .
[0054] The microprocessor 28 may be a completely integrated processor that includes an integral microprocessor, memory, input and output drivers, etc. as required in order to drive the visual display 6 and to receive and process inputs from the first through fourth buttons 8 - 14 . The memory of microprocessor 28 is configured to store non-transitory computer readable program code that the processor of microprocessor 28 executes and runs under the control of.
[0055] In operation, in response to the removal of the probe 16 from the sheath 24 , the switch 32 assumes its closed state connecting the DC power supply 30 to the microprocessor 28 . In response to receiving power from the DC power supply 30 , the processor of microprocessor 28 , under the control of the non-transitory computer readable program code stored in the memory of microprocessor 28 , initializes and commences operation in the manner next described.
[0056] In operation, upon closure of switch 32 , the processor of microprocessor 28 initializes and causes the visual display 6 to display simulated temperatures that alternate or cycle between at least two programmed temperatures T 1 and T 2 each time the switch 32 cycles from an open state to a closed state. The simulated thermometer 2 is activated in response to removing the probe 16 from the sheath 24 , whereupon the switch 32 cycles from an open state to a closed state and electrical power is supplied from the DC power supply 30 to the microprocessor 28 . The DC power supply 30 may be any suitable and/or desirable form of DC power supply, including replaceable or rechargeable batteries.
[0057] In response to the microprocessor 28 powering on, the microprocessor thereof loads previously stored settings from the memory (e.g., an EEPROM) and, depending upon an acquisition time and a display mode, a temperature is displayed on the visual display 6 . The displayed temperature is one of a plurality of different temperatures stored in the EEPROM, e.g., the temperature T 1 or the temperature T 2 . The next time power is cycled to microprocessor 28 , the other temperature T 2 or T 1 which is stored in the EEPROM is displayed on the visual display 6 . The visual display 6 may be configured to display temperatures in degrees Celsius or Fahrenheit. For example, the rightmost LED in the visual display 6 shown in FIG. 2 may be configured to display a “C” for Celsius or a “F” for Fahrenheit.
[0058] The first through fourth buttons 8 - 14 may be utilized to program the microprocessor 28 with the values of the temperature T 1 (e.g., first button 8 ), the temperature T 2 (e.g., second button 10 ), the acquisition time (e.g., third button 12 ), and the display mode Celsius/Fahrenheit (C/F) (e.g., fourth button 14 ). For example, pressing or pressing and holding first button 8 causes temperature T 1 stored in the memory (EEPROM) of microprocessor 28 to increase and be displayed on visual display 6 until a maximum temperature (e.g., 42° C. or 107° F.) is reached, whereupon temperature T 1 rolls over to the lowest temperature to be displayed, e.g., 35° C. or 95° F.
[0059] Pressing or pressing and holding second button 10 causes temperature T 2 stored in the memory of microprocessor 28 to increase and be displayed on visual display 6 to a maximum temperature (42° C. or 107° F.), whereupon the temperature rolls over to the lowest temperature, e.g., 35° C. or 95° F. In the case of first button 8 and second button 10 , each press of the button can cause the corresponding temperature T 1 and T 2 stored in the memory of microprocessor 28 to increase by some predetermined value, e.g., 0.1° C. or 0.1° F., or pressing and holding each button can cause the corresponding temperature T 1 and T 2 to automatically increase by the predetermined value.
[0060] Pressing third button 12 causes the acquisition time stored in the memory of microprocessor 28 to increase until it reaches a maximum acquisition time, e.g., fifteen seconds, whereupon the acquisition time rolls over to a minimum acquisition time, e.g., five seconds. This acquisition time is the delay time between when probe 16 is removed from sheath 24 and the microprocessor 28 first receives power from DC power supply 30 until the time that a temperature T 1 or T 2 is displayed on the visual display 6 . Each press of third button 12 can cause the acquisition time to change by a predetermined amount, e.g., 0.1 second or 1.0 second, or pressing and holding third button 12 can cause the acquisition time to automatically increase by the predetermined amount.
[0061] Each press of fourth button 14 cycles the display mode between Celsius and Fahrenheit.
[0062] Although programming of the microprocessor 28 is described above with respect to use of the first through fourth buttons 8 - 14 , preferred embodiments are not limited thereto and the microprocessor 28 may be programmed through other user input means, for example, a touch screen control or graphical user interface (GUI). Moreover, although the first through fourth buttons 8 - 14 are described with respect to programming temperature values for the simulated thermometer 2 , it is also envisioned that the buttons or other user interface may be configured to program other simulated values, such as blood glucose, pulse oximeter measurements, and the like.
[0063] The simulated thermometer 2 can be used in training scenarios of health care or patient care providers. An example user of the simulated thermometer 2 by health care or patient care providers in connection with an individual playing the role of a patient will now be described.
[0064] In this example, the person playing the role of the patient presents to the health care or patient care providers complaining of an elevated temperature, nausea, and vomiting. It is to be appreciated that in this role-playing scenario, the person playing the role of the patient does not have an elevated temperature, is not nauseous, and is not vomiting, but rather is simply complaining of these symptoms.
[0065] The health care or patient care providers perform a physical assessment of the patient including taking vital signs and the patient's temperature. One of these vital signs is simulated temperature(s) of the patient taken utilizing the simulated thermometer 2 . In this regard, the probe 16 is removed from sheath 24 , a probe cover (not shown) is placed over the distal end 22 of the probe 16 , and the distal end 22 of the probe 16 with the probe cover in place is inserted into the mouth of the role playing patient. After a period of time determined by the acquisition time programmed into microprocessor 28 via the third button 12 , the microprocessor 28 causes the visual display 6 to display the first programmed temperature T 1 , e.g., 103° F., as the first simulated temperature reading. It is to be appreciated that since probe 16 is not connected to any internal circuitry of simulated thermometer 2 , the temperature experienced by the distal end 22 of probe 16 has no bearing on or relation to the temperature displayed on the visual display 6 . Rather, the temperature T 1 displayed on visual display is the temperature T 1 that was programmed into the memory of the microprocessor 28 .
[0066] After logging the displayed temperature T 1 as well as any other vital signs of the role playing patient, the health care or patient care providers make a diagnosis based on the results of the vital signs, including the temperature displayed on the visual display 6 , and other patient data made part of the simulation. After taking the first simulated temperature reading, the probe 16 is replaced into sheath 24 after removing the probe cover. Thereafter, the patient is given a course of treatment, albeit simulated or actual, by the health care or patient care providers based on the diagnosis.
[0067] After a period of time determined by the simulation, the health care or patient care providers take a second simulated temperature of the role playing patient by removing the probe 16 from the sheath 24 , placing a probe cover (not shown) over the distal end 22 of probe 16 , and again inserting the distal end 22 of probe 16 with the probe cover in place into the mouth of the role playing patient. After a period of time determined by the acquisition time programmed into microprocessor 28 , the microprocessor 28 causes the visual display 6 to display the second temperature T 2 programmed into the memory of microprocessor 28 . Depending on the simulation, temperature T 2 may be higher or lower than temperature T 1 . In this example, the temperature T 2 displayed on the visual display 6 is 101.5° F., which is lower than temperature T 1 , i.e., 103° F. In response to taking this temperature, the health care or patient care providers may conclude that the health care or patient care providers' course of treatment is working.
[0068] As can be seen, cycling probe 16 into and out of sheath 24 causes the temperature that the microprocessor 28 displays on the visual display 6 to alternate between the temperature T 1 and T 2 , which alternating temperatures can be utilized for the purpose of training health care or patient care providers. Again, it is to be appreciated that probe 16 is only a simulated probe and is not actually utilized to measure temperature.
[0069] According to another preferred and non-limiting embodiment, the simulated thermometer 2 may include a remote RF or optical transmitter 36 ( FIG. 1C ) and an RF or optical receiver 38 ( FIG. 2 ) as an integral part of the simulated thermometer 2 for receiving radio frequency or optical signals 40 from the transmitter 36 . The combination of transmitter 36 and receiver 38 can be utilized to remotely program the memory of microprocessor 28 with one or more values of temperature T 1 , temperature T 2 , and/or acquisition time, and/or to toggle the visual display 6 between Celsius and Fahrenheit. The combination of transmitter 36 and receiver 38 can either be utilized in addition or, alternatively, to buttons 8 - 14 . However, it is envisioned that the functions provided by buttons 8 - 14 may be replaced with the combination of the transmitter 36 and the receiver 38 .
[0070] One advantage of the use of the transmitter 36 and the receiver 38 includes the ability of an instructor participating in the role playing between a role playing patient and the health care or patient care providers to change the second display temperature based upon the health care or patient care providers' course of treatment of the patient. For example, assuming that the health care or patient care providers' treatment plan was appropriate, the instructor may chose to leave the second programmed temperature T 2 at a lower value than the first programmed temperature T 1 , as discussed in the above example. However, if the health care or patient care providers make an incorrect diagnosis and prescribe an improper course of treatment, the instructor utilizing transmitter 36 may change the second temperature T 2 to be the same or a higher temperature, e.g., 103.5° F., indicating that the course of treatment is not working. The combination of the transmitter 36 and the receiver 38 can be utilized to change any of the values programmed into the memory of microprocessor 28 at any time the microprocessor 28 is receiving power from DC power supply 30 , including during the acquisition time preprogrammed into microprocessor 28 .
[0071] Simulated Glucose Strip Reader:
[0072] FIGS. 3A and 3B , respectively, show front and back views of an instrument 102 for the simulated measurement of the concentration of glucose in a simulated blood sample (hereinafter “instrument”) and display of the results of the simulated measurement similar in many respects to simulated thermometer 2 in FIGS. 1A-1C . Although preferred and non-limiting embodiments are described below with respect to instrument 102 for the display of one or more simulated medical values, in an example, a blood glucose level, from a plurality of simulated blood glucose levels, the disclosed embodiment is not limited thereto. It is envisioned that instrument 102 can also or alternatively be configured to display other simulated values or information, such as, for example, “Pass” or “Fail”. Instrument 102 is intended for use in a training environment, not a clinical environment.
[0073] Instrument 102 includes a body 104 which houses a printed circuit board (PCB) 127 (shown in phantom FIG. 3B ) which supports circuitry 131 (shown in greater detail in FIG. 4B ) including a Human Machine Interface (HMI) 120 that includes a visual display 106 which is visible through an opening in a front side of body 104 . In an example, visual display 106 can be a touchscreen display that can display, for example, virtual buttons or actuators that facilitate user interaction with microprocessor 128 . However, this is not to be construed in a limiting sense since the use of a mechanical keypad and/or one or more mechanical buttons or actuators or other user input means known in the art is envisioned.
[0074] As viewed in FIG. 3A , body 104 includes a top 112 , a bottom 114 , a left side 116 , and a right side 118 . In an example, PCB 127 supports a plurality of actuators including a first actuator 132 , shown, for example, located on left side 116 of body 104 , and a second actuator 134 , shown, for example, located on right side 118 of body 104 .
[0075] With continuing reference to FIGS. 3A and 3B , instrument 102 can further include or define a slot 107 that can include an opening 107 ′, in an example, in top 112 of body 104 and can have a light 111 , in an example, on bottom 114 of body 104 . In another example, instrument 102 can further include a speaker 200 shown, in an example, in FIGS. 3A and 3B on right side 118 . Instrument 102 can also include a strip insertion sensor 108 in slot 107 . In an example, strip insertion sensor 108 can include a light transmitter 108 a spaced across a gap from a light receiver 108 b within slot 107 . Strip insertion sensor 108 can be configured to provide to microprocessor 128 an indication when at least a portion of a simulated test strip 109 , e.g., a strip of paper, is inserted in slot 107 in said gap. Slot 107 is configured to receive at least a portion of test strip 109 . In another example, strip insertion sensor 108 can be a mechanical switch.
[0076] Referring now to FIGS. 4A and 4B and with continuing reference to FIGS. 3A and 3B , circuity 131 housed within body 104 includes an integrated control microprocessor 128 , having, in an example, an integral memory 129 . Microprocessor 128 is coupled to HMI 120 and visual display 106 and to first and second actuators 132 and 134 . Microprocessor 128 is also connected to a DC power supply 130 via first actuator 132 , such that when first actuator 132 is actuated (to a closed state), power flows from power supply 130 to microprocessor 128 and allows for instrument 102 to turn ON. Power supply 130 can be any suitable and/or desirable form of a power supply, including replaceable or rechargeable batteries. In an example, power supply 130 can be a Li battery (i.e., charge for 2 hours to supply power for 8 hours). Circuitry 131 can further include biasing resistors and a light 111 (e.g., one or more LEDs),and can further include speaker 200 , which are utilized in a manner known in the art, but which are not specifically described herein for the purpose of simplicity. In an example, each actuator described herein can be a mechanical actuator or switch or a virtual actuator that can be displayed on visual display 106 , which can be a touchscreen display, and which can be used in the manner described hereinafter to perform the functions described herein. For the purpose of description, the first and second actuators will be described as being mechanical switches. However, this is not to be construed in a limiting sense.
[0077] In another example, Human Machine Interface 120 can include visual display 106 in the nature of a non-touchscreen display, such as, for example, an LED display, a LCD display, an OLED display, a five 7-segment LED display (like the five 7-segment LED display shown in FIG. 2 ), etc. Where Human Machine Interface 120 includes a visual display 106 that is a non-touchscreen display, Human Machine Interface 120 can also include a user keyboard or keypad 122 (shown in phantom in FIG. 3A ) to facilitate user interaction with microprocessor 128 . The use of virtual actuators displayed on visual display 106 in the nature of a touchscreen display and/or keypad 122 including mechanical actuators (buttons) in combination with a touchscreen and/or non-touchscreen display is envisioned.
[0078] For the purpose of description hereinafter, first and second actuators 132 and 134 will be described as mechanical buttons or actuators, while actuators displayed on visual display 106 will be understood to be virtual actuators displayed on visual display 106 in the nature of a touchscreen display. However, this is not to be construed in a limiting sense.
[0079] With continuing reference to FIGS. 3A-4B , in operation, electrical power is applied to microprocessor 128 from power supply 130 in response to first actuator 132 being actuated and latching in a closed state. Upon de-actuation, first actuator 132 unlatches and returns to an open state. The description of actuator 132 being a latching actuator is not to be construed in a limiting sense.
[0080] Upon receiving electrical power, microprocessor 128 can display on visual display 106 an idle screen for a period of time while microprocessor 128 initializes, and then can display three user selectable actuators ( FIG. 3A ): configuration actuator 151 , quality control actuator 152 , and patient test actuator 153 . In an example, microprocessor 128 can be coupled to an interface 160 , such that one or more user inputted values 140 (shown in FIG. 5 ) can be transferred from interface 160 to microprocessor 128 (details regarding interface 160 and inputted values 140 will be described hereinafter). In an example, user inputted values 140 can be inputted manually via Human Machine Interface 120 by a user in the configuration mode (discussed hereinafter). In another example, user input values 140 can be sent wirelessly from an external wireless transmitter 136 ( FIG. 5 ) to interface 160 , similar to receiving radio frequency or optical signals 40 from transmitter 36 in FIG. 1C , to be used with microprocessor 28 in FIG. 2 . Values 140 can be used, for example, to replace or add to simulated medical values stored in memory 129 , input high and low quality test values, or input configuration values. In an example, once first actuator 132 has been actuated (to a closed state), in response to second actuator 134 being actuated to a closed state, light 111 is illuminated and speaker will sound via power from power supply 130 and light 111 can be used to simulate bar code scanning. In an example, second actuator 134 is non-latching, whereupon a user de-actuating second actuator 134 , it returns to an open state. The description of second actuator 134 as being a non-latching is not to be construed in a limiting sense. In an example, speaker 200 can be operative for sounding after a predetermined period of time (i.e., 3 seconds) after second actuator 134 is actuated and the sound can, for example, represent a “BEEP”.
[0081] With continuing reference to FIGS. 4A and 4B , when test strip 109 is inserted into slot 107 (shown in FIGS. 3A and 3B ), for example, into the gap between light transmitter 108 a and light receiver 108 b, blocking the light received by light receiver 108 b from light transmitter 108 a, microprocessor 128 can sense the change in output of light receiver 108 b in response to light receiver receiving and not receiving light from light transmitter 108 a and can display, after a predetermined period of time, on visual display 106 , a simulated medical value retrieved from the plurality of simulated medical values, or a “Pass” or “Fail” indication, retrieved from memory 129 . The simulated medical value or indication can be preselected or random. Electrical power is supplied to light transmitter 108 a and light receiver 108 b when first actuator 132 is actuated.
[0082] Referring now to FIG. 5 , in an example, interface 160 can be a wireless receiver which can wirelessly receive data or values 140 embedded in wireless signals received from external wireless transmitter 136 to be sent to microprocessor 128 for storing in memory 129 . In an example, this combination of transmitter and receiver can be utilized to remotely program memory 129 of microprocessor 128 with, for example, one or more simulated medical values and/or data to replace or be added to simulated medical values and/or data stored in memory 129 . In an example, wireless interface 160 can be an RF or optical receiver and wireless transmitter 136 can be an RF or optical transmitter.
[0083] With reference to the flow diagram of FIG. 6 , an example use of instrument 102 will now be described. In this example, visual display 106 will be described as being a touchscreen display and first and second actuators will be considered as being mechanical switches. However, this is not to be construed in a limiting sense.
[0084] In response to first actuator 132 being actuated at step 100 , microprocessor 128 receives electrical power from power supply 130 and, after an initialization period, microprocessor 128 can display on visual display 106 the user selectable options (shown in FIG. 3A ) configuration actuator 151 ; quality control actuator 152 ; and patient test actuator 153 at step 105 .
[0085] With continuing reference to FIG. 6 , in response to user actuation of configuration actuator 151 , at step 110 , microprocessor 128 can display on visual display 106 a configuration display (not shown). Through this configuration display, microprocessor 128 enables the user to manually input data, such as, for example, one or more simulated medical values (e.g., simulated blood glucose levels) and/or text into memory 129 , in effect ‘configure the device’ at step 112 , whereupon the displayed values and/or text (discussed hereinafter) in a patient test mode can optionally be based at least in part on the inputted data. Upon completion of the user manually inputting data, microprocessor 128 can then return to step 105 . The display of configuration actuator 151 and the execution of steps 110 and 112 can be optional if memory 129 is preloaded with one or more simulated medical values and/or text. In another example, the user input can be numerical values with three ( 3 ) decimals to the left of a decimal point and two ( 2 ) decimal points to the right. In another example, the user input can represent simulated blood glucose values.
[0086] With continuing reference to FIG. 6 , in response to user actuation of quality control actuator 152 at step 115 , microprocessor 128 can display on visual display 106 a quality control display (not shown) at step 115 . Via the quality control display, microprocessor 128 enables the user to input and confirm data, such as, for example, a first (high) value of the simulated medical values (e.g. a high glucose level) at step 117 and a second (low) value of the simulated medical values (e.g. a low glucose level) at step 119 or “PASS” and/or “FAIL” indication. Microprocessor 128 can then return to step 105 . The display of quality control actuator 152 and the execution of steps 115 - 119 can be optional if memory 129 is preloaded with data, e.g., a first (high) value of simulated medical values and a second (low) value of simulated medical values, and/or “PASS” and/or “FAIL” indications.
[0087] With continuing reference to FIG. 6 , in response to user actuation of patient test actuator 153 at step 105 , microprocessor 128 can be programmed to display on visual display 106 a first prompt to the user to simulate scanning a first bar code at step 140 . In an example, the user can simulate this bar code scanning by actuating second actuator 134 , whereupon light 111 can be illuminated and speaker can 200 sound. More specifically, in use, after actuating second actuator 134 resulting in illuminating light 111 and sounding speaker 200 , it is intended for the user to simulate bar code scanning of a bar code of the user, for example, a bar code of a wrist band of the user. When the user completes simulated scanning of the user bar code, the user de-actuates or releases second actuator 134 which causes light 111 to turn off. In use, it is intended that the user actuate second actuator 134 a second time which causes light 111 to illuminate a second time and speaker 200 to sound a second time, whereupon the user can simulate scanning the patient bar code. Once the user has simulated scanning the patient bar code, the user de-actuates or releases second actuator 134 a second time. In use, the user then inserts at least a portion of test strip 109 into slot 107 . In response to strip insertion sensor 108 detecting insertion of at least a portion of test strip 109 into slot 107 , at step 155 , microprocessor 128 can be programmed to display, after a predetermined period of time, on visual display 106 a first simulated medical value (glucose level) or a “PASS” or “FAIL” indication retrieved by microprocessor 128 from data stored in memory 129 . Microprocessor 128 can then return to step 105 .
[0088] If desired, the process of executing steps 120 - 155 can be repeated any number of additional times as an aid to training the user in the use of an actual glucose strip reader used in a clinical environment. In an example, each time steps 120 - 155 are repeated, the same or a different simulated medical value (glucose level) or “PASS” or “FAIL” stored in memory 129 can be displayed on display 106 in step 155 . In an example, each time steps 120 - 155 are repeated, instrument 102 can display on display 106 a different simulated medical value (glucose level) from the set of simulated medical values stored in memory 129 . In another example, each time steps 120 - 155 are repeated, a “PASS” or “FAIL” indication can display on display 106 , simulating that the simulated measured blood glucose is within “PASS” or outside “FAIL” of an acceptable level. This latter example display of “PASS” or “FAIL” is similar to a display of data in an actual glucose strip reader used in a clinical environment. However, this is not to be construed in a limiting sense.
[0089] In another example, when test strip 109 is inserted into slot 107 , strip insertion sensor 108 can determine if test strip 109 is not inserted correctly or does not include a sufficient amount of simulated blood thereon. Microprocessor 128 can then display this condition on visual display 106 .
[0090] In an example, manual user input (steps 110 and 112 ) or wireless interface 160 can be used to program new, replacement, or additional data, such as, for example, simulated medical values (glucose levels) or data into memory 129 .
[0091] Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments or aspects, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments or aspects, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. Obvious modifications and alterations will occur to others upon reading and understanding the preceding detailed description. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment or aspect.
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Disclosed is a method and apparatus for providing a realistic training environment for health care and patient care providers using a simulated medical device. The method can include actuating a first actuator of the simulated medical device that turns on the device and then actuating a second actuator of the device, where, in response to the actuation of the second actuator, the user is prompted to simulate scanning a bar code. In response to actuating a third actuator, a light can illuminate. The method can further include inserting a test strip into a slot of the device and, in response to the insertion of the test strip, the device can initiate a pre-set timer countdown where, at the completion of the countdown, the visual display can display a simulated medical value.
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TECHNICAL FIELD
[0001] The present disclosure relates generally to secure entry to a property. More particularly, the present disclosure relates to a system and method for secure entry to a property using a locking receptacle.
BACKGROUND
[0002] Locking receptacles, sometimes referred to as ‘lock boxes’, are typically containers, such as boxes, cylinders, or the like, that act as a secure access repository for valuable articles. Locking receptacles may be sealed with a secure door or access point. The secure door may provide secure access through the use of a lock; for example, a pin tumbler lock, padlock, keypad lock, radio-frequency identification (RFID) lock, magnetic lock, or the like.
[0003] A conventional function of locking receptacles is as depositories of keys for a property, building, residence, or the like. In some instances, the locking receptacle may be mounted to the exterior of the property. The keys to enter the property may be stored in the locking receptacle. Thus, a person who gains access to the locking receptacle can receive the key to enter the property.
[0004] Having a locking receptacle mounted to the exterior of a property may be advantageous where access is required for multiple properties, but a single or unified key (or other device to operate the locks) is desired for entry to the multiple properties. In an example, a real estate agency may have multiple properties for sale. Rather than having to carry keys for each property, each property may have a locking receptacle mounted to the exterior of the property. The locking receptacle may include a property key inside for entering the property. Each locking receptacle could be accessed via a keypad or tumbler code by receiving a secure code that is transmitted via telephone or text to the real estate agent upon arrival at the premises.
[0005] US Publication No. 20090153291 provides an example of a real estate security system wherein access to a lockbox, that houses a key, causes automatic notification to an owner/occupant associated with the property. Such a communication can be used to alert the owner/occupant that a real estate showing is started or completed, that a friend or family member arrived home safely, that a property management accessed the house, or that emergency personnel accessed the house. The lockbox can include additional features that cause notification to the owner, such as automated sensing of tampering with the lockbox, or depressing a button on the lockbox to generate a signal to the owner/occupant of the property.
[0006] For years firefighters or other emergency personnel have been arriving at various buildings in response to an emergency call with an urgent need to access the building. Current commercial and residential lock box programs in place across Canada and the US are called Supra™ and Knox Box™. Both utilize a specially coded mechanical key that is kept inside the cab of each fire truck using various security methods. Each mechanical key opens up a roughly 4″×3″×3″ metal lock box attached to the exterior of the building. The box houses specific keys to that building including a possible master key. These programs were set up to aid firefighters with gaining immediate access in the event of an emergency.
[0007] There are several problems with the current system. Quite often, paramedics and police arrive first and have to wait for fire truck to arrive before they can enter, which wastes precious time. The lock boxes are out in the open and not attached securely enough to the building structure; therefore theft and unlawful access are possible. The boxes are also bulky and unattractive, which is an issue for home owners. There is a high possibility for loss of the mechanical key through misplacement or loss on site. There are no current methods for tracking accessibility of the storage box, tracking accountability of personnel who access the lock box and finding lost keys from the storage box.
[0008] If a lockbox is compromised resulting in loss of the master key therein, there may be a huge financial loss to that building owner as well as a loss of security. Furthermore, insurance rates may increase as a result of the lock box due to the potential liability and high cost to re-key an entire building if the current lock box is maliciously compromised resulting in loss of a master key. If the department mechanical key is lost, the liability may be even larger since not only would each face plate of Supra have to be replaced and each Knox Box re-keyed, but all building locks/apartments with said lock boxes would have to be completely re-keyed. In the case of either a lost department mechanical key or a compromised lockbox, temporary security personnel would be required at the main doors of each affected building to verify those coming and going until the process was complete.
[0009] Other sectors also require a secure and accountable locking receptacle and container. For example, paramedics need a more secure place to temporarily store toxic medication. Police officers are often called to assist in emergency calls and also need to gain entry. Quick access to a building should be available to the first Emergency Medical Services (EMS) to arrive. There is a need for a more secure place to store department keys/cards. Accountability issues are on the rise in every sector and infallible security is being demanded globally.
[0010] The conventional practice of having a key-accessible locking receptacle mounted on the exterior of a property presents liability and security concerns. As such, there is a need for an improved system and method for secure and accountable entry to a building using a locking receptacle.
[0011] Furthermore, there is a need to provide secure emergency access to a property for emergency services. In particular, a property owner requires peace of mind that an external lockbox mounted on the exterior of the property is tamper-proof and, furthermore, that any means for accessing the lockbox is secure and accountable. In the event of an emergency unfolding inside the property, such as a fire or health crisis, with the property locked and no one available to open it, the emergency services need a prompt manner of accessing a secure, tamper-proof lockbox without having to break down the entryway of the property. Typically, it would be impractical for the emergency services to carry entry keys for all the properties in its service area.
SUMMARY
[0012] It is an object of the present disclosure to obviate or mitigate at least one disadvantage of conventional secure entry systems and methods.
[0013] In accordance with one aspect there is provided, an apparatus comprising a housing; alarm means configured to trigger a timed alarm upon removal of a receptacle key from the housing; and locking means for locking the housing.
[0014] In accordance with another aspect there is provided an apparatus wherein the locking means includes a keypad and the locking means is unlocked upon input of an access code on the keypad.
[0015] In accordance with another aspect there is provided an apparatus wherein upon input of the access code, various parameters are recorded.
[0016] In accordance with another aspect there is provided an apparatus wherein the various parameters are selected from the group consisting of a user ID, date of the input, time of the input, GPS location and combinations thereof.
[0017] In accordance with another aspect there is provided an apparatus wherein upon input of the access code, various parameters are transmitted to a central location.
[0018] In accordance with another aspect there is provided an apparatus further comprising a removable media containing a list of cylinder codes.
[0019] In accordance with another aspect there is provided an apparatus wherein at least a portion of the list of cylinder codes are transferred to the receptacle key within the housing.
[0020] In accordance with another aspect there is provided an apparatus wherein the list of cylinder codes are geographically restricted.
[0021] In accordance with another aspect there is provided an apparatus wherein the alarm means measures an amount of time that the receptacle key has been removed.
[0022] In accordance with another aspect there is provided an apparatus wherein the timed alarm includes a notification selected from the group consisting of a flashing light, an intermittent buzzer, a constant buzzer, a message to a central office, and combinations thereof.
[0023] In accordance with another aspect there is provided an apparatus wherein the timed alarm activates the notification after an elapsed time during which the receptacle key has been removed from the housing.
[0024] In accordance with another aspect there is provided an apparatus wherein the alarm means deactivates the receptacle key after a further elapsed time during which the receptacle key has been removed from the housing.
[0025] In accordance with another aspect there is provided an apparatus further comprising tracking means for locating the receptacle key outside of the housing.
[0026] In accordance with another aspect there is provided an apparatus further comprising mounting means for mounting on a mobile platform.
[0027] In accordance with another aspect there is provided an apparatus further comprising mounting means for mounting on a vehicle.
[0028] In accordance with another aspect there is provided an apparatus further comprising a power source.
[0029] In accordance with another aspect there is provided a system comprising: a secure container having a locking means for locking a housing; alarm means configured to trigger a timed alarm upon removal of a receptacle key from the housing; and at least one locking receptacle that is unlocked with the receptacle key.
[0030] In accordance with another aspect there is provided a system further comprising a removable media containing a list of cylinder codes.
[0031] In accordance with another aspect there is provided a system wherein the secure container comprises a receiver for the removable media.
[0032] In accordance with another aspect there is provided a system wherein at least a portion of the list of cylinder codes are transferred to the receptacle key within the housing.
[0033] In accordance with another aspect there is provided a system wherein the list of cylinder codes are restricted to enable access to one or more of the at least one locking receptacles within a given distance from the receptacle key.
[0034] In accordance with another aspect there is provided a system further comprising activation means configured to enable and disable the receptacle key.
[0035] In accordance with another aspect there is provided a system wherein the locking receptacle comprises a housing and a locking means, wherein the housing is mounted flush to an external wall of a property.
[0036] In accordance with another aspect there is provided a system further comprising mounting means for mounting the secure container on a mobile platform.
[0037] In accordance with another aspect there is provided a system further comprising mounting means for mounting the secure container on a vehicle.
[0038] In accordance with another aspect there is provided a system wherein the mounting means includes power means for connecting the secure container to an electrical power source of the vehicle.
[0039] In accordance with another aspect there is provided a system further comprising a power source.
[0040] In accordance with another aspect there is provided a system wherein the locking means includes a keypad and the locking means is unlocked upon input of an access code on the keypad.
[0041] In accordance with another aspect there is provided a system wherein upon input of the access code, various parameters are recorded.
[0042] In accordance with another aspect there is provided a system wherein the various parameters are selected from the group consisting of a user ID, date of the input, time of the input, GPS location and combinations thereof.
[0043] In accordance with another aspect there is provided a system wherein upon input of an access code, various parameters are transmitted to a central location.
[0044] In accordance with another aspect there is provided a system wherein the central location authorizes the various parameters and activates the receptacle key.
[0045] In accordance with another aspect there is provided a method comprising: retrieving a receptacle key from a secure container; triggering a timed alarm for return of the receptacle key; and accessing a locking receptacle with the receptacle key.
[0046] In accordance with another aspect there is provided a method wherein the step of retrieving the receptacle key comprises inputting an access code to unlock the secure container.
[0047] In accordance with another aspect there is provided a method further comprising the step of recording various parameters selected from the group consisting of a user ID, date of the input, time of the input, GPS location and combinations thereof.
[0048] In accordance with another aspect there is provided a method further comprising the step of transmitting the various parameters to a central location.
[0049] In accordance with another aspect there is provided a method further comprising the step of transferring at least a portion of a list of cylinder codes to the receptacle key within the housing.
[0050] In accordance with another aspect there is provided a method wherein the list of cylinder codes are geographically restricted.
[0051] In accordance with another aspect there is provided a method wherein the step of triggering a timed alarm comprises the step of measuring an amount of time that the receptacle key has been removed.
[0052] In accordance with another aspect there is provided a method further comprising the step of activating a notification after an elapsed time during which the receptacle key has been removed from the housing.
[0053] In accordance with another aspect there is provided a method wherein the notification is selected from the group consisting of a flashing light, an intermittent buzzer, a constant buzzer, a message to a central office, and combinations thereof.
[0054] In accordance with another aspect there is provided a method further comprising the step of deactivating the receptacle key after a further elapsed time during which the receptacle key has been removed from the housing.
[0055] In accordance with another aspect there is provided a method further comprising the step of tracking the receptacle key outside of the housing.
[0056] In accordance with another aspect there is provided an apparatus comprising: a housing; locking means for locking the housing; a removable media containing a list of cylinder codes; wherein at least a portion of the list of cylinder codes are transferred to a receptacle key within the housing.
[0057] The present secure entry system provides a secure and reliable source to secure all EMS and non-emergency keys/cards/medication etc. The system is accountable and could eliminate liability involved in lost Supra or Knox Box keys.
[0058] The present secure entry system is capable of tracking lost keys and providing reminders in order to avert a lost key. The present secure system can be used for paramedics who need a more secure place to temporarily store toxic medication. Similarly, emergency response units such as police officers and firefighters are able to use the present secure entry system to gain quick access to a building, regardless of the first emergency response team to arrive on the scene. The present secure entry system can be used for storage of keys and cards in order to increase security and provide accountability.
[0059] In one embodiment, the present secure entry system can securely house all current department keys/cards/medications and can house and charge an electronic key system that communicates with installed locks at residential/commercial buildings while in motion. The system can alert personnel that keys/cards are not safe and secure by way of a flashing light and/or audible sound. A flashing light on the face of the secure container in one embodiment indicates removal of all department keys. A further audible alarm issues in a further embodiment if the keys are not replaced back into box after set time. Such mechanisms assist in preventing the user from leaving the scene without the department keys.
[0060] In another embodiment, a GPS signal can be used to activate an electronic key. The system can accept a download of newly added codes for locks and to transfer the new codes to an external source (e.g. a department computer where they will be added to the main server site).
[0061] In a further embodiment, the electronic key includes a set timer to disable its use after a set amount of time. Thus, if the electronic key is lost/misplaced after removal from the secure container, the electronic key will become disabled and useless, thereby protecting the key from any malicious use. This system also eliminates replacement cost if the key is lost or misplaced because the key becomes inactive and disabled after a set time. Once the key is returned to the charger in the secure container, it can be activated again.
[0062] In another embodiment, the secure entry system includes a cylinder shaped lock box that is recessed into the exterior of structure. Obtaining the contents of the cylinder maliciously would involve destroying the outer brick, stone, framework etc. In this embodiment, the cylinder can be mounted securely flush to an exterior wall.
[0063] Use of the present system has an added benefit of potentially lower insurance costs through various insurance companies as a result of the secure and accountable entry system of the present invention.
[0064] The present secure entry system in another aspect is able to provide multiple individual entry codes so that each emergency response attendant with approved access to their secure container could have their own access code to the secure container, thus creating accountability respecting the last person to access the container.
[0065] Examples of various operating principles and advantages of the secure entry system described herein include:
Decoupling of key and lock Ability to access any number of locks (e.g. 5,000) with a single key Ability to access a lock with any key Key works for limited time Ability to replace damaged keys without affecting locks Access traceability Location and time of day reporting Detection of secure container access Detection of key removal and replacement Real time position updates (GPS) Real time remote communication with central office Generation and transmission of SMS packets Wide operating temperature range Simple operation requiring minimal training Robust and water resistant Audio/Visual user interface
[0082] Aspects and features of the present disclosure will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0083] The following description will be better understood with reference to the drawings in which:
[0084] FIG. 1 illustrates a block diagram of an embodiment of a secure entry system;
[0085] FIG. 2 illustrates a perspective view of one example of a locking receptacle with a corresponding receptacle key;
[0086] FIG. 3 illustrates an exploded perspective view of an embodiment of a frame for a secure container;
[0087] FIG. 4 illustrates a front view of the secure container with an access door closed;
[0088] FIG. 5 illustrates a front view of the secure container with the access door open, showing an embodiment with an alarm trigger;
[0089] FIG. 6 illustrates an example electrical block diagram of the container lock;
[0090] FIG. 7 illustrates an example electrical block diagram of the secure container;
[0091] FIG. 8 is a flowchart for an embodiment of a method for secure entry; and
[0092] FIG. 9 is a flowchart for another embodiment of a method for secure entry.
[0093] FIG. 10 illustrates an example mounting of a locking receptacle on the outside of a property.
[0094] FIG. 11 illustrates an example electronic key inserted into the end of the locking receptacle.
[0095] FIG. 12 illustrates an example manual key inserted into the end of the locking receptacle.
[0096] FIG. 13 shows two types of locking receptacles, each in a closed configuration next to their respective electronic and manual keys.
[0097] FIG. 14 illustrates a sample system configuration using an electronic key such as shown in FIG. 11 .
[0098] FIG. 15 shows a sample connection between a GPS link, local database at a central office or other location and the system including various system timers, a keypad interface and the electronic key having, for example, a general purpose input/output (GPIO), an interface and a smart charger, and a keypad interface.
[0099] FIG. 16 illustrates a front view of the secure container with the access door open, showing an embodiment with an internal alarm trigger.
[0100] FIG. 17 illustrates an example mounting bracket for attaching the secure container to a vehicle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0101] Generally, the present disclosure provides a system and method for secure entry to a property using a locking receptacle that is intended to overcome at least some of the limitations of conventional secure entry practice. The systems and methods described herein allow a user to have one key to achieve entry into multiple properties, while providing a secure and accountable container for such key.
[0102] FIG. 1 illustrates a block diagram of an embodiment of a secure entry system 100 . The secure entry system includes a secure container 102 , a receptacle key 114 and a locking receptacle 104 . In some cases, as will be described, the secure entry system 100 may also include an activator 106 and a network 108 . The secure container 102 includes a container lock 110 and an alarm unit 112 . In some cases, as will be described, the secure container 102 may also include an activation unit 116 . The locking receptacle 104 includes a receptacle lock 120 .
[0103] The locking receptacle 104 may be used as secure storage for a property key 122 . In other cases, the locking receptacle 104 may be used as secure storage for other articles along with, or instead of, the property key 122 ; for example, storage of an emergency contact sheet, a garage door opener, a parcel, or the like.
[0104] FIG. 2 illustrates a perspective view of one example of a locking receptacle 104 with a corresponding receptacle key 114 . The locking receptacle 104 may include a body 202 and a lid 204 . In this example, the body 202 is in a tubular shape that is closed at a lateral end 208 and has an opening 210 starting at a proximate end 208 . In some cases, the body 202 may be mounted on, or recessed into, an exterior surface of the property. It is intended that the design of the locking receptacle 104 of FIG. 2 is functional yet minimally aesthetically intrusive by having a relatively small lateral end face. The property key 122 may be stored inside the opening 210 of the locking receptacle 104 .
[0105] The lid 204 is mounted at the proximate end 208 of the body 202 such that the lid 204 covers the opening 210 , or at least does not permit removal of the property key 122 from the opening 210 . In further cases, the lid 204 may be integral to the body 202 . The receptacle lock 120 is incorporated into the lid 204 . The receptacle lock 120 is positioned and configured such that the receptacle key 114 can engage the receptacle lock 120 in order to open the locking receptacle 104 . The receptacle lock 120 , and the counterpart receptacle key 114 , may be, for example, a pin tumbler lock, padlock, keypad lock, radio-frequency identification (RFID) lock, magnetic lock, or the like. The locking receptacle 104 is opened when retrieval of the property key 122 is possible by, for example, removing the lid 204 . In some cases, the lid 204 may be connected to the body 202 like a hinged door.
[0106] In further cases, the locking receptacle 104 may be any suitable shape as long as the opening 210 can fit a property key 122 and/or storage of certain other articles. The locking receptacle 104 may include further mechanisms for mounting to the exterior of the property; for example, mounting brackets, epoxy, or the like. In some cases, the locking receptacle 104 may be recessed into an exterior surface of the property. Although a circular locking receptacle 104 has been illustrated, it will be understood that the locking receptacle 104 can be any shape or size desired for holding the property key 122 , emergency contact sheet, garage door opener, parcel, or the like.
[0107] FIG. 3 illustrates an exploded perspective view of an embodiment of a frame 300 for a secure container 102 . The frame 300 of the secure container 102 includes a base 302 , a cover 304 , a faceplate 306 and a door 308 . The cover 304 attaches over the base 302 to form an enclosed space 310 . The front of the cover 304 includes a first opening 314 and a second opening 312 . The faceplate 306 is attached over the front of the cover 304 such that the openings 316 , 318 in the face plate 306 coincide with the openings 312 , 314 in the cover 304 .
[0108] The first opening 312 is configured to receive a container lock (described below) and the second opening 314 is configured to receive an access door 308 . In other embodiments, there may be only one opening with the lock incorporated into the access door 308 . The access door 308 may be hinged, removably attached, or otherwise openable relative to the faceplate 306 such that the access door 308 has an open position and a closed position. In the open position, the first opening 314 is open such that the contents of the enclosed space 310 are accessible. In the closed position, the access door 308 covers the first opening 314 to prevent access to the contents of the enclosed space 310 .
[0109] The components of the frame 300 are preferably attached to each other using secure screws and/or brackets such that the frame cannot be disassembled without at least first gaining access to the enclosed space 310 .
[0110] In some cases, the frame 300 may include mounting supports, for example a bracket, shelf, or the like, to attach the secure container 102 to a wall or the like. Further, the secure container 102 may be located in a vehicle, for example a fire truck, ambulance, car, or the like; and in this case, the frame 300 may include mounting supports to mount the secure container 102 to the vehicle. Power can be provided to the secure container, if necessary, by hard wiring the container into the vehicle electrical system. Alternatively, a separate power source can be provided for the secure container, such as batteries or the like.
[0111] In other embodiments, there may be a secondary access point (not shown) to the secure container 102 . In case, for example, the entry code for the container lock is lost, the container lock is malfunctioning, the secure container 102 loses power, or the like, the secondary access point may grant access to the enclosed space 310 to retrieve the receptacle key 114 . The secondary access point may be, for example, a second locked door operable by a master key, a second locked door operable with a special screwdriver, a specialized RFID tag that opens the access door 308 or a second locked door, or the like.
[0112] FIGS. 4 and 5 illustrate a front view of the secure container 102 with the access door 308 closed and open respectively.
[0113] In one embodiment, the secure container 102 includes a container lock 110 mounted to the front of the secure container, for example, a Linear AK-21 Digital Keypad Lock. In some cases, the correct entry code to the container lock 110 may be pre-programmed. In other cases, the correct entry code may be programmed by a user. In further embodiments, other suitable locks may be used; for example, a pin tumbler lock, RFID lock, facial/fingerprint recognition lock, lock incorporating a processor and liquid-crystal-display (LCD) screen, or the like.
[0114] FIGS. 6 and 7 illustrate example electrical block diagrams of the container lock 110 and secure container 102 respectively. Upon successful entry of the entry code into the container lock 110 , the electric door strike receives a signal to open the access door 308 . The access door 308 may then be opened revealing the contents of the enclosed space 310 , as shown in FIG. 5 .
[0115] In the example of FIGS. 4 and 5 , the contents of the enclosed space 310 include an alarm unit 112 and the receptacle key 114 . In some cases, the enclosed space 310 may include a light. The receptacle key 114 may be removed from a key holder 410 so that the receptacle key 114 may then be used to open the locking receptacle 104 . When removing the receptacle key 114 , the user may also remove the alarm trigger 406 from the alarm unit 112 . Removal of the alarm trigger 406 activates the alarm unit 112 in order to alert users that the receptacle key 114 is not present inside the enclosed space 310 . In some cases, there may be linkage (not shown) between the receptacle key 114 and the alarm trigger 406 such that both must be removed approximately together. The alert by the alarm unit 112 that the receptacle key 114 is not present may include a visual indicator 408 , for example a light-emitting-diode (LED), an audible indicator (not shown), for example a buzzer, or the like. It is an intended advantage that the alarm unit 112 can provide reassurance that the receptacle key 114 will be returned to the secure container 102 after the receptacle key 114 is used to open the locking receptacle 104 . In some cases, the visual indicator 408 and/or the audible indicator may be on a timer to cycle the indicator on and off periodically. In this way, the user will be notified and reminded if the user forgets to put the receptacle key 114 back into the secure container 102 . In some cases, the alarm unit may prevent the access door from being closed if the receptacle key 114 and the alarm trigger 406 have not been returned. It is intended that where the secure container 102 travels with the user to the property, the alarm unit 112 can indicate to a user not to leave the property before retrieving and returning the receptacle key 114 to the secure container 102 . Thus, substantially preventing the possibility of lost or forgotten receptacle keys 114 .
[0116] Other types of notifications and variations of triggering the alarm unit will be understood to be possible. For example, the alarm trigger may not be a separate physical component, but may be triggered internally, automatically upon removal of the receptacle key 114 . FIG. 16 shows an illustration of an embodiment of the secure container 102 with an internal trigger without a physical external alarm trigger 406 .
[0117] In an example, where the locking receptacle 104 stores property keys 122 for emergency responders such as firefighters, the secure container 102 may be mounted in the fire truck. When the firefighters arrive to respond to an emergency situation at a property, they unlock the secure container by disengaging the container lock 110 . Upon receiving access to the enclosed space 310 , the firefighters remove the receptacle key 114 and the alarm trigger 406 . In some cases, there may be linkage (not shown) between the receptacle key 114 and the alarm trigger 406 such that both must be removed approximately together. The firefighters may then use the receptacle key 114 to open the locking receptacle 104 in order to retrieve the property key 122 and enter the property. As the alarm trigger 406 has been removed from the alarm unit 112 , the alarm unit 112 will periodically alert the firefighters that the receptacle key 114 has yet to be returned. Thus, the firefighters will be reminded before they leave to retrieve the receptacle key 114 and not leave the receptacle key 114 at the property. Especially where the receptacle key 114 can open locking receptacles 104 for multiple properties, having the alarm unit 112 may increase security and reduce liability for the fire department by preventing a lost or forgotten receptacle key 114 .
[0118] Depending on the application, there may be more than one receptacle key 114 . In the above example, there may be a receptacle key 114 for each neighborhood of properties, for each street of properties, or the like. Having multiple receptacle keys 114 may help further limit liability if one of the receptacle keys should happen to go missing because the missing receptacle key will only affect a subset of properties. In some cases, the different receptacle keys 114 may be stored in the same secure container 102 . In these cases, when one of the receptacle keys 114 is removed from the secure container 102 , the alarm trigger 406 should also be triggered. In further cases, each of the different receptacle keys 114 may be stored in a separate secure container 102 .
[0119] In some cases, the enclosed space 310 of the secure container 102 may store other articles along with the receptacle key 114 . In the above example, the enclosed space 310 may include an extra set of keys for the fire truck or information on emergency procedures. In another example, where the secure container belongs to a real estate firm, the enclosed space 310 may contain private contact information and private details about the home owners.
[0120] In further embodiments, the receptacle key 114 may be tied into the alarm unit 112 such that removal of the receptacle key 114 from the secure container 102 activates the alarm unit 112 . In these cases, the alarm trigger 406 may not be required. The receptacle key 114 may be tied into the alarm unit 112 by, for example, having a sensor connected to the alarm unit 112 that determines when the receptacle key 114 is removed from the key holder 410 .
[0121] In some cases, there may be more than one type of locking receptacle 104 , and likewise, more than one type of counterpart receptacle key 114 . In an example, there may be a ‘lower security’ locking receptacle 104 and a ‘higher security’ locking receptacle 104 . The lower security locking receptacle 104 may be used to store lower risk articles, for example property owner contact information sheets. The higher security locking receptacle 104 may be used to store higher risk articles, for example property keys 122 . In this example, the lower security locking receptacle 104 may be a less secure type of key, for example a tubular key, and the higher security locking receptacle 104 may be a more secure type of key, for example an RFID key. As well, owing to the different levels of liability, the higher security receptacle key 114 may be stored in a secure container 102 while the lower security receptacle key 114 may be kept outside of a secure container 102 .
[0122] In some instances, the secure entry system 100 of FIG. 1 may include remote activation as another layer of security. In these instances, the secure container 102 may include an activation unit 116 . In other embodiments, the activation unit 116 may be a stand-alone entity. The activation unit 116 may be connected to an activator 106 via a network 108 . The network 108 may be, for example, an Ethernet connection, a personal area network (PAN), a local-area-network (LAN), the Internet, a cellular network, or the like. The receptacle key 114 may be connected to the secure container 102 via the network 108 . In further cases, the receptacle key 114 may be connected to the secure container 102 via a different network. In other cases, the receptacle key 114 may be directly connected to the activator 106 via the network 108 without requiring the secure container 102 as an intermediary.
[0123] In some cases, the receptacle key 114 may need to be inserted into the activation unit 116 in order to receive activation. In other cases, the receptacle key 114 may be connected to the activation unit 116 via the network 108 . In further cases, the receptacle key 114 may be connected to the activation unit 116 via a separate network. In yet other cases, the receptacle key 114 may be directly connected to the activator 106 via the network 108 without requiring the activation unit 116 as an intermediary. In yet other cases, the system 100 may be connected to the network 108 via a separate intermediary device that has network connection capabilities; for example, a laptop, a cellular phone, or the like.
[0124] In the above instances, the receptacle key 114 is configured to have an activation identifier stored on a programmable memory. The activation unit 116 may be configured to read/write to the receptacle key 114 in order to change the status of the activation identifier. The receptacle lock 120 is correspondingly configured to read the status of the activation identifier and programmed to only open the locking receptacle 104 when the activation identifier is set to ‘on’. When the activation identifier is set to ‘off’, the receptacle lock 120 will not open even if the receptacle lock 120 is engaged by the counterpart receptacle key 114 .
[0125] The activation identifier may be set by the activator 106 via the activation unit 116 . The activation identifier will normally be set to ‘off’ such that the receptacle key 114 will not engage the receptacle lock 120 until activated. In anticipation of using the receptacle key 114 to open the receptacle lock 120 , a user may make a request to the activator 106 to activate the receptacle key 114 by setting the activation identifier to ‘on’. The activator 106 may similarly set the activation identifier to ‘off’. In some cases, the activation identifier may be set to ‘off’ automatically at the expiry of a predetermined timer, automatically after the receptacle key 114 opens the receptacle lock 120 , or the like.
[0126] The activator 106 may be, for example, a person at a computer with authorization powers, a computer that can automatically analyze the source of the request to grant authorization, part of an emergency dispatch system, or the like. The user may make the activation request by, for example, placing a phone call with the activator 106 , triggering an activation request switch on the secure container 102 or on the receptacle key 114 , or the like. In other cases, where the activator 106 is part of an emergency dispatch system, the activation request may be sent automatically when the emergency responders are sent out to a call. Where there is more than one receptacle key 114 , each receptacle key 114 may have a unique activation identifier such that the activator 106 can activate a specific receptacle key 114 . In some cases, the activator 106 may receive data from the alarm unit 112 regarding whether the receptacle key 114 has been removed and/or returned to the secure container 102 . It is intended that use of the activator 106 may provide a supplementary layer of security as lost or stolen receptacle keys 114 will not work without activation. As such, there may be less liability for users if they were to lose the receptacle key 114 as the receptacle key 114 would be unusable. For example, the receptacle key could have an RFID thereon that communicates with the activator or the secure container. A unique identifier system could be included to provide a further level of security.
[0127] FIG. 8 is a flowchart for an embodiment of a method for secure entry 800 . At 802 , a user disengages a container lock 110 located on a secure container 102 . The container lock 110 may be, for example, a Linear AK-21 Digital Keypad Lock, a pin tumbler lock, RFID lock, facial/fingerprint recognition lock, lock incorporating a processor and liquid-crystal-display (LCD) screen, or the like. Upon disengaging the container lock 110 , the access door 308 is openable and, at 804 , the receptacle key 114 may be removed from the enclosed space 310 . At 806 , the alarm trigger 406 is also removed from the enclosed space 310 in order to active the alarm unit 112 or the alarm trigger is triggered internally. At 808 , the user engages the receptacle lock 120 with the receptacle key 114 in order to open the locking receptacle 104 . At 810 , the user gains access to the opening 210 of the locking receptacle 104 where the user may remove the property key 122 . In other cases, other articles along with, or instead of, the property key 122 may be retrieved by the user from the locking receptacle 104 ; for example, an emergency contact information sheet, a garage door opener, a parcel, or the like. At 812 , the user may enter the property using the property key 122 .
[0128] FIG. 9 is a flowchart for another embodiment of a method for secure entry 900 . At 902 , a user disengages a container lock 110 located on a secure container 102 . At 904 , the user requests activation of the receptacle key 114 from the activator 106 . The user may make the activation request by, for example, placing a phone call with the activator 106 , triggering an activation request switch on the secure container 102 or on the receptacle key 114 , or the like. At 906 , the activator 106 , manually or automatically, determines whether the user has authorization to use the receptacle key 114 . If the activator 106 determines that the user is not authorized to gain access to the locking receptacle 104 , at 908 , the activator 106 does not activate the receptacle key 114 . If the activator 106 determines that the user is authorized to gain access to the locking receptacle 104 , at 910 , the activator 106 activates the receptacle key 114 . Upon disengaging the container lock 110 and receiving activation of the receptacle key 114 , the access door 308 is openable and, at 912 , the receptacle key 114 may be removed from the enclosed space 310 . At 914 , the alarm trigger 406 is also removed from the enclosed space 310 in order to active the alarm unit 112 or the alarm trigger is triggered internally. At 916 , the user engages the receptacle lock 120 with the activated receptacle key 114 in order to open the locking receptacle 104 . At 918 , the user gains access to the opening 210 of the locking receptacle 104 where the user may remove the property key 122 . In other cases, other articles along with, or instead of, the property key 122 may be retrieved by the user from the locking receptacle 104 ; for example, an emergency contact information sheet, a garage door opener, a parcel, or the like. At 920 , the user may enter the property using the property key 122 . In further cases, the activation of the receptacle key 114 may be prior to the disengagement of the container lock 110 (for example, when an emergency responder is travelling to the emergency), or after the receptacle key 114 is removed from the enclosed space 310 (for example, when the emergency responder is walking from the truck to the property).
[0129] An example embodiment of mounting of the locking receptacle is shown in FIG. 10 . In this example, the locking receptacle is roughly 1½ inches in diameter and 4 inches long. It is installed on the outside of a property by drilling into the brick, siding, stone etc. The locking receptacle is recessed flush to the outside wall and houses a copy of the property key internally. The locking receptacle can be opened using a receptacle key such as an electronic key obtained from the secure container, for example an electronically programmable smart key, such as provided by Medeco Nexgen XT. An example electronic key inserted into the end of a locking receptacle is illustrated in FIG. 11 . Such an electronic key can receive a signal from an activator such as via local dispatch or from an officer's cell phone, which can activate the key for a specific length of time. In one embodiment, the electronic key is locked in a secure container on a mobile platform that determines a key programming code based on a geographic position in real-time. The programming code provides the user with a secure and traceable method to gain access to a property, while at the same time still maintaining a secure environment for the property owners.
[0130] As an alternate embodiment, a traditional manual key can be used instead of the electronic key. FIG. 12 shows an example of a manual key inserted into the end of a locking receptacle, which could house a contact number inside for example. This could be a phone number or emergency contact person in case emergency crews need to gain access to the property or to at least inform the property owner that there is a problem at the property. The manual key to open this type of lock could be attached to the electronic key inside the secure container.
[0131] FIG. 13 shows both types of locking receptacles, each in a closed configuration next to the respective manual and electronic keys.
[0132] FIG. 14 illustrates a sample system configuration using an electronic key such as shown in FIG. 11 . The following discusses this sample system configuration.
[0133] A secure container interconnects with a vehicle ignition and external lighting systems to enable and activate a receptacle key. While en route a GPS constantly reviews the current position and accesses a local database containing a localized list of cylinder codes for locations enabled with lock boxes. The local database can be on an SD card in a binary format and encrypted with Advanced Encryption Standard (AES) keys. The local database can also be on any other suitable format using other suitable encryption standards.
[0134] The secure container in one embodiment can include a slot for the SD card (or other removable media), a connector to an interface with a smart security keypad having, for example, 4 digital outputs, and 2 digital inputs. An operator plugs an SD card 950 into the secure container on a firetruck 952 , for example, to enable operation. The SD card can be periodically refreshed from any controlled laptop/PC 956 via an internet connection 958 . Upon receiving an external signal from the smart keypad, the unit can use the supplied parameters to filter through a localized list of cylinder codes on the removable media (SD Card), and output a list of codes that are then downloaded to the receptacle key. The localized list of cylinder codes will preferably reside on removable media such as an SD card and will preferably be encrypted. Other telecommunication devices such as smart phones, smart watches, IPAD™s, IPOD™s, or the like can be used to refresh the SD card.
[0135] In a further related example, when the secure container is accessed, for example via a keypad, the nearest lock box codes are downloaded to the electronic key. This keypad access also records the user ID of the access code, the date and time of the access, the location (in GPS NMEA coordinates) and other operational parameters. This traceability information is then transmitted to a central office. Upon receipt of this information at the central office and authentication being granted, access is then allowed to the electronic key. Once the electronic key is removed, the alarm trigger circuitry activates and starts measuring the duration that the electronic key is not within the secure container. Replacing the electronic key, verification of the access code, and closing the secure container terminates the duration measurement and causes another communication with the central office. The communication terminates the activity report for that call providing the department with a report that contains various points of information, such as:
Operation data log Date/time of start of call Distance travelled to call Time en route User id of person gaining access to electronic key Location of access Access key codes downloaded Time of keypad access Time electronic key was removed Duration electronic key was in service Notifications prompting key replacement
[0147] The present secure entry system in another aspect is able to provide multiple individual entry codes so that each emergency response attendant with approved access to their secure container could have their own access code to the secure container, thus creating accountability respecting the last person to access the container. In another embodiment, multiple levels of notification and alarm indications can be implemented. Each notification/alarm provides increased visibility for the need to replace the key. All elapsed time values can be configurable from the central office. The electronic key can include a built-in failsafe whereby it automatically loses access to all lock boxes after a fixed interval of 24 hours. Examples of alarm levels, indicators and elapsed time are shown in the below table:
[0000]
Alarm/
Elapsed
notification
time
level
Indicators
(default)
1
Flashing light
1 Hr
2
Flashing light and intermittent buzzer
2 Hrs
3
Flashing light and constant buzzer
4 Hrs
4
Flashing light, constant buzzer and SMS to
8 Hrs
central office
5
System shutdown and key deactivation from
24 Hrs
database
[0148] In one case, audit information recorded in both the locking receptacle and electronic key shows a time-and-date stamped record of every event, including authorized accesses and unauthorized attempts.
[0149] During deployment, for example, the locking receptacle codes, access codes, GPS location, and other pertinent information can be recorded along with the quality of signal to ensure that no lockbox will be installed without an adequate signal for both GPS and cellular signals. This assists in avoiding signal ‘canyoning’ between buildings and ensuring two way communications with the central office and/or the secondary/backup facility. Canyoning is where the GPS signals bounce off adjacent buildings or other natural obstacles preventing an accurate location ‘fix’.
[0150] FIG. 15 shows a sample connection between a GPS link, local database at a central office or other location and the system including various system timers, a keypad interface and an electronic key having, for example, a general purpose input/output (GPIO), an interface and a smart charger.
[0151] In one embodiment, the secure container is a small and portable stand-alone container. The secure container can accept a message (e.g. a formatted data packet) via a standard wired interface (for example, rs232/485, USB, I2C, SPI, or other suitable wired interface) that contains filter parameters. Preferably the secure container is operable in a wide range of temperatures. Preferably the secure container operates with 12 VDC switched power source, with backup power available.
[0152] In another embodiment of the present invention, the secure container includes a computer chip board that acknowledges all locking receptacles installed in both residential and commercial use as said EMS or non-emergency vehicle moves throughout an area. In this embodiment, a vehicle starts and sends a charge to the secure container. As the vehicle moves, a signal is sent from the secure container to all installed locking receptacles. As each locking receptacle comes within range of the secure container, the secure container can read and acknowledge the locking receptacle.
[0153] In a further related case, once the vehicle stops moving, the receptacle key inside the secure container can only open locking receptacles within a given range, for example 100 feet. For example, when the vehicle arrives at the destination and the secure container is opened, a GPS signal is sent to the electronic receptacle key to make the key “live” for a specified period of time. The distance from the secure container to the locking receptacle can be varied to be any reasonable distance, for example, 50 feet, 100 feet, 200 feet or more. Similarly, such a distance limitation for the electronic key is optional.
[0154] In another aspect, the present secure entry system can include a Tile GPS locator for each set of receptacle key(s). This miniature locator finds lost/misplaced keys at a scene within a given distance, for example 100 feet. The Tile also works within a community so that if said fire truck has lost keys and is outside the range for the key, other fire trucks that are closer can pick up the signal via a cell phone app or other similar sensor/monitoring mechanism.
[0155] FIG. 17 illustrates an example mounting bracket for attaching the secure container to a vehicle.
[0156] Various sample materials that can be used include a metal shell with a commercial punch key pad, charging system for an electronic key, a chip board and a lighting system.
[0157] It is intended that the systems and methods described herein may provide convenient and secure entry into one or more properties. Particularly where there are multiple properties, each with a different property key for entry, the systems and methods described herein can provide convenience to a user as the user may carry significantly less receptacle keys than if the user were to carry around all the property keys. There is also added convenience for the user as the user does not have to wait for a property owner to open the property, or, where there is an emergency in the property, the user does not have to break down the property's entryway. Further, it is recognized that the receptacle key is a high value object as it can be used to gain entry into one or more properties. Thus, it is an intended advantage that having the receptacle key stored in a secure container provides added security and reduces liability to the user. An alarm unit is intended to further provide added security by protecting against the possibility that the receptacle key is not returned to the secure container after entry to the locking receptacle. In some cases, further security measures for the receptacle key may be implemented by requiring the receptacle key to be activated prior to use; this ensures that if the receptacle key were to get lost or stolen, the receptacle key would be unusable. The system described herein provides a quick response to security threats, lost or stolen keys, or personnel changes without the added cost of changing locks and keys.
[0158] In the preceding description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the embodiments. However, it will be apparent to one skilled in the art that these specific details may not be required. In other instances, well-known electrical structures and circuits are shown in block diagram form in order not to obscure the understanding. For example, specific details are not provided as to whether aspects of the embodiments described herein are implemented as a software routine, hardware circuit, firmware, or a combination thereof.
[0159] Embodiments of the disclosure can be represented as a computer program product stored in a machine-readable medium (also referred to as a computer-readable medium, a processor-readable medium, or a computer usable medium having a computer-readable program code embodied therein). The machine-readable medium can be any suitable tangible, non-transitory medium, including magnetic, optical, or electrical storage medium including a diskette, compact disk read only memory (CD-ROM), memory device (volatile or non-volatile), or similar storage mechanism. The machine-readable medium can contain various sets of instructions, code sequences, configuration information, or other data, which, when executed, cause a processor to perform steps in a method according to an embodiment of the disclosure. Those of ordinary skill in the art will appreciate that other instructions and operations necessary to implement the described implementations can also be stored on the machine-readable medium. The instructions stored on the machine-readable medium can be executed by a processor or other suitable processing device, and can interface with circuitry to perform the described tasks.
[0160] The above-described embodiments are intended to be examples only. Alterations, modifications and variations can be effected to the particular embodiments by those of skill in the art. The scope of the claims should not be limited by the particular embodiments set forth herein, but should be construed in a manner consistent with the specification as a whole.
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There is provided a system and method for secure entry to a property or building. One aspect includes an apparatus having a housing and alarm means for triggering a timed alarm upon removal of a receptacle key from the housing. Locking means is included for locking the housing. Another aspect includes a removable media containing a list of cylinder codes. At least a portion of the list of cylinder codes are transferred to a receptacle key within the housing. Another aspect involves a system having a secure container with locking means for locking a housing. The system includes at least one locking receptacle that is unlocked with the receptacle key. Also provided is a method comprising the steps of retrieving a receptacle key from a secure container, triggering a timed alarm for return of the receptacle key and accessing a locking receptacle with the receptacle key.
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CROSS REFERENCE TO PRIORITY APPLICATION
The present application claims priority to German Patent Application No. 102008043036.0, filed Oct. 22, 2008, titled “Internal Combustion Engine Having Turbocharging and Low-Pressure Exhaust-Gas Recirculation,” the entire contents of each of which are incorporated herein by reference.
TECHNICAL FIELD
The description relates to an internal combustion engine having a turbocharger, having a first particle filter in the exhaust section of the internal combustion engine and having a low-pressure exhaust-gas recirculation (EGR) line that comprises a second particle filter, and to a method for exhaust-gas recirculation in an internal combustion engine having turbocharging and having low-pressure exhaust-gas recirculation.
BACKGROUND AND SUMMARY
A device of said type and a method of said type are known from DE 10 2006 038 706 A1. Here, for the purpose of nitrogen oxide reduction, recirculated exhaust gas is branched off from the exhaust section downstream of a first particle filter and upstream of a catalytic converter and a silencer. The second particle filter in the low-pressure EGR line may passively assume a temperature of up to 800° C. as a result of the hot exhaust gases.
In contrast to a high-pressure EGR system, in which the recirculated exhaust gas is branched off upstream of the turbine of the turbocharger, in a low-pressure EGR system, the recirculated exhaust gas is branched off downstream of the turbine of the turbocharger after having passed through a particle filter. As a result, a low-pressure EGR system has the disadvantages, in low-load operation, of a higher back pressure, and a longer build-up phase of the proportion of unburned mass in the inlet, than a high-pressure EGR system.
The description is based on the object of providing an improved low-pressure EGR system.
Said object is achieved with a generic device and a generic method by means of the characterizing features of the claims that follow.
In one embodiment the present description provides for an EGR system for an internal combustion engine, comprising: internal combustion engine having a turbocharger, an intake system, and an exhaust system; a first particle filter located in said exhaust system at a location downstream of a turbine of said turbocharger; a second particulate filter located in a EGR line having inlet located in said exhaust system at a location upstream of said first particle filter, said second particulate filter having a heater.
By having the EGR line branch off from the exhaust section upstream of the first particle filter, less mass flow need pass through the first particle filter and/or an oxidation catalytic converter, such that the exhaust-gas back pressure is reduced. Furthermore, the volume of the EGR section can be significantly reduced. This significantly improves the response speed of the EGR system. Soot and oil particles which are contained in the recirculated exhaust gas, and which may not pass into the compressor of the turbocharger, can be combusted by means of the heatable particle filter, such that said particle filter does not become easily blocked. Furthermore, a heatable particle filter of said type may be significantly smaller than a conventional particle filter, for example less than half the volume.
It is expedient for the heatable particle filter not to be held constantly at a temperature at which soot and oil particles combust, but rather to be heated only in phases for the purpose of regeneration. Suitable times for this are for example operating states in which the turbocharger is running at only a low rotational speed, in order that soot and oil particles that may be released, un-combusted or only partially combusted, from the filter structure do not degrade the compressor of the turbocharger. Furthermore, at a low rotational speed of the turbocharger, the gas throughput through the filter is low, such that the heating power to be imparted is low.
Advantageous refinements of the description can be gathered from the subclaims and the description.
The description is explained in more detail below on the basis of the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantageous refinements of the description are disclosed in the dependent claims and in the following description of the figures:
FIG. 1 shows a schematic illustration of an engine EGR system; and
FIG. 2 shows a schematic illustration of a flow chart of a method to control exhaust-gas recirculation.
DETAILED DESCRIPTION
The FIG. 1 shows a diagrammatic sketch of an internal combustion engine having turbocharging and having low-pressure exhaust-gas recirculation. Although the exemplary embodiment relates to a diesel engine, the description may however also be applied to other types of internal combustion engine.
A schematically illustrated multi-cylinder diesel engine 2 has inlet ducts 4 and outlet ducts 6 . The outlet ducts 6 open out via a collector 8 into an exhaust line 10 , which opens out into a turbine 12 of a turbocharger 14 . The turbine 12 is coupled by means of a shaft 16 to a compressor 18 of the turbocharger 14 . The turbocharger 14 may be a turbocharger with fixed geometry (FGT) or a turbocharger with variable geometry (VGT).
The outlet of the turbine 12 is adjoined by an exhaust section 20 in which are arranged, in this sequence, a diesel oxidation catalytic converter 22 , a diesel particle filter 24 , a control system for controlling the exhaust-gas back pressure, which control system comprises a throttle flap 26 and a bypass 28 , which leads past the throttle flap 26 , with an integrated valve, and a silencer 30 .
A low-pressure EGR line 32 is connected to the exhaust section 20 downstream of the turbine 12 and upstream of the diesel oxidation catalytic converter 22 , which low-pressure EGR line 32 opens out via an EGR valve 34 into a fresh-air line 36 that conducts fresh air from an air filter 38 into the compressor 18 of the turbocharger 14 .
The mixture of fresh air and recirculated exhaust gas that is compressed by the compressor 18 passes via an air inlet line 40 into a combined inlet air cooler and distributor 42 , where said mixture is cooled and distributed between the inlet ducts 4 . The inlet air cooler and distributor 42 comprises a bypass (not shown), with the inlet air mixture being conducted, as required, either through the inlet air cooler and distributor 42 or through the bypass and past the inlet air cooler and distributor 42 .
A throttle flap 44 may also be provided in the inlet line 40 in order to close the inlet line 40 when the diesel engine 2 is shut down.
The low-pressure EGR line 32 comprises a heatable particle filter 46 that is traversed by the recirculated exhaust gas. The particle filter 46 comprises an electric heater, for example in the form of grids, which are integrated into the filter matrix, composed of heating or glow wires 47 , by means of which any soot and oil particles in the recirculated exhaust gas are burned.
The low-pressure EGR line 32 may also comprise, downstream of the particle filter 46 and upstream of the EGR valve 34 , a heat exchanger 48 that dissipates the heat contained in the exhaust gas to an arbitrary heat sink—such as for example the inlet air collector and cooler 40 . The heat exchanger 48 comprises a bypass (not shown), with the inlet air mixture being conducted selectively either through the heat exchanger 48 or through the bypass and past the heat exchanger 48 .
Referring now to FIG. 2 , a method to control EGR for an internal combustion engine is shown. Routine 200 begins at 202 where engine operating conditions are determined. Engine operating conditions are determined from sensors and actuators. In one example, routine 200 determines engine temperature, ambient temperature, the pressure drop across a particulate filter in the high pressure EGR loop, the pressure drop across a particulate filter in the exhaust system, time since engine start, engine load, engine torque demand, engine speed, and amount of air inducted to the engine. In other example embodiments, additional or fewer operating conditions may be determined based on specific objectives.
At 204 , the routine judges whether or not to flow EGR. The decision to flow EGR may be based on the operating conditions determined at 202 . In one example, EGR is activated after the engine has been operating for a threshold amount of time and after engine coolant temperature reaches a threshold level. In addition, other conditions may be used to activate or enable the EGR system. For example, EGR may be enabled after engine load is greater than a threshold or after engine speed exceeds a threshold. Routine 200 then proceeds to 206 if EGR is activated. Otherwise, routine 200 proceeds to exit.
At 206 , the EGR valve is controlled in response to engine operating conditions. In one example, the EGR valve position is related to engine speed and driver demand torque. The EGR valve positions may be stored in a table or function indexed by engine speed and driver demand torque. The EGR valve positions correspond to an empirically determined EGR flow rate. The EGR valve position may be controlled by a vacuum actuator or by a stepper motor, for example.
At 208 , routine 200 judges whether or not to regenerate a particulate filter in the EGR loop. In one embodiment, routine 200 makes a decision based on the pressure drop across a particulate filter. In another embodiment, routine 200 may decide to regenerate the particulate filter in response to a model. For example, a soot accumulation model that estimates the amount of soot produced by an engine may be the basis for regenerating a particulate filter. If the estimated amount of soot exceeds a threshold, particulate filter regeneration is initiated. On the other hand, if a pressure across the particulate filter is determined from a sensor or an estimating model, particulate filter regeneration may be initiated after the observed or estimated pressure exceeds a threshold.
In addition, other conditions may be included that determine when to regenerate the particulate filter. For example, filter regeneration may not proceed if engine temperature is above a threshold temperature or if engine temperature is below a threshold temperature.
In one embodiment an electrically heated particulate filter is activated after EGR begins flowing in the EGR tube so that oxidized particulate matter may be oxidized and released from the filter and then flow back into the engine before being exhausted. Further, in one embodiment, the temperature of the particulate filter may be elevated by flowing EGR into the engine for a predetermined amount of time before the electrical heater is activated to heat the particulate filter. In other words, current is not supplied to the particulate filter heater until exhaust gases have flowed from the exhaust system to the intake system for a threshold amount of time or until the particulate filter reaches a threshold temperature. By elevating the particulate filter temperature with exhaust gases, it is possible to lower the thermal gradient that the filter is exposed to and therefore degradation of the particulate filter and particulate filter heater may be reduced. In one example, the rate that current is applied to the particulate filter heater may be related to the temperature of the particulate filter at a time when regeneration is requested. For example, as the temperature of the particulate filter increases, the amount of current supplied to the particulate filter over a period of time can be increased. If particulate filter regeneration is desired and conditions are met, routine 200 proceeds to 210 . Otherwise, routine 200 proceeds to exit.
At 210 , current is ramped to the electrical particulate filter heater that is in the EGR loop. For example, current may be applied at a low level and increased over a period of time. In one example, the heater current is ramped when the engine is relatively cold. For example, if the engine is started at 20° C. the particulate filter heater current may be slowly ramped so that heater or particulate filter performance does not degrade. At higher temperatures, the particulate filter heater current may be ramped at a higher rate of current per second. Thus, under a first condition of a particulate filter heater current is ramped at a first rate of current, and under a second condition of a particulate filter heater current is ramped at a second rate.
At 212 , routine 200 judges whether or not particulate filter regeneration is complete or if conditions for regeneration are no longer present. In one embodiment, regeneration is determined complete when the pressure difference across the particulate filter is less than a predetermined amount. If routine 200 judges that regeneration is complete, routine 200 proceeds to exit. Otherwise, routine continues to loop back.
It will be appreciated that the configurations disclosed herein are exemplary in nature, and that these specific embodiments are not to be considered in a limiting sense, because numerous variations are possible. For example, the above systems can be applied to V-6, I-4, I-6, V-12, opposed 4, and other engine types.
The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various systems and configurations, and other features, functions, and/or properties disclosed herein.
The following claims particularly point out certain combinations and subcombinations regarded as novel and nonobvious. These claims may refer to “an” element or “a first” element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and/or properties may be claimed through amendment of the present claims or through presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.
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The description relates to an internal combustion engine having a turbocharger, having a first particle filter in the intake section of the internal combustion engine and having a low-pressure EGR line that comprises a second particle filter. A fast-reacting low-pressure exhaust gas recirculation system with small dimensions can be realized by virtue of the EGR line branching off from the exhaust section upstream of the first particle filter, and the second particle filter being provided with a heater. The description also relates to a corresponding EGR method.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field of the Invention
[0002] The present invention relates generally to a valve actuating device equipped with an electrically operated actuator and a fuel injector for internal combustion engines equipped with such a valve actuating device.
[0003] 2. Background Art
[0004] Hydraulic fuel injectors equipped with a piezoelectric valve actuator are used in internal combustion diesel engines of automotive vehicles. Such a fuel injector includes a large-diameter piston moved by the expansion and contraction of the piezoelectric valve actuator, a pressure chamber filled with hydraulic fluid, and a small-diameter piston which are arranged in alignment with each other. The movement of the large-diameter piston causes the hydraulic fluid in the pressure chamber to change in pressure, which moves the small-diameter piston. The small-diameter piston then actuates a control valve.
[0005] When it is required to emit a fuel spray, the piezoelectric valve actuator is energized so that it expands to increase the hydraulic pressure in the pressure chamber through the large-diameter piston. This causes the expansion of the piezoelectric valve actuator to be amplified hydraulically and transmitted to the small-diameter piston. The small-diameter piston then moves downward and opens the control valve. When the control valve is opened, it will cause the pressure in a back pressure chamber to drop, thereby lifting up a nozzle needle to initiate fuel injection. Contracting the piezoelectric valve actuator will cause the small-diameter piston to move upward, thereby closing the control valve to terminate the fuel injection.
[0006] There is known the above type of fuel injector which has disposed therein a hydraulic mechanism designed to supply working fluid to the pressure chamber through a check valve in order to compensate for a leakage of working fluid from the pressure chamber. For example, U.S. Pat. No. 5,779,149 to Hayes, Jr. teaches a fuel injector which has formed therein a fluid passage serving to direct the fuel leaking from a nozzle needle to a pressure chamber through a check valve made up of a ball valve and a coil spring. U.S. Pat. No. 6,155,532 (corresponding to Japanese Patent First Publication No. 11-166653) teaches a fuel injector which has a refill valve disposed in a radial direction of a pressure chamber for compensating for a leakage of fuel from the pressure chamber. The refill valve is, like the above structure, made up of a ball valve and a coil spring.
[0007] The above structures, however, have three drawbacks as discussed below.
[0008] (1) The pressure chamber being filled with the working fluid after assembly of the fuel injector, air may be left in the pressure chamber, thus resulting in instability of operation of the fuel injector. (2) The small-diameter piston falls downward by the gravity while the fuel injector is at rest for a long period of time, so that an amount of working fluid equivalent to a change in volume of the pressure chamber is supplied to the pressure chamber through the check valve, thereby making it difficult to lift up the small-diameter piston, which disenables a subsequent operation of the fuel injector. (3) If power supply to the piezoelectric valve actuator is cut undesirably during expansion of the piezoelectric valve actuator, it becomes impossible for the piezoelectric valve actuator to contract, thus resulting in the pressure in the pressure chamber being kept at higher levels, which causes the fuel to continue to be sprayed from the fuel injector. Further improvement of controllability and safety of fuel injectors is, therefore, sought.
SUMMARY OF THE INVENTION
[0009] It is therefore a principal object of the invention to avoid the disadvantages of the prior art.
[0010] It is another object of the invention to provide an improved structure of a valve actuating device which assures higher controllability and safety in operation and a fuel injector equipped with such a valve actuating device.
[0011] According to one aspect of the invention, there is provided a valve actuating device which may be used in a fuel injector for automotive internal combustion engines. The valve actuating device comprises: (a) an actuator; (b) a first piston displaced by the actuator; (c) a second piston operating a valve, the second piston being smaller in diameter than the first piston; (d) a displacement amplifying chamber provided between the first piston and the second piston, the displacement amplifying chamber being filled with working fluid to amplify and transmit displacement of the first piston to the second piston; and (e) a drain passage communicating with the displacement amplifying chamber through a pinhole for draining the working fluid within the displacement amplifying chamber.
[0012] In the preferred mode of the invention, the diameter of the pinhole is within 0.02 to 0.5 mm.
[0013] A check valve is disposed between the displacement amplifying chamber and the drain passage which allows the working fluid to flow only from the drain passage to the displacement amplifying chamber. The check valve includes a flat valve in which the pinhole is formed.
[0014] The first piston has formed therein a passage leading to the drain passage. The pinhole is provided between the passage and the displacement amplifying chamber.
[0015] The first piston has a length in which the passage extends longitudinally and has an opening formed in a first end of the length exposed to the displacement amplifying chamber. The flat valve of the check valve is disposed on the opening of the passage to allow the working fluid to flow only from the drain passage to the displacement amplifying chamber through the passage. The pinhole is formed in the flat valve of the check valve.
[0016] An oil sump is formed on a side of a second end of the first piston opposite the first end and establishes fluid communication between the drain passage and the passage.
[0017] A spring chamber is formed on the side of the first end of the first piston in which a spring is disposed to urge the actuator away from the displacement amplifying chamber. The spring chamber defines the oil sump.
[0018] According to another aspect of the invention, there is provided a fuel injector which may be employed in automotive internal combustion engines. The fuel injector comprises: (a) an injector body; (b) a fuel inlet passage formed in the injector body; (c) an actuator; (d) a first piston displaced by the actuator; (e) a second piston smaller in diameter than the first piston, the second piston operating a valve for spraying fuel supplied from the fuel inlet passage from a spray hole; (f) a displacement amplifying chamber formed between the first piston and the second piston within the injector body, the displacement amplifying chamber being filled with working fluid to amplify and transmit displacement of the first piston to the second piston; and (g) a drain passage formed in the injector body which communicates with the displacement amplifying chamber through a pinhole for draining the working fluid within the displacement amplifying chamber.
[0019] In the preferred mode of the invention, the displacement amplifying chamber is filled with the working fluid at a factory.
[0020] The working fluid is injected into the displacement amplifying chamber at the factory after the displacement amplifying chamber is evacuated.
[0021] The injector body is sealed to avoid leaking of the working fluid in the displacement amplifying chamber out of the injector body.
BRIEF DESPCRIPTION OF THE DRAWINGS
[0022] The present invention will be understood more fully from the detailed description given hereinbelow and from the accompanying drawings of the preferred embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiments but are for the purpose of explanation and understanding only.
[0023] In the drawings:
[0024] [0024]FIG. 1 is a vertical sectional view which shows a fuel injector equipped with a valve actuating device according to the first embodiment of the invention;
[0025] [0025]FIG. 2( a ) is a sectional view which shows a flat valve of a check valve installed in the fuel injector of FIG. 1;
[0026] [0026]FIG. 2( b ) is a plan view of FIG. 2( a );
[0027] [0027]FIG. 2( c ) is a perspective view which shows a conical spring of a check valve;
[0028] [0028]FIG. 3( a ) is a time chart which shows the voltage applied to a piezoelectric actuator;
[0029] [0029]FIG. 3( b ) is a time chart which shows the pressure in a displacement amplifying chamber;
[0030] [0030]FIG. 3( c ) is a time charts which shows the amount of lift of a ball valve used to control the pressure in a control chamber;
[0031] [0031]FIG. 3( d ) is a time chart which shows the pressure in a control chamber;
[0032] [0032]FIG. 3( e ) is a time chart which shows the amount of lift of a nozzle needle;
[0033] [0033]FIG. 4( a ) is a sectional view which shows a spring which may be used instead of the conical spring of FIG. 2( c ); and
[0034] [0034]FIG. 4( b ) is a plan view of FIG. 4( a ).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Referring to the drawings, wherein like reference numbers refer to like parts in several views, particularly to FIG. 1, there is shown a fuel injector 100 according to the invention. The following discussion will refer to, as an example, a common rail fuel injection system in which the fuel injector 100 is provided for each cylinder of a diesel engine. The common rail fuel injection system includes a common rail which accumulates therein fuel supplied from a fuel tank elevated in pressure by a fuel pump installed on the engine. When it is required to inject the fuel into the engine, the fuel stored in the common rail is supplied to the fuel injectors 100 under high pressure.
[0036] The fuel injector 100 is designed to move a nozzle needle 12 vertically to open or close a spray hole 11 formed in a head of a nozzle body B 1 for initiating or terminating fuel injection. The spray hole 11 is opened upon movement of the nozzle needle 12 to an upper limit position and communicates with a fuel sump 31 leading to a high-pressure passage 3 , so that the fuel is supplied to the spray hole 11 . The spray hole 11 is closed upon movement of the nozzle needle 12 to a lower limit position, so that the communication with the fuel sump 31 is blocked to cut the fuel supply to the spray hole 11 . The low limit position of the nozzle needle 12 is defined by a nozzle seat 13 on which the nozzle needle 12 is seated. The upper limit position is defined by an orifice plate P 1 disposed above the nozzle body B 1 .
[0037] The nozzle body B 1 is installed on a lower end of a housing H of a valve actuating device 1 through orifice plates P 1 and P 2 and disposed within a nozzle holder B 2 in liquid-tight form. The high-pressure passage 3 extends upward from the fuel sump 31 to the common rail through the orifice plates P 1 and P 2 and the housing H. Within the housing H, a drain passage 2 is formed which leads to the fuel tank. A control chamber 4 is defined between an upper end of the nozzle needle 12 and the orifice plate P 1 . The nozzle needle 12 is urged downward, as viewed in the drawing, by the spring pressure of a coil spring 41 and the hydraulic pressure within the control chamber 4 to close the spray hole 11 at all times.
[0038] The hydraulic pressure in the control chamber 4 is controlled by the activity of a three-way valve 5 of the valve actuating device 1 . The three-way valve 5 consists of a conical valve chamber 51 formed in a lower end of the housing H and a ball valve 52 . The valve chamber 51 always communicates with the control chamber 4 through a passage extending through the orifice plates P 1 and P 2 and a main orifice 42 formed in the passage. The valve chamber 51 has two ports: a drain port 21 and a high-pressure port 32 . The ball valve 52 closes either the drain port 21 or the high-pressure port 32 at all times, thereby establishing fluid communication between one of the drain port 21 and the high-pressure port 32 and the control chamber 4 . The drain port 21 communicates with the drain passage 2 through a spill chamber 22 formed above the valve chamber 51 . The high-pressure port 32 extends vertically through the orifice plates P 1 and P 2 and communicates with the high-pressure passage 3 through a groove 33 formed in a lower end surface of the orifice plate P 2 .
[0039] Specifically, when the valve chamber 51 communicates with the drain port 21 , it will cause the control chamber 4 to be decreased in pressure, thereby moving the nozzle needle 12 out of the nozzle seat 13 . Alternatively, when the valve chamber 51 communicates with the high-pressure port 32 , it will cause the control chamber to be increased in pressure, thereby moving the nozzle needle 12 downward into engagement with the nozzle seat 13 . The control chamber 4 communicates directly with the high-pressure passage 3 at all times through a sub-orifice 43 formed in the orifice plate P 1 . The sub-orifice 43 serves to supply the fuel from the high-pressure passage 3 to the control chamber 4 to reduce a pressure drop in the control chamber 4 at the start of fuel injection for smoothing the movement of the nozzle needle 12 , while it works to promote a pressure rise in the control chamber 4 to speed up the movement of the nozzle needle 12 when closing the spray hole 11 .
[0040] Around an opening of the drain part 21 leading to the valve chamber 51 , a conical drain seat 53 is formed. Around the high-pressure port 32 leading to the valve chamber 51 , a flat high-pressure seat 54 is formed. The drain seat 53 may alternatively be formed to be flat, while the high-pressure seat 54 may be formed to be conical. This compensates for a lateral shift of the ball valve 52 . The pressure in the valve chamber 51 is always higher than the pressure in the drain port 21 , so that the ball valve 52 is kept seated on the drain seat 53 . The pressure acting on the ball valve 52 to urge it into engagement with the high-pressure seat 54 is provided by a small-diameter piston 18 of the valve actuating device 1 .
[0041] The valve actuating device 1 includes a piezoelectric actuator 14 , an actuator piston 15 , a large-diameter piston 17 , and the small-diameter piston 18 . The piezoelectric actuator 14 is installed in an upper portion of the housing H. The actuator piston 15 is arranged to be movable in contact with a lower end of the piezoelectric actuator 14 . The large-diameter piston 17 connects with the actuator piston 15 through a rod 16 . The small-diameter piston 18 is moved by the large-diameter piston 17 through a displacement amplifying chamber 6 . The piezoelectric actuator 14 is made of a laminated piezoelectric device (also called a piezo stack) which works to expand when electrically charged and contract when discharged. The structure of the piezoelectric device is well known in the art, and explanation thereof in detail will be omitted here. The actuator piston 15 is installed slidably within an actuator cylinder H 1 and connects with the large-diameter piston 17 through the rod 16 . The large-diameter piston 17 and the small-diameter piston 18 are disposed slidably within a large-diameter cylindrical chamber H 3 and a small-diameter cylindrical chamber H 4 formed coaxially within a hollow cylinder H 2 . The rod 16 extends from an upper end surface of the large-diameter piston 17 upwards and is fitted within a lower end surface of the actuator piston 15 .
[0042] Defined below the lower end of the actuator piston 15 around the rod 16 is an oil sump 7 leading to the drain passage 2 . A coil spring 71 is disposed within the oil sump 7 to urge the actuator piston 15 upward together with the large-diameter piston 17 . Specifically, the actuator piston 15 and the large-diameter piston 17 are urged upward by the spring 71 , so that they may move following the expansion or contraction of the piezoelectric actuator 14 . An O-ring 73 is installed in an annular groove formed in a side wall of the actuator piston 15 for protecting the piezoelectric actuator 14 from contamination of working fluid (i.e., the fuel) within the oil sump 7 . The oils sump 7 communicates with the drain passage 2 through a passage 95 . The passage 95 is formed by drilling side walls of the housing Hand the actuator cylinder H 1 and closing a hole formed the housing H using a plug 74 .
[0043] The hollow cylinder H 2 has formed on an inner wall between the small-diameter cylinder chamber H 4 and the large-diameter cylinder chamber H 3 an inner shoulder working as a stopper 61 which defines an upper limit of the small-diameter piston 18 . The small-diameter cylinder chamber H 4 and the large-diameter cylinder chamber H 3 communicate with each other through a central hole formed in the stopper 61 . The small-diameter cylinder chamber H 4 defines a hydraulic chamber A between the upper end thereof and the stopper 61 . The large-diameter cylinder chamber H 3 defines a hydraulic chamber B between the lower end thereof and the stopper 61 . The hydraulic chambers A and B define the displacement amplifying chamber 6 . The displacement amplifying chamber 6 works to transmit the longitudinal displacement of the large-diameter piston 17 to the small-diameter piston 18 . Specifically, the stroke of the large-diameter piston 17 (i.e., the vertical movement of the piezoelectric actuator 14 ) is amplified through the fuel within the displacement amplifying chamber 6 as a function of a difference in diameter between the large-diameter piston 17 and the small-diameter piston 18 (e.g., two or three times the displacement of the large-diameter piston 17 ) and transmitted to the small-diameter piston 18 . A lower portion of the small-diameter piston 18 lies within the spill chamber 22 . The small-diameter piston 18 has a thin head which extends into the drain port 21 and contacts with the ball valve 52 .
[0044] Within the large-diameter piston 18 , a vertical passage 72 extends and communicates at an upper end thereof with a lateral passage opening into the oil sump 7 . The vertical passage 72 extends at a lower end thereof to the lower end of the large-diameter piston 17 and communicates with the displacement amplifying chamber 6 through a check valve 8 installed on the lower end of the large-diameter piston 17 . The check valve 8 works to compensate for a loss of fuel caused by leakage from the oil sump 7 to the displacement amplifying chamber 6 and consists of a flat valve 81 closing the lower opening of the passage 72 and a conical spring 82 urging the flat valve 81 upwards. The flat valve 81 is, as shown in FIGS. 2 ( a ) and 2 ( b ), made of a thin disc which has a thickness of 0.1 to 0.2 mm and parallel sides 86 . A pinhole 84 is formed in the center of the flat valve 81 which has a diameter of 0.02 to 0.5 mm.
[0045] The conical spring 82 is, as shown in FIG. 2( c ), made of an annular plate having a thickness of 0.01 to 005 mm and shaped to produce a pressure of 0.5 to 2N. The flat valve 81 and the conical spring 82 are disposed within a holder 83 made of a cup-shaped cylinder. The holder 83 is fitted on a lower end portion of the large-diameter piston 18 . A drop in pressure in the displacement amplifying chamber 6 arising from the leakage of fuel will cause the flat valve 81 to move downward against the pressure produced by the conical spring 82 , so that the fuel flows from the passage 72 . The holder 83 has formed in the bottom thereof a hole 85 which is much greater than the pinhole 84 and establishes communication between an inner chamber of the holder 83 and the displacement amplifying chamber 6 for facilitating the flow of fuel into the displacement amplifying chamber 6 .
[0046] In operation of the fuel injector 100 , when it is required to initiate the fuel injection, a voltage of about 100 to 150V is, as indicated as a piezo-voltage in FIG. 3( a ), applied to the piezoelectric actuator 14 . The piezoelectric actuator 14 expands, for example, 40 μm proportional to the applied voltage to move the large-diameter piston 17 downward, thereby elevating, as shown in FIG. 3( b ), the pressure in the displacement amplifying chamber 6 (time t 1 to t 2 ). The pressure in the displacement amplifying chamber 6 leaks into the drain passage 2 through the pinhole 84 of the flat valve 81 and gaps between an outer wall of the large-diameter piston 17 and an inner wall of the hollow cylinder H 2 and between an outer wall of the small-diameter piston 18 and the inner wall of the hollow cylinder H 2 , so that it drops slowly after time t 2 . The elevation in pressure in the displacement amplifying chamber 6 causes the small-diameter piston 18 to move downward to push the ball valve 52 out of engagement with the drain seat 53 , as shown in FIG. 3( c ). The ball valve 52 then rests on the high-pressure seat 54 (time t 2 ). The degree of movement of the ball valve 52 is a multiple of (e.g., two times) the degree of expansion of the piezoelectric actuator 14 which corresponds to a sectional area ratio of the large-diameter piston 17 to the small-diameter piston 18 .
[0047] When the ball valve 52 moves out of engagement with the drain seat 53 , it establishes communication between the valve chamber 51 and the drain port 21 , while it blocks communication between the high-pressure port 32 and the valve chamber 51 , so that the pressure in the valve chamber 51 drops, thereby decreasing, as shown in FIG. 3( d ), the pressure in the control chamber 4 . When the pressure in the fuel sump 31 exceeds the sum of the pressure in the control chamber 4 and the pressure produced by the coil spring 41 , it will cause the nozzle needle 12 to be lifted upwards, as shown in FIG. 3( e ), to open the spray hole 11 , thereby initiating the fuel injection.
[0048] When it is required to terminate the fuel injection, no voltage is applied to the piezoelectric actuator 14 to discharge it electrically (time t 3 to t 5 ). The piezoelectric actuator 14 contracts to an original length thereof, thereby causing the actuator piston 15 to be lifted up by the spring 71 . The large-diameter piston 17 is also lifted up, thus resulting in a decrease in pressure of the displacement amplifying chamber 6 , as shown in FIG. 3( b ). The drop in pressure in the displacement amplifying chamber 6 causes the small-diameter piston 18 to be moved upward together with the ball valve 52 (time t 4 ).
[0049] When the ball valve 52 rests on the drain seat 53 again, it establishes the communication between the valve chamber 51 and the high-pressure port 32 , while blocking the communication between the valve chamber 51 and the drain port 21 , so that the pressure in the valve chamber 51 and the control chamber 4 , as shown in FIG. 3( d ), is returned to the original level. When the pressure in the control chamber 4 rises, and the pressure urging the nozzle needle 12 downward exceeds the pressure in the fuel sump 31 , it will cause the nozzle needle 12 to move downward so that it rests on the nozzle seat 13 again to close the spray hole 11 , thereby terminating the fuel injection (time t 5 ). After time t 5 , the pressure in the displacement amplifying chamber 6 is undershot temporarily by an amount equivalent to a leakage of the fuel during the fuel injection, but the fuel in the oil sump 7 flows into the displacement amplifying chamber 6 through the check valve 8 , so that the pressure in the displacement amplifying chamber 6 is, as shown in FIG. 3( b ), returned quickly to the original level.
[0050] In FIGS. 3 ( a ) to 3 ( e ), dotted lines represent a case where wire connecting an actuator driver and the piezoelectric actuator 14 is broken during the fuel injection. Two-dot chain lines represent a case where the pinhole 84 is not formed in the flat valve 81 of the check valve 8 in such an event.
[0051] If the wire connecting the actuator driver and the piezoelectric actuator 14 is broken during application of voltage to the piezoelectric actuator 14 , it becomes impossible to discharge the piezoelectric actuator 14 , so that the piezo-voltage is kept at a high level, as indicated by the dotted line in FIG. 3( a ). The displacement or expansion of the piezoelectric actuator 14 is held as it is, thus making it impossible to move the actuator piston 15 and the large-diameter piston 17 . In the absence of the pinhole 84 , it becomes impossible to change the pressure in the displacement amplifying chamber 6 . Specifically, a drop in pressure of the displacement amplifying chamber 6 arises only from leakage of fuel from gaps between the outer walls of the large-diameter piston 17 and the small-diameter piston 18 and the inner wall of the hollow cylinder H 2 and continues only for several tens of microseconds (ms). The pressure in the displacement amplifying chamber 6 , thus, hardly decreases, as indicated by the two-dot chain line in FIG. 3( b ), so that the movement of the ball valve 52 , the pressure in the control chamber 4 , and the movement of the nozzle needle 12 hardly change, which may cause the fuel injection to continue.
[0052] In the case where the pinhole 84 is formed in the flat valve 81 of the check valve 8 , the piezo-voltage is kept at a high level, but the fuel in the displacement amplifying chamber 6 leaks into the oil sump 7 through the pinhole 84 , so that the pressure in the displacement amplifying chamber 6 , as indicated by the dotted line in FIG. 3( b ), drops gradually. 3 to 5 ms after the application of voltage to the piezoelectric actuator 14 , the pressure in the displacement amplifying chamber 6 decreases below the pressure in the high-pressure port 32 urging the ball valve 52 upwards, so that the ball valve 52 and the small-diameter piston 18 are lifted upwards together. When the ball valve 52 is seated on the drain seat 53 , it blocks the communication between the drain port 21 and the valve chamber 51 , so that the pressure in the control chamber 4 is, as indicated by the dotted line in FIG. 3( d ), elevated. This causes the nozzle needle 12 to be seated, as indicated by the dotted line in FIG. 3( e ), on the nozzle seat 13 to close the spray hole 11 or terminate the fuel injection.
[0053] In the above event, the quantity of fuel that is some multiple or several tens of multiples of normal is supplied to the internal combustion engine. Usually, the fusion of the engine or failure in engine operation occurs when the quantity of fuel that is some multiple of normal is supplied for several revolutions of the engine. Therefore, the fuel injection only for 3 to 5 ms will not be objectionable in the engine operation. It is advisable that the size of the pinhole 84 be selected so that the fuel injection does not continue over a time required for one revolution of the engine running at a maximum speed. For example, when the engine is running at 5000 rpm, the time required for one revolution of the engine is 24 ms. In this case, the size or diameter of the pinhole 84 is preferably set to within a range of 0.02 to 0.2 mm. If the fuel injection is stopped within 24 ms, most of the fuel is discharged to an exhaust pipe of the engine. However, in order to avoid the deterioration of the catalyst, it is advisable that the size of the pinhole 84 be selected so that the fuel injection does not continue over 3 to 5 ms. This may be achieved by setting the size of the pinhole 84 to 0.05 to 0.5 mm.
[0054] The pinhole 84 also produces the following effects.
[0055] If the displacement amplifying chamber 6 is not filled with the fuel after assembly of the fuel injector 100 , it will cause the displacement of the piezoelectric actuator 6 not to be transmitted to the small-diameter piston effectively. Therefore, if the fuel injector 100 is installed in the engine as it is, the displacement amplifying chamber 6 does not work properly until it is filled with the fuel, thus giving rise to a problem that much time is required to start the engine. Such a problem is eliminated by filling the displacement amplifying chamber 6 with fuel before the fuel injector 100 is shipped or installed in the engine. This may be accomplished by connecting a vacuum pump to the high-pressure passage 3 to evacuate the inside of the fuel injector 100 and supply the fuel from the drain passage 2 . In the absence of the pinhole 84 , it is difficult to evacuate the displacement amplifying chamber 6 , so that air is left in the displacement amplifying chamber 6 after the fuel is injected into the displacement amplifying chamber 6 , which will impinge upon the transmission of the displacement of the piezoelectric actuator 14 to the small-diameter piston 18 adversely.
[0056] In the structure of this embodiment, when the fuel injector 100 starts to be evacuated by a vacuum pump from the high-pressure passage 3 , the control chamber 4 , the valve chamber 51 , the drain port 21 , the spill chamber 22 , the drain passage 2 , the oil sump 7 , the passage 72 , and the displacement amplifying chamber 6 are, in sequence, evacuated through the pinhole 84 . By injecting the fuel from the drain passage 2 , the displacement amplifying chamber 6 is filled with the fuel quickly. After the displacement amplifying chamber 6 is filled with the fuel, openings of the high-pressure passage 3 and the drain passage 2 are plugged using, for example, rubber cups in order to avoid the leakage of fuel from the displacement amplifying chamber 6 . Usually, a protective cup is fitted on the nozzle head of the fuel injector 100 at the factory. When installed in the engine, the fuel injector 100 is secured in a cylinder head of the engine with the high-pressure passage 3 and the drain passage 2 plugged. Subsequently, they are unplugged and connected to fuel pipes.
[0057] The small-diameter piston 18 may fall by its own weight as the time goes by after the engine is stopped. In this case, an amount of fuel equivalent to the fall of the small-diameter piston 18 is supplied to the displacement amplifying chamber 6 from the drain passage 2 through the check valve 8 , thereby resulting in a difficulty in lifting up the small-diameter piston 18 . Specifically, when the engine is started, the dynamic pressure of fuel supplied from the high-pressure passage 3 works to lift up the ball valve 52 and the small-diameter piston 18 . In the absence of the pinhole 84 , the displacement amplifying chamber 6 is closed completely, thereby holding the small-diameter piston 18 from being lifted up. Therefore, the ball valve 52 is allowed to move from the high-pressure seat 54 slightly, but does no rest on the drain seat 53 . This causes the fuel in the high-pressure passage 3 to continue to flow into the drain passage 2 , so that a desired pressure (e.g., 10 to 20 Mpa) is not reached in the control chamber 4 , thus encountering a difficulty in starting the engine.
[0058] In the structure of this embodiment, the pinhole 84 is formed in the flat valve 81 of the check valve 8 , so that the fuel in the displacement amplifying chamber 6 flows into the drain passage 2 through the pinhole 84 quickly, thereby allowing the small-diameter piston 18 and the ball valve 52 to be lifted up. Thus, when the engine is started, the ball valve 52 is seated on the drain seat 53 quickly, thereby enabling proper fuel injection.
[0059] In the embodiment as described above, the conical spring 82 is used to press the flat valve 81 of the check valve 8 against the lower end of the large-diameter piston 17 , but a circular short spring may alternatively be used. For example, a spring disc 86 , as shown in FIGS. 4 ( a ) and 4 ( b ), may be used which consists of an annular plate and a tongue 87 which extends from an inner periphery of the annular plate in a radius direction and is bent at a given angle.
[0060] While the present invention has been disclosed in terms of the preferred embodiments in order to facilitate better understanding thereof, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments witch can be embodied without departing from the principle of the invention as set forth in the appended claims. For example, the three-way valve 5 is used to open and close the spray hole 11 formed in the head of the nozzle body B 1 , however, the invention is not limited to the same. Another known mechanism such as a two-way valve may be used to open and close the spray hole 11 . Further, the piezoelectric actuator 14 is implemented by a piezoelectric device, however, another element such as a solenoid or a magnetostrictor may be used.
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A valve actuating device is provided which may be employed in fuel injectors for automotive internal combustion engines. The valve actuating device includes an actuator, a large-diameter piston displaced by said actuator, a small-diameter piston operating a valve, a displacement amplifying chamber filled with working fluid to amplify and transmit displacement of the large-diameter piston to the small-diameter piston, and a drain passage. The drain passage communicates with the displacement amplifying chamber through a pinhole for draining the working fluid within the displacement amplifying chamber, thereby enabling the pressure in the displacement amplifying chamber to be released in order to ensure the movement of the small-diameter piston when the valve actuating device is started.
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PRIORITY APPLICATION
This application is a divisional application of U.S. application Ser. No. 11/972,209, filed Jan. 10, 2008, now issued as U.S. Pat. No. 8,291,139, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
Embodiments of this invention relate to, for example, asymmetric signaling over a parallel data bus, which can improve data reception reliability.
BACKGROUND
Circuit designers of multi-Gigabit systems face a number of challenges as advances in technology mandate increased performance in high-speed components and systems. At a basic level, data transmission between components within a single semiconductor device, or between two devices on a printed circuit board, may be represented by the system 10 shown in FIG. 1A . (Accordingly, as used herein, a “device” can refer to a discrete device, such as a microprocessor or memory controller, or a component of a device, such as an integrated circuit or a functional block, for example). In FIG. 1A , data is transferred (e.g., forwarded, returned, transmitted, sent, and/or received) between a first device 12 and a second device 14 along (e.g., across, carried by, over, on, through and/or via) channels 16 (e.g., copper traces on a printed circuit board or “on-chip” in a semiconductor device). A standard interconnect approach is shown, in which each channel 16 carries a particular bit (D 0 , D 1 , etc.) in the parallel stream of data being transmitted. (This is sometimes known in the industry as a “single-ended” approach). Because either device 12 or 14 may act as the transmitter or receiver of data at any point in time, each channel 16 in each device contains both a transmitter (tx) and a receiver (rx), each operating in accordance with a clock signal, Clk. This clock signal, Clk, can comprise a forwarded clock which, as its name suggests, is forwarded on its own channel 16 from the transmitting device to the receiving device so as to synchronize with the transmitted data. Alternatively, the clock, if not transmitted on its own channel, may be derived at the receiving device via clock data recovery (CDR) techniques, which are well known in the art and well understood by those of skill in the art. A differential clock could also be used in which true clock and complement clock are sent over two channels, which can be useful to minimize clock jitter, as is well known.
A typical receiver circuit used in conjunction with the standard interconnect approach of FIG. 1A is shown in FIG. 1B . The receiver circuit comprises an amplifier stage 20 whose output is coupled to a latch 22 , which as illustrated comprises cross-coupled NAND gates. The input to the amplifier stage 20 comprises the data as received (DataIn), which is compared to a reference voltage (Vref), which is typically a midpoint voltage of one-half of the receiving device's power supply (i.e., ½Vdd). When enabled by the clock, Clk, the amplifier stage resolves and amplifies the difference between the received data, DataIn, and the reference voltage, Vref, as is well known.
Another approach used to transmit data via a parallel bus is a differential interconnect approach, which is illustrated in FIG. 2A . In this approach, a given bit (D 0 , D 1 , etc.) is always transmitted along with its complement (D 0 #, D 1 #, etc.). As a result, a pair of channels 16 must be dedicated to each bit, one channel carrying true data, and the other, its complement. To accommodate this architecture, a transmitter circuit and receiver circuit are shared between each pair of channels, as shown. The receiver circuit used in the differential interconnect approach is shown in FIG. 2B , and is essentially the same as that illustrated in FIG. 1B , except that the complementary data state (DataIn#) is used in lieu of the reference voltage, Vref.
The differential interconnect approach of FIG. 2 has the effect of making data resolution more reliable when compared to the standard interconnect approach of FIG. 1 . Such increased reliability results from at least three effects. First, because the receiver circuitry ( FIG. 2B ) uses complementary inputs, the voltage margin of the amplifier stage 20 is increased, which leads to faster, more reliable resolution of the data state by the receiver circuitry. Second, because true data is always transmitted along with its complementary data, cross talk-by which one channel perturbs data on an adjacent channel 16 in the bus-is minimized. Third, a non-differential signal is more susceptible to simultaneous switching output (SSO) noise generated at both the transmitters and receivers. Furthermore, in addition to the increased SSO rejection capability of differential interconnects, the very nature of the typical differential driver minimizes the generation of SSO.
However, increased sensing reliability in the differential interconnect approach comes at an obvious price, namely the doubling of the number of channels 16 needed to complete the parallel bus. To offset this, and keep the number of channels 16 constant, the clock, Clk, used in the differential interconnect approach is generally faster than would be used in the standard interconnect approach. Indeed, if the clock used is twice as fast, it will be appreciated that the number of bits transmitted per channel 16 , i.e., the data capacity, is equivalent between the two approaches. Fortunately, increased sensing capability in the differential interconnect approach allows for higher clock speed to be used effectively, and clock speed even higher than double speed could be used.
As well as providing for both standard and differential interconnect approaches, the prior art also provides for data to be received with “multiphase, fractional-rate receivers,” such as is shown in FIGS. 3A , 3 B, and 4 . FIG. 3A , for example, shows multiphase, fractional-rate receivers used in the standard interconnect approach. Suppose four sequential bits of data (e.g., Da, Db, Dc, Dd) are transmitted across a given channel (e.g., 16 3 ) on both the rising and falling edge of a clock, Clk, in what would be known as a Double Data Rate (DDR) application. Each of these four bits is captured at its own receiver (rx) by one of a plurality of phase-shifted, fractional-rate clocks. Because four bits are to be sensed in this example, four clocks of four distinct phases, Clk(a), Clk(b), Clk(c), and Clk(d) are used to sense data Da, Db, Dc, and Dd at each of the receivers.
As shown in FIG. 3B , the phase-shifted, fractional-rate clocks Clk(x) are typically generated from the master clock, Clk, using known techniques. Each generated phase-shifted, fractional-rate clock, Clk(x), is a fraction of the frequency of the master clock, e.g., a quarter-rate or half-rate clock. Data capture at the receivers can occur on both the rising and falling edges of each clock, or on either the rising edge or falling edges of each clock. For example, and assuming that four receivers are used to sample the four bits, either a quarter-rate clock which samples on rising and falling edges ( 18 a ) or a half-rate clock which samples on the rising edges only ( 18 b ) can be used. However, the number of fractional-rate receivers can be varied to the same effect. Thus, eight quarter-rate clocks combined with eight fractional-rate receivers could be used to sample the data only on rising edges ( 18 c ), or two half-rate clocks used with two fractional-rate receivers could be used to sample the data on rising and falling edges ( 18 d ).
Multiphase, fractional-rate clocks at the receiver are useful in situations where data can be transmitted at a rate faster than the receiver can resolve the data state. For example, when a quarter-rate clock is used, the receiver essentially has four times longer to properly resolve the data state, which is beneficial because it can take significant time for the amplifier stage 20 in the receiver ( FIG. 1B , 2 B) to amplify and resolve the data state. Fractional-rate clocks at the receiver can also be used in differential interconnect approaches, such as is illustrated in FIG. 4 . As the operation of FIG. 4 should be apparent by extension from the foregoing explanations, it is not further discussed.
While any of the above approaches can be used in the transmission of data through a parallel bus, the use of any one approach may not be optimal, a point discussed further below. This disclosure presents a more optimal solution.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B illustrate a standard interconnection approach for transmitting signals between two devices along a parallel bus.
FIGS. 2A and 2B illustrate a differential interconnection approach for transmitting signals between two devices along a parallel bus.
FIGS. 3A , 3 B, and 4 illustrate the standard and differential interconnection approaches extended to include the use of multiphase, fractional-rate receivers.
FIG. 5 illustrates a situation in which the disclosed asymmetric interconnection approach is particularly useful, such as when the devices involved are capable of different bandwidths.
FIGS. 6A and 6B illustrate an embodiment of the asymmetric interconnection approach of the invention in which data is transmitted in standard fashion in one direction and in differential fashion in another direction.
FIG. 7 illustrates an alternative embodiment of the asymmetric interconnection approach in which the number of fractional-rate receivers has been varied.
FIG. 8 illustrates an alternative embodiment in which asymmetric communications occur across two unidirectional busses.
DETAILED DESCRIPTION
Consider a standard interconnect approach ( FIG. 1A ) in which data reception reliability at 5 Gigabits per second (Gb/s) is proving problematic. In a DDR application, in which data is triggered on rising and falling edges, this would comprise a clock speed of 2.5 GHz. One may wish to substitute the differential interconnect approach ( FIG. 2A ) to try and increase reliability as described earlier. However, as also described earlier, data capacity can only be preserved using the differential interconnect approach if a higher clock speed (i.e., at least double) is used.
Unfortunately, the use of a higher clock speed is not always possible. For example, consider FIG. 5 , which depicts two devices 12 and 14 connected by channels 16 in a parallel bus, as illustrated earlier. Due to differences in the design and processing of the devices 12 and 14 , the circuitry used in those devices may tolerate different maximum operating speeds. For example, assume that device 12 comprises a microprocessor or a memory controller, and assume that device 14 comprises a Synchronous Dynamic Random Access Memory (SDRAM). Because the processes used in the formation of the SDRAM 14 may be optimized to promote cell array operation (e.g., data retention), the transistors used to form the transition and reception circuitry may be non-optimal for high-speed applications. As a result, the maximum frequency of such circuitry, f(max), may be 4 GHz, for example. If so, a differential interconnect approach using a double-speed clock cannot be used, because this would require a 5 GHz clock, a value exceeding the maximum frequency, f(max)=4 GHz, of which the device 14 is capable. This limitation on clock speed can be unfortunate, especially when the process used to form the microprocessor or memory controller (hereinafter, “controller”) 12 is generally optimized for higher operating speeds. For example, f(max) for the controller 12 might equal 7 GHz. If so, the controller 12 could participate in a 5 GHz differential interconnect approach, while the SDRAM 14 could not. Accordingly, the system depicted in FIG. 5 would be restricted to the standard interconnect approach, even though the controller 12 is capable of operating at higher frequencies.
To solve this problem, asymmetric signaling over the parallel bus of channels 16 can be used. For example, the channels 16 in the parallel bus can operate as standard interconnects for data travelling in one direction through the bus, and operate as differential interconnects for data travelling in the other direction through the bus. So that data capacity of the bus remains the same in both directions, the data rate during differential transmission can be twice that of the data rate during standard transmissions.
One embodiment of this approach is shown in FIG. 6A . Shown are two channels 16 0 and 16 1 which, as just noted, can either carry standard or differential data, and which otherwise comprise just two of the channels in a bus comprised of a plurality of channels. Continuing with the above example, controller 12 is assumed to have a maximum operating frequency of 7 GHz, while SDRAM 12 is assumed to have a maximum operating frequency of 4 GHz. As illustrated, data transmission from the controller 12 to the SDRAM 14 occurs differentially at 10 Gb/s, while transmission from the SDRAM 14 to the controller 12 occurs non-differentially at 5 Gb/s. This is illustrated further in the timing diagram of FIG. 6B . As shown at top, transmission from the SDRAM 14 occurs in accordance with a standard interconnect approach, in which only true data is sent on the channels 16 0 and 16 1 . By contrast, at bottom, which depicts transmission from the controller 12 , true data and its complements are sent in parallel and at twice the rate. Although channel 16 1 is shown as being dedicated to the complementary data, such data could also appear on channel 16 0 , or on both channels in an interleaved fashion. In any event, the data capacity in both directions remains the same across the channels 16 that comprise the bus. Once again, the clock, Clk, can be forwarded, generated by CDR, or differential as noted earlier.
Example transmission and reception circuitry for achieving the timings of FIG. 6B is illustrated in FIG. 6A . As shown, the flow of data from the SDRAM 14 to the controller 12 employs standard interconnect approach hardware, with a transmitter (tx) and receiver (rx) being dedicated to each channel. Because as assumed data is to be transmitted at a rate of 5 Gb/s, clocks of 2.5 GHz are used in both the SDRAM's transmitters and the controller's receivers. However, multiphase, fractional-rate receivers could also be used in the controller 12 as well, which could drop the frequency of the clocks used as discussed previously with respect to FIG. 3B .
By contrast, the flow of data from the controller 12 to the SDRAM 14 employs a differential interconnect approach. Transmission starts by presentation of complementary data at a multiplexer 25 . The multiplexer 25 is clocked by a 5 GHz clock, to pass either odd or even differential data to the differential transmitter, tx, in the controller 12 . When the multiplexer clock is high, D 0 tx and D 0 tx # are sent to the transmitter, followed by D 1 tx and D 1 tx # when low, followed by D 2 tx and D 2 tx # when high again, etc. The effect is that true and complementary data are sent on each channel 16 0 and 16 1 at a rate of 10 Gb/s.
Stated another way, and assuming N channels are present, N data bits are transferred in parallel along the N channels from the SDRAM 14 to the controller 12 at 5 Gb/s, while N/2 data bits and their complements are transferred from the controller 12 to the SDRAM 14 at 10 Gb/s.
Reception of this data at the SDRAM is made using differential multiphase, fractional-rate receivers, such as was discussed with respect to FIGS. 3A , 3 B, and 4 earlier. As before, four receivers are used, each clocked by phase-shifted, fractional-rate clocks, Clk(x). To appropriately sample the incoming data at 10 Gb/s, and assuming that sampling at the receivers occurs on rising and falling edges of the clock, a clock of frequency 1.25 GHz is used (see, e.g., 18 a of FIG. 3B ). However, if the clocks only sample data on their rising edges, clocks of 2.5 GHz could be used ( 18 b of FIG. 3B ). Although not shown in FIG. 6A , if eight receivers are used, eight clocks, each at 1.25 GHz, but sampling on only rising or falling edges ( 18 c of FIG. 3B ), could be used. Or, if two receivers are used, two clocks, each at 2.5 GHz, but sampling on both rising or falling edges ( 18 d of FIG. 3B ), could be used. These are just some examples of the various clocks and multiphase, fractional-rate receiver arrangements that could be used. Furthermore, and regardless of the sampling approach chosen, if a differential clock is used, the need to specifically generate a 180-degree phase shifted clock is unnecessary because it is already present, which can simplify clock generation.
The depicted example of FIG. 6A assumes a DDR approach in which data is sampled on the rising and falling edges of the master clock, Clk. However, it should be understood that the asymmetric interconnect approach of the invention is equally applicable to non-DDR approaches in which data is sampled on either the rising or falling edges of the master clock. In other words, the invention is not limited to DDR, DDR2, DDR3, etc. implementations.
FIG. 7 shows alternative circuitry for implementing the asymmetric interconnect approach of the invention, and in this example only two fractional-rate receivers are used in the SDRAM 14 . So implemented, the two receiver clocks, Clk(a) and Clk(b), can operate at 2.5 GHz to sample the 10 Gb/s coming from each of the channels 16 0 and 16 1 , assuming that sampling occurs on both the rising and falling edges of the clocks (see 18 d , FIG. 3B ). While sampling could theoretically also occur using only the rising edges of the clocks as was discussed with reference to FIG. 6A , this would require 5 GHz clocks in the depicted example, which exceeds the maximum operating frequency (f(max)=4 GHz) assumed for the SDRAM 14 . The point illustrated by this example is that while many different clocking schemes can be used at the multiphase, fractional-rate receiver in accordance with the invention, care should be taken to ensure that no clock is faster than that permissible for the SDRAM 14 .
Regardless of the specific implementation chosen, the asymmetric interconnect approach should enhance the reliability of data transfer. As noted earlier, non-differential data transferred down standard interconnects can be susceptible to noise and crosstalk, and can suffer from poorer voltage margins at the receiver. In the embodiment discussed above, such standard reception occurs at the controller 12 , which, by virtue of its higher quality transistors, is better able to handle and accurately resolve the transferred data; by contrast, the SDRAM 14 enjoys more reliable differential reception, which helps it to overcome the non-optimal nature of its reception circuitry. Moreover, these benefits can be established without exceeding the maximum operating frequencies, f(max) of either of the devices 12 or 14 . Transmission from the SDRAM 14 to the controller occurs at 2.5 GHz, which does not exceed the maximum permissible frequency for either device. Transmission from the controller 12 occurs at a higher speed of 5 GHz, which is acceptable for that device, but sensing occurs at either 1.25 GHz or 2.5 GHz at the SDRAM 14 , as assisted by the use of multiphase, fractional-rate receivers, which again is acceptable.
Although the disclosed asymmetric interconnect technique has been illustrated in the context of a system comprising a controller 12 and an SDRAM 14 , it will be understood, by one skilled in the art, that the invention can be used with, and can benefit the communications between, any two integrated circuits or functional blocks, and is particularly useful in the situation where the two circuits have differing bandwidths, as has been illustrated.
Embodiments of the invention can also be employed in busses employing uni-directional signaling. In the embodiments shown to this point, each of the channels 16 in the bus have been bi-directional, i.e., they carry data from the controller 12 to the SDRAM 14 and vice versa. However, some high performance systems may employ unidirectional busses 50 and 51 between the two devices in the system, with each bus 50 , 51 carrying data in only one direction, as shown in FIG. 8 . As shown, bus 50 carries data from the controller to the SDRAM 14 , while bus 51 carries data from the SDRAM 14 to the controller 12 . In accordance with one or more embodiments of the invention, the data along the two busses are handled asymmetrically, with bus 50 carrying differential data, and bus 51 carrying non-differential data. Through this arrangement, each channel is coupled to only at least one receiver, or at least one transmitter on each device, but not both, and so data reception and transmission are decoupled at each of the devices 12 , 14 . When communications of the busses are implemented asymmetrically, the same benefits highlighted with respect to FIG. 6A should be achievable. Additionally, uni-directional signaling is advantageous in that each uni-directional channel is only loaded with a single transmitter and receiver at the respective ends of the channel as already mentioned, which reduces circuit-based parasitic loading of the channel and improves speed.
Further, note that it is not strictly required that the invention be used with integrated circuits coupled by interconnect channels, such as by a PCB. Instead, the invention can be used in communications between any two circuits which may be discrete or integrated on a common piece of semiconductor.
It should also be recognized that a “bit” of information need not be strictly binary in nature (i.e., only a logic ‘1’ or logic ‘0’), but could also comprise other values (e.g., logic ‘½’) or types of digits as well.
It should be understood that the disclosed techniques can be implemented in many different ways to the same useful ends as described herein. In short, it should be understood that the inventive concepts disclosed herein are capable of many modifications. To the extent such modifications fall within the scope of the appended claims and their equivalents, they are intended to be covered by this patent.
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Methods and apparatus to transfer data between a first device and a second device, is disclosed. An apparatus according to various embodiments may comprise a first device and a second device. The first device may comprise at least one first non-differential transmitter coupled to a first channel, at least one second non-differential transmitter coupled to a second channel, and at least one differential receiver to receive a data bit and its complement on the first and second channels in parallel. The second device may comprise at least one first non-differential receiver coupled to the first channel, at least one second non-differential receiver coupled to the second channel, and at least one differential transmitter to transmit a data bit and its complement on the first and second channels in parallel.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/415,578 submitted by Mehta et al. on Mar. 31, 2009 for “Antenna Selection with Frequency-Hopped Sounding Reference Signals.”
FIELD OF THE INVENTION
[0002] This invention relates generally to antenna selection in wireless communication, networks, and more particularly to selecting antennas with frequency-hopped sounding reference signals.
BACKGROUND OF THE INVENTION
[0003] OFDMA and SC-OFDMA
[0004] In a wireless communication network, such as the 3 rd generation (3G) wireless cellular communication standard and the 3GPP long term evolution (LTE) standard, it is desired to concurrently support multiple services and multiple data rates for multiple users in a fixed bandwidth channel. One scheme adaptively modulates and codes symbols before transmission based on current channel estimates. Another option available in LTE, which uses orthogonal frequency division multiplexed access (OFDMA), is to exploit multi-user frequency diversity by assigning different sub-carriers or groups of sub-carriers to different users or UEs (user equipment, mobile station or transceiver), in the single carrier frequency division multiple access (SC-FDMA) uplink of LTE, in each user, the symbols are first together spread by means of a Discrete Fourier Transform (DFT) matrix and are then assigned to different sub-carriers. The network bandwidth can vary, for example, from 1.25 MHz to 20 MHz. The network bandwidth is partitioned into a number of subcarriers, e.g., 1.024 subcarriers for a 10 MHz bandwidth.
[0005] The following standardization documents are applicable 36.211, 3rd Generation Partnership Project; Technical Specification Group Radio Access Network; Physical Channels and Modulation (Release 8), v 1.0.0 (2007-03); R.1-01057, “Adaptive antenna switching for radio resource allocation in the EUTRA uplink,” Mitsubishi Electric/Nortel/NTT DoCoMo, 3GPP RAN1#48, St. Louis, USA; R1-071119, “A new DM-RS transmission scheme for antenna selection in E-UTRA uplink,” LGE, 3GPP RAN1#48, St. Louis, USA; and “Comparison of closed-loop antenna selection with open-loop transmit diversity (antenna switching within a transmit time interval (TTI),” Mitsubishi Electric, 3GPP RAN1#47bis, Sorrento, Italy. According to the 3GPP standard, the base station (BS) is enhanced, and is called the “Evolved NodeB” (eNodeB). We use the terms BS and eNodeB interchangeably.
[0006] Multiple Input Multiple Output (MIMO)
[0007] In order to further increase the capacity of a wireless communication network in fading channel environments, multiple-input-multiple-output (MIMO) antenna technology can be used to increase the capacity of the network without an increase in bandwidth. Because the channels for different antennas can be quite different, MIMO increases robustness to lading and also enables multiple data streams to be transmitted concurrently.
[0008] Moreover, processing the signals received in spatial multiplexing schemes or with space-time trellis codes requires transceivers where the complexity can increase exponentially as a function of the number of antenna.
[0009] Antenna Selection
[0010] Antennas are relatively simple and cheap, while RF chains are considerably more complex and expensive. Antenna selection reduces some of the complexity drawbacks associated with MIMO networks. Antenna selection reduces the hardware complexity of transmitters and receivers in the transceivers by using fewer RF chains than the number of antennas.
[0011] In antenna selection, a subset of the set of available antennas is adaptively selected by a switch, and only signals for the selected subset of antennas are connected to the available RF chains for signal processing, which can be either transmitting or receiving. As used herein, the selected subset, in all cases, means one or more of all the available antennas in the set of antennas.
[0012] Antenna Selection Signals
[0013] Pilot Tones or Reference Signals
[0014] In order to select the optimal subset of antennas, channels corresponding to available subsets of antennas need to be estimated, even though only a selected optimal subset of the antennas is eventually used for transmission.
[0015] This can be achieved by transmitting antenna selection signals, e.g., pilot tones, also called reference signals, from different antennas or antenna subsets. The different antenna subsets can transmit either the same pilot tones or use different ones. Let N t denote the number of transmit antennas, N r the number of receive antennas, and let R r =N r /L r and R r =N r /L r be integers. Then, the available transmit (receive) antenna elements can be partitioned into R t (R r ) disjoint subsets. The pilot repetition approach repeats, for R t ×R r times, a training sequence that is suitable for an L t ×L r MIMO network. During each repetition of the training sequence, the transmit RF chains are connected to different subsets of antennas. Thus, at the end of the R t ×R r repetitions, the receiver has a complete estimate of all the channels from the various transmit antennas to the various receive antennas.
[0016] In case of transmit antenna selection in frequency division duplex (FDD) networks, in which the forward and reverse links (channels) are not identical, the transceiver feeds back the optima set of the selected subset of antennas to the transmitter. In reciprocal time division duplex (TDD) networks, the transmitter can perform the selection independently.
[0017] For indoor local area network (LAN) applications with slowly varying channels, antenna selection can be performed using a media access (MAC) layer protocol, see IEEE 802.11n wireless LAM draft specification, 1. P802.11n/D1.0, “Draft amendment to Wireless LAN media access control (MAC) and physical layer (PHY) specifications: Enhancements for higher throughput,” Tech. Rep., March 2006.
[0018] Instead of extending the physical (PHY) layer preamble to include the extra training fields (repetitions) for the additional antennas, antenna selection training is done at the MAC layer by issuing commands to the physical layer to transmit and receive packets by different antenna subsets. The training information, which is a single standard training sequence for an L t ×L r MIMO network, is embedded in the MAC header field.
[0019] SC-FDMA Structure in LTE
[0020] The basic uplink transmission scheme is described in 3GPP TR 25.814, v1.2.2 “Physical Layer Aspects for Evolved UTRA.” The scheme is a single-carrier transmission (SC-FDMA) with cyclic prefix (CP) to achieve uplink inter-user orthogonality and to enable efficient frequency-domain equalization at the receiver.
[0021] Broadband Sounding Reference Signals (SRS)
[0022] The broadband SRS helps the eNodeB to estimate the entire frequency domain response of the uplink channel from the user to the eNodeB. This helps frequency-domain scheduling, in which a subcarrier is assigned, in principle, to the user with the best uplink channel gain for that, subcarrier. Therefore, the broadband SRS can occupy the entire network bandwidth, e.g., 5 MHz or 10 MHz, or a portion thereof as determined by the eNodeB. In the latter case, the broadband SRS is frequency hopped over multiple transmissions in order to cover the entire network bandwidth.
SUMMARY OF THE INVENTION
[0023] The embodiments of the invention describe a method for antenna selection in a wireless communication network. The network includes a transceiver having a set of antennas. The transceiver is configured to transmit a frequency-hopped sounding reference signal (SRS) over a subband from a subset of antennas at a time. The transceiver transmits the frequency-hopped SRS from subsets of antennas in the set of antennas alternately. In response to the transmitting, the transceiver receives information indicative of an optimal subset of antennas and transmits data from the optimal subset of antennas.
[0024] In some embodiments, we assign an index for each subset of antennas. We also use the ‘selected’ and ‘unselected’ subset of antennas as an indication to select particular subset of the antennas by the transceiver for the transmission. The index of the selected subset of antennas a(n SRS ) depends on the subframe number N SRS in which the SRS is transmitted and a number of the subset of antennas. Therefore, the index pattern above can be specified in the form a functional relationship between a(N SRS ) and n SRS .
[0025] In one embodiment, the transceiver has two subsets of antennas, and the indexes are 0 and 1. Accordingly, the transmitting alternately leads to an index pattern of the selected subset of antennas [0, 1, 0, 1, 0, 1, 0, 1 . . . ]. In another embodiment, the transceiver has three subsets of antennas, the index pattern of the selected subset of antennas [0, 1, 2, 0, 1, 2, 0, 1, 2, 0, 1, 2 . . . ]. In various embodiments, we are switching the index of the selected subset of antennas every time after the transmitting the frequency-hopped SRS.
[0026] Accordingly, one embodiment of the invention discloses a transceiver having a first antenna and a second antenna for transmitting alternatively a frequency-hopped sounding reference signal (SRS) over a sub-band of a bandwidth at a time. The transceiver includes a determination unit for determining whether a number of sub-bands in the bandwidth is odd or even; a transmitter for transmitting the SRS continuously from the first antenna, if the number of sub-bands is even; and a receiver for receiving a response to the transmitting.
[0027] Another embodiment discloses a method for antenna selection (AS) in a transceiver having a number of subsets of antennas for transmitting a frequency-hopped sounding reference signal (SRS) over a sub-band of a bandwidth from a subset of antennas at a time. The method includes a determining whether a number of sub-bands in the bandwidth is an integer multiplier of the number of subsets of antennas; and transmitting the SRS alternately from the subsets of the antennas if the number of sub-bands is not the integer multiplier of the subsets of antennas, and for transmitting the SRS substantially alternatively, if the number of sub-bands is tire integer multiplier of the subsets of antennas, wherein the transmitting substantially alternatively includes transmitting the SRS continuously from the same subset of antennas.
[0028] Yet another embodiment discloses a transceiver having a first antenna and a second antenna for transmitting alternatively a frequency-hopped sounding reference signal (SRS) over a sub-band of a bandwidth at a time. The transceiver includes a processor for determining whether a number of sub-bands in the bandwidth is odd or even, for switching an index of a subset of antennas transmitting die SRS every time after the transmitting, and, if the number of sub-bands is even, for periodically altering the index to include a continuous SRS transmission from the same subset of antennas.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a block diagram of a wireless network according to an embodiment of the invention;
[0030] FIG. 2 is a block diagram of an uplink resource grid according to an embodiment of the invention;
[0031] FIG. 3 is a block diagram of a resource block according to an embodiment of the invention;
[0032] FIG. 4 is a block diagram of method for selecting antennas according to an embodiment of the invention;
[0033] FIGS. 5 and 6 are block diagrams of a frequency-hopped sounding reference signal (SRS) transmission;
[0034] FIG. 7 is a block diagram of a method and a network for training subsets of antennas with, the frequency-hopped SRS according to embodiments of the invention; and
[0035] FIGS. 8 and 9 are block diagrams of a frequency-hopped sound reference signal (SRS) transmission according to embodiments of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] LTE Network Overview
[0037] FIG. 1 shows the general structure of an LTE wireless network according to an embodiment of the invention. Multiple user equipments (UEs) or mobile transceivers 111 - 113 communicate with a stationary base station (BS) 110 . The base station also includes transceivers.
[0038] The base station is called an evolved Node B (eNodeB) in the LTE standard. The eNodeB 110 manages and coordinates all communications with the transceivers in a cell using wireless channels or connections 101 , 102 , 103 . Each connection can operate as a downlink (DL) from the base station to the transceiver or an uplink from the transceiver to the base station. Because the transmission power available at the base station is orders of magnitude greater than the transmission power at the transmitter, the performance on the uplink is much more critical.
[0039] To perform wireless communication, both the eNodeB and the transmitters are equipped with at least one RF chain and a number of antennas. Normally, the number of antennas and the number RF chains are equal at the eNodeB. The number of antennas at the base station can be quite large, e.g., eight. However, due to the limitation on cost, size, and power consumption, mobile transceivers usually have less RF chains than antennas 115 . The number of antennas available at the transceiver is relatively small, e.g., two or four, when compared with the base station. Therefore, antenna training and selection as described is applied at the transceivers.
[0040] During operation, the transceiver switches the antennas between transmit RF chain(s) to transmit. Generally, antennas selection selects a subset of antennas from a set of available antennas at the transceiver. The antennas selection includes the training, which is used for generating and transmitting and receiving antenna selection signals. The embodiments of the invention enable the network to accommodate transceivers with different SRS bandwidths in an orthogonal manner, and use the limited resource of SRS sequences well.
[0041] LTE Frame Structure
[0042] The uplink (transceiver to eNodeB) and downlink (eNodeB to transceiver) transmissions are organized into radio frames. A radio frame is 10 ms long, and consists of 20 slots 306 of duration 0.5 ms each. Two consecutive slots constitute a subframe 301 . The frame includes twenty subframes in the time domain.
[0043] FIG. 2 shows the baste structure of a SC-FDMA (single carrier frequency division multiple access) uplink resource grid 200 . The horizontal axis indicates time or SC-FDMA symbols and the vertical axis indicates frequency or subcarriers. The number of subcarriers depends on the network bandwidth, which can range from 1.25 MHz to 20 MHz for example.
[0044] The uplink resource grid consists of resource elements. Each resource element is indemnified by the subcarrier and the SC-FDMA symbol. The resource elements are grouped into resource blocks. A resource block (RB) consists of 12 consecutive subcarriers and six or seven consecutive SC-FDMA symbols in time. The number of SC-FDMA symbols depends on the cyclic prefix (CP) length. For a normal cyclic prefix, the number of SC-FDMA symbols equals 7 and for an extended cyclic prefix, the number of SC-FDMA symbols equals 6.)
[0045] Each subframe constitutes a resource block, see inset 300 and FIG. 3 for details. For the purpose of this specification and appended claims, we use the terms the subframe and the transmission time interval (TTI) interchangeably.
[0046] FIG. 3 shows a structure of a resource block (RB) 300 for the normal cyclic prefix. The vertical axis indicates frequency, and the horizontal axis time. In frequency domain, the resource block includes of a number of subcarriers. In time domain, the RB is partitioned into SC-FDMA symbols, which may include data 203 and reference signals (RS) 210 . Two types of the RS are used in the uplink: sounding reference signals (SRS) 311 and demodulation reference signals (DMRS) 310 .
[0047] Both the SRS and the DMRS are generated using a constant amplitude zero autocorrelation sequence (CAZAC) sequence such as a Zadoff-Chu sequence, as explained in Section 5.5.1 of TS 36.211 v8.5.0 incorporated herein by reference. When the sequence length is not equal to the length possible for a Zadoff-Chu sequence, the sequence of desired length is generated by extending circularly a Zadoff-Chu sequence of length close to and less than the desired length or by truncating a Zadoff-Chu sequence of length close to and greater than the desired length. The DMRS is transmitted in the fourth SC-FDMA symbol for normal cyclic prefix and in the third SC-FDMA symbol for the extended cyclic prefix. The SRS, when transmitted, is typically transmitted in the last SC-FDMA symbol of the subframe except for special subframes as described in TS 36.211 v.8.5.0. However, the embodiments of the invention do not depend on the SC-FDMA symbol in which the RS is transmitted.
[0048] Antennas Selection
[0049] Typically, the RS is transmitted along with or separately from user data from different subsets of antennas. Based on the RSs, the base station, estimates channels and identifies the optimal subset, of antennas for data transmission.
[0050] FIG. 4 shows the basic method for antenna selection according to an embodiment of the invention. The base station 110 specifies instructions 151 , e.g., frequency-hopped pattern and subsets of antennas to use for transmitting RSs 161 . The transceiver 101 transmits the RSs 161 according to the instructions 151 .
[0051] The base station selects 170 a subset of antennas 181 based on the received RSs. Then, the base station indicates 180 the selected subset of antenna 181 to the transceiver. Subsequently, the transceiver 101 transmits 190 data 191 using the selected subset of antennas 181 . The transceiver can also use the same subset of antennas for receiving transmitting data.
[0052] Sounding Reference Signal (SRS)
[0053] The SRS is usually a wideband or variable bandwidth signal. The SRS enables the base station to estimate the frequency response of the entire bandwidth available for the network, or only a portion thereof. This information enables the base station to perform resource allocation such as uplink frequency-domain scheduling. According to the embodiment of the invention, the SRSs are also used for antenna selection.
[0054] Another option for LTE is to use the frequency-hopping (FH) pattern to transmit the SRS. Specifically, a hopping SRS, with a bandwidth smaller than the network bandwidth, i.e., a subband, is transmitted based on a pre-determined frequency hopping pattern. The hopped SRSs, over multiple transmissions, span a large portion of the entire bandwidth available for the network, or even the entire available bandwidth. With frequency hopping, the probability that transceivers interfere with each other during training is decreased.
[0055] However, if performed incorrectly, antenna selection with a frequency-hopped variable bandwidth SRS results in limited, performance improvement, particularly if the transceiver is moving rapidly. For example, as shown on FIG. 5 , all the subbands of antenna Tx 1 are successively sounded by a frequency-hopped SRS. Thereafter, the subbands of antenna Tx 2 are successively sounded in a similar manner, as shown by the shaded blocks. However, the channel estimates obtained from this frequency-domain antenna selection training pattern rapidly becomes outdated.
[0056] FIG. 6 shows subframes with frequency-hopped SRS transmitted from available subsets of antennas alternately. For example, the transceiver transmits the SRS alternately from two subsets of antennas, i.e., Tx1 210 and Tx2 220 . The available bandwidth 240 is partitioned into four subbands 241 - 244 , such that the SRS covers the bandwidth with four transmissions 250 . Please note, that a subband can occupy one or multiple RB.
[0057] As can be seen from FIG. 6 , in this transmission scenario, the SRSs for the subbands 241 and 243 are always transmitted from the subset of antennas Tx1, and the SRSs for the subbands 242 and 244 are always transmitted from the subset of antennas Tx2. Hence, the transceiver is not able to estimate the channel over entire frequency domain for each available subset of antennas.
[0058] FIG. 7 shows a method and a network 700 for training for the subset of antennas with the frequency-hopped SRS transmitted from the subsets of antennas according to embodiments of the invention. Transmitting substantially alternately means, as define herein for the purpose of this specification and appended claims, that the SRSs are transmitted from each subset in the set of antennas alternately, but periodically an order of the subsets schedule for the transmission is altered.
[0059] In some embodiments, we assign an index for each subset of antennas. We also use the ‘selected’ and ‘unselected’ subset of antennas as an indication to select particular subset of the antennas by the transceiver for the transmission.
[0060] For example, if the transceiver has two subsets of antennas, the indexes will be 0 and 1. Accordingly, the transmitting alternately leads to an index pattern of the selected subset of antennas [0, 1, 0, 1, 0, 1, 0, 1 . . . ]. If the transceiver use more than two subsets of antennas for the transmission, all the subsets of antennas transmit the SRS signals alternately according indexes of the subset. For example, if the transceiver has three subsets of antennas, the index pattern of the selected subset of antennas [0, 1, 2, 0, 1, 2, 0, 1, 2, 0, 1, 2 . . . ]. Thus, we are switching the index of the selected subset of antennas every time after the transmitting the frequency-hopped SRS.
[0061] However, the transmitting substantially alternately leads to an index pattern, e.g., [0, 1, 0, 1, 1, 0, 1, 0, 0, 1 . . . ]. Please note, that for the transmitting substantially alternately method we periodically alter the index for die transmitting subset, e.g., shift or omit the indexes. The index of the selected subset of antennas a(n SRS ) depends on the subframe number n SRS in which the SRS is transmitted and a number of the subset of antennas. Therefore, the index pattern above can be specified, in the form a functional relationship between a(n SRS ) and n SRS , The functional relationship depends on other parameters such as, but not limited to, the base station index and the length of the SRS sequence.
[0062] We determine 740 a type of a transmission based on a relationship between the number of subbands 710 in the bandwidth and the number of the subsets of transmit antennas 720 to be trained. As described in details below, if 730 the number of subbands is an integer multiplier of the number of transmit antennas 731 , we transmit the SRSs substantially alternately 760 . For example, we switch an antenna index 750 every time when the end of bandwidth is reached 735 . In alternative embodiment, we switch antenna index after the end or at the beginning of the frequency-hopped pattern, if 730 the number of subbands is not integer multiplier of the number of transmit antennas 733 , we transmit the SRSs alternately.
[0063] FIG. 8 shows a diagram for a method for transmitting alternately the frequency-hopped SRS. The available bandwidth of B Hz 810 is split into N f 830 subbands of bandwidth
[0000]
B
N
f
[0000] Hz each. If number of subbands is odd, e.g., N f =5, and the number of the subsets of antennas is even, e.g., two, then the number of subbands is not integer multiplier of the number of transmit antennas. Thus, the transmission from the two antennas, Tx1 and Tx2, alternately results in a time-interleaved frequency hopping pattern.
[0064] FIG. 9 shows a diagram for a method for transmitting substantially alternately the frequency-hopped SRS. In this embodiment, the number of subbands, i.e., tour, is integer multiplier of the number of transmitting antennas, i.e., two. Accordingly, when the transmission reaches the end of the bandwidth, e.g., a pattern of transmissions 920 , we switch the indexes of the subset of the antennas. Thus, the next pattern of transmissions 930 starts from the subset of antennas Tx2, instead of the subset Tx1 as for the cycle 920 .
[0065] As described above, in one embodiment, the decision of which training pattern to use is made by the base station. The training pattern is transmitted to the transceiver as part of the instruction 151 . In alternative embodiment, the transceiver has knowledge about the possible training patterns, and the instruction 151 includes only identification of the training pattern to use.
[0066] 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.
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A transceiver has a first antenna and a second antenna for transmitting alternatively a frequency-hopped sounding reference signal (SRS) over a sub-band of a bandwidth at a time. The transceiver includes a determination unit for determining whether a number of sub-bands in the bandwidth is odd or even, a transmitter for transmitting the SRS continuously from the first antenna, if the number of sub-bands is even, and a receiver for receiving a response to the transmitting.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of the patent application having Ser. No. 10/905,826, having filing date Jan. 21, 2005.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to indoor/outdoor area rugs or mats and, more particularly, to bamboo area rugs. Bamboo is a grass, that belongs to the sub-family Bambusoidae of the family Poaceae (Graminae). Bamboo occurs naturally on every industrialized and populated continent with the exception of Europe. There are over 1000 known species of bamboo plants. It is a durable and versatile material, that has been utilized by various cultures and civilizations for various applications. Bamboo has been an integral part of the cultural, social and economic traditions of many societies. There is a vast pool of knowledge and skills related to the processing and usage of bamboo, which has encouraged the use of bamboo for various applications.
[0003] Clumping bamboo can be widely grown in tropical climates. The trunk of the plant is called the “culm”. The culm is wider at the trunk or bottom and narrows toward the top. In some varieties of bamboo the culm may grow 40 to 60 feet tall. Once established, bamboo plants can replenish themselves in two or three years. Each year a bamboo will put out several full length culms, that are generally hollow, in the form of a tube having “nodes”. There are other parts of the bamboo plant that can be utilized other than the culm, including commonly used parts of a bamboo such as branches and leaves, culm sheaths, buds and rhizomes. Some species are very fast growing at the rate of one metre per day, in the growing season.
[0004] As mention above, bamboo occurs naturally on most continents, mainly in the tropical areas of a given continent. Its natural habitat ranges in latitude from Korea and Japan to South Argentina. It has been reported that millions tons of bamboo are harvested each year, almost three-fifths of it in India and China. One known source of quality bamboo is found in the Anji Mountains of China.
[0005] Bamboo has many uses such as substituting commercially for wood, plastics, and composite materials in structural and product applications. There is a large diversity of species, many of which are available in India, which is the second largest source of bamboo in the world ranking only behind China. These grow naturally at heights ranging from sea level to over 3500. Most Indian bamboo is sympodial (clump forming); the singular exception is Phylostacchus bambuisodes, cultivated by the Apa Tani tribe on the Ziro plateau in Arunachal Pradesh.
[0006] A common application for bamboo-based products is to utilize bamboo as a wood substitute. These applications include boards of various size and specifications and uses—laminates, flooring, panels, particleboard, insulation material, chipboard, wafer board, woven mat-board, bamboo ply-substitutes and veneer. Bamboo is in many respects, stronger than many wood products, and is comparable for some critical parameters with even some hardwoods. Bamboo laminates could replace the use of wood in many applications mostly including building and construction. Thin walled bamboo species may not be suitable for boards/laminates, but the thick walled bamboo is suitable. There are various thick walled bamboo species like tulda.
[0007] Bamboo has to undergo certain processing stages to convert them into boards/laminates. The green bamboo culms are converted into slivers/slats and then to boards. The boards are finally finished by surface coating. The common primary processing steps for making sliver/slats from green bamboo culms are 1. Cross Cutting; 2. Radial Splitting; 3. Internal Knot Removing & Two-side Planing; 4. Four-side Planing; and 5. forming slivers/slats. The common secondary processing steps for making board/laminate from slivers/slats are 1. Starch Removal & Anti-fungal Treatment; 2. Drying; 3. Resin Application; 4. Laying of Slivers/Slats; 5. Hot Pressing & Curing; and 6. form Laminates/Boards. The common surface coating and finishing stages are 1. Surface Sanding & Finishing; 2. Surface Coating with melamine/polyurethane; 3. Curing of Laminate; 4. Fine Sanding; 5. Evaluation of Surface Properties.
[0008] There are various types of bamboo flooring including tongue and groove and the type that needs to be butted together. The lacquered flooring tiles are finished using wear resistant UV lacquer and the unlacquered flooring tiles need to be coated/waxed and polished after installation. The strength of Bamboo Boards can be better than common wood board for its special Hi-steam pressure process. The board has good water resistance for its shrinking and expanding rate. Its water-absorbing rate is better than wood and is further humidity resistant and smooth. It has been reported that the strength of 12 mm bamboo ply-board is equivalent to that of a 25 mm plywood board.
[0009] There are also various types of bamboo area rugs made of flat elongated slats or strips arranged side by side length wise and having thread woven around and between the strips binding them together in a side by side arrangement. There is also usually a cloth or felt backing or some other fibrous material bonded to the underside. The bamboo area rugs also usually have a boarder edge binding made of cloth or other durable fibrous material.
[0010] The bamboo material is very durable for an area rug application, however, the construction of many bamboo rugs are lacking and the indoor/outdoor capability is limited. A novel bamboo area rug construction is needed.
SUMMARY OF THE INVENTION
[0011] The invention is a bamboo Indoor/Outdoor Area Rug that is manufactured from 100% Anji Mountain bamboo from China. The bamboo is all treated with various protective coatings to add resistance to natural factors including water, sun and dirt. All bamboo rugs manufactured for outdoor/indoor use are made from the harder portions of the bamboo trunk. (Some bamboo used for indoor purposes only are manufactured from the softer fibers of the inside of the bamboo trunk). This portion of the bamboo trunk is not utilized for this invention. The bamboo utilized in the present invention is taken from the harder part of the bamboo trunk to assure maximum endurance and longevity. The lower trunk portion of the bamboo plant is harder and less porous.
[0012] The bamboo for the present invention is kiln dried to prevent warping and remove moisture that can cause future warping. Certain styles of bamboo are oxidized in a boiling vat of liquid to bring out different variations of color vs. the common method of spray staining the bamboo slats to a particular color. The oxidation process also makes the bamboo less porous to moisture. The bamboo is assembled with slats laying next to one another and then assembling in a rug or carpet loom using poly resin fibers, fibrous tape strips, interwoven nylon fibers and/or other fibers, to avoid rot, mold, mildew and decay. During the assembly process in the loom a poly mesh sheet is placed on the bottom side of the rug. A mastic layer is then placed over the poly mesh sheet before a final layer of high density jute or coconut fiber is applied, which is preferably about approximately 2 mm in thickness. Then the rugs are cut to the desired dimensions and a boarder is bonded about the perimeter. The boarder is preferably made of polypropylene or other like material and the boarder is preferably sewn using poly thread or like material. The boarder material is preferred in order to avoid problems with rot, mildew and decay.
[0013] The present Outdoor/indoor Bamboo Area Rug can be manufactured with either a coconut fiber backing or a jute backing. Both of these backings are natural fibers that are resistant to mold, mildew and decay. The coconut fiber and jute fiber backing is processed into a porous matting that allows for natural drainage of water and allows for easy evaporation of moisture that is a primary cause of mold and mildew created in the felt backing or solid resin backing that is most commonly used as a padding surface for bamboo area rugs or most area rugs for that matter. Certain bamboo that is used in the manufacture of the present Outdoor/indoor Bamboo Area Rug is oxidized and gives it an extra step in making the bamboo more impermeable to water, sunlight and dirt. Once the elongated bamboo strips have been processed, they are adjacently aligned lengthwise, and side by side. A fiber mesh sheet is applied and bonded to the underside to hold the strips together. Then the porous mating is bonded to the underside. The present inventions construction provides a product that is resistant to damage from rain, rot, mold, mildew and decay.
[0014] These and other advantageous features of the present invention will be in part apparent and in part pointed out herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In referring to the drawings, for a better understanding of the present invention, reference may be made to the accompanying drawings in which:
[0016] FIG. 1 is a perspective exploded partial cut away view of the bamboo rug layers without the border; and
[0017] FIG. 2 is a perspective partial cut away view of the bamboo rug assembled with a border.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] According to the embodiment(s) of the present invention, various views are illustrated in FIGS. 1-2 and like reference numerals are being used consistently throughout to refer to like and corresponding parts of the invention for all of the various views and figures of the drawing. Also, please note that the first digit(s) of the reference number for a given item or part of the invention should correspond to the FIG. number in which the item or part is first identified.
[0019] One embodiment of the present invention comprising bamboo slats and a jute or coconut fiber backing teaches a novel apparatus and method for an outdoor/indoor bamboo rug that is resistant to moisture.
[0020] The details of the invention and various embodiments can be better understood by referring to the figures of the drawing. Referring to FIG. 1 , a perspective exploded partial cut away view of the present invention's bamboo rug layers without the border is shown. The outdoor/indoor area rug 100 is shown without a border and with the layers revealed in an exploded view. The rug 100 comprises a plurality of elongated flat bamboo slats 102 arranged lengthwise and side by side and each slat connected in a substantially abutting relationship with respect to an adjacent slat forming a seams 114 between adjacent slats. The connected slats form the bamboo rug portion 104 (bamboo layer). The abutting edges of adjacent slats can be unattached.
[0021] The adjacent slats can be connected to each other on the rug's bamboo layer underside 108 (the underside of the slats) by at least one loom fibrous tape strip extending orthogonally with respect to the lengthwise extension of the slats, see item 210 of FIG. 2 , using a loom system forming a rug. The loom fibrous tape strip can have some adhesive or adhesion properties on at least one facing surface of the tape strip such that it bonds to the underside of the slats to connect the adjacent slats together from the underside of the slat. The strip can extend orthogonally with respect to the lengthwise extension of the slats and can extend edge to edge of the bamboo layer portion 104 .
[0022] Alternatively or in addition to continuous fibers can be woven extending orthogonally around and between each of the slats connecting the slats together. Also, the slats can be connected by a series of substantially parallel fibers having adhesive properties extending orthogonally with respect to the lengthwise extension of the slates. The connecting tape strips or fibers 210 can also extend in a crossing angular fashion with respect to the lengthwise extension of the seams 114 . A fiber mesh sheet 106 can then be applied on the rug's underside 108 . The mesh sheet further bonds the bamboo slats together.
[0023] A resin material layer applied to the fiber mesh sheet underside 110 bonding the mesh sheet to the underside of the rug's bamboo layer. The resin material can be for example a mastic resin layer. The mastic resin layer will assist in providing a moisture seal for the underside of the rug for outdoor usage as well as bond the mesh sheet to the bamboo slats' underside 108 . Then a high density layer 112 of matted natural fiber is applied to the mesh sheet underside 110 . The resin layer assists in bonding the natural fiber layer to the mesh underside. The natural fiber layer can be moisture and mildew resistant for outdoor usage. The natural fiber layer can be made of matted jute bonded under and to the resin material layer or the fiber layer can be matted coconut fiber. Jute and coconut fiber have moisture and mildew resistance characteristics, thus can be for outdoor as well as indoor usage. One embodiment of the natural fiber layer can be about approximately 2 mm in thickness. However, the thickness of the natural fiber layer can vary significantly depending on the application and the environment for which the rug is to be used. The high density layer may also be made of matted felt, a natural rubber, or a synthetic polymer type of padding that is bonded over and to the resin material layer. Then, the combination of the slats, tape, mesh, and high density layer are pressured rolled for bonding.
[0024] Referring to FIG. 2 , the layers are shown assembled together forming the bamboo rug with a border 200 . Once the layers are assembled, a fibrous material border 202 can be folded about and attached around the perimeter of the rug edges 208 . The border 202 can be attached on the rug top surface 204 and then wrapped about the rug edges 208 around and attached to the bottom rug surface 206 . The border can be attached by stitching completely through the border material and all of the rug layers.
[0025] The rug as described herein can be such that the bamboo slats are kiln dried to prevent warping. The bamboo slats may also be carbonized in a boiling vent of liquid for use for coloring of the bamboo. This has a tendency to take out the sugars from the bamboo which prevents deterioration, and allows for its coloration. The rug as described can also be such that the bamboo slats are oxidized in a boiling vat of liquid for coloring the bamboo rather than performing a staining process. The rug as described, can have a resin layer that is a mastic resin layer for sealing and moisture resistance. The rug invention as described herein can be such that the bamboo slats are made of the harder lower trunk portions of the bamboo plant. The loom fiber such as the fibrous tape strip, can be a poly resin fiber.
[0026] The fiber mesh sheet can also be a poly fiber mesh sheet, as well as the fibrous material border can be made of polypropylene and attached around the perimeter of the rug with a poly thread sewn stitch. This polypropylene border embodiment provides a significant moisture barrier assisting in preventing moisture penetrating between the layers of the rug.
[0027] All of these features provide significant moisture mildew resistance, therefore, providing a bamboo rug with good outdoor characteristics. The construction of the layers bonded under the bamboo slats provide strength and durability as well as characteristics for outdoor usage. The construction and the material contained in the construction described herein also provide substantial flexibility such that the rug can be easily rolled up. The bamboo slats are made of the hardest portions of the bamboo, and the slats have multiple layers of UV coating, and may also have a polyurethane coating, to assist in their endurance during usage.
[0028] The various bamboo rug examples shown above illustrate a novel outdoor/indoor bamboo rug construction. A user of the present invention may choose any of the above bamboo rug construction embodiments, or an equivalent thereof, depending upon the desired application. In this regard, it is recognized that various forms of the subject outdoor/indoor bamboo rug could be utilized without departing from the spirit and scope of the present invention.
[0029] As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. It is accordingly intended that the claims shall cover all such modifications and applications that do not depart from the spirit and scope of the present invention.
[0030] Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings, the disclosure and the appended claims.
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A bamboo Indoor/Outdoor Area Rug that is manufactured from 100% Anji Mountain bamboo from China. The bamboo is all treated with various protective coatings to add resistance to natural factors including water, sun and dirt. All bamboo rugs manufactured for outdoor/indoor use are made from the harder portions of the bamboo trunk. (Some bamboo used for indoor purposes only are manufactured from the softer fibers of the inside of the bamboo trunk). This portion of the bamboo trunk is not utilized for this invention. The bamboo utilized in the present invention is taken from the harder part of the bamboo trunk to assure maximum endurance and longevity. The lower trunk portion of the bamboo plant is harder and less porous.
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TECHNICAL FIELD
[0001] This invention relates to making connections between integrated circuit (IC) packages and circuit boards.
BACKGROUND
[0002] Ball grid array (BGA) and land grid array (LGA) packages are becoming increasingly popular because of their low profiles and high densities. With a BGA package, for example, the rounded solder balls of the BGA are generally soldered directly to corresponding surface mount pads of printed circuit board rather tan to plated thru-holes which receive pins from, for example, a pin grid array (PGA) package.
[0003] Sockets are used to allow particular IC packages to be interchanged without permanent connection to a circuit board. More recently, sockets for use with BGA and LGA packages have been developed to allow these packages to be non-permanently connected (e.g., for testing) to a circuit board.
SUMMARY
[0004] This invention features intercoupling components and terminals that can enable high-density interconnections between electrical components such as, for example, printed circuit boards and integrated circuit packages. As used herein, the term “integrated circuit package” is intended to mean integrated circuit packages including, for example, PGA, BGA, and LGA packages. Intercoupling components can include: an insulative support member and a plurality of terminals. Terminals can include a socket, a pin, and a resilient member.
[0005] In an aspect of the invention, intercoupling components, used to couple an array of electrical connection regions disposed on a first substrate to an array of electrical connection regions disposed on a second substrate, include: an insulative support member including an array of holes extending therethrough, the array of holes located in a pattern corresponding to the array of electrical connection regions on the first substrate; and a plurality of terminals, each terminal including: a socket including a socket body extending from a socket head, the socket defining a socket cavity within the socket body; a pin including a pin body extending from a pin head, the pin head positioned within one of the array of holes and contacting the insulative member, the pin body at least partially received within the socket cavity; and a resilient member configured to bias the socket head away from the pin head.
[0006] In another aspect of the invention, terminals, for use with an integrated circuit package having an array of electrical connection regions disposed on a first substrate, include: a socket including a socket body extending from a socket head, a socket cavity formed within the socket, and a socket retaining element disposed on an opposite end of the socket body from the socket head; a pin including a pin body extending from a pin head, the pin body at least partially received within the socket cavity; and a resilient member configured to bias the socket away from the pin head.
[0007] In another aspect of the invention, methods of assembling an intercoupling component include: providing an insulative support member including an array of holes extending therethrough, the array of holes located in a pattern corresponding to the array of electrical connection regions on the first substrate; inserting a socket into each of the array of holes; inserting a pin having a pin body extending from a pin head into each of the array of holes such that the pin head contacts the insulative support member; and inserting a resilient member into each of the array of holes; such that, after the socket, the pin, and the resilient member are inserted, the resilient member is interposed between the pin head and the socket and the pin body is received within a socket cavity defined within the socket.
[0008] Embodiments can include one or more of the following features.
[0009] In some embodiments, the resilient member includes a coiled spring.
[0010] In some embodiments, the resilient member includes electrically conductive material and forms part of a first electrically conductive path between the array of electrical connection regions disposed on the first substrate to the array of electrical connection regions disposed on the second substrate. In some cases, contact between the pin and the socket forms part of a second electrically conductive path between the array of electrical connection regions disposed on the first substrate to the array of electrical connection regions disposed on the second substrate. The pin body can include a protrusion extending radially outward from a cylindrical portion of the pin body and/or the socket body can include a protrusion extending into the socket cavity.
[0011] In some embodiments, each hole includes a first section having a first diameter and a second section having a second diameter that is smaller than the first diameter. In some cases, the pin head is press-fit within the first section of a corresponding hole. In some cases, the pin head is press-fit within the second section of the corresponding hole.
[0012] In some embodiments, the pin head includes a proximal contacting surface. In some cases, the proximal contacting surface includes a ball-shaped end.
[0013] In some embodiments, the socket head includes a concave ball-contacting surface. In some embodiments, the socket head includes a sharp protrusion extending from a contacting surface.
[0014] In some embodiments, a lateral distance between centers of adjacent holes is less than about 0.8 millimeter.
[0015] In some embodiments, the resilient member includes a coiled spring. In some cases, the coiled spring has a coil diameter of less than about 0.005 inch (e.g., less than about 0.0025 inch).
[0016] In some embodiments, the socket comprises a contact spring disposed within the socket cavity. In some cases, the pin body comprises an enlarged end and the pin is received into the socket such that the contact spring engages sides of the pin body between the pin head and the enlarged end. In some cases, the contact spring comprises a first spring end and a second spring end, the first spring end having a greater diameter than the second spring end, the first spring end disposed nearer the pin head than the second spring end.
[0017] In some embodiments, the socket retaining element includes projections extending outward from an outer surface of the socket body.
[0018] In some embodiments, the socket retaining element includes projections extending inward from an inner surface of the socket body.
[0019] In some embodiments, the socket retaining element includes a contact spring disposed within the socket cavity, the contact spring having a first spring end and a second spring end, the first spring end having a greater diameter than the second spring end, the first spring end disposed nearer the pin head than the second spring end. In some cases, the pin body includes an enlarged end and the pin is received into the socket such that the contact spring engages sides of the pin body between the pin head and the enlarged end.
[0020] In some embodiments, the socket head comprises an open end of the socket body. In some cases, the socket head further includes a contacting element inserted into the open end of the socket body with a press-fit engagement between contacting element and the socket body.
[0021] In some embodiments, the resilient member provides a conductive path between the pin and the socket.
[0022] In some embodiments, the resilient member includes a coiled spring.
[0023] In some embodiments, the pin body includes a protrusion extending radially outward from a cylindrical portion of the pin body.
[0024] Terminals and intercoupling components (e.g., socket converter assemblies) as described herein can advantageously provide for an increased density of terminal connections. For example, a terminal having a socket which receives a portion of the pin but in which an interposed spring (i.e., resilient member) is not contained within the socket can have smaller outer dimensions than similar terminals in which the socket must be sufficiently large to contain the spring. Thus, intercoupling components can be configured with a decreased pitch or spacing between the centers of adjacent connections (e.g., 0.8 millimeter or 0.5 millimeter).
[0025] Another advantage relates to applications in which a specific pitch is desired. Reduced terminal diameters can increase the distance between the outer surfaces of adjacent terminals for intercoupling components of a given pitch (e.g., 1 millimeter). This increased separation can limit the “crosstalk” that can occur between adjacent signal paths in high-density intercoupling components.
[0026] The configuration of the pins and sockets can also provide an increased range of motion to compensate for variations of the in the surface of the integrated circuit package being, for example, tested. In addition, because these terminals and intercoupling components can be soldered or connected directly to underlying printed circuit boards, terminals and intercoupling components as described herein dispense with holed drill in printed circuit boards required to install intercoupling components which require separate hold down devices. This can reduce the likelihood of damage to such printed circuit boards.
[0027] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0028] FIG. 1 is an exploded, somewhat diagrammatic, perspective view of a BGA converter socket assembly, a BGA package, and a hold-down assembly positioned over a printed circuit board.
[0029] FIG. 2 is a cross-sectional view of the circuit board, two socket terminals of the socket converter assembly, and the BGA package of FIG. 1 .
[0030] FIGS. 3 - 9 are cross-sectional views of embodiments of socket terminals.
[0031] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0032] Referring to FIGS. 1 and 2 , a socket converter assembly 10 intercouples a BGA package 12 to a printed circuit board 14 . Socket converter assembly 10 includes an electrically insulative member 16 (e.g., a unitary sheet of liquid crystal polymer plastic, polyphenyl sulfide (“PPS”), or other electrically insulative material) for supporting converter terminals 18 . Each of the terminals 18 is press-fit within a corresponding one of an array of holes 20 ( FIG. 2 ) in insulative member 16 . The array of holes 20 is provided in a pattern corresponding to a footprint of rounded solder balls 51 ( FIG. 2 ) of BGA package 12 as well as a footprint of surface mount pads 24 of printed circuit board 14 . Insulative member 16 with converter socket terminals 18 is press-fit into a guide box 26 having sidewalls 28 along which the peripheral edges of BGA package 12 are guided so that solder balls 51 of the BGA package ( FIG. 2 ) are aligned over converter socket terminals 18 . In some instances, insulative member 16 and guide box 26 can be formed as a one-piece, integral unit. In this illustrative embodiment, socket converter assembly 10 is configured to intercouple BGA package 12 to circuit board 14 . However, as described in more detail below, other socket converter assemblies can be configured with similar terminals to intercouple other types of IC packages (e.g., LGA packages or PGA packages) to circuit boards.
[0033] As is shown in FIG. 1 , socket converter assembly 10 includes a hold-down cover 30 for securing BGA package 12 into the socket converter assembly. Cover 30 includes a pair of opposite walls 31 having tab members 33 which engage recessed portions 37 along the underside of insulative member 16 . Hold-down cover 30 includes a threaded thru-hole 34 which threadingly receives a heat sink 32 to provide a thermal path for dissipating heat generated within BGA package 12 from the IC device. Heat sink 32 is inserted and backed-in from the bottom of cover 30 and includes a lip 49 which engages a flat counter-bored surface (not shown) on the bottom surface of the cover to ensure that the heat sink will contact the surface of BGA package 12 . A slot 36 formed in heat sink 32 facilitates threading the heat sink (e.g., with a screwdriver or coin) within cover 30 . Other latching mechanisms (e.g., clips or catches) may also be used to secure IC packages within the socket converter assembly. In some instances, other heat sink arrangements, including those with increased surface areas (e.g., heat sinks with finned arrangements), are substituted for the lower profile heat sink shown in FIG. 1 . In some instances, a heat sink is not required and only cover 30 applies downward force to the IC package.
[0034] Referring to FIG. 2 , each terminal 18 includes a socket 52 , a pin 54 , and a resilient member 56 . Each socket 52 has a socket head 58 formed at the end of a socket body 60 . In this embodiment, socket heads 52 have concave upper surfaces 59 sized to receive and engage solder balls 51 of BGA package 12 . A socket cavity 62 is located within socket body 60 of each socket 52 and a socket retainer 70 extends outward relative to an outer surface 72 of the socket body. In the illustrated embodiment, socket body is substantially cylindrical in shape but, in some cases, other shapes and configurations are used. Insulative member 16 has projections or detents 64 defining narrow ends 66 of holes 20 that are oriented toward an IC package (e.g., BGA package 12 as illustrated) when converter assembly 10 is in use. Narrow ends 66 of holes 20 have a smaller cross-sectional dimension (e.g., diameter) than wide ends 68 of the holes. Sockets 52 are configured with socket bodies 60 that are sized to fit though narrow ends 66 of holes 20 with socket retainers 70 sized to fit into wide ends 68 of the holes and engage detents 64 . The engagement between socket retainers 70 and detents 64 prevents sockets 52 from passing completely thru-holes 20 .
[0035] Similarly, pins 54 have pin heads 74 formed at ends of pin bodies 76 . Pins 54 are configured with pin bodies 76 sized to have outer dimensions (e.g., diameters) at least slightly smaller than inner dimensions of socket cavities 62 and pin heads 74 sized to engage inner surfaces 78 of wide ends 68 of holes 20 . Each pin head 74 is positioned within a corresponding one of the array of holes 20 . Pin bodies 76 extend from pin heads 74 and can be received at least partially within corresponding socket cavities 62 .
[0036] Resilient members 56 are configured to bias socket heads 58 away from pin heads 74 . In this embodiment, resilient members 56 are springs (e.g., annular springs such as coiled springs or spring washers) positioned around pin bodies 76 with the resilient member of each terminal 18 extending between pin head 74 and socket retainer 70 of the terminal. In certain embodiments, resilient members 56 are made of electrically conductive material (e.g., beryllium copper, stainless steel, or music wire) such that the resilient members provide a electrically conductive connection between sockets 52 and pins 54 . Resilient members 56 are generally sized such, that under normal operation, an outer dimension (e.g., diameter) of the resilient members is smaller than an inner dimension (e.g., diameter) of wide ends 68 of holes 20 and an inner dimension (e.g., diameter) of the resilient members is larger than an outer dimension (e.g., diameter) of pin body 76 . Such sizing facilitates the movement (e.g., compression and expansion) of resilient members 56 in response to forces applied to sockets 52 as described below.
[0037] The above-described configuration can facilitate the installation of terminals 18 in insulative member 16 . In one approach, insulative member 16 is positioned with narrow ends 66 of holes 20 below wide ends 68 of the holes (i.e., rotated 180 degrees from the orientation shown in FIG. 2 ). Each socket 52 is then placed into corresponding hole 20 with gravity acting to move or help move the socket downward until socket retainer 70 engage detent 64 . Each resilient member 56 can then be placed into corresponding hole 20 . Each pin 54 can then be placed into a corresponding hole 20 with pin body 76 extending through resilient member 56 (e.g., through the open central region of coiled spring). Pressure can then be applied to pin head 74 and/or solder ball 50 attached to the pinhead to compress resilient member 56 and bring the pin head into a press-fit engagement with insulative member 16 . Holes 20 and pins 54 can be sized such that the press-fit engagement between pin heads 74 and insulative member 16 can hold terminals 18 in place against forces applied to the pin heads through sockets 52 and resilient members 56 as BGA package 12 approaches circuit board 14 .
[0038] In operation, terminals 18 can provide electrically conductive paths between IC package 12 and circuit board 14 with individual terminals providing some degree of compensation for irregularities in the surface and/or electrical contacts (e.g., solder balls 51 ) of the IC package. For example, if an individual solder ball 51 extends farther from surface 80 of IC package 12 than other solder balls 51 , the farther-extending solder ball will contact its corresponding socket head 58 sooner than the other solder balls will contact their corresponding socket heads as the IC package approaches (e.g., is pressed towards) insulative member 16 . However, socket head 58 contacted by the farther-extending solder ball 51 will compress resilient member 56 of that specific terminal 18 , thus allowing IC package 12 to continue to approach converter assembly 10 such that all solder balls 51 can be brought into engagement with corresponding socket heads. Thus, the movement of individual terminals 18 can provide improved electrical contact between IC package 12 and overall converter assembly 10 .
[0039] In this embodiment, resilient members 56 provide the primary electrically conductive connection between sockets 52 and pins 54 . However, incidental contact between pin 54 and socket 52 can also provide a direct electrically conductive connection between the pin and the socket and, thus, between IC package 12 and circuit board 14 . In some instances, the outer surface of pin body 76 and/or the inner surface of socket body 60 can be configured with projections to provide contact between pin 54 and socket 52 . However, while such projections can provide a consistent direct electrical contact between pin 54 and socket 52 , the resulting contact can also reduce the ease with which the socket moves relative to the pin and, thus, the ability of individual socket terminals 18 to compensate for irregularities in surface 80 and/or solder balls 50 of IC package 12 .
[0040] In addition to providing for easy assembly, embodiments of terminals 18 can also provide other advantages including improved electrical characteristics and reduced pitch (i.e., spacing between the centers of adjacent terminals). In general, changes in the diameter of components forming the electrically conductive path through a terminal can produce undesirable effects (e.g., reduced bandwidth, increased insertion and/or return signal losses). By limiting the number of such diameter changes, terminals 18 can have improved electrical characteristics relative to other terminals with more diameter changes. This simpler configuration also can allow for machining of terminals components with small diameters and, thus, manufacture of converter assemblies with pitches of less than about 1 millimeter (e.g., 0.8 millimeter, 0.5 millimeter, or 0.3 millimeter). For clarity of illustration, additional embodiments are illustrated in FIGS. 3-9 with only the insulative member and socket terminals shown. Where the resilient member is shown in a compressed state, it will be understood that such compression would be produced by an IC package engaging the socket heads of the terminals.
[0041] Referring to FIGS. 3 and 4 , in some embodiments (e.g., in converter assemblies configured to intercouple other types of IC packages to circuit board 14 ), socket heads can be configured to engage other contacts than solder balls. For example, terminals 82 and terminals 83 are configured in substantially similar fashion to terminal 18 ( FIGS. 1 and 2 ) described above. Terminals 82 and terminals 83 are disposed in insulative member 16 and include pin 54 , resilient member 56 , and solder balls 50 . The primary difference between terminals 18 ( FIGS. 1 and 2 ), terminals 82 ( FIG. 3 ), and terminals 83 ( FIG. 4 ) is in their socket head configurations. Referring to FIG. 3 , terminals 82 have sockets 84 with socket heads 86 whose upper surfaces 88 are substantially flat (rather than concave) with pointed projections extending away from the socket heads. The pointed projection can, to some extent, pierce through the layers of oxidation that sometimes form on the contacts of IC packages. Socket heads 86 provide terminals 82 with a configuration that is appropriate for use with IC packages including, for example, LGA packages. Referring to FIG. 4 , terminals 83 have sockets 90 with socket heads 92 whose upper surfaces 94 are slightly concave. Socket heads 92 provide terminals 83 with a configuration that is appropriate for use with IC packages including, for example, LGA packages.
[0042] Referring to FIG. 5 , in some cases, terminals can be is configured such that engagement between the pin and the socket of individual elements retains the socket in the terminal. For example, terminal 96 is disposed in insulative member 16 and includes a pin 98 press-fit within a hole 100 in the insulative member. In this embodiment, resilient member 56 is a coiled spring which can be made of an electrically conductive material. As in the previously embodiments, resilient member 56 biases socket head 102 of socket 104 away from pin head 106 . In this embodiment, resilient member 56 is disposed around pin 98 with ends engaging socket 104 and projections 105 extending from insulative member 16 . Pin 98 includes a pin body 110 having a proximal section 112 and distal section 114 with intermediate projections 108 extending radially outward from pin body 110 between the proximal and distal sections. In some embodiments, distal section 114 has a smaller diameter than proximal section 112 .
[0043] Socket 104 has inward socket retainer 116 disposed at the open end of the socket and extending inward from a substantially tubular socket body 118 . Thus, socket retainers 116 define a thru-hole with a smaller diameter than at least an adjacent portion of socket body 188 . The inner diameter of inward socket retainer 116 is sized to be at least as large as the outer diameter of proximal section 112 of pin body 110 but smaller than the outer diameter of intermediate projections 108 of pin body 110 . The inner diameter of at least a portion of socket body 118 is sized to be at least as large as the outer diameter of intermediate projections 108 of pin body 110 .
[0044] In this embodiment, inward socket retainer 116 is an integrally constructed unit with a substantially annular configuration. However, inward socket retainer 116 can have other configurations (e.g., multiple tabs spaced at intervals around an inner surface of the socket).
[0045] As illustrated, socket head 102 can have the same cross-section as socket body 118 . This configuration facilitates manufacture of socket 104 as socket head 102 and socket body 118 can be a single integral unit with a inner diameter sized and shaped such that the open end of the socket end can receive and engage electrical contacts of an IC package (e.g., solder balls on a BGA package).
[0046] Terminal 96 can be partially assembled before it is installed in insulative member 16 . For example, while holding socket 104 with socket head 102 upwards, pin 98 can be placed into the socket with proximal section 112 of pin body 110 extending downward through inward socket retainers 116 such that intermediate projections 108 of pin body 110 engage inward socket retainers 116 . The assembled pin 98 and socket 104 can then be reversed and resilient member 56 can be installed around proximal section 112 of pin body before the combined pin/socket/resilient member unit can be pressed into insulative member 16 to bring pin head 106 into press-fit engagement with the insulative member.
[0047] In operation, resilient member 56 biases inward socket retainer 116 towards engagement with intermediate projection 108 of pin body 110 . This engagement keeps socket 104 from being pushed out of insulative member 16 by resilient member 56 . As in previously described embodiments, movement of an IC package (not shown) towards insulative member 16 brings electrical contacts of the IC package into contact with socket 104 and compresses resilient member 56 . In this embodiment, pin 98 and socket 104 are sized to produce ‘wiping’ engagement between intermediate projections 108 of pin body 110 and socket body 118 as well as between inward socket retainers 116 and proximal section 112 of the pin body. This wiping engagement provides for a direct electrical path between socket 104 and pin 98 that can be supplemented by a secondary electrical path through resilient member 56 . In some cases, distal section 114 of pin 98 can extend to or slightly past an upper surface 122 of insulative member 16 such that movement of the IC package (not shown) towards the insulative member can bring electrical contacts of the IC package into contact with the distal section of the pin.
[0048] In terminals with socket heads including pointed projections (see FIGS. 2 and 3 ), the pointed projections can leave ‘witness’ marks or indentations on the ends of the solder balls of BGA packages. In some cases, this can be undesirable because some users perceive such indentations as a possible source or harbor for contamination. Referring to FIG. 5 , open-ended socket heads 102 can be less likely to leave witness marks and, to the extent that they occur, on the sides rather than bottoms of the solder balls.
[0049] Referring to FIGS. 6A-9 , in some cases, sockets can include a contact spring, rather than the socket retainers described above. Such contact springs can provide electrical contact between pins and sockets and can also act as a mechanism to keep the sockets in place on the pins. Similarly, in some cases, pins can include a retention feature to aid or replace the press-fit engagement between the insulative member and the pins.
[0050] For example, referring to FIGS. 6A and 6B , terminal 124 is configured with a double-headed pin 126 , a contact spring socket 128 , and resilient member 56 interposed between the pin and the socket in a substantially similar fashion to terminal 96 illustrated in FIG. 5 and described above. Double-headed pin 126 includes first pin head 130 with an attached solder ball 50 , a pin body 132 with a proximal section 134 adjacent the first pin head and a distal section 136 , and a enlarged end 138 disposed at an opposite end of the pin body from the first pin head. First pin head 130 includes outwardly extending shoulders 140 and main head section 142 . In this embodiment, proximal section 134 has a larger outer diameter than distal section 136 . The larger size of proximal section 134 provides increased strength and stability to pin 126 . In some embodiments, pin body 132 can have other configurations (e.g., multiple sections, a gradually varying outer diameter, or a single constant outer diameter). Double-headed pin 126 is disposed in insulative member 16 with main head section 142 in press-fit engagement with projections 105 from insulative member 16 and with shoulders 140 engaging a top surface of the projections from the insulative member. Resilient member 56 is disposed with one end engaging shoulders 140 of first pin head 130 and the other end engaging contact spring socket 128 .
[0051] Contact spring socket 128 has a hollow socket body 144 with an open end 146 in which a contact spring 148 is disposed. In this embodiment, contact spring 148 has multiple leaves 150 extending from an annular base 152 . Annular base 152 is disposed at or near open end 146 of socket body 144 with spring leaves 150 extending into the socket body from the base. Spring leaves 150 are biased towards a rest position in which the leaves extend diagonally inwards relative to an inner surface of annular base 152 . Spring leaves 150 are sized and configured such that, in the rest position, the distance between the ends of the leaves that are farthest from base 152 is less than the outer diameter of distal section 136 of pin body 132 .
[0052] Contact spring socket 128 has a socket head 154 with a concave upper surface from which a pointed projection extends. Socket head 154 configures terminal 124 to receive and engage solders balls of a BGA package (not shown). However, use of different socket head configurations allows the use of contact spring sockets with other types of IC packages (e.g., LGA or PGA packages). For example, referring to FIG. 7 , terminal 156 has contact spring socket 157 with a socket head 158 with a substantially flat upper surface from which a pointed projection extends thus configuring the socket head 158 to receive and engage electrical contacts of an LGA package (not shown). Other elements of terminal 156 are substantially similar to those illustrated in FIGS. 6A and 6B and described above.
[0053] Referring to FIGS. 6A-7 , when terminal 124 and terminal 156 are assembled, distal section 136 and enlarged end 138 of pin 126 are inserted through contact spring 148 into socket body 144 , 160 . The configuration of contact spring 148 biases spring leaves 150 towards engagement with an outer surface of pin body 132 . At the same time, resilient member 56 biases contact spring socket 128 , 158 away from first pin head 130 . Engagement between enlarged end 138 of pin 126 and spring leaves 150 keeps contact spring socket 128 , 157 from being pushed out of insulative member 16 by resilient member 56 (see FIG. 6A ).
[0054] Referring to FIGS. 6A-7 , this configuration facilitates installation of terminals 124 , 156 in insulative member 16 . Pins 126 can be inserted into insulative member 16 until main head sections 142 are press-fit into the insulative member and shoulders 140 engage a top surface of the projections from the insulative member. Resilient members 56 can then be disposed into insulative member 16 around pins 126 . As contact spring sockets 128 , 157 are then pressed onto pins 126 , enlarged ends 138 of the pins pass through contact spring leaves 150 . After enlarged ends 138 are past contact spring leaves 150 , the bias of the contact spring leaves towards their rest position can maintain ends of the contact springs leaves in contact with pin bodies 132 .
[0055] In operation, these terminals 124 , 156 function in substantially the same fashion as those embodiments previously described. However, shoulders 140 extending from first pin heads 130 provide an additional mechanism resisting forces applied to pins 126 through contact spring sockets 128 , 157 and resilient members 56 as an IC package (not shown) approaches circuit board (not shown). This additional mechanism allows for greater tolerances in sizing the holes and pins 126 as the press-fit engagement between first pin heads 130 and insulative member 16 are not alone in keeping these forces from forcing the pins out of the insulative member. Shoulders 140 can also function to keep pins 126 in place as solder balls 50 are reflowed to attach a converter socket assembly to a circuit board.
[0056] In some embodiments, first pin heads 130 and/or insulative member 16 can be deliberately sized to provide for a reduced press-fit engagement between the first pin heads and the insulative member such that it is feasible to replace damaged pins by pulling them out of insulative member 16 . Similarly, contact spring leaves 150 can be configured such that the bias of the spring leaves towards their rest position which provides an engagement with enlarged end 138 of pins 126 which counters the forces applied by the resilient members 56 but allows application of additional force (e.g., by pulling) to remove contact spring sockets 128 , 157 for replacement. Such replacement can be desirable to replace damaged sockets and/or to reconfigure terminals 124 , 156 for other electrical contacts.
[0057] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, referring to FIGS. 8 and 9 , some terminals can have solder tails 164 (rather than solder balls) that extend from double-headed pins 166 that are otherwise substantially similar to pins 126 (see FIGS. 6A-7 ). In some cases, solder tails 164 can be inserted into prepared sockets in a circuit board to provide electrical connections without a need for actual soldering to provide for attachment to the circuit board. In some cases, solder tails 164 can be inserted through thru-holes extending through a circuit board and then reflowed to provide attachment and electrical connection to the circuit board. In another example, contact spring sockets 168 can be configured with open ends 170 for receiving solder balls of BGA packages as described above (see FIG. 5 ). Referring to FIG. 9 , such open-ended sockets 168 can be converted for contact with other IC packages by addition of inserted socket heads 172 which is sized such that outer surfaces 174 of the inserted heads can be press-fit into open ends 170 of the sockets. Accordingly, other embodiments are within the scope of the following claims.
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An intercoupling component used to couple an array of electrical connection regions disposed on a first substrate to an array of electrical connection regions disposed on a second substrate. The intercoupling component includes an insulative support member including an array of holes extending therethrough, the array of holes located in a pattern corresponding to the array of electrical connection regions on the first substrate; and a plurality of terminals. Each terminal includes a socket including a socket head and a socket body, the socket defining a socket cavity; a pin including a pin head and a pin body, the pin head positioned within one of the array of holes, the pin body extending from the pin head and received at least partially within the socket cavity; and a resilient member configured to bias the socket head is biased away from the pin head.
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FIELD OF THE INVENTION
This invention relates to the art of stretch forming metal sheets and more particularly to a jaw assembly for a stretch forming press for gripping the edges of the metal sheet to be stretch formed.
BACKGROUND OF THE INVENTION
Stretch forming is a method of forming parts by stretching a metal sheet beyond its elastic limit over a die. The sheet is deformed by tension forces into a shape corresponding to the die, and retains this shape because it is stretched beyond its elastic limit. This method is widely used in aircraft and automotive fields for fabricating sheet metal components, and is further described in U.S. Pat. Nos. 2,824,594, 2,835,947, 3,073,373, 3,299,688 and 3,575,031.
In conventional stretch forming presses, a metal blank, typically flat aluminum or steel sheet stock having a generally rectangular shape, is loaded into a pair of opposed gripping jaws which are then positioned by associated tensioning hydraulic cylinders to an initial stretch forming position. A die carried by a main hydraulic cylinder is driven against the blank with sufficient force that the blank is stretched beyond its elastic limit over the die. Alternatively, the jaws are further moved by the tensioning cylinders to wrap the blank over the die. The blank is thereby formed into a desired shape which corresponds to the shape of the die.
The jaw assembly of such stretch forming presses may have a wide non-segmented jaw for gripping the end of the metal blank, or may have a multiple-segmented jaw. For example, in instances where the die has a straight contour transverse to the metal blank, it is desirable that the margins of the blank be gripped by a wide non-segmented jaw or by multiple-segmented jaw in which the segments are aligned in a straight line. When the die has a curved contour transverse to the metal blank, it is desirable to grip the ends of the workpiece with a plurality of jaw segments which can be moved relative to each other to follow the contour of the die.
In U.S. Pat. No. 2,835,947 to Gray et al, a jaw assembly is disclosed having four jaw segments. The jaw segments are mounted on a pair of spaced-apart platens which are in turn mounted on a single mount. The mount is connected by a shaft to a tensioning device for moving the jaw horizontally forwardly and rearwardly. The platens can be rotated relative to the mount. Each segment is pivotally coupled to adjacent segments and can rotate and move transversely within guideways in the platens. The jaw segments can be aligned in a straight line or one which curves downward on one or both sides.
U.S. Pat. No. 3,299,688 to Gray discloses a stretch forming press having a plurality of jaw segments wherein each segment is separately connected to a hydraulic cylinder and forms an independent tensioning unit. In such an apparatus, the position of the jaw segments is independently adjustable. A cable extends through the jaw segments to loosely maintain their relation to each other.
In another known multiple segment jaw assembly, the segments are simply hinged to each other with the center segment being connected to the tensioning device by means of a yoke and a rearwardly extending shaft. In such an assembly, the widths of the segments are generally equal, however, to provide adequate strength, the length of the center segment is greater than the next adjacent segments, whose lengths are greater than the next adjacent segments and so on.
In the above-mentioned stretch forming presses, the jaws assemblies are attached to the tensioning device at positions spaced apart rearwardly of their centers of gravity, in some instances by as much as 10 feet. This creates a substantial rotational moment on the point of attachment which must be compensated for, e.g., by stop pins or the like. Any upward swing of the jaw results in loss of die table stroke. Further, movement of the jaw segments relative to each other, e.g., to form a curve, generally causes a change in the center of pull which creates an additional rotational moment about the point of attachment of the jaw assembly to the tensioning device during stretch forming operation.
SUMMARY OF THE INVENTION
Accordingly, there is provided a jaw assembly for a stretch forming press comprising a jaw frame and a flexible jaw mounted on the jaw frame for gripping the edges of a metal blank. The jaw frame comprises a generally flat front wall having a pair of horizontally extending side slots spaced apart from and on separate sides of the midpoint of the front wall.
The flexible jaw comprises a plurality of jaw segments interconnected by means of hinges. The jaw is mounted on the frame by means of a pair of side support pins which extend rearwardly from the jaw into the side slots of the jaw frame. The side support pins are slidably secured within their respective slots.
Means, preferably hydraulic means, are provided for raising and lowering the center of the jaw. As the center of the jaw moves away from the elevation of the side support pins, the side support pins are caused to move horizontally inwardly along the length of the side slots resulting in curvature of the jaw. As the center of the jaw moves toward the elevation of the side support pins, the side support pins move horizontally outwardly along the lengths of the side slots.
The jaw assembly further comprises means for mounting the jaw frame between a pair of laterally spaced-apart jaw carriages of a stretch forming press. Preferred means comprise a pair of coaxial trunnions which extend laterally from the ends of the jaw frame at about the same elevation as the elevation of the side slots and which rotatably engage a pair of laterally spaced-apart jaw carriages of the stretch forming press. In such an arrangement, the center of pull of the jaw is always at about the elevation of the trunnions which minimizes any movement which could cause rotation about the trunnions. Means, preferably hydraulic means, are provided for rotating the jaw assembly about the axis of the trunnions.
In a preferred embodiment of the invention, the flexible jaw comprises a center support pin which extends rearwardly from the center of the jaw into a generally vertical center slot in the front wall of the jaw frame and a pair of side support pins which extend rearwardly from the jaw at positions spaced apart laterally from the center support pin and into side slots in the front wall of the jaw frame.
Vertical movement of the center support pin and hence, the center of the jaw is preferably controlled by a first hydraulic cylinder which is mounted on the frame at a position above the center support pin and is coupled to the center support pin. Second and third hydraulic cylinders are also provided for controlling pivotal movement of the end jaw segments. The second and third hydraulic cylinders are hingedly mounted to the top of the jaw at or about the center of the jaw, the piston rods of the second and third hydraulic cylinders extending outwardly to and being hingedly connected to separate end jaw segments. Activation of the first, second and/or third hydraulic cylinders controls the curvature of the jaw. Adjustable stops may be provided between adjacent jaw segments to further control the curvature of the jaw.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
FIG. 1 is a perspective view of a preferred stretch forming press;
FIG. 2 is a front view of a preferred jaw assembly mounted on a pair of jaw carriages;
FIG. 3 is a front view of the jaw frame of the jaw assembly shown in FIG. 2;
FIG. 4 is a fragmentary top cross-sectional view of the jaw assembly shown in FIG. 2 through line 4--4;
FIG. 5 is a front view of the jaw assembly shown in FIG. 2 in a curved configuration;
FIG. 6 is a front view of the jaw assembly shown in FIG. 2 in an "S" configuration;
FIG. 7 is a side cross-sectional view of the jaw angle assembly of the jaw assembly of FIG. 2 through line 7--7;
FIG. 8 is a top cross-sectional view of the jaw angle assembly of FIG. 7 taken through line 8--8;
FIG. 9 is a front view of a preferred jaw assembly comprising a hold-down bar;
FIG. 10 is a side cross-sectional view of a preferred jaw assembly on which an auxiliary jaw is mounted;
FIG. 11 is a front view of a preferred jaw frame on which side mounting blocks are mounted; and
FIG. 12 is a top cross-sectional view of the jaw frame of FIG. 11 taken through line 12--12.
DETAILED DESCRIPTION
With reference to FIG. 1, there is shown a preferred stretch forming press 10 comprising a preferred jaw assembly 11 constructed in accordance with the present invention. The stretch forming press 10 comprises a base 12 which rests on a concrete or other solid foundation 13 forming a pit 14 below the level of the surrounding floor. The base 12 comprises a pair of elongated laterally spaced-apart horizontal I-beam 16 secured together at their ends by end plates 17.
A large lower die support 18 extends transversely below the base 12 of the stress press 10 within the pit 14. The lower die support 18 is fixedly attached at positions adjacent its ends to the beams 16 generally about the midpoint of the beams. A vertically movable die table 19 for supporting a die (not shown) is positioned over the lower die support 18. A pair of hydraulic cylinders 21 are mounted on the underside of lower die support 18 with the piston rods (not shown) of hydraulic cylinders 21 extending upwardly through the lower die support for connection to the bottom side of the die table 19. Activation of hydraulic cylinders 21 controls vertical movement of die table 19.
Lower die support 18 extends laterally beyond the beams 16. A pair of vertically extending hydraulic cylinders 23 are mounted on the ends of lower die support 18 which extend beyond the beams 13. The piston rods 24 of hydraulic cylinders 23 extend upwardly and are pivotally connected at their upper ends to the lateral ends of an upper die support 26 which extends transversely across the stretch forming press 10. An upper die (not shown) can be mounted on upper die support 26 which can then be moved vertically relative to lower die support 18 and die table 19 by activation of hydraulic cylinders 23.
The stretch forming press 10 further comprises four main tension hydraulic cylinders 28 which are clamped at the ends of beams 16 by means of brackets 29. A jaw carriage 32 is slidably mounted on beam 16 in front of each main tension cylinder 28 and is connected to the forward end of a piston rod 33 of main tension cylinder 28. Activation of main tension cylinders 28 causes jaw carriages 32 to move forwardly or rearwardly along the length of horizontal beams 16. The jaw assembly 11 is rotatably mounted on and extends between two jaw carriages 32 at each end of stretch forming press 10.
With reference to FIGS. 2-6, the jaw assembly 11 comprises a flexible jaw 36 which is mounted on a jaw frame 37. The jaw frame 37, as shown in FIG. 4, comprises a generally flat vertical front wall 38, a pair of side walls 39 which extend rearwardly and inwardly from the front wall 38 and a rear wall 41 generally parallel to the front wall 38.
Front wall 38 of the jaw frame 37 defines three slots (FIG. 3), a generally vertical center slot 48 and a pair of generally horizontal side slots 49 spaced apart on opposite sides of center slot 48. Center slot 48 extends from a lower end about the elevation of side slots 49 to an upper end above the elevation of side slots 49. In the embodiment shown, front wall 38 has a raised center section and is generally in the form of an inverted "T". It is to be understood that the shape of the front wall is not restricted to the shape shown in the drawings but may be any suitable shape.
Jaw frame 37 further comprises a pair of supporting end walls 42 which extend forwardly at the ends of front wall 38. A pair of generally coaxial, horizontal trunnions 44 extend laterally outwardly from end walls 42 and engage bearings 46 in jaw carriages 32. Jaw assembly 11 is thus afforded rotatable movement about the horizontal axis of trunnions 44. Trunnions 44 are at about the same level as side slots 49 and are located at positions whereby the axis of trunnions 44 passes through about the center of mass of the jaw assembly.
Jaw 36 comprises seven jaw segments 51-57 respectively which are hingedly connected together by pivot pins 59 (FIG.4). The jaw segments are all generally the same, each comprising a mouth 61 which opens forwardly to receive and grip the edge or margin of a metal blank. The metal blank is gripped by means of a pair of stationary lower gripping inserts 62 on the floor of mouth 61 and a pair of movable upper gripping inserts 63 spaced apart above lower gripping inserts 62. Movement of upper gripping inserts 63 is controlled by a pair of hydraulic cylinders 64 mounted on the top of each jaw segment. The piston rod (not shown) of each hydraulic cylinder 64 extends downwardly through the jaw segment and is connected to the tops of upper gripping inserts 63.
Jaw 36 is mounted on jaw frame 37 by means of three generally cylindrical support pins, a pair of side support pins 66 and a center support pin 67 (FIG.4). Center support pin 67 extends rearwardly from the center or fourth jaw segment 54 through center slot 48. It also extends through a generally circular opening in a center support pin carriage 69 located behind front wall 38. The vertical edges of center support pin carriage 69 are slidably disposed in generally vertical tracks 71 behind front wall 38 on each side of center slot 48.
A retaining ring 72 having a diameter greater than the opening in center support pin carriage 69 is fixedly mounted on center support pin 67 at a position behind center support pin carriage 69. Center support pin 67 and center support pin carriage 69 are afforded vertical slidable movement along the length of center slot 48 and track 71. Center support pin 67 is also afforded rotatable movement relative to center slot 48 and center support pin carriage 69.
Center support pin 67 and hence center jaw segment 54 are afforded vertical movement along the length of center slot 48 from a lower position at the lower end of the center slot 48 as shown in FIG. 2 wherein the jaw segments are all aligned in a straight horizontal row to an upper position at the upper end of center slot 48 as shown in FIG. 6 wherein the jaw segments form an arch.
Side support pins 66 extend horizontally rearwardly from second and sixth jaw segments 52 and 56 respectively through side slots 49 of front wall 38 of jaw frame 37. The diameters of side support pins 66 are slightly less than the widths of side slots 49 so that side support pins 66 can slide and rotate within side slots 49. A pair of retaining rings 68 having diameters greater than the widths of side slots 49 engages side support pins 55 at positions behind front wall 38 of jaw frame 37. Retaining rings 68 are fixedly mounted on side support pins 66 at positions which afford side support pins 66 horizontal slidable and rotatable movement within side slots 49.
In this arrangement, the center of pull of the jaw is at about the level of the axis of the trunnions 44 when the jaw segments are aligned in a straight row. That is, the center of pull passes through the jaw assembly at about the axis of trunnions 44. As used herein "center of pull" refers to the line or vector at the center of the forces acting on a metal blank by the jaw.
In addition, the precise location of side support pins 66 on second and sixth jaw segments 52 and 56 is preferably selected so that, for a metal sheet approximately the same width as the width of the jaw, change in the center of pull of the jaw does not occur, or is at least minimized, when the jaw is moved to a different configuration when the center jaw segment is raised.
Movement of center jaw segment 54 is controlled by a hydraulic cylinder 73 mounted on the top of front wall 38 of jaw frame 37 directly above center support pin carriage 69. The piston rod 74 of hydraulic cylinder 73 extends downwardly and is connected to center support pin carriage 69. Activation of hydraulic cylinder 73 results in vertical movement of center support pin carriage 69 which also results in vertical movement of center support pin 67 and center jaw segment 54.
Because the jaw segments are hingedly interconnected by pivot pins 59, movement of center jaw segment 54 results in movement of the remaining jaw segments. For example, upward movement of center jaw segment 54 causes third and fifth jaw segments 53 and 55 to rotate and to move upwardly and inwardly, i.e., toward the midpoint of front wall 38. Second and sixth jaw segments 52 and 56 move horizontally toward the midpoint of front wall 38, vertical movement being restricted by side support pins 66 and side slots 49. Second and sixth jaw segments 52 and 56 also rotate about the axis of side support pins 66.
The extent of the rotation of the various jaw segments is controlled by means of adjustable stop pins 76 located between adjacent jaw segments. Stop pins 76 control the maximum angle which can be obtained between adjacent jaw segments.
The first and seventh or end jaw segments 51 and 57 also move inwardly as a result of upward vertical movement of the center jaw segment 54. However, rotatable movement of first and seventh jaw segments 51 and 57 cannot be controlled solely by the movement of center jaw segment 54 and by stop pins 76.
Rotatable movement of the first and seventh jaw segments 51 and 57 is controlled by hydraulic cylinders 77 and 78 respectively which are hingedly attached to center jaw segment 54 by brackets 79 and 81. The piston rods 82 and 83 of hydraulic cylinders 77 and 78 extend to and are hingedly connected to brackets 84 and 86 mounted on top of first and seventh jaw segments 51 and 57 respectively. Hydraulic cylinders 77 and 78 can be activated independently of each other and independently of hydraulic cylinder 73 which controls vertical movement of center jaw segment 54. For example, by activating hydraulic cylinder 77 to extend piston rod 82 and by activating hydraulic cylinder 78 to retract piston rod 83, the jaw can be made to form the shape of an "S" as shown in FIG. 6.
In FIGS. 2-6, the jaw assembly is in a horizontal orientation wherein the direction of pull on a metal blank gripped by the jaw segments along a horizontal line and the face of front wall 38 of jaw frame 37 is generally vertical. Jaw assembly 11, however, can be rotated about the axis of trunnions 44 to other orientations, i.e., orientations wherein the direction of pull is other than horizontal by means of a jaw rotating assembly.
With reference to FIG. 7, a preferred jaw rotating assembly 88 comprises a hydraulic cylinder 89 mounted on one of the jaw carriages 32 at a location above and rearward of trunnion 44 which engages that jaw carriage 32. The piston rod 91 of the hydraulic cylinder extends downwardly between the sides of a generally vertical track 92 fixedly attached to or integral with jaw carriage 32. The lower end of piston rod 91 engages a sled 93 slidably disposed in the track 92. Activation of hydraulic cylinder 89 results in vertical movement of sled 93 along the length of track 92.
The jaw rotating assembly 88 further comprises a bracket 94 which is fixedly mounted at the top of end wall 42 of jaw frame 37 adjacent the jaw carriage 32 and linkage 96 which is pivotally connected at its forward end to bracket 94 by means of a first pivot pin 97 and pivotally connected at its rearward end to sled 93 by means of a second pivot pin 98.
In this arrangement, activation of hydraulic cylinder 89 resulting in downward movement of sled 93 results in rotation of jaw assembly 11 in one direction, e.g., counterclockwise, when observing jaw assembly 11 from the view shown in FIG. 7. Upward movement of sled 93 results in rotation of the jaw assembly in the opposite direction.
In addition to providing a means for rotating the jaw assembly, the jaw rotating assembly provides an effective lock for the jaw assembly which prevents rotation. When a metal blank is stretched over a die, it creates an upward force at the front of jaw assembly 11 which tends to rotate jaw assembly 11 in the direction of the force, e.g., counterclockwise in the view shown in FIG. 7. Such rotational movement would result in rearward movement of linkage 96 which in turn would result in vertical movement of the sled 93. However, movement of the sled 93 is prevented by hydraulic cylinder 89. In such an arrangement, the hydraulic cylinder 89 carries some load, but the load is far less than that resulting in an arrangement wherein the hydraulic cylinder is connected directly to the jaw frame.
The load which is carried by the hydraulic cylinder depends on the angle of the linkage 96 from horizontal. That is, the closer the linkage 96 is to horizontal, the less the load on the hydraulic cylinder 89. At horizontal, the load on the hydraulic cylinder 89 is essentially zero. That is, when jaw assembly 11 is in its horizontal position, linkage 96 is also in a horizontal position and rotation of the jaw assembly 11 would translate into horizontal rearward movement of linkage 96. However, such rearward horizontal movement of linkage 96 is prevented by jaw carriage 32 which is stationary and sled 93 which can only move vertically along track 92 in jaw carriage 32. With no vertical component in the direction of linkage 96 movement, the sled 93 will not move. Thus, in its horizontal position, linkage 96 acts as a brace which prevents rotation of jaw assembly 11 and there is essentially no load on the hydraulic cylinder 89.
In a particularly preferred embodiment of the invention, as shown in FIG. 9, jaw assembly 11 comprises a removable hold-down bar 101 which is mounted at its ends to brackets 102 on end walls 42 of jaw frame 37 by bracket pins 103. Hold-down bar 101 extends transversely across the tops of jaw segments 51-57 and prevents upward movement of the jaw segments. It is apparent that the hold-down bar may be straight as shown in FIG. 8 or may be curved to maintain the jaw segments in a specific curvature.
In another particular preferred embodiment of the invention, an auxiliary jaw is mounted on the jaw frame, preferably at a position so that the center of mass of the jaw assembly remains the same and the center of pull of the auxiliary jaw is at the same elevation as the trunnions. For example, with reference to FIG. 10, there is shown a conventional extrusion jaw 104 mounted on jaw frame 37. So that extrusion jaw 104 may be mounted at the same elevation as trunnions 44, jaw 36 is moved to its upper position (see also FIG. 5). In the exemplary embodiment shown, front wall 38 has an enlarged circular opening 106 (shown in FIGS. 3 and 5) at the lower end of center slot 48 at about the level of trunnions 44. Extrusion jaw 104 has a generally cylindrical shaft 107 having a diameter larger than the width of center slot 48 which extends through the opening 106 in front wall 38 until a shoulder 108 at the forward end of the shaft abuts front wall 38. Because the diameter of shaft 107 is larger than the width of center slot 48, vertical movement of shaft 107 is prevented. The rearward end of shaft 107 extends through an opening 110 in rear wall 41 of jaw frame 37 and a retaining ring 109 is mounted on the rearward end of shaft 107 to prevent lengthwise movement of the shaft through the openings. In such an arrangement, the center of pull of auxiliary jaw 104 is at the level of trunnions 44.
With the above-described jaw assembly, the center of pull will not change significantly when the jaw is curved as long as the metal sheet has a width about the same as the width of the jaw. However, with metal sheets having widths less than the width of the jaw, the change in the center of pull may be significant. Accordingly, in another particularly preferred embodiment of the invention, the horizontal side slots are incorporated in a pair of vertically movable side mounting blocks mounted on the frame.
With reference to FIGS. 11 and 12, the side mounting block 120 comprises a generally rectangular front face having a generally horizontal front slot 121 generally the same as the horizontal side slots 49 of FIG. 3, through which the side support pin 66 of the jaw 36 extends. Rearward of the front slot 121 is a generally horizontal rear slot 122 having a width and length greater than that of the front slot 121. The side support pins 66 of the jaw 36 extend through and are afforded slidable horizontal movement within the front slot 121. Retaining rings 68 are fixedly mounted on the ends of the side support pins 66 which extend into the rear slot 122 and are afforded horizontal slidable movement within the rear slot 122. The retaining rings 68 have a diameter larger than the width of the front slot 121 and thereby secure the jaw to the side mounting block 120.
The side mounting block 120 is mounted in a generally vertical side slot 124 in the jaw frame 37. The side mounting block comprises a pair of vertically extending side rails 131 which extend laterally into and afforded vertical movement within a pair of generally vertical tracks 132 in the jaw frame 37.
The vertical position of the side mounting blocks 120 can be adjusted along the length of the vertical side slots 124 by means of adjusting screws 133. The adjusting screws 133 extended from gear drives 134 mounted on the top of the jaw frame 37 above the side mounting blocks 120 to the top of the side mounting block 120. Activation of the gear drives 134 rotates the adjusting screws 133 resulting in vertical movement of the side support blocks 120 and hence vertical movement of the jaw segment mounted on the side mounting block 120.
The gear drives 134 for the two side mounting plates 120 are preferably independently controlled so that the vertical positions of the two side mounting plates 120 can be independently adjusted. This enables a wider variety of jaw configurations.
The jaw assembly of the present invention provides several unique advantages. For example, because the jaw is mounted on the frame by means of three support pins rather than a single supporting shaft, a smaller, lighter and consequently less expensive jaw frame can be utilized.
Further, because the center of mass of the jaw assembly is at about the axis of the trunnions, there is essentially no moment of rotation which must be compensated for, e.g., by stop pins or the like, due to an unbalanced distribution of weight. Also, for a metal sheet having a width about equal to the width of the jaw, center of pull will remain substantially the same no matter what shape or curvature the jaw is in. This eliminates or at least minimizes the rotational moment or torque which rotates the jaw assembly about the trunnions when the center of pull is not at the same level as the trunnions. This latter feature also allows for a greater jaw curvature than the conventional multiple segmented jaws.
For metal sheets having a width smaller than the width of the jaw, changes in the center of pull may be avoided by incorporating vertically movable side support blocks into the jaw assembly. Such a feature provides the additional advantage of enabling the operator to simulate rotation of the jaw to some degree. This can be accomplished, for example, by adjusting the vertical position of one side mounting plate upwardly and that of the other side mounting plate downwardly.
The present invention also provides the unique advantage that auxiliary jaws can be mounted on the jaw frame without removal of the existing multi-segmented jaw. Further, auxiliary jaws can be selected so that the center of mass of the jaw assembly will not change and that the center of pull will remain at the same level as the trunnions.
The preceding description has been presented with reference to the presently preferred embodiments of the invention shown in the accompanying drawings. Workers skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described apparatus and structure can be practiced without meaningfully departing from the principles, spirit and scope of this invention.
For example, it is apparent that the number of jaw segments may vary. While it is preferred that an odd number of jaw segments be used, jaws having an even number of jaw segments may be used. When such a jaw is used, the center support pin will preferably extend rearwardly from the hinge connecting the two center jaw segments together.
While preferred, it is apparent that a center slot and center support pin need not be used. In such an embodiment, the hydraulic cylinder which raises and lowers the center of the jaw may be connected directly to the jaw.
It is also apparent that the individual jaw segments may vary in size and shape as desired. Likewise, the support pins need not be of the same size to support the same load. If the side support pins are located on the end jaw segments, movement of the entire jaw may be controlled by a single hydraulic cylinder which raises and lowers the center of the jaw.
If desired, the center slot may extend below the level of the side slots. In such an embodiment, the jaw can be curved in the shape of a "U".
It is apparent that in addition to the extrusion jaw mentioned above, numerous other types of auxiliary jaws can be mounted on the jaw frame.
Accordingly, the foregoing description should not be read as pertaining only to the precise structures and techniques described, but rather should be read consistent with and as support for the following claims which are to have their fullest fair scope.
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A jaw assembly for a stretch forming press is disclosed. The jaw assembly comprises a flexible jaw having a plurality of hingedly connected jaw segments mounted to a supporting jaw frame by means of three support pins so arranged as to distribute the loads from the part being formed into the support jaw frame through the three support pins.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit from U.S. Provisional Patent Application No. 61/128,507, entitled “Airbag Clamp,” filed on May 22, 2008, which is hereby incorporated in its entirety by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a clamp and a method for securing a clamp to an airbag to an inflating device.
BACKGROUND
[0003] Automobile safety regulations in the United States and globally have increased and remain an important concern for automobile manufacturers. In 1984, the U.S. government required all cars produced after Apr. 1, 1989 to have driver's side airbags. Dual front airbags were required in automobiles in 1998. Airbags consist of a flexible and inflatable envelope. Airbags are commonly used for cushioning against hard interior objects, such as steering wheels, in the event of a crash.
[0004] In a vehicle equipped with an air bag system, the airbag is instantly inflated in the event of a collision to protect the occupant from injury. The airbag is typically inflated by pressurized gas from an inflating tube mounted within the vehicle. Typically, airbag systems are designed to inflate the airbag within 20 to 40 milliseconds after the initial impact. The pressurized gas supplied to inflate the airbag within such a short period of time produces forces tending to pull and separate the airbag from the inflating tube. If the airbag is separated from the inflating tube, the airbag may not inflate or only partially inflate and, as a result, fail to adequately prevent the occupant's impact with hard interior objects of the vehicle, such as a steering wheel, door or the like.
[0005] To resist these forces, a clamping device of considerable strength must be provided to insure safety of the occupant. Ring clamps are typically used to secure the airbag to the inflating tube. These ring clamps are positioned around the inflating tube and the airbag to clamp the airbag to the inflating tube. However, these ring clamps are problematic for a number of reasons. First, during inflation of the airbag, these ring clamps tend to slip off of the inflating tube. Others have attempted to cure this problem by attaching a hook-like device to the inflating tube to prevent the ring clamp from sliding off of the inflating tube. However, this solution is costly and is only a preventive measure rather than curing the deficiencies of the clamps.
[0006] Second, these ring clamps are locked in a closed position by crimping or otherwise locking the ring clamp. However, the crimping or locking occurs in the same direction of the load path. In other words, the ring clamp is locked in the same direction as the applied force, which is typically a direction parallel to the clamp's circumference. As a result, the residual clamp load of these clamps is miniscule in view of the initial compression load applied to these ring clamps.
[0007] FIG. 12 illustrates a prior art clamp tested by applying different initial clamp loads and determining the residual load. As shown in FIG. 12 , the residual clamp load is about 5% of the initial compression load. Therefore, these ring clamps are unreliable in maintaining connection of the airbag to the inflating tube, especially if the occupant contacts the airbag with a high amount of force.
[0008] As a result of the relatively low residual clamp load, manufacturers are forced to use expensive metal materials, such as high grade stainless steel. Mild steels, which typically cost less, were thought to be incapable of adequately resisting the forces caused by the nearly instantaneous inflation of the airbag. Therefore, these prior art ring clamps were relatively costly to manufacture.
[0009] The installation of these ring clamps is also deficient. The compression load used in installing these clamps varies widely and cannot be consistently applied. In addition, automobile manufacturers are unable to effectively record and track the installation of the clamps.
[0010] Therefore, a need exists for an improved clamp and method for installing clamps onto airbag inflating devices. While discussed in terms of use of clamps on airbag inflating devices, this is for illustration purpose only, and this invention should not be deemed as limited to the field of air bag systems. The clamps and methods for installing the clamps are applicable to many other fields as will be appreciated by a person of ordinary skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Objects and advantages together with the operation of the invention may be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein:
[0012] FIG. 1 illustrates a perspective view of a clamp in a relaxed state or open position in an embodiment of the present invention.
[0013] FIG. 2 illustrates a front view of the clamp of FIG. 1 in the open position.
[0014] FIG. 3 illustrates a side view of the clamp of FIG. 2 .
[0015] FIG. 4 illustrates a top view of the clamp of FIG. 2 .
[0016] FIG. 5 illustrates a front view of the clamp of FIG. 1 secured in a compressed state or closed position.
[0017] FIG. 6 illustrates a cross-sectional side view of the clamp of FIG. 5 taken along line A-A.
[0018] FIG. 7 illustrates a partial view of a device for closing and securing the clamp.
[0019] FIG. 8 illustrates a perspective view of the device of FIG. 7 for closing and securing the clamp.
[0020] FIG. 9 illustrates a perspective view of the device of FIG. 8 from a side opposite that shown in FIG. 8 .
[0021] FIG. 10 illustrates a side view of the device of FIG. 8 .
[0022] FIG. 11 illustrates a front view of the device of FIG. 8 .
[0023] FIG. 12 illustrates the residual load of prior airbag clamps compared to the compression load.
[0024] FIG. 13 illustrates the residual load of the clamp compared to the compression load.
[0025] FIG. 14 illustrates a comparison of the separation forces of the clamp and a prior airbag clamp.
SUMMARY OF INVENTION
[0026] The present invention is directed to an apparatus and method for utilizing an airbag clamp for securing an airbag onto an inflating tube of an airbag system. An embodiment of the present invention includes a body, a first engaging portion, and a second engaging portion. The body may be capable of surrounding the device, wherein the body may include a first end and a second end that are capable of moving towards each other. The first engaging portion may be located at a first end, wherein the first engaging portion may include at least one plate. The second engaging portion may be located at the second end, wherein the second engaging portion may include at least one plate. The engaging portions may be capable of being fitted together and the plates may be capable of being fastened together to secure the clamp around the material and device.
[0027] An embodiment of the present invention includes a method for clamping material to a device. A clamp having two ends may be placed over the material and the device, and then placing said clamp, material and device into an apparatus. The apparatus may then be utilized to move one end of the clamp towards the other end of the clamp into a closed position. The apparatus may also be utilized to secure the ends together around the material and the device. Once secured, the clamp, material and device may be removed from the apparatus.
DETAILED DESCRIPTION
[0028] FIGS. 1-6 illustrate a clamp 10 capable of securing an airbag (not shown) to an inflating or injector tube 110 of the airbag system, as shown in FIGS. 7-11 . While the clamp 10 is being shown and described in terms of an airbag clamp and system, the clamp 10 as shown is only one embodiment of the present invention and should not be deemed as limiting the clamp 10 to the embodiment shown. For example, the clamp 10 may be of any appropriate shape or thickness without deviating from the spirit of the present invention, such as of a substantially circular shape and a relatively small thickness. However, a person of ordinary skill in the art will appreciate that the clamp 10 may be of may different shapes and have many different dimensions.
[0029] As discussed above, the clamp 10 may be of any appropriate shape, such as substantially circular, as shown in FIGS. 1-7 , or of any other appropriate shape, such as rectangular, elliptical, square or the like, for example. The clamp 10 may be made of any appropriate type of material including many different combinations or types of materials. For example, the clamp 10 may be made out of metal, such as stainless steel or a lower grade steel, such as a mild carbon based steel. Use of a mild steel may provide substantial cost savings. In addition, while the clamp 10 is shown as a single piece construction, it is to be understood that the clamp 10 could be made out of any number of appropriate pieces and secured together by any appropriate means, such as welding, adhesives or the like, for example.
[0030] Due to the strength of the clamp 10 , as will be described in more detail below, the clamp 10 may be used with materials that are more elastic than materials used with prior art airbag clamps. Advantageously, the increased elasticity (or flexibility) of the material of the clamp 10 may improve its ability to effectively clamp onto devices, such as an injection tube 110 for an airbag, for example.
[0031] The clamp 10 may include a first end 12 and a second end 14 . The clamp 10 may have a length, or circumference in a circular embodiment, that may be defined between the first end 12 and the second end 14 . The clamp 10 may further include a coating (not shown). The coating may cover any appropriate portion or amount of the clamp 10 . The coating may substantially cover the entire clamp 10 . The coating may also be of any appropriate color, such as similar color to the material of the clamp 10 , or a color distinct from the material of the clamp 10 , for example.
[0032] In an embodiment utilizing a coating having a color that is different from the material, any undesired manipulation or unauthorized servicing of the clamp 10 may cause scratching, flaking or otherwise removing the coating from the clamp 10 . Advantageously, where the coating color is distinct from the color of the clamp 10 , any undesired manipulation or unauthorized servicing of the clamp 10 may be readily apparent.
[0033] The coating of the clamp 10 may be of any type of appropriate coating known to a person of ordinary skill in the art. In an embodiment, the coating may be an organic coating having a color distinct from the inflating tube, the air bag and the clamp 10 . In a preferred embodiment, the coating may be able to stretch with the clamp 10 . For example, as the first end 12 and/or the second end 14 is stretched and moved to close and secure the clamp 10 around a device, the coating may remain consistent around the clamp 10 .
[0034] The clamp 10 may have a width W as best shown in FIG. 3 . The width W may be of any appropriate size or dimension. The width W may be determined based on any appropriate means, such as by the strength and size of the device in which the clamp 10 is to be used. In addition, the width W may be a function of the required clamping strength to be imparted with the clamp 10 . The width W of the clamp 10 may be tuned to change the residual load of the clamp 10 as a function of the compression load of the clamp 10 . Generally, increasing the width W of the clamp 10 may increase the residual clamp load as a function of the compression load. For a predetermined compression load, the greater the width W of the clamp 10 the lower the residual load.
[0035] The residual clamp load and the compression load may be determined or limited by the device in which the clamp 10 will be used. For example, if the clamp 10 is used to clamp an airbag to an inflating tube 110 , then the inherent strength of the inflating tube 110 may limit the compression load and/or residual clamp load that may be applied by the clamp 10 without damaging the inflating tube 110 . Therefore, an analysis of the device in which the clamp 10 will be used may be necessary before tuning the width W of the clamp 10 .
[0036] As shown in FIGS. 1-6 , the clamp 10 may also include an annular ring portion 16 . The annular ring portion 16 may terminate near the first end 12 and the second end 14 . The annular ring portion 16 may have any appropriate size and shape diameter, such as a diameter substantially similar in size and shape to the device in which the clamp 10 is to be attached. As shown in FIGS. 1 and 2 , the structure of the clamp 10 may permit a relatively large amount of travel or movement prior to being secured in the closed position. Accordingly, the clamp 10 may be easily connectable to a device 110 , such as an inflating tube of an airbag system prior to closing the clamp 10 .
[0037] The clamp 10 may include a first engaging portion 18 and a second engaging portion 20 . The first engaging portion 18 and the second engaging portion 20 may be of any appropriate size or shape. In addition, the first engaging portion 18 and the second engaging portion 20 may be of a similar shape or size or of different shapes or sizes. The first engaging portion 18 and the second engaging portion 20 may also be positioned at any appropriate locations on the clamp 10 .
[0038] As shown in FIGS. 3 and 4 , the first engaging portion 18 and the second engaging portion 20 may be of a substantially similar shape and size so that the first or second engaging portions 18 , 20 may be able to fit and slide within the other engaging portion 18 , 20 . For example, the first engaging portion 18 may be slightly wider than the second engaging portion 20 , so that the second engaging portion 20 may slide within the first engaging portion 18 . While shown with the first engaging 18 portion being slightly larger than the second engaging portion 20 , it is to be understood that the roles may be reversed so that the second engaging portion 20 is larger than the first engaging portion 18 .
[0039] The first engaging portion 18 and the second engaging portion 20 may be capable of securing the clamp 10 in a compressed state or closed position. In an embodiment, the first and second engaging portions 18 , 20 may be extended portions of the annular ring portion 16 that may be bent to a direction substantially perpendicular to the circumference of the clamp 10 . Alternatively, the first and second engaging portions 18 , 20 may be molded or otherwise formed at a position substantially perpendicular to the circumference of the clamp 10 .
[0040] In an embodiment, the first engaging portion 18 may include first plate 30 a and a second plate 30 b . As best shown in FIG. 1 , the plates 30 a , 30 b and first engaging portion 18 may be of any appropriate shape, such as a general U-shape. The first plate 30 a and second plate 30 b may be of any appropriate shape or size, such as a generally square, rectangular, semicircular shape or the like, for example. The first plate 30 a and the second plate 30 b may be positioned at any appropriate location on the clamp 10 , such as at the first end 12 . The first plate 30 a may be opposing the second plate 30 b . In such an embodiment, the second engaging portion 20 may include a first plate 32 a and a second plate 32 b . As best shown in FIG. 1 , the plates 32 a , 32 b and first engaging portion 20 may be of any appropriate shape, such as a general U-shape. The first plate 32 a and second plate 32 b may be of any appropriate shape or size, such as a generally square, rectangular, semicircular shape or the like, for example. The first plate 32 a and the second plate 32 b may be positioned at any appropriate location on the clamp 10 , such as at the second end 14 . The first plate 32 a may be opposing the second plate 32 b . The first and second engaging portions 18 , 20 may be utilized to move the clamp 10 from an open position to the closed position.
[0041] While the plates 30 a , 30 b , 32 a , 32 b are shown in FIGS. 1 , 2 and 5 as having substantially similar shapes and sizes, it is to be understood that each of the plates 30 a , 30 b , 32 a , 32 b may have different or corresponding shapes and sizes. For example, plates 30 a , 32 a may be of a similar shape and size, while plates 30 b , 32 b may each have a different and unique shape or size. In addition, while shown and discussed in terms of each engaging portion 18 , 20 having two plates, it is to be understood that any appropriate number of plates may be utilized, such as one plate per engaging portion 18 , 20 , and should not be limited to those examples described herein.
[0042] As best shown in FIG. 3 , the first plate 30 a and second plate 30 b of the first engaging portion 18 may be slightly more open than the first plate 32 a and second plate 32 b of the second engaging portion 20 . While shown with the plates 30 a , 30 b of the first engaging portion 18 being more open than the plates 32 a , 32 b of the second engaging portion 20 it is to be understood that the roles may be reversed. In other words, the plates 32 a , 32 b of the second engaging portion 20 may be slightly wider open than the plates 30 a , 30 b of the first engaging portion 18 .
[0043] In use, the relaxed state or open position may be any position in which the clamp 10 may be removable from the device 110 that it may be clamping, such as the airbag to the injector tube, for example. The compressed state or closed position may be any position in which the clamp 10 is not removable from the device 110 in which it may be clamping. The first and second engaging portions 18 , 20 should overlap in the closed position, but may also overlap in an open position.
[0044] For example, the first and second engaging portions 18 , 20 may be partially overlapped while allowing the clamp 10 to be easily removed from the injector tube 110 of the airbag system. In such an example, the clamp 10 may be in the open position. To move the clamp 10 in such an example to the closed position, the first and second engaging portions 18 , 20 may be moved closer to one another such that clamp 10 tightens a predetermined amount on the inflating tube 110 of the airbag system. In an airbag system, the clamp 10 at the closed position may have a diameter substantially equal to that of the injector tube 110 .
[0045] FIGS. 1-4 illustrate an embodiment of the clamp 10 in the open position. FIGS. 5 and 6 illustrate an embodiment of the clamp 10 in the closed position. In a preferred embodiment, a substantial portion of one of the first or second engaging portions 18 , 20 may overlap a substantial portion of the other first or second engaging portion 18 , 20 when in the closed position, as best shown in FIGS. 5 and 6 .
[0046] The first engaging portion 18 and the second engaging portion 20 may be moved such that the plates 30 a , 30 b of the of the first engaging portion 18 abut the plates 32 a , 32 b of the second engaging portion 20 . In a preferred embodiment, one of the first or second engaging portions 18 , 20 may be moved within the other engaging portion 18 , 20 as shown in FIGS. 3 and 4 .
[0047] The clamp 10 may be secured in the closed position by any appropriate means, such as by attaching the plates 30 a , 30 b , 32 a , 32 b together by crimping, puncturing, welding, adhesives, fasteners or the like. For example, the plates 30 a , 30 b , 32 a , 32 b may be secured by crimping or pinching the plates 30 a , 30 b , 32 a , 32 b together. Advantageously, the crimping of the plates 30 a , 30 b , 32 a , 32 b may be in a direction substantially perpendicular to the load path of the clamp and the length of the clamp 10 . Securing the clamp 10 in the closed position by applying force in a direction substantially perpendicular to the load path may increase the residual clamp load.
[0048] In a preferred embodiment, the plates 30 a , 30 b , 32 a , 32 b may be fastened to lock or otherwise secure the engaging portions 18 , 20 together, such as by puncturing, piercing or the like. It is to be understood that any appropriate number of the plates 30 a , 30 b , 32 a , 32 b may be pierced. In a preferred embodiment, all of the plates 30 a , 30 b , 32 a , 32 b may be pierced; however, at a minimum one of the plates 30 a , 30 b , 32 a , 32 b from each of the engaging portions 18 , 20 may be pierced. A resulting pierced portion 50 may be bent into or through a portion of the engaging portions 18 , 20 to lock the engaging portions 18 , 20 .
[0049] For example, the plates 30 a and 32 a may be pierced whereby the pierced portion 50 of the plate 30 a may be pushed through or at least partially into the pierced portion 50 of the plate 32 a . In one embodiment, the pierced portion 50 of the plate 30 a is pushed through the plates 32 a and 32 b . The pierced portion of any of the plates 30 a , 30 b , 32 a , 32 b may be pushed or inserted through any of the other plates 30 a , 30 b , 32 a , 32 b so long as the engaging portions 18 , 20 are securely locked together. At such a position, the engaging portions 18 , 20 may lock the clamp 10 in the closed position to effectively secure and clamp, for example, the airbag to the inflating tube 110 . While described in terms of the plates 30 a and 32 a being pierced, it is to be understood that the opposite may also be true, such that plates 30 b and 32 b may be pierced whereby the pierced portion 50 of the plate 30 b may be pushed through or at least partially into the pierced portion 50 of the plate 32 b.
[0050] The pierced portion 50 may be moved in any appropriate direction, such as being moved in a direction substantially perpendicular to the direction of the load path of the clamp 10 . The load path typically occurs along length of the clamp 10 . Therefore, the first and second engaging portions 18 , 20 may be engagable and lockable in a direction substantially perpendicular to the length of the clamp 10 and the direction of the load path. The advantages of securing the clamp 10 at a closed position with forces perpendicular to the length of the clamp 10 and the load path are significant.
[0051] FIG. 13 illustrates the residual clamp load as compared to compression load applied to the clamp 10 in an embodiment of the present invention. Comparing FIG. 13 FIG. 12 , the clamp 10 has a residual clamp load of more than seventeen times the amount.
[0052] FIG. 14 illustrates the improvement of the separation force exhibited by the clamp 10 as compared to prior art airbag clamps. In FIG. 14 , the max load was set to 1000 lb to prevent damage to the test mandrel pins. The clamp 10 did not separate in any of the tests below but gradually loosened to zero compression. On the other hand, the prior art clamp separated in each case.
[0053] FIGS. 7-11 illustrate an embodiment of an assembly tool or apparatus 100 that may be utilized for attaching the clamp 10 to a device, such as an injector or inflating tube 110 , for example. The apparatus 100 may be operated by any appropriate means, such by being manually operated, for example, but may preferably be actuated using a computer or processing device (not shown) such that the operation is automated.
[0054] The clamp 10 may compress the airbag material onto the inflating tube 110 using approximately 320° of surface area. The clamp 10 may be tightened to a pre-load of any appropriate amount, such as approximately 750 lbs, thereby leaving a residual loan of approximately 400 lbs of clamping force of the airbag material to the inflating tube 110 .
[0055] The apparatus 100 may include a first arm 115 , a chuck 120 , and a second arm 130 . The first arm 115 , the chuck 120 and the second arm 130 may be of any appropriate type, shape or size. The first arm 115 may move to drive the chuck 120 against the clamp 10 , as illustrated in FIG. 7 . The chuck 120 may push one of the first or second engaging portions 18 , 20 toward the other engaging portion 18 , 20 thereby altering the clamp 10 from the relaxed state or open position to the compressed state or closed position. The engaging portion 18 , 20 not moved by the chuck 120 may be held stationary by the second arm 130 , as best shown in FIG. 7 .
[0056] The chuck 120 may be connected to load cells (not shown) for measuring the amount of force applied to the first or second engaging portion 18 , 20 and/or the amount of spring back force on the engaging portion 18 , 20 . Load cells (not shown) may also be connected to the second arm 130 to measure the force applied or realized by the locking arm 130 as the engaging portion 18 , 20 is moved to the closed position.
[0057] The apparatus 100 may also include a locking device 140 , as illustrated in FIGS. 9 and 10 . The locking device 140 may secure the first and second engaging portions 18 , 20 of the clamp 10 by any appropriate means. For example, the locking device 140 may crimp the engaging portions 18 , 20 and/or pierce the engaging portions 18 , 20 of the clamp 10 , as discussed above. The locking device 140 may utilize loading cells (not shown) or other sensing devices to determine the amount of force applied in crimping the engaging portions 18 , 20 , the distance the engaging portions 18 , 20 moved, the resistance force to the crimping exerted by the engaging portion 18 , 20 , force applied to pierce the engaging portions 18 , 20 , and the distance in which the pierced portion 50 may be moved by the locking device 140 .
[0058] The load cells may be connected to a database (not shown) and/or a processor (not shown) for recording the amount of force and the time the force occurred. In an embodiment, the clamp 10 may have an identifier, such as a serial number, inscribed, such as laser inscribed on the clamp 10 . The clamp 10 may be identified in relation to the forces recorded by the database. The processor and/or the database may be used to control the amount of force applied to the engaging portion 18 , 20 of the clamp 10 . For example, use of the load cells, the processor and/or the database permits the apparatus 100 to apply a substantially similar force to each of the engaging portions 18 , 20 of the clamps 10 .
[0059] As discussed above, the clamp 10 may be of any appropriate size, such that the clamp 10 may fit over both the airbag material and the injector tube 110 . Once in place over the material and tube 110 , one of the first or second engaging portions 18 , 20 may be pushed toward the other portion 18 , 20 until the appropriate amount of force, such as 750 lbs of force, is applied. After the engaging portions 18 , 20 are moved towards each other, a shear or piercing may be placed through the engaging portions 18 , 20 thereby locking the clamp 10 in position. The assembly tool or apparatus 100 may then be removed and the clamp 10 is secured and complete.
[0060] The apparatus 100 may be of any appropriate type, such as a multi-directional tool for applying an axial load around the circumference of the clamp 10 and then shear or piece the engaging portions 18 , 20 through themselves to lock the clamp 10 in place. The shears may be 90° to the load, thereby ensuring a solid one-piece locking clamp 10 . In addition, the clamp force may be fully adjustable.
[0061] The apparatus 100 may be incorporated into an assembly line where each of the clamps 10 is secured. For example, an airbag may be positioned over the injector tube 110 , the clamp may be aligned to secure the airbag to the injector tube 110 , and the clamp 10 may be moved from the open position to the closed position via the apparatus 100 . The clamp 10 may be locked in the closed position by the locking device 140 of the apparatus 100 . The apparatus 100 may be connected to the processor and/or the database to control the forces applied to the clamp 10 . The processor and/or the database may record the forces and time in which the forces occurred and link the information to the clamp 10 . The resulting data may then be stored and analyzed.
[0062] While the present invention is described with reference to embodiments described herein, it should be clear that the present invention is not limited to such embodiments. Therefore, the description of the embodiments herein is merely illustrative of the present invention and will not limit the scope of the invention as claimed.
[0063] The invention has been described above and, obviously, modifications and alternations will occur to others upon a reading and understanding of this specification. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof.
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The present invention is directed to an apparatus and method for utilizing an airbag clamp for securing an airbag onto an inflating tube of an airbag system. An embodiment of the present invention includes a body, a first engaging portion, and a second engaging portion. The body may be capable of surrounding the device, wherein the body may include a first end and a second end that are capable of moving towards each other. The first engaging portion may be located at a first end, wherein the first engaging portion may include at least one plate. The second engaging portion may be located at the second end, wherein the second engaging portion may include at least one plate. The engaging portions may be capable of being fitted together and the plates may be capable of being fastened together to secure the clamp around the material and device.
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RELATED APPLICATIONS
[0001] This application claims priority to Provisional Application for U.S. Patent, Ser. No. 60/443,769, “Control of Tristate Buses During Scan-Test—A Strategy” by Kodihalli, et. al., filed Jan. 30, 2003.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] [Not Applicable]
[MICROFICHE/COPYRIGHT REFERENCE]
[0003] [Not Applicable]
BACKGROUND OF THE INVENTION
[0004] Due to the increasing numbers of transistors that are incorporated on integrated circuits, exhaustive testing of integrated circuits is practically impossible. Rather, digital circuits are usually tested by applying a variety of test signals to the system and monitoring the output signals produced in response.
[0005] Adding to this technique, digital circuits have also been designed with memory stages which can be operated in one of two modes—a first mode where the memory stages operate primarily as designed, and a second mode where the memory stages are connected in series to form one or more extended shift registers, otherwise known as scan chains. During the second mode, bit patterns, known as test vectors, are shifted or scanned into the scan chains. The logic system is returned to its first mode configuration and permitted to operate for one clock. The logic system is then returned to the second mode and the results extracted from the logic system (again by scanning) are analyzed to determine the operability of the stages and interconnections of the logic system. This testing technique is usually referred to as “scan testing”.
[0006] Fault coverage measures the degree to which test vectors are capable of uncovering potential defects and faults. It is a goal of scan testing to achieve a high degree of fault coverage in a reasonable amount of time. Accordingly, there are a number of tools which generate a combination of test patterns which achieve a requisite degree of fault coverage in short amount of time.
[0007] Many of the digital circuits tested include tristate buses, which can be used by two or more entities. Competing requests for use by the two or more entities result in a resource contention. Use of test patterns which cause resource contention on tristate buses result in erroneous error reporting. Accordingly, automatic test pattern generators remove test patterns which cause resource contention on tristate buses and replace the test patterns with other test patterns which achieve the same fault coverage and avoid the resource contention. Nevertheless, some fault coverage is still lost.
[0008] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art through comparison of such systems with embodiments presented in the remainder of the present application with reference to the drawings.
BRIEF SUMMARY OF THE INVENTION
[0009] Described herein are system(s), method(s), and apparatus for controlling tristate buses during scan testing. In one embodiment, there is presented a method for testing a circuit. The method for testing the circuit includes serially shifting a test pattern into at least a portion of the circuit. While serially shifting the test pattern, each of a plurality of tristate drivers except a default driver from the plurality of tristate drivers are disabled. The method also includes capturing a test response from at least a portion of the circuit. While capturing the test response from the portion of the circuit, each of the plurality of tristate drivers except a selected one of the plurality of drivers are disabled.
[0010] In another embodiment, there is described a system for testing a circuit. The system includes scan line registers, and a decoder. The scan line registers are for shifting a test pattern into at least a portion of the circuit and capturing a test response from at least a portion of the circuit. The decoder is for disabling each of a plurality of tristate drivers except a default driver from the plurality of tristate drivers while the scan line registers serially shift the test pattern, and disabling each of the plurality of tristate drivers except a selected one of the plurality of drivers while the scan line registers capture the test response.
[0011] In another embodiment, there is presented a circuit for testing a device under test. The circuit includes scan line registers and a decoder. The scan line registers shift a test pattern into at least a portion of the device under test and capturing a test response from at least a portion of the circuit. The decoder is connected to the scan line registers and disabling each of a plurality of tristate drivers except a default driver from the plurality of tristate drivers while the scan line registers serially shift the test pattern, and disables each of the plurality of tristate drivers except a selected one of the plurality of drivers while the scan line registers capture the test response.
[0012] These and other advantages and novel features of the present invention, as well as details of illustrated embodiments thereof, will be more fully understood from the following description and drawings.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0013] [0013]FIG. 1 is a block diagram describing a system for testing a circuit in accordance with an embodiment of the present invention;
[0014] [0014]FIG. 2 is a flow diagram for testing a circuit in accordance with an embodiment of the present invention;
[0015] [0015]FIG. 3 is a block diagram of a circuit for testing a device under test in accordance with an embodiment of the present invention; and
[0016] [0016]FIG. 4 is a logic diagram of a decoder for disabling tristate driver in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring now to FIG. 1, there is illustrated a circuit 100 in accordance with an embodiment of the present invention. The circuit 100 comprises a functional portion 105 , also known as a sea of logic, and additional testing hardware. The circuit 100 can be implemented in a number of ways, such as an integrated circuit on a chip or a printed circuit on a printed circuit board.
[0018] The circuit 100 can operate in either a functional mode or a scan mode. The functional mode is the primary function of operation for the circuit 100 . The functional portion 105 is the portion of the circuit that performs the primary functions. For example, the circuit 100 can be incorporated into an end product. In general, the functional portion 105 is the portion of the circuit 100 that performs the chip functions after incorporation into the end product. The circuit 100 also includes additional elements that are used for testing functions.
[0019] The scan mode is a testing mode to verify proper operation of the functional portion 105 . During the scan mode, state devices, such as flip-flops, are connected in series to form one or more extended shift registers, otherwise known as scan chains 110 . During the second mode, bit patterns, known as test vectors, are shifted or scanned into the scan chains 110 . After scanning the test vectors into the scan chains 110 , the functional portion 105 of the circuit 100 operates as though in the functional mode for one cycle. After the cycle, the contents of the scan chain 110 are extracted. The foregoing can be repeated any number of times.
[0020] The circuit 100 also includes shared resources 115 , such as a bus, that can be used by two or more entities. Each of the entities accesses the bus through a tri-state driver 120 . The tri-state drivers 120 can operate in one of three states—a high impedance state, a high state, and a low state. When a tri-state driver 120 is in the high impedance state, the tri-state driver 120 does not attempt to set the shared resource 115 into any state. When the tri-state drivers 120 are in either the high state or the low state, the tri-state drivers 120 attempt to drive the shared resource into the high or low state.
[0021] A resource contention occurs when two or more tri-state drivers 120 attempt to drive the shared resource 115 . Serious damage to the circuit 100 can occur when two or more tri-state drivers 120 attempt to drive the shared resource 115 to two different states. Another problem occurs when none of the tri-state drivers 120 attempt to drive the share resource 115 . The foregoing can cause the shared resource 120 to enter a floating state. The foregoing problems are alleviated during the functional mode by an arbiter that prevents resource contentions.
[0022] During testing mode, the test patterns that are scanned into the scan chain 110 can potentially cause resource contentions with the shared resource 115 . To prevent resource contentions, a decoder 125 and logic circuits 130 are connected to each of the tri-state drivers 120 that can potentially drive a shared resource 115 .
[0023] The scan mode is indicated by the assertion of the scan_mode signal. The decoder 125 receives the scan_mode signal, and upon receiving the scan mode signal, the decoder disables (e.g., sets to a high impedance state) all but one of the tri-state drivers 120 . As noted above, during the scan mode, test patterns are serially shifted through the scan chain 110 . The shifting is indicated by assertion of the scan_enable signal. While the bits are shifted through the scan chain 110 , the decoder 125 disables all of the tri-state drivers 120 , except for one default driver 120 d . The foregoing prevents resource contention.
[0024] After the serial bit shift, the functional portion 105 operates as though in the functional mode for one clock cycle. During the one clock cycle, the decoder 125 disables each of the tri-state drivers 120 except one. The one tri-state driver 120 that is not disabled is controllable by controllable input signals. For example, in one embodiment, the selected state driver 120 can be a function of the test pattern. Additionally, the selected state driver 120 can be selected by receiving the controllable input signals from the scan chain 110 .
[0025] During the functional mode, the decoder 125 does not disable any of the tri-state drivers 120 . The tri-state drivers 120 are controlled by functional enable signals 130 from the functional portion 105 of the circuit 100 . The tri-state drivers 120 are controlled by logic circuits 135 that are connected thereto. The logic circuits 135 receive a signal from the decoder 125 and functional enable signals 130 from the functional portions 105 of the circuit 100 . During the functional mode, the decoder 125 transmits signals to the logic circuits 135 that cause the output of the logic circuits 135 to be determined by the functional enables 130 .
[0026] Referring now to FIG. 2, there is illustrated a flow diagram for testing a circuit in accordance with an embodiment of the present invention. At 205 , a determination is made whether the circuit 100 is operating in the scan mode or functional mode. As noted above, the mode of operation may be indicated by assertion of the scan_mode signal. If the circuit 100 is not operating in scan mode, the circuit is operating in the functional mode. Accordingly, at 240 , the tri-state drivers 120 are controlled by functional enables 130 . The decoder 125 can allow the tri-state drivers 120 to be controlled by the functional enables 130 by either not transmitting any signal, or alternatively, transmitting a signal to the logic circuits 135 , such that the output of the logic circuit 135 is determined by the functional enables 130 .
[0027] If at 205 , the circuit 100 is in the scan mode, all of the tri-state drivers 120 except for a default tri-state driver 120 d for a shared resource 115 are disabled ( 210 ) during scan shifting ( 215 ). The decoder 125 disables the tri-state drivers 120 transmitting of a signal to the logic circuits 130 controlling each of the tri-state drivers 120 except the default tri-state driver 120 d , causing the tri-state drivers 120 to be disabled. As noted above, the scan shifting is indicated by assertion of the scan_enable signal.
[0028] At 220 , after the scan shift, a tri-state driver 120 is selected based on the controllable inputs. The selected tri-state driver 120 can be a function of the test pattern shifted into the scan chain 110 . As well, the controllable inputs can be received from the scan chain 110 , itself.
[0029] At 230 , each of the tri-state drivers 120 except for the selected tri-state driver 120 are disabled while data is captured ( 235 ). After the data is captured during 235 , 205 - 240 are repeated.
[0030] Referring now to FIG. 3, there is illustrated a block diagram describing a system for testing a circuit in accordance with an embodiment of the present invention. The circuit 300 . The circuit 300 also includes a bus 315 that is shared by two or more entities. Each of the entities accesses the bus through a tri-state driver 320 . A resource contention may occur when two or more tri-state drivers 320 attempt to drive the bus 315 . Serious damage to the circuit 300 can occur when two or more tri-state drivers 320 attempt to drive the bus 315 to two different states. Another problem may occur when none of the tri-state drivers 120 attempt to drive the bus 315 . The foregoing can cause the bus 315 to enter a floating state. An arbiter that prevents resource contentions may alleviate the foregoing problems during the functional mode.
[0031] During testing mode, the test patterns that are scanned into the scan chain 310 can potentially cause resource contentions with the bus 315 . To prevent resource contentions, a decoder 325 and AND gates 335 are connected to each of the tri-state drivers 320 that can potentially drive the bus 315 .
[0032] The scan mode is indicated by the assertion of the scan_mode signal. The decoder 325 receives the scan_mode signal, and upon receiving the scan mode signal, the decoder disables (e.g., sets to a high impedance state) all but one of the tri-state drivers 320 . As noted above, during the scan mode, test patterns are serially shifted through the scan chain 310 . The shifting is indicated by assertion of the scan_enable signal. While the bits are shifted through the scan chain 310 , the decoder 325 disables all of the tri-state drivers 320 , except for one default driver 320 d . The foregoing prevents resource contention.
[0033] After the serial bit shift, the circuit 300 operates as though in the functional mode for one clock cycle. During the one clock cycle, the decoder 325 disables each of the tri-state drivers 320 except one. The one tri-state driver 320 that is not disabled is controllable by controllable input signals from two particular flip-flops 322 in the scan chain 310 .
[0034] The tri-state drivers 320 are controlled by functional enable signals 335 . The tri-state drivers 320 are connected to AND gates 335 . The AND gates 335 receive a signal from the decoder 325 and functional enable signals 330 . The decoder 325 disables a particular tri-state driver 325 by transmitting a logical “0” to the AND gate 335 connected to the tri-state driver 320 .
[0035] During the functional mode, the decoder 325 transmits a logical “1” to each of the AND gates 335 connected to the tri-state drivers 320 . The logical “1's” transmitted by the decoder 325 cause the output of the AND gates 335 to be determined by the functional enables 330 .
[0036] Additionally, in one embodiment, the decoder 325 can also include an IDDQ_enable signal that causes all of the drivers except the default driver 320 d to be disabled.
[0037] The decoder 325 can be implemented in a number of different ways. For example, the decoder 325 can be implemented by programmable hardware that executes instructions from a memory. Storage of the instructions in the memory physically, chemically, and/or electromagnetically alters the memory.
[0038] In an exemplary case, the plurality of instructions can include the follow instructions:
If (iddq_enable) OUT0 = 1; else If (scan_test_mode) { If(scan_enable) { OUT 0=1; (DRIVER0 active) OUT1= 0; (DRIVER1 inactive) OUT2 = 0; (DRIVER2 inactive) OUT3 = 0; (DRIVER3 inactive) } else Active output is selected by S1, S2; else OUT0, OUT1, OUT2, OUT3 = ‘1’ ; (Functional enables will decide the active driver )
[0039] Alternatively, the decoder 325 can be implemented as logic. In an exemplary case, the logic design of the decoder 325 can adhere to the following truth table describing the input/output behavior:
Scan — Scan — Mode enable S1 S2 O0 O1 O2 O3 0 X X X 1 1 1 1 1 0 0 0 1 0 0 0 1 0 0 1 0 1 0 0 1 0 1 0 0 0 1 0 1 0 1 1 0 0 0 1 1 1 X X 1 0 0 0
[0040] Referring now to FIG. 4, there is illustrated an exemplary logic design for a decoder 325 in accordance with an embodiment of the present invention. The decoder 325 receives inputs S 1 , S 2 , scan_enable, and scan_mode. Inputs S 1 and S 2 are received by a 2:4 demultiplexer 405 . The demultiplexer 405 has four outputs 410 that are controlled by the inputs S 1 and S 2 . If S 1 , S 2 =0, output 410 ( 0 ) is set. If S 1 =0, S 2 =1, output 410 ( 1 ) is set. If S 1 =1, S 2 =0, output 410 ( 2 ) is set and if S 1 =1, and S 2 =1, output 410 ( 3 ) is set.
[0041] The outputs 410 , except 410 ( 0 ) are each received by a stage of AND gates 415 . The AND gates 415 receive the inverse of scan_enable signal. When the scan_enable signal is set, the output of the AND gates 415 is 0. The output of the AND gates 415 are received by OR gates 420 . The output of the OR gates 420 ( 0 ), 420 ( 1 ), 420 ( 2 ), and 420 ( 3 ), are O 0 , O 1 , O 2 , and O 3 . The OR gates 420 also receive the inverse of scan_mode signal.
[0042] Accordingly, when the scan_mode signal is not set, each of the outputs O 0 , O 1 , O 2 , and O 3 are “1”. When the scan_enable signal is set, and the scan_enable signal is set, the outputs O 0 , O 1 , O 2 , and O 3 are 1,0,0, and 0 respectively, where O 0 is associated with the default tri-state driver. When the scan_mode signal is set, and the scan_enable signal is not set, the outputs O 0 , O 1 , O 2 , and O 3 are determined by the outputs 410 of the multiplexer. As noted above, the outputs 410 of the multiplexer are determined by S 1 and S 2 .
[0043] While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt particular situations or materials to the teachings of the intention without departing from its scope. Therefore, the invention is noted limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the claims.
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A system, method, and apparatus for controlling tri-state drivers are presented herein. During scan testing, a decoder controls the tri-state drivers and prevents more than one tri-state driver from driving a shared resource, regardless of the test patterns shifted into the scan chain. During functional mode, the tri-state drivers are driven by functional enables.
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RELATED APPLICATION
This application is a Continuation-in-Part of U.S. patent application Ser. No. 09/560,415, filed Apr. 27, 2000 abandoned, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/131,629 filed on Apr. 28, 1999, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates to a modular anterior cervical plate designed to provide internal stabilization (temporary strengthening) to the spine in the cervical region (neck) during surgical repairs through an anterior approach to the neck.
This device is designed to improve healing and make it more likely that surgical fusion will be followed by bony union, and reduce the need for external braces following surgery. This is not the first anterior cervical plate ever designed, but it has several novel features that will facilitate decompressive aspects of cervical spine surgery, and will facilitate compression and distraction during cervical fusion and will allow dynamic settling if necessary in the first several weeks after surgery.
Devices presently on the market are basically thin (less than about 2.5 mm thick) molded metal plates that bridge gaps in the front of the cervical spine caused by surgery. (Examples are the Orion plate by Sofomor-Danke, the Codman plate by Johnson and Johnson, the Morsher plate by Synthes Inc., the Acromed plate, and others.) They stabilize the spine when screws are inserted through holes in the plate into bone above and below the surgical gap in the spine. As such, all plates on the market today are basically a single unit design.
SUMMARY OF THE INVENTION
The present invention provides an anterior cervical plate comprising modular parts: a pair of base plates and a connecting plate. The connecting plate is connected to the base plates so as to allow a controlled movement between the base plates and the connecting plate. The base plate design has two advantages. First, because of its small size, it does not obscure surface landmarks on the spine, reducing instances of errant screw insertion and surgical complications. When surface landmarks are obscured, chances for errant screw insertion and surgical complications increase. Secondly, the base plate can be used with distracting instruments to facilitate distraction during dicectomy or other decompressions, which is not a feature of any other anterior plate design. Distracting instruments, such as distracting forceps, stretch the vertebrae of the spine by bearing against distraction-compression portions on the base plates. The base plate may also be designed to interface with retractor blades.
The anterior cervical plate of the invention facilitates decompressive aspects of cervical spine surgery, and facilitates distraction (i.e. stretching of the spine) during cervical fusion. The base plate and connecting plate combination allows for insertion of fusion bone with distraction or compression, finely manipulated by the surgeon. No other plate design allows for this. With all other plates, one must rely on the tightness of fit obtained with the fusion bone (the degree to which the bone achieves a proper fit) to maximize conditions for fusion. The tighter the fit, the more likely fusion is to take place. Since this plate can maximize compression forces beyond what can be obtained with traditional plate designs, fusion rates should be higher. Finally, the connecting plate to base plate interface can be modified to allow dynamic settling of the spine over several weeks time in the saggital and coronal planes to the spine. Particularly when large surgical gaps are created, this kind of settling caused by gravity is felt to promote and enhance fusion. This function is available in only one other plate design on the market (Acromed), but by a different mechanism.
These advantages are derived from the modular design. With the development of a thickened midsection of the base plate, a lock screw has been shown in pullout tests to hold the two plates together very tightly, while allowing a controlled movement at the interface. While a controlled movement at the interface between the connecting plate and the base plate is allowed, the connecting plate is constrained from rotational movement by raised distraction and compression knobs at the lateral margins of the base plate. Therefore, the design will not fail under expected mechanical stresses, yet the unique advantages of the modular design will remain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the connecting plate of the invention;
FIG. 2 is a perspective view of the base plate of the invention;
FIG. 3 is a perspective view of the connecting plate and two base plates, as they would be assembled in use;
FIG. 4 is a cross sectional view of the assembled device according to one embodiment;
FIG. 5 is a schematic side view of the assembly of the invention attached to the spine;
FIG. 6 is a cross sectional view of the assembled device according to another embodiment, using lock screws to provide a movable interface between the base plates and the connecting plate;
FIG. 7 is a schematic plan view of the assembly of the invention attached to the spine, with a distraction tool attached;
FIG. 8 is a cross sectional view of the assembled device attached to the spine according to an embodiment of the invention, with a retractor blade attached.
FIG. 9 is a top view of a base plate, illustrating the process of inserting a retractor blade into a retractor knob of the base plate.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides an anterior cervical plate designed to facilitate settling of the spine in the saggital and coronal planes by allowing a controlled movement between a base plate assembly and a connecting plate. The invention will be described below relative to an illustrative embodiment. One skilled in the art will recognize that the invention is not limited to the illustrative embodiment and that variations may be made in accordance with the teachings and scope of the invention.
The anterior cervical plate of an illustrative embodiment of the present invention includes a pair of base plates for engaging vertebral bodies and a connecting plate connecting the two base plates. The anterior cervical plate is used to stabilize the spine during spinal surgery by aligning and maintaining the vertebral bodies in selected positions and orientations relative to each other to promote and enhance spinal fusion of the vertebral bodies.
As shown in FIG. 1 , the connecting plate 10 of the invention is a generally rectangular plate, preferably made from an alloy having good corrosion resistance, relatively low density and high strength and durability, such as titanium or a titanium alloy. One skilled in the art will recognize that any suitable materials may be used to form the plate. The connecting plate has screw slots 12 at either end, and at least two screw holes 14 in the middle for receiving bone graft screws or another suitable fastening element for connecting the connecting plate to a bone graft. One skilled in the art will recognize that the invention is not limited to bone graft screws and that any suitable fastening element, such as a pin, can be used.
In a preferred embodiment, the connecting plate is between about 1.9 mm and about 3.1 mm thick. Preferably, the connecting plate is about 2.02 mm thick. The length of the connecting plate may vary, for example, at 5 mm intervals, from about 20 mm to about 110 mm. The width of the illustrative connecting plate may be between about 15 mm and about 18 mm and is preferably about 16 mm.
The base plate 20 , as shown in FIG. 2 , is generally rectangular, and preferably has a width of between about 8 mm and about 10 mm and preferably about 9 mm, a length of between about 18 mm and about 22 mm and preferably about 20 mm, and a maximum height, i.e. a raised central section 22 , of between about 1.5 mm and about 3 mm and preferably about 2.54 mm. One skilled in the art will recognize that the base plate is not limited to the illustrative dimensions and that variations in the width, length and thickness may be made. The base plate 20 may also be formed of titanium or a titanium alloy, though one skilled in the art will recognize that any suitable material may be used.
Each base plate 20 includes a raised central section 22 that is generally rectangular and insertable in one of the screw slots 12 of the connecting plate 10 (see FIG. 3 ). The base plate raised central section 22 has a threaded screw hole 24 for receiving a central screw 25 , preferably of titanium alloy, for securing the base plate 20 to the connecting plate 10 . One skilled in the art will recognize that other suitable materials may be used to form the screw 25 . The illustrative screw 25 has a 6/32 thread with 3 turns over about 2.0 mm, though the invention is not limited to these parameters. The threaded screw hole 24 may or may not extend through the base plate 10 . The screw slot 12 and the central screw 25 may form a controllably movable interface between the base plate 20 and the central plate 10 , to be described in detail below.
At either side of the base plate 20 are raised distraction-compression knobs or portions 26 , defining holes 28 oriented parallel to the spine, for the insertion of elements of distraction tools.
Between the raised central portion 22 of the base plate and the distraction-compression sections 26 at either end, are planar reduced thickness sections 28 (between about 0.25 mm and about 1 mm thick and preferably about 0.5 mm thick). These reduced thickness sections 28 of the base plate include two or more bone screw holes 30 for receiving unicortical bone screws, to attach the base plate to vertebral bodies. According to an illustrative embodiment, the bone screws 32 have an outside diameter of between about 3 mm and about 4.5 mm and preferably about 3.5 mm and a length between about 14 mm and about 18 mm.
To stabilize the spine using the anterior cervical plate of the present invention, retractor blades may be utilized to initially expose and provide access to the anterior vertebral column. As shown in FIG. 4 and FIG. 5 , a pair of base plates 20 are secured to vertebral bodies 40 in the spine by bone screws 32 passing through the bone screw holes 30 of the base plate 20 . The connecting plate 10 is placed over the base plates 20 (see FIG. 3 ), and the central screw 25 is threaded into each base plate screw hole 24 to secure the connecting plate 10 to the base plates 20 . The width of the base plate central section 24 , and the distance between the base plate central section 24 and the distraction-compression knobs 26 are selected so that the connecting plate 10 fits snugly and angular movement of the connecting plate 10 relative to the base plate 20 is prevented.
According to one embodiment, shown in FIG. 6 , the central screw 25 may comprise a lock screw to allow for a controlled movement between the base plates 20 and the connecting plate 10 during fusion of the spine. As shown, the perimeter of the screw slot 12 of the connecting plate 10 may comprise a beveled edge 120 that contacts the edge 251 of the screw head 250 to connect the base plate 20 to the connecting plate 10 . The amount of surface area contact between the beveled edge 120 of the slot 12 and the edge 251 of the screw head 250 determines the amount of friction holding the connecting plate to the base plate and may be varied to allow for controlled movement between the base plate and the connecting plate. For example, the length and configuration of the screw 25 and the angle of the edge 251 of the screw head 250 may be varied to provide varying amounts of pressure between the screw and the connecting plate. As shown in FIG. 6 , the screw 25 may be configured to allow minimal surface area contact with the connecting plate 10 , resulting in less friction at the base plate to connecting plate interface, thereby allowing the base plate 20 to controllably slide in the slot 12 relative to the connecting plate 10 . Alternatively, the beveled edge 120 may slope at substantially the same angle as the edge 251 of the screw head 250 to increase the amount of contact between the edge 251 of the screw and the beveled edge 120 of the slot, thereby providing a relatively tighter fit.
Over the course of healing and fusion of the vertebrae, different screws 25 may be inserted to vary the amount of contact between the connecting plate edge and the screw, which varies the amount of force holding the base plate to the connecting plate and allows a controlled movement of the base plate along the slot of the connecting plate.
According to another embodiment, the movable interface may be achieved by increasing the length of the body of the lock screw, i.e. the threaded portion, such that the threaded portion is longer than the length of the screw hole 24 . The increased length of the screw 25 relative to the screw hole 24 causes the screw head 250 to protrude from the screw hole 24 and the connector plate slot 12 . When the lock screw 25 is screwed into the threaded hole 24 of the base plate 20 , the bottom surface 260 of the screw 25 abuts the bottom surface 240 of the threaded hole 24 . When the bottom surface 260 abuts the bottom surface of the threaded hole 24 , the screw head 250 sits slightly above, and spaced from, the beveled edge 120 of the connecting plate 10 . The screw head thus forms a gap between the edge 251 of the screw head 250 and the beveled edge 120 on the connecting plate 10 . The gap between the screw head 250 and the connecting plate 10 may allow for a controlled movement of the connecting plate 10 relative to the base plate 20 . The lock screw 25 limits the amount of relative movement between the connecting plate 10 and the base plate 20 .
According to an alternate embodiment, the screw head 250 may have a flat edge, rather than a beveled edge, and/or the perimeter of the slot 12 may also be flat. The contact area between the edge of the screw head and the perimeter of the slot may be varied, allowing for a controlled movement of the connecting plate relative to the base plate. One skilled in the art will recognize that any suitable configuration for varying the amount of surface contact area between the screw head and the connecting plate or for forming a gap between the screw head and the slot may be utilized to allow for a controlled movement between the base plate and the connecting plate.
The length of the threaded hole 24 and the screw 25 and the configuration of the screw head 250 may be specifically selected to determine the contact area and control the amount of potential movement between the connecting plate and the base plate when anterior cervical plate is assembled. One skilled in the art will recognize that alternate means for providing a movable interface may be utilized according to the teachings of the invention.
The ability to provide a controlled movement between the base plate and the connecting plate allows for compression or distraction of the spine during the performance of a decompression and facilitates decompression or compression during subsequent fusion of the vertebrae. This controlled movement of the base plate and the connecting plate relative to each other allows gravitational settling to place further compression on a graft as the base plate moves along the slots in the connecting plate. The controlled movement thus promotes, facilitates and enhances a controlled amount of settling of the vertebrae, while preventing rotation, falling and flexing of the connecting plate, which significantly improves healing and fusion of the vertebrae in the cervical region of the spine.
As also shown in FIG. 6 , the distraction-compression knobs 26 ′ may be configured to interface with retractor blades. The distraction-compression knobs 26 ′ include slots 270 configured for the insertion of retractor blades. The details of the retractor blade interface will be described in detail below.
As shown in FIG. 7 a distraction tool 50 may be used with the assembly 10 . Pins 52 the distraction tool 50 are insertable into the holes 28 the distraction-compression knobs 26 . The assembly facilitates distraction by allowing for a controlled movement between the connecting plate and the base plates when a force is applied to the distraction-compression knobs 25 by the pins 52 of the distraction tool. In this manner, fusion of the spine is promoted, enhanced and accelerated.
As shown in FIG. 8 and FIG. 9 , retractor blades may also be used with the assembly 10 . The retractor blades are used to hold open an incision in the skin 300 to expose and provide access to the spine 400 . As shown in FIG. 8 , the retractor blades 60 are unattached to the base plate 20 and may be inserted into the slots 270 on knobs 26 ′ of the base plate 20 . As shown in FIG. 9 , the retractor blade fits into an open end 271 of the slot 270 , which is formed at a first end of the knob 26 ′ in the base plate 20 and slides through the slot 270 to allow for retraction. The slot 270 may includes a closed end 272 to retain the retraction blade 60 .
Variations on the assembly are possible. For example, the connecting plate 10 may have screw notches in one or both of the screw slots 12 .
A preferred material to construct the modular anterior cervical plate assembly of the present invention is titanium, though one skilled in the art will recognize that alternate materials may be utilized.
Since certain changes may be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. It is also to be understood that the following claims are to cover all generic and specific features of the invention described herein, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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An anterior cervical plate system consists of a base plate and a connecting plate movably connected to the base plate. The base plate can be inserted into any number of cervical vertebral bodies in any one construct. The base plate contains holes for two unicortical bone screws and a third hole to accommodate a rather large diameter, but short screw that movably secures the connecting plate, and raised middle portion to strengthen screw purchase and fit of the connecting plate. The connecting plate has a central trough opening to accommodate this screw.
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TECHNICAL FIELD
[0001] The present invention relates to a process for producing a bicyclo [3.1.0] hexane derivative, which is a metabotropic glutamate receptor modulator useful as a pharmaceutical. Furthermore, the invention relates to a novel intermediate compound produced in the above production process.
BACKGROUND ART
[0002] An excitatory amino acid such as glutamic acid modulates various physiological processes such as long term potentiation (learning and memory), synaptic plasticity development, motion control, respiration, cardiovascular modulation, and perception in the central nervous system (CNS) of a mammal.
[0003] Presently, glutamate receptors are classified into two major groups, that is, “an ionotropic type in which the receptor has an ion channel structure”: ion channel type glutamate receptor (iGluR), and “a metabotropic type in which the receptor is coupled to a G protein”: metabotropic glutamate receptor (mGluR) (see, Non-Patent Document 1). It appears that receptors of either class mediate normal synaptic transmission in accordance with an excitatory pathway. It also appears that they are involved in modification of synaptic binding from the development stage throughout the lifetime (see, Non-Patent Document 2).
[0004] Eight subtypes of the metabotropic glutamate receptor that have been identified so far are classified into three groups (group I, II, and III) depending on pharmacological characteristics and intracellular second messengers to which they are coupled. Of these, group II receptor (mGluR2/mGluR3) binds with adenylate cyclase, and inhibit the accumulation of cyclic adenosine-1-phosphate (cAMP) stimulated by forskolin (see, Non-Patent Document 3). Thus, it is suggested that compounds that antagonize the group II metabotropic glutamate receptors are effective for the treatment or prevention of acute and chronic psychiatric disorders and neurological diseases.
[0005] It is recognized that a 2-amino-6-fluoro bicyclo [3.1.0] hexane-2,6-dicarboxylic acid derivative having a substituent group on position 3 has a strong antagonistic effect on group II metabotropic glutamate receptors. As such, it is effective for the treatment and prevention of psychiatric disorders such as schizophrenia, anxiety, and related ailments thereof, bipolar disorder, or epilepsy, and also of neurological diseases such as drug dependence, cognitive disorders, Alzheimer's disease, Huntington's disease, Parkinson's disease, dyskinesia associated with muscular rigidity, cerebral ischemia, cerebral failure, encephalopathy, or head trauma (see, Patent Documents 1 to 3 and Non-Patent Documents 4 to 6).
[0006] For example, as an antagonist of group II metabotropic glutamate receptor, 2-amino-3-alkoxy-6-fluoro bicyclo [3.1.0] hexane-2,6-dicarboxylic acid derivative represented by the following formula (A), a pharmaceutically acceptable salt thereof, or a hydrate thereof is disclosed (see, Patent Document 1). Since those compounds are useful as a therapeutic agent, it is believed that development of a synthetic process suitable for commercial production thereof, that is effective in terms of cost and also can be carried out on a safe and large scale, is in need.
[0000]
[0007] (in the formula (A), R A and R B , which may be the same or different, each represents a hydroxyl group, a C 1-10 alkoxy group, a phenoxy group, a naphthyloxy group, a C 1-6 alkoxy group which is substituted with one or two phenyl groups, a C 1-6 alkoxy C 1-6 alkoxy group, a hydroxy C 2-6 alkoxy group, an amino group, an amino group which is substituted with the same or different one or two C 1-6 alkyl groups, an amino group which is substituted with the same or different one or two C 1-6 alkoxy C 1-6 alkyl groups, an amino group which is substituted with the same or different one or two hydroxy C 2-6 alkyl groups, an amino group which is substituted with the same or different one or two C 1-6 alkoxycarbonyl C 1-6 alkyl groups, or a native or non-native amino acid residue represented by NR F —CHR G —A—CO 2 R H (in which R F and R G , which may be the same or different, each represents a hydrogen atom, a hydroxy C 1-6 alkyl group, a hydroxycarbonyl C 1-6 alkyl group, a C 1-10 alkyl group, a phenyl group, a phenyl C 1-6 alkyl group, a hydroxyphenyl group, a hydroxyphenyl C 1-6 alkyl group, a naphthyl group, a naphthyl C 1-6 alkyl group, an aromatic heterocyclic C 1-6 alkyl group, a C 1-6 alkoxy C 1-6 alkyl group, an amino C 2-6 alkyl group, a guanidino C 2-6 alkyl group, a mercapto C 2-6 alkyl group, a C 1-6 alkylthio C 1-6 alkyl group, or an aminocarbonyl C 1-6 alkyl group, or R F and R G may bind to each other to represent a group capable of forming a methylene group, an ethylene group or a propylene group, or may together form a cyclic amino group; R H represents a hydrogen atom or a protecting group for carboxyl group; and A represents a single bond, a methylene group, an ethylene group or a propylene group); R C represents a C 1-10 acyl group, a C 1-6 alkoxy C 1-6 acyl group, a hydroxy C 2-10 acyl group, a C 1-6 alkoxycarbonyl C 1-6 acyl group, a hydroxycarbonyl C 1-6 acyl group, or an amino acid residue represented by R I —NH—A—CH—R G —CO (wherein R G and A are as defined above, and R I represents a hydrogen atom or a protecting group for amino group); and R D and R E , which may be the same or different, each represents a hydrogen atom, a C 1-10 alkyl group, a C 2-10 alkenyl group, a phenyl group, a naphthyl group, a 5-membered heteroaromatic ring containing one or more heteroatoms, or a phenyl group substituted with 1 to 5 substituent groups selected from the group consisting of a halogen atom, a C 1-10 alkyl group, a C 1-10 alkoxy group, a trifluoromethyl group, a phenyl group, a hydroxycarbonyl group, an amino group, a nitro group, a cyano group, and a phenoxy group, or R D and R E may bind to each other to form a cyclic structure).
[0008] With respect to a lab-scale synthesis of antagonist substance of group II metabotropic glutamate receptor that is represented by the formula (A) and synthetic intermediate thereof, several studies have been made (see, Patent Documents 1 and 3 and Non-Patent Documents 4 and 6). For any process, an optically active compound represented by the following formula (IA) is used as a starting material for synthesis or as a production intermediate.
[0000]
[0009] (R A in the above formula (IA) is as defined in the formula (A)).
[0010] Thus, from the viewpoint of establishing a process for industrial production of an antagonist substance of group II metabotropic glutamate receptor represented by the formula (A), which is believed to be useful as a therapeutic agent, it is important to develop a process of synthesizing an optically active compound represented by the formula (IA), that is effective in terms of cost, safety, and suitable for mass production. Non-Patent Document 7 discloses the enantiomer synthesis process of the optically active compound represented by the formula (IA). According to the synthetic process disclosed in Non-Patent Document 7, a catalytic asymmetric arylation developed by Trost, et al. is described as a process of synthesizing the optically active compound. By replacing the Trost ligand (N, N′-(1R, 2R)-cyclohexane-1,2-diylbis[2-diphenylphosphanylbenzamide]) that is used as an optically active ligand for the catalytic asymmetric arylation in Non-Patent Document 7 with its enantiomer (N, N′-(1S, 2S)-cyclohexane-1,2-diylbis[2-(diphenylphosphanyl)benzamide]), the optically active compound represented by the formula (IA) can be synthesized. Thus, it can be said that the asymmetric synthesis of the optically active compound represented by the formula (IA) is already disclosed in Non-Patent Document 7.
[0011] Further, a process of synthesizing a racemate of the compound represented by the formula (IA) is disclosed in Non-Patent Documents 8 and 9 and Patent Document 4. In Non-Patent Document 8, it is described that the optically active compound represented by the formula (IA) can be obtained by isolating racemate of the compound represented by the formula (IA) by using an HPLC column for isolating optical isomers. Further, in Non-Patent Document 10, it is disclosed that the optically active compound represented by the formula (IA) can be obtained with enantiomeric excess ratio of 38% and 54% based on a reaction which uses an asymmetric ligand. However, those synthetic processes essentially require an operation of isolating the optically active compound represented by the formula (IA) from enantiomers, and therefore it is difficult to say that they are more suitable for mass production than the asymmetric synthesis process disclosed in Non-Patent Document 7.
RELATED DOCUMENT
Patent Document
[Patent Document 1] International Publication No. 2003/061698
[Patent Document 2] International Publication No. 2005/000790
[Patent Document 3] International Publication No. 2005/000791
[Patent Document 4] International Publication No. 2002/000595
Non-Patent Document
[Non-Patent Document 1] Science, 258,597-603 (1992)
[0012] [Non-Patent Document 2] Trends Pharmacol. Sci., 11, 508-515 (1990)
[Non-Patent Document 3] Trends Pharmacol. Sci., 14, 13-20 (1993)
[Non-Patent Document 4] J. Med. Chem., 47, 4570-4587 (2004)
[Non-Patent Document 5] Bioorg. Med. Chem., 14, 3405-3420 (2006)
[Non-Patent Document 6] Bioorg. Med. Chem., 14, 4193-4207 (2006)
[Non-Patent Document 7] Org. Lett., 6, 3775-3777 (2004)
[Non-Patent Document 8] J. Med. Chem., 43, 4893-4909 (2000)
[Non-Patent Document 9] Tetrahedron, 57, 7487-7493 (2001)
[0013] [Non-Patent Document 10] Org. Biomol. Chem., 2, 168-174 (2004)
DISCLOSURE OF THE INVENTION
Problem to be Solved by the Invention
[0014] However, according to the conventional process for asymmetric synthesis of the compounds represented by the formula (IA) (Non-Patent Document 7), it is necessary to use an expensive chemical reagent like Trost ligand to obtain an optically active substance, and therefore production cost is extremely high. Based on such reasons and from the viewpoint of establishing an industrially suitable method for production of a compound represented by the formula (IA), a significant reduction in production cost has been remained as a problem to be solved.
Means for Solving Problem
[0015] As a result of an intensive investigation by the inventor of the present application, a novel production process, and a novel synthetic intermediate compound have been found for efficient synthesis of an optically active compound represented by the formula (I) with high optical purity from an optically inactive compound represented by the formula (II), which can be produced without using an expensive chemical reagent, by carrying out an asymmetric acylation by causing an enzyme to act on an optically inactive compound represented by the formula (II), developing a process of converting with high stereo selectivity the compound to an optically active compound represented by the following formula (III), and devising a novel synthetic pathway for converting the compound represented by the formula (III) to the compound represented by the following formula (I).
[0016] The invention is to provide a process for producing a bicyclo [3.1.0] hexane derivative represented by the formula (I) and a salt thereof which enables significant reduction in production cost compared to conventional processes, wherein the derivative is useful for production of an antagonist substance represented by the formula (A) that is a group II metabotropic glutamate receptor regarded as a useful therapeutic agent.
[0017] Specifically, the invention relates to (i) a process for producing a bicyclo [3.1.0] hexane derivative represented by the formula (I) and a salt thereof, including:
[0000]
[0000] (in the formula (I), R 1 represents
(1) —OH,
(2) 'O—R a , or
(3) —NR b R c ,
[0018] R a represents a C 1-6 alkyl group or a C 3-8 cycloalkyl group (wherein the C 1-6 alkyl group or the C 3-8 cycloalkyl group is either unsubstituted or substituted with one or more of a C 1-6 alkoxy group, a hydroxyl group, a halogen atom, an aryl group, or a heteroaryl group),
R b and R b , which may be the same or different from each other, each represents a hydrogen atom, a halogen atom, a C 1-6 alkyl group, or a C 3-8 cycloalkyl group (the C 1-6 alkyl group or the C 3-8 cycloalkyl group is either unsubstituted or substituted with one or more of a hydroxyl group, a C 1-6 alkoxy group, an aryl group, or a heteroaryl group), or R b and R c may bond to each other and form a 4- to 7-membered saturated heterocycle together with an adjacent nitrogen atom (wherein the saturated heterocycle is either unsubstituted or substituted with a hydroxyl group, a C 1-6 alkyl group, or a C 1-6 alkoxy group)),
[0019] (A) converting a compound represented by the formula (II) to a compound represented by the formula (III),
[0000]
[0000] (in the formula (II), R 1 is as defined in the formula (I) above)
[0000]
[0000] (in the formula (III), R 1 represents
(1) —OH,
(2) —O—R a , or
(3) —NR b R c ,
[0020] R a represents a C 1-6 alkyl group, or a C 3-8 cycloalkyl group (wherein the C 1-6 alkyl group or C 3-8 cycloalkyl group is either unsubstituted or substituted with one or more of a C 1-6 alkoxy group, a hydroxyl group, a halogen atom, an aryl group, or a heteroaryl group),
R b and R b , which may be the same or different from each other, each represents a hydrogen atom, a halogen atom, a C 1-6 alkyl group, or a C 3-8 cycloalkyl group (wherein the C 1-6 alkyl group or C 3-8 cycloalkyl group is either unsubstituted or substituted with one or more of a hydroxyl group, a C 1-6 alkoxy group, an aryl group, or a heteroaryl group), or R b and R b form a 4- to 7-membered saturated heterocycle together with an adjacent nitrogen atom (wherein the saturated heterocycle is either unsubstituted or substituted with a hydroxyl group, a C 1-6 alkyl group, or a C 1-6 alkoxy group),
R 2 represents a hydrogen atom, a C 1-6 alkyl group, a C 3-8 cycloalkyl group, or a —(CH 2 ) n -phenyl group (wherein the C 1-6 alkyl group, C 3-8 cycloalkyl group, or —(CH 2 ) n -phenyl group is either unsubstituted or substituted with one or more of a halogen atom, a hydroxyl group, a C 1-6 alkyl group, or a C 1-6 alkoxy group), and n represents 0, 1, or 2),
[0021] (B) converting the compound represented by the formula (III) to a compound represented by the formula (IV),
[0000]
[0000] (in the formula (IV), R 1 and R 2 are as defined in the formula (I) and the formula (III) above),
[0022] (C) converting the compound represented by the formula (IV) to a compound represented by the formula (V),
[0000]
[0000] (in the formula (V), R 1 is as defined in the formula (I) above), and
[0023] (D) converting the compound represented by the formula (V) to the compound represented by the formula (I),
[0024] (ii) A process for producing a compound represented by the formula (III) or a salt thereof, which includes converting a compound represented by the formula (II) to the compound represented by the formula (III),
[0000]
[0000] (in the formula (III), R 1 is as defined in the formula (I) above,
R 2 represents a hydrogen atom, a C 1-6 alkyl group, a C 3-8 cycloalkyl group, or a —(CH 2 ) n -phenyl group (wherein the C 1-6 alkyl group, C 3-8 cycloalkyl group, or —(CH 2 ) n -phenyl group is either unsubstituted or substituted with one or more of a halogen atom, a hydroxyl group, a C 1-6 alkyl group, or a C 1-6 alkoxy group), and n represents 0, 1, or 2)
[0000]
[0000] (in the formula (II), R 1 is as defined in the formula (III) above),
[0025] (iii) The process described in above (i) or (ii), wherein R 1 is (2)—O—R a and R a is a methyl group or an ethyl group,
[0026] (iv) The process described in any one of above (i) to (iii), wherein R 2 is a methyl group,
[0027] (v) The process described in any one of above (i) to (iv), wherein the step of converting the compound represented by the formula (II) to the compound represented by the formula (III) includes reacting the compound represented by the formula (II) with an acyl group donor in the presence of an enzyme derived from a microorganism to produce the compound represented by the formula (III),
[0028] (vi) The process described in above (v), wherein the microorganism is at least one selected from the group consisting of the genus Candida , the genus Aspergillus , the genus Thermomyces , the genus Penicillium , the genus Alcaligenes , the genus Geotrichum , the genus Galactomyces , and the genus Dipodascus,
[0029] (vii) The process described in above (v) or (vi), wherein the enzyme derived from a microorganism is a lipase, a protease, or a pectinase,
[0030] (viii) The process described in above (v), wherein the enzyme derived from a microorganism is a lipase derived from Candida cylindracea, Candida rugosa , or Alcaligenes sp,
[0031] (ix) The process described in any one of above (v) to (viii), wherein the enzyme is immobilized on a support,
[0032] (x) The process described in any one of above (v) to (ix), wherein the acyl group donor is vinyl acetate or isopropenyl acetate,
[0033] (xi) A compound represented by the formula (III) or a salt thereof
[0000]
[0000] (in the formula (III), R 1 represents
(1) —OH,
(2) —O—R a , or
(3) —NR b R c ,
[0034] R a represents a C 1-6 alkyl group or a C 3-8 cycloalkyl group (wherein the C 1-6 alkyl group or C 3-8 cycloalkyl group is either unsubstituted or substituted with one or more of a C 1-6 alkoxy group, a hydroxyl group, a halogen atom, an aryl group, or a heteroaryl group),
R b and R c , which may be the same or different from each other, each represents a hydrogen atom, a halogen atom, a C 1-6 alkyl group, or a C 3-8 cycloalkyl group (wherein the C 1-6 alkyl group or C 3-8 cycloalkyl group is either unsubstituted or substituted with one or more of a hydroxyl group, a C 1-6 alkoxy group, an aryl group, or a heteroaryl group), or R b and R c bond to each other and form a 4- to 7-membered saturated heterocycle together with an adjacent nitrogen atom (wherein the saturated heterocycle is either unsubstituted or substituted with a hydroxyl group, a C 1-6 alkyl group, or a C 1-6 alkoxy group), R 2 represents a hydrogen atom, a C 1-6 alkyl group, a C 3-8 cycloalkyl group, or a —(CH 2 ) n -phenyl group (wherein the C 1-6 alkyl group, C 3-8 cycloalkyl group, or —(CH 2 ) n -phenyl group is either unsubstituted or substituted with one or more of a halogen atom, a hydroxyl group, a C 1-6 alkyl group, or a C 1-6 alkoxy group), and n represents 0, 1, or 2), or
[0035] (xii) A compound represented by the formula (IV) or a salt thereof
[0000]
[0000] (in the formula (IV), R 1 represents
(1) —OH,
(2) —O—R a , or
(3) —NR b R c ,
[0036] R a represents a C 1-6 alkyl group or a C 3-8 cycloalkyl group (wherein the C 1-6 alkyl group or C 3-8 cycloalkyl group is either unsubstituted or substituted with one or more of a C 1-6 alkoxy group, a hydroxyl group, a halogen atom, an aryl group, or a heteroaryl group),
R b and R c , which may be the same or different from each other, each represents a hydrogen atom, a halogen atom, a C 1-6 alkyl group, or a C 3-8 cycloalkyl group (wherein the C 1-6 alkyl group or C 3-8 cycloalkyl group is either unsubstituted or substituted with one or more of a hydroxyl group, a C 1-6 alkoxy group, an aryl group, or a heteroaryl group), or R b and R c bond to each other and form a 4- to 7-membered saturated heterocycle together with an adjacent nitrogen atom (wherein the saturated heterocycle is either unsubstituted or substituted with a hydroxyl group, a C 1-6 alkyl group, or a C 1-6 alkoxy group), R 2 represents a hydrogen atom, a C 1-6 alkyl group, a C 3-8 cycloalkyl group, or a —(CH 2 ) n -phenyl group (wherein the C 1-6 alkyl group, C 3-8 cycloalkyl group, or —(CH 2 ) n -phenyl group is either unsubstituted or substituted with one or more of a halogen atom, a hydroxyl group, a C 1-6 alkyl group, or a C 1-6 alkoxy group), and n represents 0, 1, or 2).
Advantageous Effects of Invention
[0037] According to the invention, use of an expensive chemical reagent like Trost ligand, which has been considered to be essential for production of the bicyclo [3.1.0] hexane derivative represented by the formula (I) and a salt thereof, that is useful as a therapeutic agent, and useful for production of an antagonist substance of group II metabotropic glutamate receptor represented by the formula (A), can be avoided, and therefore a significant reduction in production cost can be achieved.
DESCRIPTION OF EMBODIMENTS
[0038] In the specification, the numerical range described with “-” or “to” includes the value of both ends, unless specifically described otherwise.
[0039] The “C 1-6 alkyl group” denotes a straight chain or branched alkyl group having 1 to 6 carbon atoms, and examples thereof include methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, isopentyl, neopentyl, and n-hexyl groups.
[0040] The “C 3-8 cycloalkyl group” denotes a cyclic alkyl group having 3 to 8 carbon atoms, and examples thereof include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, and cyclooctyl groups.
[0041] The “C 1-6 alkoxy group” denotes a straight chain or branched alkoxy group having 1 to 6 carbon atoms, and examples thereof include methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, sec-butoxy, tert-butoxy, n-pentyloxy, isopentyloxy, neopentyloxy, and n-hexyloxy groups.
[0042] The “halogen atom” is a fluorine atom, a chlorine atom, a bromine atom, or an iodine atom.
[0043] The “aryl group” denotes an aromatic hydrocarbon substituent group and may be monocyclic or polycyclic (preferably monocyclic to tricyclic), and the rings in the polycycle may or may not be fused. Examples thereof include phenyl, naphthyl, and biphenyl groups.
[0044] The “heteroaryl group” denotes an aromatic ring having at least one heteroatom (nitrogen, oxygen, or sulfur) in the ring skeleton. The heteroaryl group may be monocyclic or polycyclic (preferably monocyclic to tricyclic), and the rings in the polycycle may or may not be fused. Examples thereof include groups such as pyrrole, pyrazole, imidazole, pyridine, pyrazine, pyrimidine, furan, pyran, oxazole, isooxazole, purine, benzimidazole, quinoline, isoquinoline, and indole. When the heteroaryl group defined here is substituted, the substituent group may be bonded to a carbon atom forming the ring of the heteroaryl group or may be bonded to a nitrogen atom forming the ring, and has a valence that enables substitution. The substituent group is preferably bonded to a carbon atom forming the ring.
[0045] The term “bonding to each other and, together with the adjacent nitrogen atom, forming a 4- to 7-membered saturated heterocycle” denotes groups such as azetidinyl, pyrrolidinyl, piperidinyl, or azepanyl.
[0046] The term “enzyme derived from a microorganism” denotes for example an enzyme derived from a microorganism such as a fungus or a bacterium, and may be obtained from an extract in which such a microorganism is disrupted or a culture supernatant of such a microorganism. As the enzyme, there can be cited a lipase, an acylase, a protease, a pectinase, and the like; it is not limited to one type, and a plurality of enzymes may be present simultaneously. Examples of the fungus include the genus Candida, the genus Aspergillus , the genus Thermomyces , the genus Penicillium , the genus Geotrichum , the genus Galactomyces , and the genus Dipodascus . Examples of the bacterium include the genus Alcaligenes.
[0047] The term “support” is not particularly limited as long as it is a support that can immobilize an enzyme; examples thereof include Celite (trade name), which is a diatomaceous earth calcined together with sodium carbonate, and Toyonite (trade name), which is a porous ceramic-based support obtained by hydrothermally processing a kaolin mineral under hydrochloric acid-acidified conditions, then granulating, and calcining it. It is possible to easily modify the surface of Toyonite particles with various organic functional groups. By changing the type of organic functional group (methacryloyloxy group, phenylamino group, amino group, and the like) of a coupling agent used for modification of the surface of Toyonite, various types of enzyme may be more selectively immobilized. By immobilizing an enzyme on a simple substance such as Celite or Toyonite, the stability, reaction activity, and the like of the enzyme are increased.
[0048] The term “salt” includes, for example, a salt with an inorganic acid such as sulfuric acid, hydrochloric acid, hydrobromic acid, phosphoric acid, or nitric acid; a salt with an organic acid such as acetic acid, oxalic acid, lactic acid, tartaric acid, fumaric acid, maleic acid, citric acid, benzenesulfonic acid, methanesulfonic acid, p-toluenesulfonic acid, benzoic acid, camphorsulfonic acid, ethanesulfonic acid, glucoheptonic acid, gluconic acid, glutamic acid, glycolic acid, malic acid, malonic acid, mandelic acid, galactaric acid, or naphthalene-2-sulfonic acid;
[0000] a salt with one or more types of metal ions such as lithium ion, sodium ion, potassium ion, calcium ion, magnesium ion, zinc ion, or aluminum ion; or
a salt with an amine such as ammonia, arginine, lysine, piperazine, choline, diethylamine, 4-phenylcyclohexylamine, 2-aminoethanol, or benzathine.
[0049] The term “enantiomerically pure” denotes that a target enantiomer is present in at least 50% e.e. (enantiomeric excess) or more relative to an untargeted enantiomer, preferably at least 80% e.e. or more, and yet more preferably at least 90% e.e. or more.
[0050] A preferred embodiment of the process for producing the compound represented by the formula (I) in the invention employs the compound represented by the formula (II) as a starting material. It is preferable that R 1 is (1) —OH, (2) —O—R a , R a is a C 1-6 alkyl group, or (3) —NR b R c , and both R b and R c are a hydrogen atom. More preferably, R 1 is (2) —O—R a and R a is a methyl group or an ethyl group. Particularly preferably, R 1 is (2) —O—R a and R a is a methyl group.
[0051] A preferred embodiment of the process for producing the compound represented by the formula (V) in the invention employs the compound represented by the formula (II) as a starting material. It is preferable that R 1 is (1) —OH, (2) —O—R a , R a is a C 1-6 alkyl group, or (3) —NR b R c , and both R b and R c are a hydrogen atom. More preferably, R I- is (2) —O—R a and R a is a methyl group or an ethyl group. Particularly preferably, R 1 is (2) —O—R a and R a is a methyl group.
[0052] A preferred embodiment of the process for producing the compound represented by the formula (IV) in the invention employs the compound represented by the formula (II) as a starting material. It is preferable that R 1 is (1) —OH, (2) —O—R a , R a is a C 1-6 alkyl group, or (3) —NR b R c , and both R b and R c are a hydrogen atom, and R 2 is a C 1-6 alkyl group, a C 3-8 cycloalkyl group, or a —(CH 2 ) n -phenyl group. More preferably, R 1 is (2) —O—R a , R a is a methyl group or an ethyl group, and R 2 is a methyl group, an ethyl group, a propyl group, a butyl group, a heptyl group, a monochloromethyl group, or a phenyl group. Particularly preferably, R 1 is (2) —O—R a , R a is a methyl group, and R 2 is a methyl group.
[0053] A preferred embodiment of the process for producing the compound represented by the formula (III) in the invention employs the compound represented by the formula (II) as a starting material. It is preferable that R 1 is (1) —OH, (2) —O—R a , R a is a C 1-6 alkyl group, or (3) —NR b R c , and both R b and R c are a hydrogen atom, and R 2 is a C 1-6 alkyl group, a C 3-8 cycloalkyl group, or a —(CH 2 ) n -phenyl group. More preferably, R 1 is (2) —O—R a , R a is a methyl group or an ethyl group, and R 2 is a methyl group, an ethyl group, a propyl group, a butyl group, a heptyl group, a monochloromethyl group, or a phenyl group. Particularly preferably, R 1 is (2) —O—R a , R a is a methyl group, and R 2 is a methyl group.
[0054] One embodiment of the production process of the invention is shown in the Scheme 1 and the Scheme 2 below.
[0000]
[0055] In the formulae of the Scheme 1, R 1 is as defined above. R 3 and R 4 represent
(1) —OH,
(2) —O—R a , or
(3) —NR b R c ,
[0056] R a represents a C 1-6 alkyl group or a C 3-8 cycloalkyl group (wherein the C 1-6 alkyl group or the C 3-8 cycloalkyl group is either unsubstituted or substituted with one or more of a C 1-6 alkoxy group, a hydroxyl group, a halogen atom, an aryl group, or a heteroaryl group),
R b and R c , which may be the same or different from each other, each represents a hydrogen atom, a halogen atom, a C 1-6 alkyl group, or a C 3-8 cycloalkyl group (the C 1-6 alkyl group or the C 3-8 cycloalkyl group is either unsubstituted or substituted with one or more of a hydroxyl group, a C 1-6 alkoxy group, an aryl group, or a heteroaryl group), or R b and R c may form a 4- to 7-membered saturated heterocycle together with an adjacent nitrogen atom (wherein the saturated heterocycle is either unsubstituted or substituted with a hydroxyl group, a C 1-6 alkyl group, or a C 1-6 alkoxy group).
[0057] The compound represented by the formula (VI) may be an optically active substance or an optically inactive substance. The compound represented by the formula (VI) may be synthesized by oxidizing cyclopentadiene using, for example, a peracid such as peracetic acid (J. Am. Chem. Soc., 82, 4328 (1960), Org. Synth., 42, 50 (1962)., Org. Lett., 7, 4573 (2005)). Furthermore, an optically active substance of the compound represented by the formula (VI) may be synthesized by asymmetric oxidation of cyclopentadiene in the presence of, for example, a metal catalyst (Synlett, 827 (1995), Tetrahedron Letters, 37, 7131 (1996), Japanese Patent Application Laid-Open No. H09-052887).
[0058] By reacting the compound represented by the formula (VI) and the compound represented by the formula (VII) in the presence of a base, a mixture of the compound represented by the formula (VIIIa) and the compound represented by the formula (VIIIb) is obtained.
[0059] Herein, it is preferable that R 3 and R 4 , which may be the same or different from each other, represent a hydroxyl group, a C 1-6 alkoxy group, or an amino group. More preferably, R 3 and R 4 are a methoxy group or an ethoxy group. Particularly preferably, they are a methoxy group.
[0060] Examples of the base used in the reaction include an alkali metal alkoxide such as sodium methoxide, sodium ethoxide, or potassium tert-butoxide; an alkali metal hydride such as sodium hydride or potassium hydride; an alkali metal hydroxide such as sodium hydroxide or potassium hydroxide; an organic amine such as 1,8-diazabicyclo [5.4.0]-7-undecene, and; a metal amide such as lithium diisopropylamide or lithium hexamethyldisilazide; it is preferable to use an alkali metal alkoxide, it is more preferable to use an alkali metal methoxide or an alkali metal ethoxide, and it is yet more preferable to use sodium methoxide.
[0061] The amount of base used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it may usually be used in the range of 0.5 to 5 molar equivalents relative to the compound represented by the formula (VI), preferably in the range of 1 to 3 molar equivalents, and more preferably in the range of 1 to 2 molar equivalents.
[0062] The amount of compound represented by the formula (VII) used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it may usually be used in the range of 0.5 to 5 molar equivalents relative to the compound represented by the formula (VI), preferably in the range of 1 to 3 molar equivalents, and more preferably in the range of 1 to 2.5 molar equivalents.
[0063] A solvent used in the reaction is not particularly limited as long as it is stable under relevant reaction conditions and does not inhibit a target reaction, but since the yield of the mixture of the compound represented by the formula (VIIIa) and the compound represented by the formula (VIIIb), which are products, depends on the type of solvent, it is preferable to use an alcohol, and more preferably methanol, as a solvent.
[0064] The amount of reaction solvent used is usually 1 to 100 times by mass relative to the compound represented by the formula (VI), and preferably in the range of 5 to 30 times by mass.
[0065] The reaction temperature may be usually equal to or more than −80° C. and equal to or less than the boiling point of the solvent used, is preferably in the range of −20 to 60° C., and is more preferably in the range of 20 to 40° C.
[0066] Subsequently, by heating the mixture of the compound represented by the formula (VIIIa) and the compound represented by the formula (VIIIb) in the presence of an additive, a mixture of the compound represented by the formula (IXa) and the compound represented by the formula (IXb) is obtained.
[0067] A solvent used in the reaction is not particularly limited as long as it is stable under relevant reaction conditions and does not inhibit the target reaction. Since the yield of the mixture of the compound represented by the formula (IXa) and the compound represented by the formula (IXb), which are products, depends on the type of solvent, it is preferable to use a mixture of water and a polar organic solvent, more preferably water and dimethyl sulfoxide, and yet more preferably water and dimethyl sulfoxide at a ratio in the range of 0:5 to 1:5.
[0068] The amount of reaction solvent used may be usually 1 to 100 times by mass relative to the mixture of the compound represented by the formula (VIIIa) and the compound represented by the formula (VIIIb), is preferably in the range of 1 to 20 times by mass, and is more preferably in the range of 1 to 10 times by mass.
[0069] The reaction temperature may usually be 80° C. to 200° C., but is preferably in the range of 90° C. to 160° C., and more preferably in the range of 100 to 130° C.
[0070] When the reaction temperature exceeds the boiling point of the solvent used, the reaction may be carried out in a pressure-resistant vessel such as an autoclave.
[0071] Furthermore, the present reaction is accelerated by addition of the additive; examples of the additive that can be used include a salt, preferably an alkali metal halide salt such as lithium chloride, sodium chloride, potassium chloride, lithium bromide, sodium bromide, potassium bromide, lithium iodide, sodium iodide, or potassium iodide; an alkali metal cyanide salt such as sodium cyanide; a quaternary ammonium salt such as tetra-n-butyl ammonium chloride, tetra-n-butyl ammonium bromide, or tetra-n-butyl ammonium iodide; or an organic amine salt such as triethylamine hydrochloride salt, or a mixture thereof. It is also possible to use an alkali metal halide salt such as sodium chloride and an acid such as acetic acid in combination.
[0072] The amount of additive used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it is usually in the range of 0.5 to 5 molar equivalents relative to the mixture of the compound represented by the formula (VIIIa) and the compound represented by the formula (VIIIb), preferably in the range of 1 to 4 molar equivalents, and more preferably in the range of 1 to 3 molar equivalents.
[0073] Subsequently, the mixture of the compound represented by the formula (IXa) and the compound represented by the formula (IXb) is oxidized in the presence of an additive, thus giving a mixture of the compound represented by the formula (Xa) and the compound represented by the formula (Xb).
[0074] The present reaction proceeds by adding an oxidizing agent such as tert-butyl hydroperoxide in the presence of a catalyst such as vanadyl acetylacetonate (VO(acac) 2 ).
[0075] A solvent used in the reaction is not particularly limited as long as it is stable under relevant reaction conditions and does not inhibit the target reaction. Since the yield of the mixture of the compound represented by the formula (Xa) and the compound represented by the formula (Xb), which are products, depends on the type of solvent, it is preferable to use an aromatic hydrocarbon or a halogenated hydrocarbon, more preferably chlorobenzene or toluene, and yet more preferably chlorobenzene.
[0076] The amount of reaction solvent used may be 3 to 100 times by mass relative to the mixture of the compound represented by the formula (IXa) and the compound represented by the formula (IXb), is preferably 3 to 20 times by mass, and is more preferably 5 to 10 times by mass.
[0077] The reaction temperature may usually be 0° C. to 100° C., but is preferably in the range of 30° C. to 80° C., and more preferably 50 to 60° C.
[0078] The amount of oxidizing agent used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it may usually be used at 1 to 3 molar equivalents relative to the mixture of the compound represented by the formula (IXa) and the compound represented by the formula (IXb), and is preferably in the range of 1 to 2 molar equivalents.
[0079] The amount of catalyst used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it may usually be used at 0.01 to 1 molar equivalents relative to the mixture of the compound represented by the formula (IXa) and the compound represented by the formula (IXb), and is preferably in the range of 0.2 to 0.5 molar equivalents.
[0080] Furthermore, epoxidation of the mixture of the compound represented by the formula (IXa) and the compound represented by the formula (IXb) may also be carried out by reacting with a halogenating agent such as N-bromosuccinimide or N-iodosuccinimide in an appropriate solvent (for example, a mixture of dimethyl sulfoxide and water) to convert them into halohydrin derivatives, and then treating with a base such as 1,8-diazabicyclo [5.4.0]-7-undecene.
[0081] Subsequently, by subjecting the mixture of the compound represented by the formula (Xa) and the compound represented by the formula (Xb) to an intramolecular cyclopropanation accompanied by epoxide ring opening, the compound represented by the formula (II) is obtained.
[0082] This reaction proceeds by adding a base in the presence of a Lewis acid.
[0083] In a preferred embodiment, first, the mixture of the compound represented by the formula (Xa) and the compound represented by the formula (Xb) is treated with a Lewis acid, and a base is then added. The compound represented by the formula (II) is obtained as the desired stereoisomer.
[0084] Examples of the Lewis acid include R 3 Al, R 2 AlX, RAlX 2 , Al(OR) 3 , Ti(OR) 4 , RTi(OR) 3 , R 2 Ti(OR) 2 , a BF 3 ether complex, Et 2 Zn, and Sc(OTf) 3 ; it is preferably Et 3 Al, Al(OiPr) 3 , Ti(OiPr) 4 , a BF 3 ether complex, Et 2 Zn, and Sc(OTf) 3 , more preferably Et 3 Al, Et 2 AlCl, and Et 2 Zn, and yet more preferably Et 3 Al. Here, X is a halogen atom or an inorganic radical, and each of the Rs is hydrocarbon group.
[0085] Further, in the present specification, “Et” is an abbreviation of ethyl, “Tf” is an abbreviation of trifluoromethane sulfonic acid, and “iPr” is an abbreviation of isopropyl.
[0086] The amount of Lewis acid used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it may usually be used in the range of 1 to 5 molar equivalents relative to the mixture of the compound represented by the formula (Xa) and the compound represented by the formula (Xb), preferably in the range of 1.5 to 3 molar equivalents, and more preferably in the range of 2 to 2.5 molar equivalents.
[0087] Examples of the base include lithium hexamethyldisilazide and lithium diisopropylamide, and it is preferably lithium hexamethyldisilazide.
[0088] The amount of base used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it may usually be used in the range of 1 to 5 molar equivalents relative to the mixture of the compound represented by the formula (Xa) and the compound represented by the formula (Xb), preferably in the range of 1.5 to 3 molar equivalents, and more preferably in the range of 2 to 2.5 molar equivalents.
[0089] A solvent used in the reaction is not particularly limited as long as it is stable under relevant reaction conditions and does not inhibit the target reaction. Since the yield of the compound represented by the formula (II), which is a product, depends on the type of solvent, it is preferable to use an ether-based solvent such as tetrahydrofuran (THF).
[0090] With regard to the amount of reaction solvent used, it may be used at 1 to 100 times by mass relative to the mixture of the compounds represented by the formula (Xa) and the compound represented by the formula (Xb), is preferably in the range of 3 to 20 times by mass, and is more preferably in the range of 5 to 10 times by mass.
[0091] The reaction temperature may usually be −80° C. to 0° C., and is preferably −60° C. to −40° C.
[0092] The reaction time is usually 0.5 hours to 6 hours, and is preferably 1 to 3 hours.
[0093] Furthermore, the hydroxyl group of the mixture of the compound represented by the formula (Xa) and the compound represented by the formula (Xb) may be protected by a tert-butyl dimethylsilyl group and the like and then subjected to a cyclopropanation reaction. By building a cyclopropane ring and then removing the protecting group, the compound represented by the formula (II) is obtained.
[0000]
[0094] In the formulae of the Scheme 2, R 1 and R 2 are as defined above.
[0095] By stereoselectively protecting only one of the two hydroxyl groups of the compound represented by the formula (II), the compound represented by the formula (III) is obtained.
[0096] The present reaction gives a desired stereoisomer in the presence of an appropriate enzyme.
[0097] In a preferred embodiment of the present reaction, by reacting the compound represented by the formula (II) with an acyl group donor in the presence of an enzyme, the compound represented by the formula (III) is obtained.
[0098] As the enzyme, a microorganism-produced enzyme having stereoselective acylation capability is used. By reacting the compound represented by the formula (II) and an acyl group donor in an organic solvent and the like in the presence of this enzyme, stereoselective acylation can be carried out. Furthermore, by immobilizing the enzyme on a support, it may also be used in the reaction as an immobilized enzyme. In this case, after the compound represented by the formula (II) is mixed with an acyl group donor in an organic solvent and the like, the support having an enzyme immobilized thereon is added to the above mixture and stirred, or a column is charged with the support having an enzyme immobilized thereon, and the above mixture is passed through the column, thus carrying out a stereoselective acylation reaction. The reaction temperature may usually be −20° C. to 60° C. The organic solvent and the like used are not particularly limited as long as it is stable under relevant reaction conditions and does not inhibit the target reaction. Since the yield and optical purity of the compound represented by the formula (III), which is a product, depend on the type of solvent, it is preferable to use an organic solvent such as toluene, isopropyl ether, tetrahydrofuran, n-hexane, n-heptane, acetone, or chloroform or an ionic fluid such as 1-butyl-3-methylimidazolium hexafluorophosphate or 1-butyl-3-methylimidazolium tetrafluoroborate (Org. Lett., 2, 4189 (2000)).
[0099] Examples of the acyl group donor include vinyl acetate, isopropenyl acetate, vinyl propionate, isopropenyl propionate, vinyl butyrate, isopropenyl butyrate, vinyl caproate, isopropenyl caproate, vinyl caprate, isopropenyl caprate, vinyl caprylate, isopropenyl caprylate, vinyl chloroacetate, isopropenyl chloroacetate, vinyl pivalate, and isopropenyl pivalate, and it is preferably vinyl acetate or isopropenyl acetate. More preferably, it is vinyl acetate.
[0100] The microorganism as an enzyme source is preferably a fungus or a bacterium. It is more preferably at least one type of fungus or bacterium selected from the group consisting of the genus Candida , the genus Aspergillus , the genus Thermomyces , the genus Penicillium , the genus Geotrichum , the genus Galactomyces , the genus Dipodascus , and the genus Alcaligenes , and it is yet more preferably at least one type of fungus or bacterium selected from the group consisting of Candida cylindracea, Candida rugosa, Aspergillus pulverluentus, Aspergillus niger, Aspergillus oryzae, Thermomyces langinosus, Penicillium roqueforti, Penicillium citrinum, Geotrichum fermentans, Galactomyces aurantii, Galactomyces reessii, Dipodascus australiensis , and Alcaligenes sp.
[0101] The microorganism-derived enzyme is preferably a lipase, a protease, or a pectinase, and particularly preferably a lipase derived from Candida cylindracea, Candida rugosa, Penicillium roqueforti , or Alcaligenes sp. Most preferably, it is a lipase derived from Candida cylindracea, Candida rugosa , or Alcaligenes sp. The microorganism-derived enzyme may be purified from an extract in which a microorganism is disrupted or a culture supernatant in accordance with a standard method. It is not always necessary to purify the microorganism-derived enzyme as a single product, and it may also be used as a crude enzyme. The enzyme may be used either singly or a mixture of types thereof may be used as a mixture. It is also possible to obtain a commercial product.
[0102] Examples of commercially available products of Candida cylindracea -derived lipase include Lipase OF (trade name, available from Meito Sangyo. Co.) and also Lipase from Candida cylindracea (trade name, available from Sigma-Aldrich Japan Co.).
[0103] Examples of commercially available products of Candida rugosa-derived lipase include Lipase AY “Amano” 30G (trade name, available from, Amano enzyme), Lipase AYS “Amano” (trade name, available from Amano enzyme), and Lipase from Candida rugosa (trade name, available from Sigma-Aldrich Japan Co.).
[0104] Examples of commercially available products of Penicillium roqueforti -derived lipase include Lipase R (trade name, available from Amano enzyme).
[0105] Examples of commercially available products Alcaligenes sp.-derived lipase include Lipase QLM (trade name, available from Meito Sangyo. Co.).
[0106] Examples of the other lipases include Sumizyme CT-L (trade name, available from SHINNIHON CHEMICALS Corporation [ Thermomyces langinosus -derived lipase]), Lipase AS “Amano” (trade name, available from Amano Enzyme Inc. [ Aspergillus niger -derived lipase]), Sumizyme NSL3000 (trade name, available from SHINNIHON CHEMICALS Corporation [ Aspergillus niger -derived lipase]), and Lipase A “Amano”6 (trade name, available from Amano enzyme [ Aspergillus niger -derived lipase]).
[0107] Examples of the protease include Protease M “Amano” (trade name, available from, Amano enzyme [ Aspergillus oryzae -derived protease]).
[0108] Examples of the pectinase include Pectinase G “Amano” (trade name, available from Amano enzyme [ Aspergillus pulverulentus -derived protease]).
[0109] The microorganism-derived enzyme may also be immobilized on a support and used as an immobilized enzyme. Examples of the support used for immobilization of the enzyme include Celite or a Toyonite (Toyonite 200, Toyonite 200P, Toyonite 200M, Toyonite 200A (available from Toyo Denka Kogyo Co., Ltd.)). Other than an immobilized enzyme obtained by immobilizing the above-mentioned commercial lipase, an enzyme immobilized by applying a cultured cell supernatant obtained by culturing a specific microorganism to the above support may be used as an enzyme having lipase activity. As the specific microorganism, Geotrichum fermentans, Galactomyces aurantii, Galactomyces reessii, Dipodascus australiensis and the like are preferable.
[0110] Subsequently, by oxidizing the hydroxyl group of the compound represented by the formula (III), the compound represented by the formula (IV) is obtained.
[0111] In a preferred embodiment of the present reaction, by reacting the compound represented by the formula (III) with an oxidizing agent in the presence of a catalyst, the compound represented by the formula (IV) is obtained.
[0112] Examples of the catalyst include RuCl 3 and 2,2,6,6-tetramethylpiperidine 1-oxyl (TEMPO).
[0113] The amount of catalyst used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it may usually be used in the range of 0.001 to 1 molar equivalents relative to the compound represented by the formula (III), and preferably in the range of 0.01 to 0.1 molar equivalents.
[0114] Examples of the oxidizing agent include sodium hypochlorite.
[0115] The amount of oxidizing agent used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it may usually be used in the range of 1 to 3 molar equivalents relative to the compound represented by the formula (III), and preferably in the range of 1 to 1.5 molar equivalents.
[0116] A solvent used in the reaction is not particularly limited as long as it is stable under relevant reaction conditions and does not inhibit the target reaction. Since the yield of the compound represented by the formula (IV), which is a product, depends on the type of solvent, it is preferably dichloromethane, chloroform, chlorobenzene, acetonitrile, and the like, and more preferably dichloromethane.
[0117] With regard to the above solvent, one type may be used either singly or combination of two or more types may be used as a mixture.
[0118] The amount of reaction solvent used may be 1 to 100 times by mass relative to the compound represented by the formula (III), and is preferably in the range of 3 to 10 times by mass.
[0119] The reaction temperature may usually be −20° C. to 50° C., preferably −20° C. to 20° C., and more preferably −10° C. to 0° C.
[0120] The reaction time is usually 0.5 hours to 6 hours, and preferably 1 to 3 hours.
[0121] Furthermore, the oxidation reaction of the hydroxyl group of the compound represented by the formula (III) may be carried out by a method (for example, Swern oxidation and the like) well known to a person skilled in the art, and the compound represented by the formula (IV) is obtained.
[0122] Subsequently, by reacting the compound represented by the formula (IV) with a base or an acid, the compound represented by the formula (V) is obtained.
[0123] Examples of the base include an organic amine such as triethylamine or 1,8-diazabicyclo [5.4.0]-7-undecene.
[0124] The amount of base used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it may usually be used in the range of 0.5 to 3 molar equivalents relative to the compound represented by the formula (IV), and preferably in the range of 0.8 to 1.2 molar equivalents.
[0125] Examples of the acid include trifluoro methanesulfonic acid and silica gel.
[0126] The amount of acid used is not particularly limited as long as it is an amount that does not inhibit the reaction and does not cause a side reaction, but it may usually be used in the range of 0.1 to 3 molar equivalents relative to the compound represented by the formula (IV).
[0127] A solvent used in the reaction is not particularly limited as long as it is stable under relevant reaction conditions and does not inhibit the target reaction. It is preferable to use dichloromethane or methanol.
[0128] By reacting the compound represented by the formula (V) with the catalyst under hydrogen atmosphere as a reducing agent, the compound represented by the formula (I) is obtained.
[0129] Examples of the catalyst include Lindlar catalyst.
[0130] The solvent used for the reaction is not specifically limited if it is stable under the relevant reaction condition and does not inhibit the target reaction. Preferably, ethyl acetate is used.
EXAMPLES
[0131] More specific examples are illustrated below, but the disclosure of the invention is not limited thereto. Examples 1 to 6 show the process of the Scheme 1. Examples 7 to 10 show the process of the Scheme 2.
Reference Example 1
[0132] Mixture of dimethyl fluoro[(1R,5R)-5-hydroxycyclopent-2-en-1-yl]propanedioate (8a) and dimethyl fluoro[(1S,5S)-5-hydroxycyclopent-2-en-1-yl]propanedioate (8b)
[0000]
[0133] 23.81 g (110.2 mmol) of a 25 w/w % methanol solution of sodium methoxide (NaOMe) was added to a methanol (90.4 mL) solution of 18.19 g (121.2 mmol) of dimethyl fluoropropanedioate (7) over 3 minutes while keeping the internal temperature between 25° C. and 38° C. After stirring the solution thus obtained for 15 minutes, 4.52 g (55.1 mmol) of 6-oxabicyclo [3.1.0] hex-2-ene (6) was added thereto over 2 minutes while keeping the internal temperature between 25° C. and 38° C. After stirring at room temperature for 1 hour, 45 mL of a saturated ammonium chloride aqueous solution was added over 10 minutes while keeping the internal temperature between 26° C. and 35° C. The reaction mixture was concentrated under reduced pressure, most of the methanol was removed by evaporation, and 108 g of a brown solution containing solids was obtained. After extraction with 136 mL of ethyl acetate was carried out twice, washing with 45 mL of water was carried out. After the organic layer was concentrated under reduced pressure, 100 mL of toluene was added, and concentration under reduced pressure was carried out again. The concentrated residue was purified by flash silica gel column chromatography (eluent:toluene/ethyl acetate), thus giving 7.21 g of a mixture of the compound of the formula 8a and the compound of the formula 8b as a yellow oily substance.
[0000] 1 H NMR (500 MHz, DMSO-d 6 ): δ (ppm) 2.13-2.17 (m, 1H), 2.56 (dddd, J=2.2, 4.3, 7.1, 17.2 Hz, 1H), 3.32-3.40 (m, 1H), 3.77 (s, 3H), 3.79 (s, 3H), 4.20 (m, 1H), 5.04 (d, J=6.1 Hz, 1H), 5.47 (ddd, J=2.1, 4.3, 6.1 Hz, 1H), 5.85 (ddd, J=2.2, 4.4, 6.1 Hz, 1H). 13 C NMR (125 MHz, DMSO-d 6 ): δ (ppm) 41.93, 53.39 (d, J=19.5 Hz), 58.70 (d, J=20.8 Hz), 70.43 (d, J=2.6 Hz), 93.55, 95.14, 125.59, 133.32, 165.42 (d, J=15.6 Hz), 165.62 (d, J=14.3 Hz). 19 F NMR (470 MHz, DMSO-d 6 ): δ (ppm) −172.43, −172.36. HRMS(ES)m/z: [M+Na] + calcd for C H H 13 O 5 FNa; 255.0645, found 255.0635. IR (neat) 3528, 3408, 2960, 1755, 1438, 1284, 1253, 1173, 1111, 1068, 1031, 936, 838, 787, 722, 668, 415 cm −1 .
Reference Example 2
[0134] Mixture of methyl fluoro[(1R,5R)-5-hydroxycyclopent-2-en-1-yl]acetate (9a) and methyl fluoro[(1S,5S)-5-hydroxycyclopent-2-en-1-yl] acetate (9b)
[0000]
[0135] 172.51 g of dimethyl sulfoxide (DMSO) and 25.92 g of water were added to 17.27 g (74.50 mmol) of a mixture of the compound of the formula 8a and the compound of the formula 8b. 9.65 g (227.65 mmol) of lithium chloride was added to this solution, and the mixture was heated and stirred at 130° C. for 2 hours. After allowing it to cool, the reaction mixture was extracted with 500 mL of ethyl acetate three times, and the organic layer was then concentrated under reduced pressure, thus giving a concentrated residue. This concentrated residue was purified by flash silica gel column chromatography (eluent:n-hexane/ethyl acetate=1:1), thus giving 3.674 g of a mixture of the compound of the formula 9a and the compound of the formula 9b as a yellow oily substance.
[0000] 1 H NMR (500 MHz, DMSO-d 6 ): δ (ppm) 2.11-2.17 (m, 1.6H), 2.53-2.60 (m, 1.6H), 2.87-2.96 (m, 1.6H), 3.71 (s, 1.8H), 3.73 (s, 3H), 4.23-4.28 (m, 1.6H), 4.93 (d, J=5.0 Hz, 0.6H), 5.07 (d, J=5.4 Hz, 1H), 5.11 (dd, J=4.2, 48.3 Hz, 0.6H), 5.17 (dd, J=3.8, 48.5 Hz, 1H), 5.42-5.45 (m, 1H), 5.55-5.58 (m, 0.6H), 5.78-5.80 (m, 1.6H). 13 C NMR (125 MHz, DMSO-d 6 ): δ (ppm) 41.29, 41.83, 51.95, 52.13, 56.80 (d, J=20.8 Hz), 57.06 (d, J=19.5 Hz), 70.49 (d, J=5.2 Hz), 71.90 (d, J=2.6 Hz), 88.36 (d, J=184.3 Hz), 88.48 (d, J=184.3 Hz), 125.93 (d, J=5.2 Hz), 127.28 (d, J=3.9 Hz), 131.76, 132.13, 169.05 (d, J=24.7 Hz), 169.21 (d, J=24.7 Hz). 19 F NMR (470 MHz, DMSO-d 6 ): δ (ppm) −197.87 (dd, J=29.2, 47.5 Hz), -194.53 (dd, J=25.7, 47.8 Hz). HRMS(ES)m/z: [M+Na] + calcd for C 8 H 11 O 3 FNa; 197.0590, found 197.0578. IR (neat) 3410, 3060, 2956, 2851, 1747, 1440, 1357, 1288, 1228, 1127, 1097, 1067, 1048, 1025, 952, 856, 724, 584, 450 cm −1 .
Reference Example 3
[0136] Mixture of methyl fluoro[(1R,5R)-5-hydroxycyclopent-2-en-1-yl]acetate (9a) and methyl fluoro[(1S,5S)-5-hydroxycyclopent-2-en-1-yl]acetate (9b)
[0137] 70.06 g of dimethyl sulfoxide and 45.64 g (33.16 mol) of triethylamine hydrochloride were added to 70.02 g (0.3015 mmol) of a mixture of the compound of the formula 8a and the compound of the formula 8b, and the mixture was heated and stirred at 110° C. to 120° C. for 5 hours. After allowing it to cool, 350.9 g of water was added thereto, and the reaction mixture was extracted with 350 g of methyl isobutyl ketone twice. The organic layer was concentrated under reduced pressure, thus giving 65.40 g of a yellowish brown oily substance containing 46.78 g (value quantitatively determined by gas chromatography) of a mixture of the compound of the formula 9a and the compound of the formula 9b.
Reference Example 4
[0138] Mixture of methyl fluoro[(1R,5R)-5-hydroxycyclopent-2-en-1-yl]acetate (9a) and methyl fluoro[(1S,5S)-5-hydroxycyclopent-2-en-1-yl] acetate (9b)
[0139] 1 mL of dimethyl sulfoxide, 0.073 g (1.25 mmol) of sodium chloride, and 0.061 g (1.00 mmol) of acetic acid were added to 0.232 g (1.00 mmol) of a mixture of the compound of the formula 8a and the compound of the formula 8b, and the mixture was heated and stirred at 110 to 120° C. for 5 hours. After allowing it to cool, analysis was carried out using a high-performance liquid chromatography, and it was found that 0.146 g (the value quantitatively determined by high performance liquid chromatography) of a mixture of the compound of the formula 9a and the compound of the formula 9b was obtained.
Reference Example 5
[0140] Mixture of methyl fluoro[(1R,2S,3R,5S)-3-hydroxy-6-oxabicyclo [3.1.0] hex-2-yl]acetate (10a) and methyl fluoro[(1S,2R,3S,5R)-3-hydroxy-6-oxabicyclo [3.1.0] hex-2-yl]acetate (10b)
[0000]
[0141] 0.1176 g (0.444 mmol) of vanadyl acetylacetonate (VO(acac) 2 ) was added to a chlorobenzene (18.37 g) solution of 3.644 g (20.92 mmol) of a mixture of the compound of the formula 9a and the compound of the formula 9b at room temperature. The mixture was heated to 60° C., and 5.445 g (42.29 mmol) of a 70% toluene solution of tert-butyl hydroperoxide (tBuOOH) was added thereto over 10 minutes while keeping the internal temperature between 55° C. and 60° C. The mixture was stirred at 55° C. for 4 hours and then allowed to cool to room temperature. After 22 g of a 20% sodium thiosulfate aqueous solution was added and stirring was carried out for 30 minutes, extraction was carried out with 50 mL of ethyl acetate four times. The organic layers were combined and concentrated under reduced pressure, thus giving a concentrated residue. This concentrated residue was purified by flash silica gel column chromatography (eluent:n-hexane/ethyl acetate=2:1 to 1:1), thus giving 2.402 g of a mixture of the compound of the formula 10a and the compound of the formula 10b as a yellow oily substance.
[0000] 1 H NMR (500 MHz, DMSO-d 6 ): δ (ppm) 0.1.76 (s, 0.6H), 1.79 (s, 1H), 1.99 (dt, J=7.6, 1.5 Hz, 1H), 2.02 (dt, J=7.6, 1.5 Hz, 0.6H), 2.42-2.44 (m, 0.6H), 2.48-2.51 (m, 1H), 3.38 (d, J=2.5 Hz, 1H), 3.55-3.56 (m, 1.6H), 3.59 (m, 0.6H), 3.75 (s, 1.8H), 3.77 (s, 3H), 4.08 (t, J=6.9 Hz, 0.6H), 4.18 (t, J=6.9 Hz, 1H), 4.41 (d, J=6.5 Hz, 0.6H), 4.49 (d, J=6.1 Hz, 1H), 5.32 (dd, J=4.0, 47.0 Hz, 1H), 5.35 (dd, J=3.0, 48.0 Hz, 0.6H). 13 C NMR ( 125 MHz, DMSO-d 6 ): δ (ppm) 37.37, 37.88, 51.87 (d, J=19.5 Hz), 51.93 (d, J=18.2 Hz), 52.34, 52.42, 56.83 (d, J=7.8 Hz), 57.73, 57.84, 58.20 (d, J=2.6 Hz), 70.85 (d, J=5.2 Hz), 72.65 (d, J=2.6 Hz), 125.93 (d, J=181.7 Hz), 127.28 (d, J=183.0 Hz), 168.63 (d, J=23.4 Hz), 168.71 (d, J=24.7 Hz). 19 F NMR ( 470 MHz, DMSO d 6 ): δ (ppm) −198.56 (dd, J=32.9, 47.5 Hz), −198.20 (dd, J=32.9, 48.0 Hz). HRMS (ES)m/z: [M+Na] + calcd for C 8 H 11 O 4 FNa; 213.0539, found 213.0530. IR (neat) 3506, 3032, 2959, 1758, 1639, 1440, 1408, 1364, 1288, 1226, 1098, 1077, 1012, 965, 917, 838, 802, 732, 668, 564, 444 cm −1 .
Reference Example 6
[0142] Methyl (1R,2R,4S,5S,6R)-6-fluoro-2,4-dihydroxybicyclo [3.1.0] hexane-6-carboxylate (2)
[0000]
[0143] A THF (dehydrated, 20 mL) solution of 2.334 g (12.27 mmol) of a mixture of the compound of the formula 10a and the compound of the formula 10b was cooled to −50° C., and 29.0 mL (27.26 mmol) of a 0.94 mol/L triethyl aluminum (Et 3 Al) hexane solution was added thereto over 30 minutes while keeping the internal temperature between −60° C. and −50° C. After stirring at −50° C. for 30 minutes, 23.6 mL (23.60 mmol) of a 1 mol/L lithium hexamethyl disilazide (LiHMDS) hexane solution was added thereto over 45 minutes while keeping the internal temperature between −50° C. and −40° C. After stirring at −50° C. for 2 hours, the reaction mixture was added over 30 minutes to 44.3 g of a 25% citric acid aqueous solution cooled to 5° C. This reaction mixture was extracted with 50 mL of ethyl acetate four times and concentrated under reduced pressure. The concentrated residue was purified by flash silica gel column chromatography (eluent:ethyl acetate), thus giving a yellow oily substance. This oily substance was crystallized from a mixed liquid of 3.0 g of ethyl acetate and 0.5 g of water, thus giving 1.027 g of the compound of the formula 2 as colorless crystals.
[0000] mp 73.9-76.5° C., 1 H NMR (500 MHz, DMSO-d 6 ): δ (ppm) 1.64 (dd, J=4.4, 15.3 Hz, 1H), 1.96 (m, 1H), 2.17 (s, 2H), 3.72 (br s, 3H), 4.18 (d, J=5.0 Hz, 2H), 4.93 (br s, 2H). 13 C NMR (125 MHz, DMSO-d 6 ): δ (ppm) 38.03 (d, J=11.7 Hz), 45.76 (d, J=7.8 Hz), 52.64, 71.53, 77.52, 79.42, 168.78 (d, J=26.0 Hz). 19 F NMR (470 MHz, DMSO-d 6 ): δ (ppm) −216.827. HRMS (ES)m/z: [M+Na] + calcd for C 8 H 11 O 4 FNa; 213.0539, found 213.0537. IR (KBr) 3549, 3413, 3295, 3246, 2964, 2922, 1732, 1616, 1467, 1442, 1381, 1336, 1285, 1265, 1235, 1198, 1181, 1130, 1078, 1041, 994, 947, 890, 805, 777, 733, 646, 566, 537, 480 cm −1 .
Example 1
[0144] Methyl (1S,2S,4R,5R,6S)-2-(acetyloxy)-6-fluoro-4-hydroxybicyclo [3.1.0] hexane-6-carboxylate (3)
[0000]
[0145] 1.6 g of immobilized enzyme Lipase OF/Toyonite 200P which had been prepared in the same manner as the Example 11 (described below) was added to a mixture solution in which 4.0 g of the monohydrate of the compound of the formula 2 is dissolved in 32 mL of tetrahydrofuran (THF) and added with 64 mL of vinyl acetate and 64 mL of toluene, and reacted at room temperature for 18 hours by stirring (600 rpm) using a stirrer. The reaction solution was filtered under reduced pressure using Kiriyama filter paper No. 4 and then the filtrate was concentrated under reduced pressure. The resulting oily substance was subjected to HPLC analysis as described above, and as a result, production of 4.0 g of the compound of the formula 3 (optical purity of 93.2% e.e.) was identified. Part of the oily substance was kept at −20° C. As a result, crystal precipitates were produced and they are washed with a mixture solvent of toluene and n-heptane on a filter paper. As a result of HPLC analysis, the optical purity was 98.1% e.e. The remaining oily substance (including 3.9 g of the compound of the formula 3) was purified by flash silica gel column chromatography using silica gel 60N (purchased from Kanto Chemical Co., Inc.). As a result, 2.84 g (optical purity of 93.14% e.e.) of the compound of the formula 3 was isolated.
[0000] 1 H NMR (500.16 MHz, CDCl 3 ): δ (ppm) 1.96 (m, 1H, J=5.0, 16.4 Hz), 2.11 (s, 3H), 2.28 (ddd, J=6.1,7.3,13.4 Hz, 1H), 2.42 (dd, J=6.5, 14.5 Hz, 1H), 2.44 (dd, J=6.5, 14.5 Hz, 1H), 3.82 (s, 3H), 4.44 (m, 1H), 5.29(m, J=6.1 Hz, 1H). 13 C NMR (125.77 MHz, CDCl 3 ): δ (ppm) 21.22, 35.00 (d, J=10.4 Hz), 37.98 (d, J=11.7 Hz), 42.50 (d, J=9.2 Hz), 52.96, 73.09, 75.56, 168.45, 168.66, 170.23. MS (ESI/APCI Dual positive) m/z 255.0[M+Na] − .
Example 2
[0146] Methyl (1S,2S,5R,6R)-2-(acetyloxy)-6-fluoro-4-oxobicyclo [3.1.0] hexane-6-carboxylate (4)
[0000]
[0147] A dichloromethane (dehydrated, 5 mL) solution of 946 mg (4.07 mmol) of the compound of the formula 3 was cooled to −5° C., 14.0 mg (0.090 mmol) of 2,2,6,6-tetramethylpiperidine 1-oxyl (TEMPO), 102.0 mg (1.21 mmol) of sodium hydrogen carbonate, and 2.0 mL of water were added in sequence, and 3.86 g (5.19 mmol) of a 10% sodium hypochlorite aqueous solution was then added while keeping the internal temperature between −5° C. and 0° C. After stirring at −5° C. to 0° C. for 1 hour, the mixture was separated. The organic layer was washed with 1 mL of water and dried over anhydrous sodium sulfate. After concentration under reduced pressure, 899 mg of the compound of the formula 4 was obtained as an oily substance with yellow color.
[0000] 1 H NMR (500.16 MHz, CDCl 3 ): δ (ppm) 2.12 (s, 3H), 2.37 (dd, J=3.4, 19.5 Hz, 1H), 2.65 (dd, J=19.5, 6.1 Hz, 1H), 2.73 (d, J=6.1 Hz, 1H), 2.93 (dd, J=1.9, 6.1 Hz, 1H), 3.83 (s, 3H), 5.50 (d, J=6.1 Hz, 1H). 13 C NMR (125.77 MHz, CDCl 3 ): δ (ppm) 20.88, 38.19 (d, J=11.6 Hz), 39.01 (d, J=13.0 Hz), 43.49 (d, J=3.9 Hz), 53.43, 69.13, 165.78, 165.93, 170.03, 204.35.
Example 3
[0148] Methyl (1R, 5R, 6R)-6-fluoro-4-oxo bicyclo [3.1.0] hexa-2-ene-6-carboxylate (5)
[0000]
[0149] A dichloromethane (18 mL) solution of 719 mg (3.12 mM) of the compound of the formula 4 was added with 0.63 mL (4.07 mmol) of 1,8-diazabicyclo [5.4.0]-7-undecene (DBU), stirred for 1 hour at room temperature, added with 4.2 mL of 1 N hydrochloric acid, and then followed by stirring and liquid fractionation. The aqueous layer was re-extracted with 5 mL of dichlomethane and the organic layer was washed with 5 mL of saturated brine. The organic layer was dried over sodium sulfate and concentrated under reduced pressure. The concentrated residue was purified by flash silica gel column chromatography (eluent:n-hexane/ethyl acetate), thus giving the compound of the formula 5 as a colorless oily substance (413.7 mg).
[0000] 1 H NMR (500.16 MHz, CDCl 3 ): δ (ppm) 2.79 (d, J=5.0Hz, 1H), 3.23 (dd, J=3.0, 6.0 Hz, 1H), 3.86 (s, 3H), 6.06 (d, J=5.5 Hz, 1H), 7.42 (dd, J=3.0, 5.5 Hz, 1H). 13 C NMR (125.77 MHz, CDCl 3 ): δ (ppm) 34.05 (d, J=14.2 Hz), 34.47 (d, J=13.0 Hz), 53.21, 133.34, 152.30 (d, J=2.6 Hz), 165.99, 166.21, 198.56. MS (ESI/APCI Dual positive) m/z 170.9[M+H] − , (ESI/APCI Dual negative) m/z 168.9[M-H] −
Example 4
[0150] Methyl (1R, 5R, 6R)-6-fluoro-2-oxo bicyclo [3.1.0] hexane-6-carboxylate (1)
[0000]
[0151] 360.7 mg (2.12 mmol) of the compound of the formula 5 was dissolved in 18 mL of ethyl acetate, added with 143 mg of Lindlar catalyst, and stirred for 16 hours under hydrogen atmosphere at room temperature. The obtained solution was filtered through cellulose powder and concentrated under reduced pressure. The concentrated residue was purified by flash silica gel column chromatography (eluent:chloroform), thus giving the compound of the formula 1 as a colorless oily substance (337 mg).
[0000] 1 H NMR (500.16 MHz, CDCl 3 ): δ (ppm) 2.22 (m, 1H), 2.28-2.34 (m, 2H), 2.43 (m, 1H), 2.59 (m, 1H), 2.73 (d, J=2.0 Hz), 3.86 (s, 3H). 13 C NMR (125.77 MHz, CDCl 3 ): δ (ppm) 19.47 (d, J=5.2 Hz), 34.11 (d, J=13.0 Hz), 35.47 (d, J=5.2 Hz), 40.19 (d, J=13.1 Hz), 53.11, 167.46, 167.67, 208.73. MS (ESI/APCI Dual positive) m/z 172.9[M+H] − , TOFMS EI m/z 172.1 [M] + .
[0152] Examples 5 to 12 below show the results of examining reaction conditions in order to obtain the compound of the formula 3 by asymmetric acetylation of the compound of the formula 2 using various microorganism-derived enzymes.
[0000]
[0153] The state of formation of the starting material compound of the formula 2, the target compound of the formula 3 and its enantiomer, the compound of the formula 3′, were confirmed by the TLC method and the HPLC method below.
[0000] (TLC method: TLC plate; silica gel Si 60 (Art 1.5715, manufactured by Merck & Co., Inc.))
Developing solvent; n-hexane/ethyl acetate=10/1
Coloration; anisaldehyde/conc. sulfuric acid/acetic acid=1/2/100
Rf value; compound of the formula 1=0.20, compounds of the formula 3 and the formula 3′=0.40
(HPLC method: column CHIRALCEL OJ-RH 4.6 mm ID×150 mm L (Daicel Chemical Industries, Ltd.))
Mobile phase; methanol/0.1% phosphoric acid aqueous solution=38/62
Flow rate; 0.8 mL/min
Temperature; 35° C.
Detection; UV 195 nm
[0154] Retention time;
compound of the formula 2: 3.8 min
compound of the formula 3: 9.0 min
compound of the formula 3′: 10.3 min
Example 5
[0155] <Investigation of Enzymes>
[0156] 50 mg of an enzyme to be tested was placed in a 10 mL stoppered test tube, 2.7 mL of vinyl acetate, 0.3 mL of acetone, and 20 mg of the compound of the formula 2 were added thereto, and stirring was carried out using a stirrer at 25° C. for 18 to 48 hours (600 rpm). After the reaction was completed, enzyme residue was removed by filtration using an Ekicrodisc 25CR (manufactured by Japan Pall Corporation, 25 mm of diameter), the solution was dried under reduced pressure and then dissolved in 1 mL of methanol, and part thereof was then sampled and subjected to TLC analysis and HPLC analysis. The 41 types of enzymes shown in the Table 1, Table 2, and Table 3 were screened.
[0157] From the results of TLC analysis, in reactions using the enzymes shown in the Table 1 and Table 2, spots that had an Rf value on TLC coinciding with the Rf value (0.40) of an authentic racemic sample (compound of the formula 3 and compound of the formula 3′) and exhibited the same color (brown) were detected. Among enzymes for which the detection of an acetylated form was prominent in the TLC analysis, those for which the target product compound of the formula 3 was confirmed by HPLC analysis are shown in the Table 1 with the amount of target product formed and the optical purity. Furthermore, among enzymes for which the detection of an acetylated form was prominent in the TLC analysis, those for which the optical isomer compound of the formula 3′, which is different from the target product, was confirmed by HPLC analysis are shown in the Table 2 with the amount thereof formed and the optical purity.
[0158] In the present Examples, enzymes for which formation of neither the compound of the formula 3 nor the compound of the formula 3′ was detected are shown in the Table 3.
[0000]
TABLE 1
AMOUNT OF 3
ENZYME NAME
DERIVED FROM
FORMED (mg)
% E.E. OF 3
Lipase from Candida cylindracea
Candida cylindracea
13.57
66.04
Lipase AYS “Amano”
Candida rugosa
4.54
36.99
Lipase AK “Amano” 20
Pseudomonas fluorescens
3.15
34.41
Lipase AY “Amano” 30G
Candida rugosa
1.84
48.06
Sumizyme CT-L
Thermomyces langinosus
1.64
99.99
Lipase R “Amano”
Penicillium roqueforti
0.67
99.99
Lipase AS “Amano”
Aspergillus niger
0.57
57.18
Lipase A “Amano” 6
Aspergillus niger
0.52
49
Lipase PS “Amano” SD
Burkholderia cepacia
0.51
25.5
CHE “Amano” 2
Pseudomonas sp.
0.43
48.02
Sumizyme NSL3000
Aspergillus niger
0.39
99.99
Pectinase G “Amano”
Aspergillus pulverulentus
0.32
99.99
Nuclease “Amano” G
Penicillium citrinum
0.13
99.99
[0000]
TABLE 2
AMOUNT OF 3′
ENZYME NAME
DERIVED FROM
FORMED (mg)
% E.E. OF 3′
Lipase A CLEA
Candida antarctica
17.82
94.06
Novozym 735
Candida antarctica
14.25
96.34
Lipozym TL
Thermomyces
2.93
39.87
100L IM
langinosus
Novozym 435
Candida antarctica
0.17
99.99
[0000]
TABLE 3
ENZYME NAME (TRADE NAME)
DERIVED FROM
Acylase 15000
Aspergillus melleus
Protease P “Amano”
Aspergillus melleus
Lipase M “Amano” 10
Mucor javanicus
Deamizyme
Aspergillus melleus
Lipase II
Porcine Pancreas
Lipozyme IM20
Rhizomucor miehei
Lactase F
Aspergillus oryzae
Lipase F-AP-15
Rhizopus oryzae
Papain W-40
Carica papaya
Lipase G
Penicillium camemberti
Protease M “Amano”
Aspergillus oryzae
Protease N “Amano” G
Bacillus subtilis
Newlase F3G
Rhizopus niveus
Protease S “Amano” G
Bacillus stearothermophilus
Sumizyme PLE
Aspergillus niger
Catalase Nagase
Micrococcus lysodeikticus
Amylase AD “Amano”
Bacillus subtilis
Sumizyme PGO
Penicillium chrysogenum
Novozym CALBL
Candida antarctica
Bromelain F
Ananas comosus M
Proleather FG
Bacillus sp.
Sumityme MMR
Rhizomucor miehei
Lipozym TL 100
Thermomyces langinosus
Subtilicin A
Bacillus subtilis
Example 6
[0159] <Preparation of Immobilized Enzymes>
[0160] 0.5 g of each of the eleven kinds of enzyme (trade names: Sumizyme NSL3000 and Sumizyme CT-L manufactured by SHINNIHON CHEMICALS Corporation, trade names: Nuclease “Amano” G, Pectinase G “Amano”, Lipase A “Amano” 6, Lipase AY “Amano” 30G, Lipase PS “Amano” SD, Lipase AK “Amano” 20, Lipase AYS “Amano” and Lipase R manufactured by Amano Enzyme, trade name: Lipase Candida cylindracea manufactured by Sigma-Aldrich Japan Co.) (only liquid enzyme Sumizyme CT-L that was used in an amount of 2.0 mL) was dissolved in 10 mL of 100 mM potassium phosphate buffer solution (pH 7) at room temperature (insoluble matters were filtered using Kiriyama filter paper No. 5B) and mixed with 0.5 g of Toyonite 200M (purchased from TOYO DENKA KOGYO CO., LTD.) as an immobilization support within the 15 mL SUMILON tube (manufactured by Sumitomo Bakelite Co., Ltd.), and shaken at 160 rpm for 18 hours at 20° C. After the shaking, each mixture was filtered through Kiriyama filter paper No. 704 (manufactured by Nihon Rikagaku Industry Co., Ltd.) and dried overnight under reduced pressure at room temperature, thus giving each types of immobilized enzymes.
[0161] By following the same process, the same eleven kinds of the enzymes were mixed with 0.5 g of Toyonite 200P (purchased from TOYO DENKA KOGYO CO., Ltd.) as an immobilization support, thus giving each type of immobilized enzymes.
Example 7
[0162] <Test for Measuring Compound Conversion Capability of Immobilized Enzymes>
[0163] 50 mg of each of the twenty two types of immobilized enzymes obtained from the Example 6 and 25 mg of the compound of the formula 2 were mixed to 1 mL of vinyl acetate solution containing 10% acetone (volume), and the enzyme reaction was carried out by stirring for 18 hours using an inverting stirrer (600 rpm, inverted with an interval of 2.5 min) at room temperature. After the enzyme reaction was completed, the reaction solution was filtered using an Ekicrodisc 25CR (manufactured by Japan Pall Corporation), and the solution was dried under reduced pressure, dissolved in 1 mL of methanol, and then subjected to HPLC analysis. The results obtained from the HPLC analysis are shown in the Table 4.
[0000]
TABLE 4
ENZYME NAME/
AMOUNT OF 3
SUPPORT FOR IMMOBILIZATION
ORIGIN OF ENZYME
FORMED (mg)
% E.E. OF 3
Sumizyme NSL3000/Toyonite200M
Aspergillus niger
1.69
0
Sumizyme CT-L/Toyonite200M
Thermomyces langinosus
NOT DETECTED
Nuclease “Amano” G/Toyonite200M
Penicillium citrinum
NOT DETECTED
Pectinase G “Amano”/Toyonite200M
Aspergillus pulverulentus
11.18
77.6
Lipase A “Amano” 6/Toyonite200M
Aspergillus niger
0.64
28.3
Lipase AY “Amano” 30G/Toyonite200M
Candida rugosa
17.8
75.9
Lipase PS “Amano” SD/Toyonite200M
Burkholderia cepacia
7.3
12.5
Lipase AK “Amano” 20/Toyonite200M
Pseudomonas fluorescens
13.35
39.4
Lipase AYS “Amano”/Toyonite200M
Candida rugosa
8.38
76
Lipase R/Toyonite200M
Penicillium roqueforti
1.03
>99
Lipase from Candida cylindracea /Toyonite200M
Candida cylindracea
12.68
80.3
Sumizyme NSL3000/Toyonite200P
Aspergillus niger
1.75
57.2
Sumizyme CT-L/Toyonite200P
Thermomyces langinosus
NOT DETECTED
Nuclease “Amano” G/Toyonite200P
Penicillium citrinum
NOT DETECTED
Pectinase G “Amano”/Toyonite200P
Aspergillus pulverulentus
1.38
77.5
Lipase A “Amano” 6/Toyonite200P
Aspergillus niger
1.4
72.3
Lipase AY “Amano” 30G/Toyonite200P
Candida rugosa
21.92
81.6
Lipase PS “Amano” SD/Toyonite200P
Burkholderia cepacia
6.29
28
Lipase AK “Amano” 20/Toyonite200P
Pseudomonas fluorescens
8.38
43.7
Lipase AYS “Amano”/Toyonite200P
Candida rugosa
18.17
67.1
Lipase R “Amano”/Toyonite200P
Penicillium roqueforti
3.59
83.8
Lipase from Candida cylindracea /Toyonite200P
Candida cylindracea
9.93
72.6
Example 8
[0164] <Preparation of Immobilized Enzyme and Test for Measuring Compound Conversion Capability>
[0165] Each of the fifteen types of enzymes (see, the Table 5) was dissolved in 10 mL of 100 mM of potassium phosphate buffer solution (pH 7) at room temperature, in which the solid enzyme is used in an amount of 0.5 g and the liquid enzyme is used in an amount of 2.0 mL (insoluble matters were filtered through Kiriyama filter paper No. 5B). After that, each mixture was mixed with 0.5 g of Toyonite 200M (purchased from TOYO DENKA KOGYO CO., LTD.) which is an immobilization support within a 15 mL volume SUMILON tube (manufactured by Sumitomo Bakelite Co., Ltd.), and then shaken at 150 rpm for 17 hours at 25° C. After the shaking, each mixture was filtered through Kiriyama filter paper No. 704 (manufactured by Nihon Rikagaku Industry Co., Ltd.) and dried overnight under reduced pressure at room temperature, thus giving each types of immobilized enzymes.
[0166] 50 mg of each of the fifteen types of the immobilized enzyme and 25 mg of the compound of the formula 2 were mixed to 1 mL of vinyl acetate solution containing 10% acetone (volume), and the enzyme reaction was carried out by stirring for 18 hours using an inverting stirrer (600 rpm, inverted with an interval of 2.5 min) at room temperature. After the enzyme reaction was completed, the reaction solution was filtered using an Ekicrodisc 25CR (manufactured by Japan Pall Corporation), and the solution was dried under reduced pressure, dissolved in 1 mL of methanol, and then subjected to HPLC analysis. The results obtained from the HPLC analysis are shown in the Table 5.
[0000]
TABLE 5
ENZYME NAME/SUPPORT
AMOUNT OF 3
FOR IMMOBILIZATION
ORIGIN OF ENZYME
FORMED (mg)
% E.E. OF 3
Acylase 15000/Toyonite200M
Aspergillus melleus
0
Protease P “Amano”/Toyonite200M
Aspergillus melleus
0.27
17.4
Lipase M “Amano10”/Toyonite200M
Mucor javanicus
0
Sumizyme PLE/Toyonite200M
Aspergillus niger
0
Deamizyme/Toyonite200M
Aspergillus melleus
0
Lipase II/Toyonite200M
Porcine pancreas
0
Lipase F/Toyonite200M
Aspergillus oryzae
0
Lipase F-AP-15/Toyonite200M
Rhizopus oryzae
0.83
18.5
Novozym CALB/Toyonite200M
Candida antarctica
0
Bromelain F/Toyonite200M
Ananas comosus M
0
Protease “Amano” G/Toyonite200M
Bacillus subtilis
0
Newlase F3G/Toyonite200M
Rhizopus niveus
0
Protease S “Amano” G/Toyonite200M
Bacillus stearothermophilus
0
Protease M “Amano”/Toyonite200M
Aspergillus oryzae
0.34
72.9
Proleather FG/Toyonite200M
Bacillus sp.
0.41
26.5
Sumizyme MMR/Toyonite200M
Rhizomucor miehei
0
Lipozym TL 100/Toyonite200M
Candida rugosa
0
Subtilicin A/Toyonite200M
Bacillus subtilis
0
Example 9
[0167] <Preparation of Immobilized Enzyme and Test for Measuring Compound Conversion Capability>
[0168] 111 strains of filamentous fungus were subjected to aeration agitation culture in a 200 mL Erlenmeyer flask containing 40 mL of a medium formed from defatted rice bran 3%, corn steap liquor 3%, soybean oil 1%, and ammonium sulfate 0.2% (pH 6) at 18° C. to 28° C. for 3 days. After culturing was completed, each microorganism culture fluid was individually transferred to a centrifuge tube, and the culture fluid was centrifuged into cells and cell supernatant by a centrifuge (8000 rpm, 12 to 15 minutes). 0.1 volume of a 1 M potassium phosphate pH 7 buffer and 0.5 g of Toyonite 200M (purchased from TOYO DENKA KOGYO CO., LTD) as a support were added to each microorganism cell supernatant thus obtained (in a centrifuge tube such as a Sumilon tube) and shaken at 25° C. overnight (maximum 20 hours). After shaking was completed, the mixture was allowed to stand for 5 minutes; after the insoluble matters including the support settled down on the bottom of the centrifuge tube, an upper layer solution was removed by decantation, 15 mL of a 0.1 M potassium phosphate pH 7 to pH 7.5 buffer was added, and resuspension by stirring was carried out. This was repeated a total of two times, and the suspension was filtered under reduced pressure using a Kiriyama funnel (trade name) equipped with Kiriyama filter paper No. 5B (trade name), thus giving each of the microorganism culture fluid supernatant-derived immobilized enzymes on the filter papers. Each immobilized enzyme was filtered and dried under reduced pressure for a few minutes on the filter, placed in a vacuum desiccator (with dry silica gel), and dried overnight (maximum 20 hours). Each of the immobilized enzymes that had completed drying was used in the enzymatic reaction below.
[0169] 20 to 40 mg of each of the 111 types of the immobilized enzyme that are obtained by the above was placed in a sample tube having screw stopper with 3.5 mL volume, and added with a solution in which 40 mg of the crystals of the compound of the formula 2 is added with 1.8 mL of vinyl acetate and 0.2 mL of acetone, and the reaction was carried out by stirring for 18 to 21 hours at room temperature using a stirrer (600 rpm). After the reaction was completed, the immobilized enzyme was removed by filtration using an Ekicrodisc 25CR, and the solution was dried under reduced pressure, dissolved in 1 mL of methanol, and then subjected to the HPLC analysis.
[0170] For a case in which a significant amount of the compound of the compound with the formula 3 is produced as a target product, the amount of the target product formed and its optical purity are shown in the Table 6.
[0000]
TABLE 6
MICROORGANISM AS
ORIGIN OF ENZYME
(SUPPORT FOR
IMMOBILIZATION IS
TOYONITE 200M FOR
AMOUNT OF 3
ALL CASES)
FORMED (mg)
% E.E. OF 3
Geotrichum fermentans JCM2467
5.48
72.8
Dipodascus australiensis NBRC10805
3.04
63.1
Galactomyces citri - aurantii
2.16
55.7
NBRC10821
Galactomyces reessii JCM1942
3.73
53.3
Geotrichum capitatum JCM3908
2.52
48.7
Dipodascus armillariae NBRC10803
3.35
43.6
Dipodascus armillariae NBRC10802
1.48
40.8
Example 10
[0171] <Preparation of Immobilized Enzyme and Test for Measuring Compound Conversion Capability>
[0172] 4 g of each of Lipase TL, Lipase PL, Lipase OF and Lipase QLM (all obtained from Meito Sangyo. Co.) was dissolved in 150 mL of 100 mM potassium phosphate buffer solution (pH 7) at room temperature, and added with 1 g of the support, Toyonite 200M (purchased from TOYO DENKA KOGYO CO., LTD.), and shaken at 150 rpm for 19 hours at room temperature by using a shaker. After shaking was completed, the mixture was allowed to stand for 5 minutes; after the insoluble matters containing the support settled down on the bottom of the centrifuge tube, an upper layer solution was removed by decantation, 15 mL of a 0.1 M potassium phosphate pH 7 to pH 7.5 buffer was added, and resuspension by stirring was carried out. This was repeated a total of two times, and the suspension was filtered under reduced pressure using a Kiriyama funnel (trade name) equipped with Kiriyama filter paper No. 5B (trade name), thus obtaining each immobilized enzyme on the filter paper. 50 mg of each of the four types of the immobilized enzyme that are obtained by the above was placed in a sample tube having screw stopper with 3.5 mL volume, and added with a solution in which 40 mg of the crystals of the compound of the formula 2 is added with 1.8 mL of vinyl acetate and 0.2 mL of acetone, and the reaction was carried out by stirring for 16 hours at room temperature using a stirrer (600 rpm). After the reaction was completed, the immobilized enzyme was removed by filtration using an Ekicrodisc 25CR, and the solution was dried under reduced pressure, dissolved in 1 mL of methanol, and then subjected to the HPLC analysis. The results obtained from the HPLC analysis are shown in the Table 7.
[0000]
TABLE 7
ENZYME NAME/
SUPPORT FOR
AMOUNT OF 3
IMMOBILIZATION
ORIGIN OF ENZYME
FORMED (mg)
% E.E. OF 3
Lipase PL/Toyonite200M
Alcaligenes sp.
NOT DETECTED
Lipase OF/Toyonite200M
Candida cylindracea
34.87
86.5
Lipase QLM/Toyonite200M
Alcaligenes sp.
31.14
80.5
Lipase TL/Toyonite200M
Pseudomonas stutzeri
22.10
32.9
Example 11
[0173] <Preparation of Immobilized Enzyme and Test for Measuring Compound Conversion Capability>
[0174] 2 g of each of Lipase OF and Lipase QLM was placed in two separate plastic bottles, dissolved in 100 mM of potassium phosphate buffer solution (pH 7) (that is, four solutions are prepared in total), and mixed with 4 g of Toyonite 200M or Toyonite 200P, thus yielding four combinations of enzyme and support. The resultant was shaken at 120 rpm for 18 hours at room temperature by using a shaker. After shaking was completed, the mixture solution including the support and the enzyme was filtered under reduced pressure through Kiriyama filter paper No. 4, suspended and washed with 40 mL of 100 mM potassium phosphate buffer solution (pH 7), and filtered and dried under reduced pressure to obtain each immobilized enzyme. 40 mg of each of the immobilized enzymes that are obtained from the above and Lipase TL, Lipase PL, Lipase OF and Lipase QLM was placed in a sample tube having screw stopper with 3.5 mL volume, and added with a solution in which 80 mg of the crystals of the compound of the formula 2 is added with 1.8 mL of vinyl acetate and 0.2 mL of acetone, and the reaction was carried out by stirring for 18 hours at 25° C. using a stirrer (600 rpm). The immobilized enzyme (four types) was separately subjected to the reaction with the same condition and reaction temperature of 16° C. After the reaction was completed, the immobilized enzyme was removed by filtration using an Ekicrodisc 25CR, and the solution was dried under reduced pressure, dissolved in 1 mL of methanol, and then subjected to the HPLC analysis. The results obtained from the HPLC analysis are shown in the Table 8.
[0000]
TABLE 8
ENZYME NAME/SUPPORT
FOR IMMOBILIZATION
AMOUNT OF 3
REACTION TEMPERATURE
ORIGIN OF ENZYME
FORMED (mg)
% E.E. OF 3
Lipase PL 25° C.
Alcaligenes sp.
NOT DETECTED
Lipase OF 25° C.
Candida cylindracea
1.06
51.9
Lipase QLM 25° C.
Alcaligenes sp.
63.45
78.2
Lipase TL 25° C.
Pseudomonas stutzeri
NOT DETECTED
Lipase OF/Toyonite200M 25° C.
Candida cylindracea
80.32
87.3
Lipase OF/Toyonite200P 25° C.
Candida cylindracea
81.35
87.0
Lipase QLM/Toyonite200M 25° C.
Alcaligenes sp.
68.23
75.0
Lipase QLM/Toyonite200P 25° C.
Alcaligenes sp.
57.87
77.6
Lipase OF/Toyonite200M 16° C.
Candida cylindracea
70.80
89.3
Lipase OF/Toyonite200P 16° C.
Candida cylindracea
74.22
87.1
Lipase QLM/Toyonite200M 16° C.
Alcaligenes sp.
35.97
80.0
Lipase QLM/Toyonite200P 16° C.
Alcaligenes sp.
33.74
77.3
Example 12
[0175] <Test with Modified Enzyme Amount and Composition of Reaction Solution>
[0176] 1.0 g of the monohydrate compound of the formula 2 was dissolved in 8 mL of THF, and added with 103 mg of Lipase OF/Toyonite 200P, that is, immobilized enzyme produced in the same manner as the Example 7, in a mixture solution of 16 mL of vinyl acetate and 16 mL of toluene, and subjected to the reaction for 24 hours at room temperature by stirring (600 rpm) using a stirrer. The reaction solution was filtered under reduced pressure through the Kiriyama filter paper No. 5B. The filtrate was concentrated under reduced pressure and the resulting oily substance was analyzed by HPLC by following the method described above. As a result, it was found that the compound of the formula 3 is produced in an amount of 1.0 g (optical purity of 91.7% e.e.).
INDUSTRIAL APPLICABILITY
[0177] According to the invention, 2-amino-3-alkoxy-6-fluoro bicyclo [3.1.0] hexane-2,6-dicarboxylic acid derivative, which is an antagonist of mGluR2/mGluR3, and a pharmaceutically acceptable salt thereof can be synthesized in a large amount with low cost by using inexpensive reacting materials.
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There is provided a process for producing a bicyclo [3.1.0] hexane derivative represented by the formula (I) and a salt thereof including; causing an enzyme to act on an optically inactive compound represented by the formula (II) causing an asymmetric acylation reaction and a highly-stereoselective conversion to an optically active compound represented by the formula (III); and converting the compound represented by the formula (III) to the compound represented by the formula (I) or a salt thereof.
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This application is a division of application Ser. No. 08/606,111 filed Feb. 23, 1996 which application is now U.S. Pat. No. 5,709,740.
TECHNICAL FIELD
The present invention relates generally to wax compositions for use as expandable media in actuators, and more particularly to such materials including a conductive filler and a viscosity modifier to increase the viscosity of the mixture in the melt.
BACKGROUND
Thermally operated actuators utilizing wax compositions as the expandable medium are known in the art, and used in thermostats, for example. Waxes are particularly suitable for use in actuators because they exhibit a relatively large amount of expansion as they are heated and melt to the liquid phase as the temperature is raised. Long-chain waxes may exhibit a volume change upon melting of more than 10 and even close to 20 volume percent. Another advantage of using waxes is that their melting temperature can be tailored, if so desired, by utilizing a wax of a particular molecular weight. A still further advantage of waxes is that their rate of crystallization from the melt and re-crystallization may be relatively fast as compared to other materials, such as high polymers.
It is desirable to increase thermal conductivity of waxes in thermal actuator applications to facilitate heat transfer and ultimately cycle time of the actuator device. To this end, it is known in the art to add 10, up to 30 and even 50 weight percent of a conductive filler, such as copper spheres and the like. The addition of conductive material does increase the thermal conductivity of the wax-based medium; however, like any heterogeneous system, non-uniformities can arise through particle segregation or stratification and like phenomena. This leads to erratic performance which is likely to become more severe as the amount of filler is increased or the density difference (and consequently the buoyant forces) become more pronounced.
SUMMARY
It has been found in accordance with the present invention, that a better performing wax composition for actuator use is produced through adding a viscosity modifier to increase the viscosity of the wax matrix material in the melt. More specifically, a thermally expandable wax composition for use in actuators is provided including: a wax matrix material in a proportion of about 20 to about 90 percent by weight of said composition; a polymeric viscosity modifier having a melt index of less than about 30 present in an amount of about 0.5 to about 30 weight percent of the wax composition and being operative in said proportions to increase the melt viscosity of said wax matrix material by a factor of at least 100 and up to a factor of 10 6 as compared to the viscosity of unmodified wax matrix material, the increase being measured at a temperature of about 120° C., with the proviso that the weight ratio of said wax matrix material to said polymeric viscosity modifier is from about 5:1 to about 99:1. There is also present, a conductive filler present in an amount of from about 10 weight percent to about 50 weight percent of said composition and optionally including a thermoxidative stabilizer.
Particularly preferred viscosity modifiers are relatively high molecular weight olefin polymers including poly(ethylene), poly(propylene) and especially poly(ethylene-co-vinyl acetate). Less than 20 mole percent vinyl acetate polymers have been found especially effective. Typically, these modifiers are included in the inventive compositions in amounts from about 1 to about 15 weight percent, with from 2-10 percent being preferred. The modifiers are generally effective to increase the viscosity of melted wax by a factor of 100 or more to a factor of 10 6 or even more, but factors of about 10 3 to 10 5 are more typical. Melt index is a particularly convenient method to characterize the polymeric viscosity modifiers of the present invention. Unless otherwise indicated, all values of melt index appearing in this specification and claims are those measured in accordance with test method ASTM D-1238, Procedure A, Condition E, that is, at a temperature of 190° C. with a weight of 2.16 kilograms. Generally, the polymeric viscosity modifiers exhibit a melt index of less than 30, less than 10 being typical and less than 5 being particularly preferred.
Conductive fillers useful in connection with the present invention include copper flake, aluminum flake and certain forms of carbon such as, for example, graphitic fillers.
Any suitable graphite filler may be used, however, flake, powder and fibers are typical. Spherical powder is especially preferred.
Particularly preferred thermoxidative stabilizers are selected from the group consisting of hydroxycinnamates, phosphites, pentaerythritol diphosphites and hindered phenols.
The present invention has as its basic and novel characteristics the fact that wax, viscosity modifier, and graphitic filler cooperate to provide a highly stable thermally expandable composition which resists segregation over time. Other materials, such as thermoxidative stabilizers may be added to make a more durable material without departing from the spirit and scope of the present invention.
In another aspect of the present invention, the inventive compositions are used in a mechanical actuator and may be heated directly with an electric current.
DESCRIPTION OF DRAWING
The invention is described in detail below, with reference to the FIGS. 1A and 1B, which is a schematic diagram of a polymer-based mechanical actuator.
DETAILED DESCRIPTION
Wax, as the term is used herein, refers to those materials which are solid materials at ambient temperatures with a relatively low melting point and are capable of softening when heated and hardening when cooled. They are either natural or synthetic and of petroleum, mineral, vegetable or animal origin. Typical of petroleum waxes are paraffin waxes and microcrystalline waxes. The latter consisting primarily of isoparaffinic and naphthenic saturated hydrocarbons, while the former are generally composed of n-alkanes. Beeswax, on the other hand, is primarily made of non-glyceride esters of carboxylic and hydroxy acids with some free carboxylic acids, hydrocarbons and wax alcohols present. The most important commercial mineral wax, montan wax, has as its main compositions nonglyceride esters of carboxylic acids, alcohols, acids, resins and hydrocarbons. Vegetable-based waxes tend to have relatively large amounts of hydrocarbons. Esters and amides of higher fatty acids are also waxy materials and may be used in connection with the present invention. The foregoing waxes generally have molecular weight less than 1,000; while polyethylene waxes generally have higher molecular weights in the range of 2,000 to less than 10,000.
Hoechst Wax E, commercially available from Hoechst AG, Frankfurt, Germany, is a reprocessed montan wax esterified with higher alcohols and has a melting point of approximately 90° C. Hoechst WAX PED-521 is a polar polyethylene wax also available from Hoechst AG which has a melting point slightly higher, perhaps 100° C. or more.
Conductive fillers useful in connection with the present invention include those which conduct electricity as well as those which conduct heat readily. Particularly suitable fillers are graphitic fillers such as fibers or spherical powders as well as aluminum or copper powders or flakes having a relatively high surface area. Graphite fiber may be obtained from Amoco Corporation, Chicago, Ill., while the other fillers referred to herein are generally available.
Suitable polymeric viscosity modifiers to add to the wax include relatively high molecular weights >10,000 and more typically >50,000. Polyethylenes with molecular weights of 200,000 or more may be suitable, even ultra high density material with molecular weights from 3 to 6 million may be used. Polypropylene of like molecular weights may likewise be employed.
Especially suitable polymeric viscosity modifiers are poly(ethylene-co-vinyl acetate) polymers having melt indexes of 30 or less. These materials are available from duPont, Wilmington, Del. and are marketed under the Elvax® trademark. Particularly preferred Elvax® products have a relatively low vinyl acetate content (about 20 mole percent or less) and have a melt index less than 5.
Antioxidants
It is desirable to include antioxidants in the formulation of the actuating material to inhibit oxidation and resultant degradative effects. Such antioxidants are commercially available and include such chemical species as amines, phenols, hindered phenols, phosphites, sulfides, and metal salts of dithioacids. It is further known when carbon black is compounded with organic resins that this can inhibit degradation of the polymer. The presence of two or more antioxidant additives can provide synergistic benefit against degradation of the base resin. Examples of increased stability achieved by the addition of such additives are shown below. Thermogravimetric analysis (TGA) showed significantly reduced loss in weight of samples containing antioxidants when these combinations are heated in air at 200° C. and at 225° C. These materials are available throughout the world from Ciba-Geigy and are generally marketed under the Irganox® trademark.
In a typical embodiment, a thermoxidative stabilizer such as tetrakis (methylene (3,5-di-tert-butyl-4-hydroxycinnamate)) methane and bis(2,4-di-tert-butylphenol) pentaerythritol diphosphite may be included. Preferably, each stabilizer comprises about 0.1-0.5% by weight of the wax composition. Alternatively, the bis(2,4-di-tert-butylphenol) pentaerythritol diphosphite may be replaced by 0.1-0.5% diestearyl pentaerythritol diphosphite.
The present invention may be further appreciated from the following notion of resistance to flow in a fluid: For a suspension of spherical particles in a fluid medium, the terminal sedimentation velocity is given by ##EQU1## where r is the radius of the particle ρ and ρ 0 are the densities of the particle and the surrounding fluid respectively, g is the acceleration due to gravity, and η is the viscosity of the fluid. In other words, the rate at which suspended particles separate from the suspension can be minimized by reducing the size of the particle, matching the density of the particle to that of the fluid, or increasing the viscosity of the fluid. So also, flaked material has more surface area and tends not to segregate.
The addition of ethylene-vinyl acetate copolymers (e.g., Elvax® from duPont) may be used conveniently to increase the melt viscosity of Hoechst Wax E.
______________________________________Wax Sample Melt Viscosity (poise)______________________________________Wax E 2.54 × 10.sup.-1Wax E with 15% Elvax 7.75 × 10.sup.3______________________________________
Thus the addition of only 15% viscosity enhancer results in an increase of more than four orders of magnitude in the melt viscosity of the base wax. It is desirable to keep the percentage of additives as low as possible so as not to lose the volume expansion which occurs upon melting of the wax.
The following data demonstrating the increased viscosity of Hoechst Montan Wax E and PED-521 polar polyethylene containing Elvax 770 (An ethylene-vinyl acetate copolymer) is likewise illustrative of the effect of the modifier on the matrix wax.
______________________________________VISCOSITY OF WAX E AND PED-521 WITH ELVAX 770 (TESTTEMPERATURE = 120° C.) Average Viscosity Viscosity increaseWax Sample (Poise) due to Additive (%)______________________________________Wax E 2.60 × 10.sup.-1 N/AWax E #2 2.48 × 10.sup.-1 N/AWax E w/15% Elvax 770 7.75 × 10.sup.3 3 × 10.sup.4PED-521 2.53 N/APED-521 #2 2.22 N/APED-521 w/15% 1.22 × 10.sup.3 5 × 10.sup.2Elvax 770______________________________________ Note: Elvax ® 770 typically has a melt index of 0.6 to 1.0.
The following process was used to prepare wax samples containing:
(a) Conductive additives such as graphite powder, fiber and flakes
(b) Thermal stabilizers such as Irganox 1010 and Irganox 1425 (Ciba Geigy)
(c) Viscosity modifier such as ELVAX 770 (duPont). The process description given below further illustrates the present invention.
Process Description:
In a batch process (1000 ml beaker), 188 g of Hoechst Wax E, 10 g of ELVAX 770, 1 g of Irganox 1010 and 1 g of Irganox 1425 were slowly heated under constant agitation for approximately 3 to 4 hours at 140° C. After making a clear solution (of ELVAX, Irganox and wax), the mixture was cooled to room temperature and removed as brownish wax product referred to as Stabilized Wax. The final composition of this mixture was: 94 wt % Hoechst Wax E, 5 wt % ELVAX 770, 0.5 wt % Irganox 1010 and 0.5 wt % Irganox 1425. After grinding into fine powder, the product was used for subsequent melt blending with conductive additives.
Melt blending of the Stabilized Wax with graphite powder was performed in a Haake System 90 Melt Mixer. The blend mixture was prepared by introducing 70 g of a sample consisting of 35 wt % graphite powder and 65 wt % Stabilized Wax into the mixing bowl which was preheated to 120° C. The blending was completed by continuous mixing of the melt at 200 RPM for approximately 15 minutes. After cooling, the material was ground and evaluated for particle distribution by microscopy.
Graphite fiber such as P-120 (Amoco) and GY-70 graphite fiber produced at Hoechst Celanese was also evaluated as a conductive additive. Using the same blending system, P-120 was evaluated with Stabilized Wax (same formulation as above) at 7 wt % and 20 wt %. GY-70 was tested at 5 weight percent.
Additive Sources
Graphite Powder: High Purity Crystalline Graphite, Series 4900 from Superior Graphite Company, 120 South Riverside Plaza, Chicago, Ill. 60606. The copper and aluminum powders have a grain size less than about 20 μm and may be flaky or spheric. They are commercially available from Schlenk Gmbh, Erlangen, Germany, under the trade names MULTIPRINT or LUMINOR.
Viscosity Modifier: ELVAX 770 Resin from duPont Company, Polymer Products Department, Wilmington, Del. 19898
The invention is further understood by reference to FIG. 1, a schematic of a polymer based mechanical actuator. In general, this type of actuator 10 includes a cavity 20 wherein there is placed a thermally expandable composition 30 which in turn contacts a movable piston 40. In FIG. 1(a), the thermally expandable composition, a wax composition in the case of the present invention, is in solid form in contact with the piston. Heat is applied by any suitable means and as the wax melts, composition 30 expands on the order of twenty volume percent and occupies more of cavity 20, forcing piston 40 upwardly out of the cavity as shown in FIG. 1(b).
Typically, heating is accomplished by external heating means; however since the compositions of the present invention are electrically conductive, heating may be accomplished through direct application of current through the expandable compositions. To this end, the actuator body 50 may be made of an insulative material and produced with electrodes 60 to contact the polymer composition 30. Typically, this may be accomplished with a voltage source (not shown) of 12 volts provided that sufficient current is conducted through composition 30. One may use the above described heating method as the sole heating means; or use this heating means as supplemental to conventional apparatus.
While the present invention has been described in detail, various modifications will be readily apparent to those of skill in the art. Such modifications are within the spirit and scope of the present invention which is defined in the appended claims.
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A thermally expandable wax composition and its use in polymer-based actuators is disclosed and claimed. The compositions are wax-based and include conductive filler as well as a viscosity modifier to stabilize the composition against segregation. Optionally included are thermoxidative stabilizers.
| 2
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The invention relates to fishing lures, methods of fabricating fishing lures, methods of disassembling fishing lures and molding dies for fishing lures which utilize a rapid connect hook hanger of the type defined in U.S. Pat. No. 4,095,315, issued June 20, 1978. This application is a division of U.S. patent application Ser. No. 905,738 on "Method And Apparatus For Fabricating Fishing Lures Etc." filed by Welbourne D. McGahee on May 16, 1978 and is co-pending with U.S. patent application Ser. No. 59,951 on "Method And Apparatus For Fabricating Fishing Lures Etc." filed on July 23, 1979 by Welbourne D. McGahee. The novel concepts embodied herein embrace special techniques of injection molding and the mechanical assembly of molded products.
BACKGROUND OF THE INVENTION
The production of fishing lures has progressed from a relatively early state of the art where lure bodies were carved of wood and similar materials to the present technology which utilizes injection molding techniques. However, regardless of whether the lure body is a hand carved object or an injection molded piece, the hook hangers, hooks and leader connectors must be attached by a time consuming manual procedure. These procedures include riveting or screwing hook hanger devices onto lure bodies with the hook in position on the hanger or subsequently attached thereto with a split ring. Alternate methods of production are utilized where a screw eye is assembled to a hook eye and the screw eye is then manually threaded into the lure body. Similar techniques are used to affix the leader connecting mechanism at the front of the lure body and each apparatus which is affixed to the lure necessitates a number of manual manipulations.
Prior art fishing lures are dangerous to ship and store because of the danger presented by the hooks which are permanently installed during manufacture. This permanency of installation also contributes to the relatively short useful life of fishing lures which is a direct function of the deterioration of hook points. Because hooks cannot be interchanged quickly, the lures are usually discarded.
OBJECTIVES OF THE INVENTION
Therefore, it is a primary objective of the present invention to provide a method for assembling a lure in which the hangers and hooks may be affixed with a minimal amount of manual labor.
A further objective of the present invention is to provide a method of fabricating a lure which may be completely automated.
A still further objective of the present invention is to provide a die for injection molding which is adapted to position hook hangers so that they will become an integral part of the final molded object.
A further objective of the present invention is to provide a method and apparatus for forming a bore within a molded lure body that is dimensioned to cooperate with a spring hook hanger.
A still further objective of the present invention is to provide a method for manufacturing fishing lures which will reduce labor requirements and result in an inexpensive end product.
Another objective of the present invention is to provide a fishing lure in which final assembly of hooks is accomplished by the user immediately prior to use thus making it safer to ship and store.
A still further objective of the present invention is to provide a fishing lure which incorporates a means to permit easy and rapid hook exchange and thus greatly extend lure flexibility and life.
SUMMARY OF THE INVENTION
This invention presents a fishing lure and a method of assembling fishing lures which may be accomplished manually with a minimal amount of labor expended or alternately may be completely automated. It includes the steps of forming a lure body with integral cups and associated hook hangers, and affixing the hooks thereto by pressing them into the cups so that the spring hook hanger snaps into the hook eye. Alternate embodiments are disclosed which includes the concept of molding a one piece body in a split die incorporating recesses to secure the hook hangers so they will be properly positioned during the forming process.
The patent also presents methods for forming cups within lures which include the use of a removable cup forming male mold piece that may be used to hold a spring hook hanger in proper position and then removed from the lure body after the injection molding step is completed.
The foregoing and other objectives of the invention will become apparent in light of the drawings, specification and claims contained herein.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a typical fishing lure in the process of manual assembly.
FIG. 2 illustrates the two halves of a hollow lure adapted to utilize the assembly methods contained herein.
FIGS. 3A through 3D depict the sequence of placing a hook eye on the retainer.
FIGS. 4A through 4D depict the sequence of events required to remove a hook.
FIGS. 5A through 5D depict the sequence of events required to place an eyelet on the retainer when the retainer end is in close proximity to the bore bottom.
FIGS. 6 through 14 illustrate various embodiments of the present invention.
FIG. 15 is a cutaway view of a metal die adapted to mold a solid lure incorporating the improvements required to enable fabrication by the method disclosed herein.
FIG. 16 is a detailed view of a cup forming means used in an alternate method of injection molding a solid lure.
FIGS. 17 and 19 illustrates integral cups and spring hangers used in alternate embodiments of lure assembly.
FIG. 18 is a flow diagram depicting an automated lure assembly sequence.
DESCRIPTION OF THE INVENTION
Referring to the drawings, FIG. 1 illustrates the essence of the present invention, that is, assembling the hooks to a fishing lure by simply pressing them into the lure body and removing them by pressing them into the lure body and twisting.
In FIG. 1 the tail hook 6 has been connected to the hanger 8 by pressing it into the cup so that the free end 3 of the hanger snaps into the hook eye 7. The hook has not been fully drawn onto the hanger loop in this view. Hook 4 has been pressed into the lure body 1 and is being rotated 90 degrees so that it will disengage the spring hanger 5 so that it may be withdrawn free of the lure and hanger.
FIG. 1 illustrates a manual assembly and disassembly procedure but it should be realized that these simple mechanical assembly movements can readily be accomplished by a machine.
A hollow lure may be fabricated using the techniques disclosed herein by first molding two halves of a lure body similar to those illustrated in FIG. 2. The halves 21 and 22 incorporate a plurality of one-half cup shaped recesses 23 which form the bores for the hook hangers when final assembly is accomplished. Adjacent to each bore 23 in both lure body halves 21 and 22 are channels 24 adapted to receive one leg of the spring hook hangers 25.
Lure body half 22 includes a small bore 26 at the end of channel 24 which is adapted to receive the hook portion 27 of hanger 25 so that when the lure is assembled the hangers 25 will be held securely within the lure body and their free ends 28 will be suspended within the cups formed by depressions 23.
A channel 29 is provided in the front portion of each lure half 21 and 22 and the channel in half 22 incorporates a bore 33 which is adapted to receive a connector which may be provided with a simple eyelet 31 or it may be a more secure connector 32 such as illustrated in FIG. 1 and described in U.S. Pat. No. 3,869,821 on "Connector Combined With Fishing Float, Leader, Sinker Or Lure Apparatus" issued Mar. 11, 1975 to Welbourne D. McGahee.
An alternate embodiment of the present invention may be accomplished by providing a hook hanger configuration in place of the connector 31 or 32.
When assembling the hollow lure, the hangers 25 and connector 31 or 32 are properly positioned and the two halves are sealed together. Once the halves have been sealed together, hooks may be inserted by simply pressing them into the cups formed by cup halves 23 so that the end 28 of the hangers 25 will engage the hook eye.
FIGS. 3A, B, C and D illustrate the steps of connecting a hook eye to a preferred embodiment of the invention. In FIG. 3A the bore or cup 2 has a radius formed in the bottom dimensioned so that as the free end 3 of the spring retainer is forced toward the center of the bore it will not bind on the bottom. Thus when a hook eye 7 is placed between leg 3 and the wall of the bore as illustrated in FIG. 3A and pushed down as illustrated in FIG. 3B the spring arm 3 is deflected toward the center of the bore as the hook eye 7 approaches the bottom of the bore 2. When the wire forming the hook eye passes the end of spring retainer leg 3 as in FIG. 3C, the spring retainer snaps toward the wall of bore 2 and enters the hook eye. The hook 7 may then be drawn out of the bore 2 as in FIG. 3D with the spring retainer passing through the hook eye securing it to the body 1.
Any attempt to remove the hook from the connector by pushing the hook into the bore 2 and pulling it out will fail to disconnect the hook eye from the connector 4. For instance in FIG. 3C note that when the hook is in the extreme down position the end of retainer leg 3 is still through the eye of the hook and if the hook is depressed even further it is stopped by the bottom of the bore and forced toward the center causing the retainer arm 3 to enter further into the eye.
FIGS. 4A, B, C and D illustrate the steps of removing a hook from the retainer. In FIG. 4A the hook 7 is positioned so that the eye is moved down the free leg 3 of the retainer spring until it stops at the position shown in FIG. 4B, which is the same position as when the hook is installed in FIG. 3C. The eye is pressed against the wall of bore 2 and the end of spring retainer leg 3 is in the center of the eye. The hook eye is then twisted 90 degrees as illustrated in FIG. 4C. This causes one side of the hook eye to engage spring retainer arm 3 and create a fulcrum against which the hook eye may be rotated to snap it free from the end of the spring retainer leg 3. The hook eye becomes disengaged from the retainer as illustrated in FIG. 4C because the rotating motion of the hook eye deflects the end of the spring retainer arm 3 away from the wall of the bore 2, allowing the material of the hook eye to pass therebetween. Once the hook eye is free of the retainer it is removed by pulling it straight out of the bore 2 as illustrated in FIG. 4D.
FIGS. 5A, B, C and D illustrate an embodiment where the bore or cup 2 has a flat bottom and the spring retainer is positioned so that inward deflection by the hook eye closes the gap between the bottom of the cup and the end of the retainer leg 3. A hook 7 is inserted in this embodiment by sliding it down the wall of the bore as illustrated in FIG. 5A, twisting the hook past 90 degrees as illustrated in 5B and withdrawing the hook with the spring retainer arm through the eye as illustrated in FIG. 5C. The hook is removed by reversing the installation procedure, that is sliding the hook down the shaft of spring retainer arm 3 until it is in the position illustrated in FIG. 5C and rotating the shaft greater than 90 degrees and withdrawing it along the side of the spring arm 3 as illustrated in FIG. 5A.
Solid lures are produced by using a die similar to that illustrated in FIG. 15. The die incorporates grooves 41, 42 and 52 which are adapted to receive the arcuate portions of hangers 43 and 44 and the section of connector 31 or 32 which will extend outside of the completed lure body. The embedded ends 53 of the hangers 43 and 44 and connector 31 or 32 are bent 90 degrees as illustrated in FIG. 16 so they will not pull out under stress. This bent section 53 cannot be seen in FIG. 15 due to the viewing angle.
The die halves also include channels 45 which are adapted to receive a shoulder portion of male mold inserts 46 which are placed over the free ends of the hangers to form a cup thereabout during the molding process.
The male mold sections 46 are more clearly illustrated in FIG. 16 which shows a slit 47 in the side of the male mold which will permit the mold to be drawn off of the hanger after the lure body has been molded.
In FIG. 15 two mold halves have been brought together with the hangers and male molds in place ready for injection molding.
The male molds 46 may be dispensed with in solid body molds by using a pre-assembled hanger comprised of a hollow cup 61 with a spring hanger member 62 welded to the outside as illustrated in FIG. 17. In this embodiment the hanger is completely self contained and no further manipulations are required after the mold halves are removed from the lure body and before hooks are inserted. However, the die must be dimensioned so that the channels 41 and 42 will hold the hangers 62 so that they will hold the open end of the cups 61 firmly against the inner surface of the mold cavity to prevent mold material from entering.
In the alternate embodiment illustrated in FIG. 19, the pre-assembled hanger is comprised of a preformed cup 63 which has a continuous channel 64 along one side and the bottom dimensioned to receive the section 65 of spring hanger 66 which will be immobile after final assembly. A resilient ring 67 is positioned about the preformed cup 63 and spring hanger 66 as illustrated to hold the two pieces together during the molding process. The ring 67 may be fabricated from a plastic or metallic material. In a preferred embodiment, section 65 of spring hanger 66 is bent to form an angle smaller than the angle of the channel 64 at the transition from side to bottom. This is provided so that the spring hanger 66 will urge the preformed cup 63 against the mold cavity wall to keep molding material from entering the cup.
Fishing lures may be assembled as previously described using a variety of hanger shapes similar to those illustrated in FIGS. 5 through 14.
FIG. 6 illustrates a hanger having relatively straight restraining and free legs 10. This retainer configuration, as well as the other retainer configurations illustrated and discussed herein may be incorporated with dome shaped cup or bores, or flat bottom cups or bores which are closely spaced to the retainer and/or spaced at a relatively great distance therefrom.
FIG. 7 illustrates a spring retainer having a leg 20 wherein the end portion is bent at an angle of approximately 45 degrees away from the constrained leg.
The spring retainer illustrated in FIG. 8 utilizes a leg 30 having a modified "S" form.
FIG. 9 illustrates the use of a cup 41 which has an under cut portion 42 adapted to receive the end of spring retainer leg 40. The spring retainer is shown with a hook portion formed in the free end but it is to be understood that retainers having configurations similar to 10, 20 and 30 illustrated in FIGS. 6, 7 and 8 respectively may also be used with an under cut portion.
FIG. 10 discloses a spring retainer configured so that leg 50 curves back toward the secured leg and stops essentially against the wall of the bore adjacent to the secured leg. When hooks having this configuration or the configuration illustrated in FIGS. 11 or 12, the method of inserting a hook eye 7 is to slide the eye 7 down the wall of the bore between the secured and free legs.
FIG. 11 illustrates a retainer wherein the free end 60 is bent at an angle of between 20 and 90 degrees toward the fixed leg.
FIG. 12 illustrates a retainer configuration similar to that disclosed in FIGS. 10 and 11 adapted to cooperate with an under cut portion 72. In this configuration, the bore or cup 71 is configured with an under cut portion 72 adapted to receive the end of the spring retainer 70.
The retaining rod 90 illustrated in FIG. 13 is relatively rigid and the cup 91 is provided with an under cut portion 92 and 93. One end of the rod 90 is secured in the under cut portion 92 by a hinge pin 94. The rod is dimensioned so that the other end will swing within the under cut portion 93 but will be prevented from exiting the surface of the body. A hook 7 is secured in this retainer by forcing the hook 7 into the bore so that the rigid arm swings toward the bottom of the bore. The bore must be held in a straight down position so that gravity will cause the rigid arm to drop through the hook eye 7 as one edge of the eye passes thereby. The hook is removed in this embodiment by rotating the hook eye 7 90 degrees when held in the bottom of the bore.
FIG. 14 discloses another use of a straight retainer rod 80. This rod is resilient and adapted to cross and descend the bore so that a hook eye 7 will cause the end to be deflected downward as it is pushed into the bore. As the eye 7 passes the free end of retainer 80, retainer 80 will snap into the eye opening of eye 7.
The sequence of the assembly method utilizing hook hangers similar to those disclosed in the co-pending patent application Ser. No. 760,920 on "Loop Retainer" filed by Welbourne D. McGahee on Jan. 21, 1977 and the devices previously discussed herein require steps similar to the flow diagram illustrated in FIG. 18. In this flow diagram note that two different processes are used to produce solid and hollow lure bodies but both processes merge in the common step 89 of pressing hooks into hangers.
Considering each process in detail, note the first step 81 of producing a solid lure requires placing the hangers in a mold half adapted to receive them. The next step, 82 is to close the mold after which step 83 is performed wherein a suitable plastic is injected into the mold cavity. Once the injection molded lure body has been suitably cured, it is removed in step 84 from the mold halves. After removable, the lure body complete with hangers is processed in step 89 where hooks are pressed into the hangers. In some instances step 89 will be done by the fisherman when lures are shipped with the hooks off.
In fabricating a hollow lure body the first step 85 is to mold two body halves. When the body halves have cured, they are removed from the molds in step 86 and hangers are placed in the hanger reception channels in step 87. After the hangers have been placed in the molded half, the other molded half is brought into position and the two halves are sealed together in step 88. After the halves have been assembled into a hollow lure body, hooks are pressed into the hanger cups in step 89.
The preceeding steps can be accomplished manually or they may be accomplished by an automated machine utilizing well known automated assembly procedures.
Although the preferred embodiments of this invention have been illustrated and described, variations and modifications may be apparent to those skilled in the art. Therefore, I do not wish to be limited thereto and ask that the scope and breadth of this invention be determined from the claims which follow rather than the above description.
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A method and apparatus for producing fishing lures incorporating hook hangers which utilize a bore formed in the lure body as part of the connection mechanism. Injection molding techniques are utilized to fill cavity molds having removable inserts therein.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a Continuation-in-Part of Application Ser. No. 408,809 filed Oct. 23, 1973 entitled: "METHOD AND APPARATUS FOR COMPRESSOR SURGE CONTROL", and the subject matter of that application is hereby wholly incorporated by reference in the present application.
BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to a velocity probe for measuring the velocity of a fluid stream, and particularly for measuring the change in flow patterns of a fluid stream. Prior art devices have had several problems associated therewith. Many prior art devices in the general field of the invention, such as that shown in U.S. Pat. No. 3,759,098, require at least two sets of orifices within members disposed within a flow stream, or within the flow stream confining member itself. This may require extra expense and the necessity of forming a plurality of orifices (which should be sealed) within structural members, affecting the transferability of a measuring device from one system to another. Also, many prior art devices, U.S. Pat. No. 1,834,392 for example, have a tendency to clog up when placed in the flow stream if the fluid has impurities and contaminants therein.
According to the teachings of the present invention, the above problems are avoided. A velocity probe is provided that has only a single connection to a chamber confining a fluid stream to be sensed. The probe has an opening in a sensing portion thereof that is orientated in a particular manner so that the probe opening will not clog up during normal use in a contaminated fluid stream, yet will effectively sense the velocity of the stream.
The velocity probe of the present invention is especially useful in sensing the flow reversal occurring in the boundary layer of material flowing through a compressor and thereby controlling impending surge conditions in a compressor, as more fully described in the abovementioned parent application Ser. No. 408,809. The probe of the present invention is adapted to be inserted into the boundary layer of material flowing through a compressor, and will not clog up as a result of the contaminated flow often associated with a compressor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view of a probe according to the present invention with the probe arranged to sense the fluid flow velocity of the boundary fluid layer in the outlet or discharge chamber of a compressor.
FIG. 2 is a schematic view of the probe shown in FIG. 1 with the fluid to be sensed flowing in the normal flow direction; and
FIG. 3 is a schematic view of the probe shown in FIGS. 1 and 2 with the probe sensing a reversal of boundary layer fluid flow from the direction shown in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
A velocity probe, shown generally at 10, for sensing the fluid flow in a chamber, shown generally at 12, is depicted in FIG. 1. The probe consists of a supply conduit 15 for supplying fluid at a constant pressure to a pair of plenum chambers, 20 and 22. The plenum chambers function as transient energy storage means to remove pulsations from the flow of fluid to an indicating means, such as the differential gauge shown generally at 30. Since separate plenum chambers are provided for the supply conduit 15 and for the conduit 40 connected to the flow to be sensed in chamber 12, it follows that pulsations from either source are effectively damped by the plenum chambers.
A plate 25 having an orifice 27 therein is disposed between the plenum chambers 20 and 22. The orifice 27 restricts the flow of fluid from one chamber to the other and is so dimensioned that substantial pressure drop occurs thereacross and so that the drop is linear with respect to the sensed flow velocity in the flow range of interest. The flow A of fluid from the supply conduit 15 takes a path through chamber 20, through orifice 27, to chamber 22, through probe sensing portion 40, and out through probe opening 42. The quantity of flow A is determined by the pressure of the fluid supplied through conduit 15 and the size of orifice 27.
The probe sensing portion 40 is at least partially inserted within the chamber 12 to sense both the direction and magnitude -- which is proportional to the pressure, the pressure of the flow A being known -- of the flow within chamber 12. The sensing portion 40 is relatively thin so as not to affect the flow in the chamber in which it is injected. In the case where the probe 10 is used to sense flow reversal in a boundary layer of material flowing through a compressor, it is located adjacent the wall of chamber 12, near the compressor outlet as shown in the drawings. The probe opening 42 is orientated with respect to the chamber 12 and the sensing portion 40 so that fluid passing from the interior of sensing portion 40 through opening 42 has the same direction as the normally expected direction of the normal fluid flow B within the chamber 12; that is the opening 42 is protected from any fluid flow contaminants within the chamber 12 by the back surface of the sensing portion 40 within the chamber 12. Even when the flow is quite contaminated, it only impinges on opening 42 for a slight period of time during normal operation of the device so no clogging of the opening 42 will normally result. However, even if slight clogging thereof should result, the normal flow A of fluid after the reversal in chamber 12 has been sensed will usually result in automatic purging of the contaminants from the opening 42 and conduit 40.
The probe opening 42 -- and the conduits 15 and 40 -- are made slightly larger than the orifice 27 so that flow restriction will occur only at orifice 27. The opening 42 may be only slightly larger than the orifice 27, however, otherwise the pressure gauge 30 will indicate an impractically large pressure difference in the static condition of the device (FIG. 1).
The probe 10 is shown sensing a static air condition in chamber 12 in FIG. 1. In this case, the steady state pressure in chambers 20 and 22 is substantially equalized, therefore the heights of the liquid in legs 32 and 34 of differential gauge 30 are substantially the same. A normal flow condition in chamber 12 is shown in FIG. 2. Here the flow B in chamber 12 is in the same direction as the fluid coming from the opening 42 in sensing portion 40 as a result of the constant pressure A. The flow B causes the flow of fluid through the opening 42 to be much more rapid than it is under static conditions within chamber 12, thus fluid from flow A cannot bleed fast enough through orifice 27 to make up for the loss, and a pressure differential between the chambers 20 and 22 results. The pressure in chamber 20 will be greater than the pressure in chamber 22 by an amount proportional to the velocity of the flow B in chamber 12. The legs 32 and 34 of the differential gauge 30 may be calibrated to indicate the magnitude of the difference.
An abnormal flow direction C is shown in FIG. 3. The flow C is a result of a reversal of the normal flow direction B in chamber 12 (such as ensues in the boundary layer flow impending surge in a compressor), and this flow reversal is sensed by the probe 10 as shown in FIG. 3. In this case, the flow C will impinge directly on the surface of the sensing portion 40 having opening 42 therein, resulting in some fluid flow entering opening 42, and consequently increasing the pressure within the chamber 22 over that in the chamber 20. This pressure differential is sensed by the differential gauge 30 as the liquid within legs 32, 34 moves to the position indicated in FIG. 3. Again the legs 32 and 34 may be calibrated to indicate the magnitude of the pressure difference.
In the method of operation of the exemplary velocity probe illustrated, a reference flow A under constant pressure is established in conduit 15, damped in plenum chamber 20, and then restricted by orifice 27 in divider 25. During normal conditions, it then is expanded in plenum chamber 22, and passes through conduit 40 and opening 42 along a path whereby it is directed in the same direction as the normal flow direction B in chamber 12. The indicating means 30 senses the pressure differential on either side of flow restricting means 25, 27. When flow reversal to direction C occurs in chamber 12, part of reversed flow C passes through opening 42 against the pressure of the reference flow A (or causes the "backing up" of fluid flow A through opening 42), oscillations in the back-flow being damped by the plenum chamber 22.
Pressure differential on either side of restricting means 25, 27 is again sensed by indicating means 30. As shown in FIG. 1, the indicating means 30 may also be operatively connected to a control for a compressor connected to the chamber 12. Such a means may take the form of a simple light source and photoelectric cell, indicated generally at 50, which controls an electrically controlled valve 52 in response to the level of liquid in pressure gauge 30. The valve 52 when operated then allows a small portion of boundary layer fluid at the outlet of the compressor to bleed through lines 54 and 56 back to the compressor inlet 57 to delay the onset of surge (as more fully explained in copending parent application No. 408,809). Of course other suitable sensing means could be used, or alternatively, after visually reading the indicating means 30 an operator could appropriately act on the compressor connected to chamber 12.
It will thus be seen that a velocity probe, and velocity sensing method, have been provided that include means for damping out any pulsations in a flow to be sensed and/or in a reference flow, a probe that provides a reference flow, a probe that will not be impaired or fail to function even when sensing a contaminated flow, a probe that is substantially self correcting even if contaminated by brief exposure to a contaminated reverse flow, and one that is capable of sensing both the direction and magnitude of a fluid flow while not substantially affecting the flow it senses. Although the invention has been disclosed in what is presently conceived to be the most practical and preferred embodiment, it will be obvious to one of ordinary skill in the art that many modifications of the velocity probe and method of the invention may be made within the scope of the invention, which scope is not to be limited except by the appended claims.
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A method and apparatus for sensing the velocity of a fluid flow, especially within the boundary layer of a fluid flow path through a compressor. A reference flow under constant pressure is established through an orifice dividing two plenum chambers, and directed through a flow sensing opening in a probe positioned in the flow to be sensed. The flow sensing opening is slightly larger than the orifice. A relative pressure indicator connected to the two plenum chambers indicates the velocity of the sensed fluid flow. The flow sensing opening is arranged so that the normal reference flow of fluid therethrough is in the same direction as the normally expected flow direction of the flow to be sensed.
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BACKGROUND
[0001] A chloralkali process is a process that produces chlorine or a related oxidizer and an alkaline salt such as sodium hydroxide (“NaOH,” also known as lye and caustic). Chlorine and NaOH are among the most produced chemicals in the world and are used in the manufacturing of a wide range of materials and products.
[0002] An exemplary chloralkali process is illustrated in FIG. 1 . The figure illustrates a typical brine electrolysis process 100 known to those skilled in the art using an electrolyzer. The electrolyzer of the illustrated typical brine electrolysis process 100 is a membrane cell 101 . The membrane cell 101 includes an anode compartment 102 , which contains an anode 103 and a cathode compartment 104 , which contains a cathode 105 . The anode and cathode compartments 102 , 104 are separated from each other by a membrane 106 . By way of example, the membrane 106 separating the anode and cathode compartments may be an ion exchange membrane. The membrane 106 separating the anode and cathode compartments may be operable to allow sodium ions and water to pass therethrough while preventing unreacted sodium chloride (NaCl) from entering the cathode compartment 104 . A direct current 107 may be passed through the anode 103 and cathode 105 . A stream 111 of saturated brine may be fed into the anode compartment 102 where chlorine from the NaCl is liberated at the positively charged anode 103 . A portion of the chlorine, in the form of a gas, may be collected 112 from the anode compartment 102 . Positively charged sodium ions from the NaCl migrate through the membrane 106 separating the anode and cathode compartments into the cathode compartment 105 .
[0003] In the cathode compartment 104 , hydrogen gas evolves from water molecules at the negatively charged cathode 105 . The hydrogen gas may be collected 108 from the cathode compartment 104 . The evolution of hydrogen from water also produces hydroxyl ions that react with the sodium ions to form NaOH. A portion of the NaOH is withdrawn 110 from the cathode compartment 104 . Water may be added 109 to, and the NaOH may be withdrawn 110 from, the cathode compartment 104 to maintain desirable levels of NaOH in the cathode compartment 104 . Accordingly, the overall reaction for the described chloralkali process is:
[0000] 2NaCl+2H 2 O→Cl 2 +H 2 +2NaOH
[0004] A depleted brine (e.g., brine no longer saturated with NaCl) stream 113 may be removed from the anode compartment 102 . The depleted brine may be processed through brine processing 114 that prepares a saturated brine stream 111 to be fed into the anode compartment. Accordingly, a brine loop 115 comprises brine processing 114 to produce a saturated brine stream 111 , feeding the saturated brine stream 111 into the anode compartment 102 , the anode compartment 102 , and removing depleted brine from the anode compartment 102 via a depleted brine stream 113 which is then fed back into the brine processing 114 .
[0005] FIG. 2 illustrates a typical prior art brine loop 115 used in brine electrolysis. Hydrochloric acid (HCl) is added 201 to the depleted brine stream 113 removed from the anode compartment 102 to adjust the pH levels (e.g., increase acidity) of the depleted brine stream 113 . This reduces the solubility of chlorine gas within the stream. The depleted brine stream 113 may then be subjected to vacuum dechlorination 202 where chlorine gas is drawn 203 from the depleted brine stream 113 . A vacuum dechlorinated depleted brine stream 204 may be fed from vacuum dechlorination 202 and into chemical dechlorination 206 . NaOH may be added 205 to the vacuum dechlorinated depleted brine stream 204 to adjust the pH upward (e.g., to make the depleted brine stream neutral or slightly alkaline). The NaOH may also help to stop gaseous chlorine from evolving from the dechlorinated depleted brine stream 204 . The chemical dechlorination 206 may be achieved in a variety of ways known to those skilled in the art (e.g., by adding reducing agents such as sodium bisulfite (NaHSO 3 ) and/or sodium sulfite (Na 2 SO 3 )).
[0006] After chemical dechlorination 206 , the dechlorinated stream may be fed into a saturation step 207 where NaCl 208 may be added to create a saturated brine stream and water 209 may be added to replenish the volume of the stream and adjust the concentration of NaCl. Typically the NaCl 208 may include varying amounts of impurities that must be removed in order to run the membrane cell 101 at a high current efficiency. Major impurities typically include calcium, magnesium and sulfates. To remove these major impurities, the saturated brine stream may be passed through a precipitation process 210 . This is typically a reactor or reactors where sodium carbonate (Na 2 CO 3 ) and NaOH are added 211 to precipitate calcium carbonate (CaCO 3 ) and magnesium hydroxide (Mg(OH) 2 ). Depending on the particular impurities present, other reactions may be promoted.
[0007] The outflow of the precipitation process 210 may contain suspended solids from the precipitation process 210 and therefore is typically passed through a separation process 213 . The separation process 213 may include the use of one or more gravity settlers, and/or one or more media filters including pre-coat and non pre-coat filters. The separation process may, for example, remove 212 precipitated CaCO 3 and Mg(OH) 2 . The saturated brine stream may next be exposed to an optional activated carbon bed 214 to further remove any residual oxidizing materials. The saturated brine stream exiting the activated carbon bed 214 , or the brine stream exiting the separation process 213 if an activated carbon bed 214 is not present, may still contain unacceptable levels of impurities. To further remove these impurities (e.g., calcium, magnesium, iron), the saturated brine stream may next be passed through an ion exchange process 215 that may include passing the saturated brine stream through a column containing an ion exchange resin. After the ion exchange process 215 , the saturated brine stream 111 may be fed into the anode compartment 102 to complete the brine loop 115 .
[0008] Known variations exist with respect to the above-described exemplary processes. For example, by altering process chemistry and temperature, the membrane cell 101 can be used to produce chlorate. It is also known by those skilled in the art that various steps as shown in the brine loop 115 may be added, altered or removed based on, inter alia, the quality of materials used in the process or manufacturing considerations. For example, in a particular brine loop, the activated carbon bed 214 may not be present, particularly if the levels of oxidizing materials in the brine stream after separation 213 are below a certain level. Furthermore, chloralkali processing may be achieved using, for example, mercury cells or diaphragm cells in place of the described membrane cells.
SUMMARY
[0009] The present inventors have recognized that the above brine processing may benefit from the replacement or enhancement of known separation processing with filtration. Filtration, as compared to known separation processing, may reduce system complexity, reduce system operating costs, and/or increase the quality of the saturated brine being delivered to the electrolyzer. The present inventors have also recognized that the above processes may contain contaminants, particularly organics introduced with the NaCl and/or process water. These organics may often include biological organics that may be characteristic of the NaCl source. Such biological contaminants may, for example, include humic acid and/or residue from algae in seawater. The organics may build up on and/or reduce the efficiency of filters used in a chloralkali process. Maintenance of filters, such as replacing the filters when they lose efficiency or cleaning the filters using known cleaning methods, such as the use of dedicated cleaning solutions, may be costly and time consuming and counterbalance the aforementioned benefits of the use of filtration.
[0010] In view of the foregoing, an object of embodiments described herein is to provide improved methods and apparatuses to clean filters used in chloralkali processes, thereby, for example, reducing the maintenance and operating costs associated with filtration while maintaining the benefits associated with filtration. In certain chloralkali processing plants, filtration may have previously been considered not to be economically feasible due to contamination levels and the associated costs of filtration (e.g., replacement costs and/or cleaning costs) due to those contamination levels. However, the reduced equipment, maintenance and operating costs associated with embodiments of filter washing methods and systems described herein may facilitate the use of filtration where contamination levels previously discouraged such use.
[0011] Another objective of embodiments described herein may be to provide a cleaning solution for cleaning filters used in chloralkali processes, thereby eliminating and/or reducing the need for separate chemicals and/or materials to clean the filters. Embodiments described herein may provide methods of washing filters in situ with cleaning solution from the chloralkali process and returning the cleaning solution to the chloralkali process after the filters are washed. Such embodiments provide filter washing systems that have low equipment and material requirements. Embodiments described herein may provide filter washing systems for chloralkali processes yielding reduced chemical and operating costs, improved in-process brine stream quality, and reduced equipment down time.
[0012] In an aspect, a method of brine electrolysis is provided. The method may include providing a brine feed and treating the brine feed to form a treated brine solution. The treating may include mixing the brine feed with reactants to precipitate solids. The method may further include filtering the treated brine solution with a filter material to form a brine filtrate and purifying the brine filtrate to form a purified brine. The purifying may include removing cations from the brine filtrate through an ion exchange process. The filter material may be a non-precoated filter material. The filter material may be a membrane filter and may comprise expanded polytetrafluoroethylene (ePTFE). The method may further include providing an electrolytic cell. The electrolytic cell may include a cathode disposed in a cathode compartment and an anode disposed in an anode compartment. A membrane (e.g., an ion exchange membrane) may separate the anode and cathode compartments from each other. The method may further include feeding the purified brine into the anode compartment. Within the anode compartment, chlorine may be liberated from the purified brine at the anode, and sodium ion and water may migrate from the anode compartment through the membrane separating the anode and cathode compartments to the cathode compartment. This egress of sodium ion and chlorine from the anode compartment may result in the formation of depleted brine within the anode compartment. The method may further include removing the depleted brine from the anode compartment, adding an acid (e.g., HCl) to the depleted brine removed from the anode compartment, and separating, after the adding an acid step, the depleted brine into a feed solution and a remaining portion. The feed solution may then be subjected to vacuum dechlorination and chemical dechlorination. The method may further include adding NaCl to the feed solution and adjusting the concentration of NaCl by adding water to form the brine feed. The method may further include contacting the filter material with the remaining portion. The contacting of the filter material with the remaining portion may remove material from the filter material. The removed material may include organic material and/or mineral scaling.
[0013] In another aspect, an improved method of brine electrolysis is provided. The method comprises a brine solution saturation step, a treatment step, a filtration step, an ion exchange step, an electrolysis step, and at least one dechlorination step. A first output of the at least one dechlorination step may be an input to the brine solution saturation step. The improvement of the method may comprise providing a second output from the at least one dechlorination step and contacting a filter of the filtration step with at least a portion of the second output. The contacting of the filter with the at least a portion of the second output may remove materials (e.g., organic materials and/or mineral scale) from the filter. The filter may be a membrane filter.
[0014] In an embodiment, the at least one dechlorination step may comprise a first vacuum dechlorination step and a second chemical dechlorination step. The second output may be disposed after the first vacuum dechlorination and before the second chemical dechlorination step. The second output may contain between about 0.01 parts per million (ppm) and about 200 ppm of active chlorine.
[0015] In an arrangement, the contacting step may include soaking the filter with the at least a portion of the second output. The contacting step may include circulating the at least a portion of the second output through the filter under pressure. The contacting step may include a combination of soaking and circulating.
[0016] In still another aspect, a method of electrolysis of filtered brine is provided. The method may comprise providing a brine feed solution, filtering the brine feed solution with a filter material to form a brine filtrate, and providing an electrolytic cell. The electrolytic cell may have a cathode disposed in a cathode compartment and an anode disposed in an anode compartment. A membrane may separate the cathode compartment from the anode compartment. The method may further comprise feeding the brine filtrate into the anode compartment. The brine filtrate may undergo electrolysis in the electrolytic cell, forming depleted brine in the anode compartment. The method may further comprise removing the depleted brine from the anode compartment and contacting the filter material with the depleted brine solution after the removing step. The contacting of the filter material with the depleted brine solution may remove at least some material (e.g., organic material and/or mineral scale) from the filter material. The filter material may include one or more filter membranes.
[0017] In yet another aspect, a method of washing a filter used in a chloralkali process is provided. The method may comprise isolating the filter from the chloralkali process, removing a portion of a flow of brine from within the chloralkali process, contacting the portion of flow to the isolated filter, and returning the filter to the chloralkali process after the contacting step. The removal of the portion of the flow of brine may be from a point in the chloralkali process between an output of a membrane cell and an input of a chemical dechlorination apparatus. The contacting of the portion of flow to the isolated filter may wash the filter.
[0018] The washing of the filter may result in the removal of organic materials and/or mineral scaling from the isolated filter. Regarding organic materials, the contacting step may comprise changing the organic material from a first state to a second state, wherein the organic material in the second state has a reduced affinity toward the filter relative to the organic material in the first state. By way of example, organic material in the second state may be less likely to be collected at the filter relative to organic material in the first state. Regarding mineral scaling, the portion of the flow may be acidic and the contacting step may comprise removing mineral scaling from the filter.
[0019] In an embodiment, the method may further comprise returning the portion of the flow to the chloralkali process after the contacting step. The portion of the flow may be returned to the chloralkali process between the output of the membrane cell and the input of the chemical dechlorination apparatus.
[0020] In an arrangement, the isolating step and the returning the filter step may comprise actuating one or more valves. In this regard, the filter may remain in situ during the performance of the method obviating the need to move the filter for cleaning.
[0021] The removed portion of the flow may comprise between about 0.01 ppm and about 250 ppm of active chlorine. In an embodiment, the portion of the flow may be removed from between the output of the membrane cell and an input of a vacuum dechlorination apparatus. In another embodiment, the portion of the flow may be removed from between an output of the vacuum dechlorination apparatus and an input of a chemical dechlorination apparatus. The portion of the flow may be returned to a point in the chloralkali process between an output of a vacuum dechlorination apparatus and an input of a chemical dechlorination apparatus.
[0022] The chloralkali process may include a plurality of filters. The current method may comprise performing the isolating, removing, contacting, returning the filter, and returning the portion of the flow steps for each of the plurality of filters. The method may be performed for each of the plurality of filters in succession. While the method is being performed on a particular one of the plurality of filters, the other filters of the plurality of filters may continue to filter the portion of the flow of brine that remained within the chloralkali process.
[0023] In still another aspect, an apparatus for washing a filter used in a brine loop of a chloralkali process is provided. The apparatus may comprise a wash tank, a first fluid interconnection, a second fluid interconnection, and a third fluid interconnection. The wash tank may be operable to hold a predeterminable volume of liquid. The first fluid interconnection may fluidly connect the wash tank and a portion of the brine loop between an output of a membrane cell and an input of a chemical dechlorination apparatus. The second fluid interconnection may be between the wash tank and an upstream side of the filter. The third fluid interconnection may interconnect the wash tank and a downstream side of the filter. The apparatus may be operable to cause fluid to flow from the wash tank, then through the filter, and then back to the wash tank.
[0024] In an embodiment, the filter may be a non-precoated filter and/or a membrane filter. The filter may comprise a fluoropolymer membrane. The fluoropolymer may, for example, comprise polytetrafluoroethylene (PTFE), ePTFE, and/or polyvinylidene difluoride (PVDF).
[0025] In an arrangement, the apparatus may further comprise a fourth fluid interconnection between the wash tank and a portion of the brine loop between an output of a vacuum dechlorination apparatus and an input of a chemical dechlorination apparatus. Furthermore, the first fluid interconnection may fluidly interconnect the wash tank and a portion of the brine loop between an output of the membrane cell and an input of a vacuum dechlorination apparatus. In the present arrangement, fluid may be operable to flow through the first fluid interconnection into the wash tank and through the fourth fluid interconnection from the wash tank. In this regard, in the current arrangement the apparatus may be operable to draw fluid into the wash tank, via the first fluid interconnection, from a point in the chloralkali process between the output of the membrane cell and the input of a vacuum dechlorination apparatus. Further in this regard, the apparatus may be operable to return fluid, via the fourth fluid interconnection, from the wash tank to a point in the chloralkali process between the output of the vacuum dechlorination apparatus and the input of the chemical dechlorination apparatus.
[0026] In an embodiment, the first fluid interconnection may be between the wash tank and a portion of the brine loop between an output of a vacuum dechlorination apparatus and an input of a chemical dechlorination apparatus. In such an embodiment, the apparatus for washing a filter may further comprise a fourth fluid interconnection between the wash tank and the portion of the brine loop between the output of the vacuum dechlorination apparatus and the input of the chemical dechlorination apparatus. In the instant embodiment, fluid may be operable to flow through the first fluid interconnection into the wash tank and through the fourth fluid interconnection from the wash tank. In this regard, the apparatus may be operable to draw fluid into the wash tank, via the first fluid interconnection, from a point in the chloralkali process between the output of the vacuum dechlorination apparatus and the input of the chemical dechlorination apparatus. Further in this regard, the apparatus may be operable to return fluid, via the fourth fluid interconnection, from the wash tank to a point in the chloralkali process between the output of the vacuum dechlorination apparatus and the input of the chemical dechlorination apparatus.
[0027] The apparatus may comprise a pump operable to selectively pump fluid from the wash tank through the second fluid interconnection, through the fourth fluid interconnection, or through a combination of the second and fourth fluid interconnections. In this regard, fluid pumped through the second fluid interconnection may contact the upstream side of the filter.
[0028] In an embodiment where the first fluid interconnection is between the wash tank and a portion of the brine loop between an output of a vacuum dechlorination apparatus and an input of a chemical dechlorination apparatus, the apparatus may be operable to selectively flow fluid through the first fluid interconnection into the wash tank or through the first fluid interconnection from the wash tank. In this regard, the first fluid interconnection may be used to selectively fill or empty the wash tank.
[0029] In an arrangement, the apparatus may further comprise at least one fluid pump operable to pump fluid from the wash tank through the second fluid interconnection and through the filter. In an arrangement, the filter may be disposed downstream from a precipitation apparatus and upstream from an ion exchange apparatus.
[0030] In an embodiment, the apparatus for washing a filter may be operable to cause fluid to flow from the wash tank, then through the second fluid interconnection, then through the filter, then through the third fluid interconnection, and then back to the wash tank. Valving may be included that is operable to fluidly isolate the filter from the brine loop of the chloralkali process. Valving may also be included that is operable to fluidly isolate the apparatus for washing a filter from the brine loop.
[0031] In a configuration the brine loop may comprise a plurality of filters. The plurality of filters may be divided into a plurality of sub-groups. In such a configuration, the apparatus for washing a filter may further comprise valving operable to fluidly isolate, in succession, each of the sub-groups from the brine loop of the chloralkali process. Each of the sub-groups may comprise one and only one of the plurality of filters. Alternatively, some of the sub-groups may include a single filter and some of the sub-groups may contain multiple filters. Alternatively, each of the sub-groups may include more than one of the plurality of filters.
[0032] The various methods discussed above may be performed manually, automatically, or through a combination thereof. Moreover, the initiation of the performance of any of the methods may be achieved in an automated fashion, manually, or through a combination of automated and manual actions. Similarly, the apparatuses discussed above may be operable to function automatically and/or manually.
[0033] The various features, arrangements and embodiments discussed above in relation to each aforementioned aspect may be utilized by any of the aforementioned aspects. Additional aspects and corresponding advantages will be apparent to those skilled in the art upon consideration of the further description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is block diagram of a prior art chloralkali process flow.
[0035] FIG. 2 is block diagram of a brine loop of the prior art chloralkali process flow of FIG. 1 .
[0036] FIG. 3 is a block diagram of an embodiment of an improved brine loop of a chloralkali process flow.
[0037] FIG. 4 is a block diagram of an apparatus for washing a filter used in a brine loop of a chloralkali process.
DETAILED DESCRIPTION
[0038] FIGS. 1 and 2 represent exemplary membrane cells 101 and brine loops 115 known to those skilled in the art of brine electrolysis and/or chloralkali processing. Variation to these processes and apparatuses are also known to those skilled in the art. Turning to the separation step 213 of the brine loop 115 of FIG. 2 , known separation systems typically incorporate gravity settlers and media filters operable to remove a portion of the suspended solids that remain in the brine after the preceding precipitation 210 step.
[0039] FIG. 3 is a block diagram of an embodiment of an improved brine loop 300 of a chloralkali process flow. In the improved brine loop 300 , the separation step 213 , has been replaced with a filtration step 308 . Alternatively, the separation step 213 (or portions thereof) may be retained and the filtration step 308 may be positioned downstream of the separation step 213 (or retained portion thereof). The filtration step 308 may incorporate one or more filters. The filters may be operable to filter out suspended solids, for instance CaCO 3 and Mg(OH) 2 , that remain in the brine stream after the precipitation process 210 . The filtration step 308 may incorporate known back-pulse filtration techniques to occasionally remove 312 accumulated particles (e.g., accumulated CaCO 3 and Mg(OH) 2 particles) from the filters. The filters may also be operable to filter organic contaminants from the brine stream. In this regard, organic contaminants may accumulate on the filters and at least a portion of the accumulated organics may not be removed by typical back-pulse filtration methods. Some mineral scaling may also accumulate on the filters. The mineral scaling may also be resistant to removal using typical back-pulse filtration methods. The organic contaminants may, for example, be introduced with the NaCl 208 and process water 209 introduced during the saturation step 207 . These organic contaminants may negatively affect the performance of the anode compartment 102 and/or other processing equipment in the brine loop 300 . Accordingly, it may be beneficial to filter out these organics at the filtration step 308 .
[0040] As organics are filtered from the brine stream by the filters, the performance of the filters may degrade as materials (e.g., filtered organics, mineral scaling) build up on the filters. In this regard, the filters may need to be replaced or the materials that have built up on the filters may need to be removed at regular intervals. Typically, filter replacement is expensive. Filter washing may be a less expensive alternative to replacement, but typically would require special filter washing equipment along with dedicated filter washing chemicals.
[0041] The brine loop 300 of FIG. 3 illustrates an efficient alternative to filter replacement and/or special filter washing equipment using dedicated filter washing chemicals. In the brine loop 300 , fluid is taken from the brine stream via connection 301 from a point in the brine loop 300 after vacuum dechlorination 202 and prior to the addition of NaOH 205 . Such fluid taken from the brine stream will subsequently be referred to as cleaning solution.
[0042] The cleaning solution typically has a low pH value (e.g., is acidic) and may contain 20 - 30 parts per million (ppm) of active chlorine. This cleaning solution may be diverted to a wash tank 302 . Water or other substances may be added to the cleaning solution to enhance the washing process. From the wash tank 302 , the cleaning solution may be pumped by a pump 303 and run through one or more of the filters. The cleaning solution may be allowed to remain in contact with the one or more filters such that the one or more filters soak in the cleaning solution for a certain amount of time or the cleaning solution may be continuously pumped through the one or more filters for a certain amount of time. A combination of soak time and pumping may also be utilized. After running through the one or more filters, the cleaning solution may return to the wash tank 302 via fluid interconnection 305 . It may then be recirculated through the one or more filters an appropriate number of times. The composition of the cleaning solution may be operable to change the organic contaminants that may have built up on the one or more filters from a first state to a second state, where the organic contaminants in the second state have a reduced affinity toward the one or more filters. Accordingly, the organic contaminants in the second state may pass through the one or more filters. One exemplary mechanism by which this may occur is where the cleaning solution breaks down (e.g., oxidizes) long chain molecules of the organic contaminants that may have built up on the one or more filters into smaller constituent parts that are no longer attracted to the one or more filters and therefore may pass through the one or more filters. Additionally, the cleaning solution, which as noted may have a low pH value, may also be operable to clean non-organic contamination (e.g., mineral scaling) from the one or more filters. In this manner, the one or more filters may be cleaned by exposure to the cleaning solution. Generally, the organic contaminants in the second state (e.g., reduced affinity toward the one or more filters) will not be harmful to the equipment used in the brine loop 300 . The cleaning time may depend on several variables including contamination levels of the NaCl and introduced water, time between cleaning, and desired filter efficiency and may range, for example, from several minutes to an hour or more.
[0043] After washing of the one or more filters as described above, the cleaning solution may be returned to the wash tank 302 . The pump 303 may then pump the cleaning solution back into the brine loop 300 , returning the cleaning solution via a cleaning solution return interconnection 306 to a point in the process between vacuum dechlorination 202 and chemical dechlorination 202 . It will be appreciated that by using already existing, in-process chemicals and returning those chemicals to the process, such a cleaning process requires no separate washing chemicals and can be performed with the one or more filters in situ.
[0044] In another configuration, the cleaning solution for the cleaning process may be obtained from the brine stream via fluid connection 307 at a point in the brine loop 300 after the addition of HCl 201 and prior to vacuum dechlorination 202 . The brine stream at this point typically has a low pH and may contain about 200 ppm of active chlorine. Such obtaining of the cleaning solution for the cleaning process may include separating at least a portion of the brine stream into a feed solution, which may continue into the vacuum dechlorination step, and the cleaning solution, which may proceed to the wash tank 302 .
[0045] In yet another configuration, a single fluid interconnection may exist between the wash tank 302 and pump 303 , and the point in the chloralkali process between vacuum dechlorination 202 and chemical dechlorination 206 . In such a configuration, the same fluid connection that is used to draw process fluid from the chloralkali process to the wash tank 302 may be used to return fluid from the wash tank 302 to the chloralkali process.
[0046] FIG. 4 illustrates an exemplary configuration of a filter washing system 400 integrated with a chloralkali process. The wash tank 302 is interconnected to the chloralkali process at a valve 403 disposed between a vacuum dechlorination apparatus 401 and a chemical dechlorination apparatus 402 . Valve 403 may selectively divert a portion of the flow of the chloralkali process (e.g., from the flow between vacuum dechlorination apparatus 401 and chemical dechlorination apparatus 402 ) to the wash tank 302 . Once a sufficient amount of flow, which will subsequently be referred to as cleaning solution, has been collected in the wash tank 302 , the valve 403 may be set so that the normal chloralkali process flow from vacuum dechlorination apparatus 401 to chemical dechlorination apparatus 402 may continue.
[0047] A filtration apparatus 404 may be used to complete the filtration step 308 . The filtration apparatus 404 may contain any appropriate number of filters, such as filter 405 a or 405 b. The input 406 to the filtration apparatus 404 may come from the preceding precipitation step 210 and the output 407 of the filtration apparatus 404 may continue to a subsequent processing step (e.g., activated carbon bed 214 or ion exchange 215 ). The filters may be non-precoated filters. Non-precoated filters may include any filter that separates solids from a fluid directly without the use of precoats or body aids. The filters may be in the form of membrane filters, tubes and/or filter bags. The filters may, for example, include one or more layers of PTFE, ePTFE, PVDF and/or other fluoropolymer membranes. ePTFE, in particular, generally is chemically inert and is operable to withstand exposure to a wide range of harsh chemical environments without significant damage. The filters may be comprised of laminates that include one or more of above-mentioned materials laminated to felts or woven fabrics. The filters may, for example, comprise nonwoven and/or spunbond fabrics of PVDF, polypropylene, and/or polyethylene.
[0048] To wash a filter, the filter must first be isolated from the chloralkali process flow. For example, to wash filter 405 a, valve 408 a may be changed form its normal operating position (connecting input 406 to filter 405 a ) to a position where only cleaning solution from a wash tank source line 409 may enter into the filter 405 a. Furthermore, valve 410 a may be changed form its normal operating position (connecting filter 405 a to output 407 ) to a position where flow from the filter 405 a is diverted back to the wash tank 302 via a wash tank return line 411 . In this regard, the filter 405 a may be isolated from the chloralkali process flow and interconnected to the membrane filter washing system 400 . Meanwhile, other filters of the filtration apparatus 404 , such as filter 405 b may remain interconnected to the chloralkali process flow and may continue to operate in a normal fashion. The sizes and quantities of the various filters of the filtration apparatus 404 may be selected so that the chloralkali process flow may not be interrupted when one or more of the filters is removed form the chloralkali process flow for washing.
[0049] Once the filter 405 a is isolated from the chloralkali process flow and interconnected to the filter washing system 400 , the pump 303 may be activated and cleaning solution from the wash tank 302 may be circulated through the wash tank source line 409 , through valve 408 a, through filter 405 a, through valve 410 a, through wash tank return line 411 , and back into wash tank 302 . The fluid may be circulated in such a manner to wash the filter 405 a until the filter 405 a is satisfactorily cleaned. During the process, the pump 303 may be turned off or slowed down and the filter 405 a may be allowed to soak in the cleaning fluid. A combination of washing and soaking may be utilized to clean the filter 405 a.
[0050] Once the cleaning of the filter 405 a is completed, the cleaning solution may be returned to the wash tank 302 . The filter 405 a may then be rinsed, for example with water, to remove residual oxidizer that may present. The filter 405 a may then be returned to the chloralkali process flow by changing valve 408 a back to its normal operating position (connecting input 406 to filter 405 a ) and changing valve 410 a back to its normal operating position (connecting filter 405 a to output 407 ). A valve 412 may be then set to connect the wash tank 302 to the chloralkali process flow at a point 413 between the vacuum dechlorination apparatus 401 and the chemical dechlorination apparatus 402 . The pump 303 may then be activated and the cleaning solution may be pumped from the wash tank 302 back to the chloralkali process flow at point 413 .
[0051] Other filters of the filtration apparatus 404 may be washed in a similar manner. For example, filter 405 b may be washed by using valves 408 b and 410 b to isolate filter 405 b from the chloralkali process and interconnect the filter 405 b to the filter washing system 400 .
[0052] The washing of the filters described above may be achieved in an automated fashion, manually, or through any combination thereof. For example, once a washing cycle is initiated, the wash tank 302 may be automatically filed, the filter to be cleaned may be automatically isolated from the chloralkali process, the washing cycle may be automatically conducted, and then the cleaning solution may be automatically returned to the chloralkali process.
[0053] The initiation of the washing cycle may also be automated or it may be operator-initiated. For example, sensors (e.g., flow sensors, pressure sensors) may monitor the performance of the filters within the filtration apparatus 404 and a washing cycle may be automatically initiated when the monitored performance of a particular filter meets predetermined criteria (e.g., once a predetermined pressure drop across a filter is sensed). Alternatively, a technician may monitor the performance of the filtration apparatus 404 and initiate a washing cycle when certain conditions are met. In another exemplary method of initiation of a washing cycle, washing cycles may be manually or automatically initiated at predetermined intervals (e.g., based on time or flow). The length of the predetermined intervals may be dependent on many factors, such as contamination levels, contamination composition, and desired filter efficiency.
[0054] The foregoing description of embodiments has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the present invention to the forms disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and skill and knowledge of the relevant art, are within the scope of the present invention as defined by the claims that follow.
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Filter wash methods and apparatuses for chloralkali processes are provided. The filter wash uses in-process fluids from the chloralkali process to wash filters. The in-process fluids may be drawn from a point in the chloralkali process where the in-process fluids contain active chlorine values such as bleach. A filter may then be isolated from the chloralkali process and contacted with the in-process fluids containing active chlorine values to wash the filter. The in-process fluids containing active chlorine values may be operable to oxidize organic material clinging to the filter, thereby cleaning the filter. After washing, the in-process fluids containing active chlorine values may be returned to the chloralkali process to a point at or near where they were drawn from. The filters may be membrane filters. The filters may comprise expanded polytetrafluoroethylene.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2013/056683 filed Mar. 28, 2013, and claims the benefit thereof. The International application claims the benefit of European Application No. EP13150842 filed Jan. 10, 2013. All of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The present invention relates to a safety device for ensuring the safety of an operator for an arrangement in a rotor, more particularly a wind turbine. It furthermore relates to a method for ensuring the safety of an operator for an arrangement in a rotor, more particularly a wind turbine.
BACKGROUND OF INVENTION
[0003] By “rotors” are meant for example the drive propellers of aircraft, hovercraft and ships as well as also the wind and water wheels serving for obtaining energy. Wind turbines, more particularly industrial scale wind turbines, have a nacelle which is mounted on a tower, as well as a rotor which is mounted on the nacelle. The rotor represents a movable part of the wind turbine. It is connected by means of a shaft on the drive train to the interior of the nacelle in which typically the generator as well as further electrical and electronic elements are located. Within the scope of the invention by “rotor” is understood the complete unit of a hub, rotor blades fastened on the hub, and a rotatable substantially horizontally lying rotor axis. When the rotor is used as intended the rotor blades drive the hub and the rotor axis and thus the generator.
[0004] The rotor of the wind turbine is normally fitted with a plurality of rotor blades, by way of example two, three or more rotor blades, which are mounted protruding radially away from the substantially horizontal centre axis of the rotor. During operation the rotor blades are often turned continuously in the wind by means of an adjusting mechanism so that an optimum energy yield can be obtained from the existing wind. This can be achieved for example by means of a rotation of the nacelle (yaw drive) and/or by means of a blade angle adjustment (pitch drive) of the rotor blades.
[0005] The rotor represents a highly complex system in which in particular numerous movable elements such as the rotor blades and the corresponding adjusting mechanism are arranged. It is therefore necessary from time to time to carry out maintenance work and when required even repairs to the rotor. In particular, the hub of the rotor, that is a rotatable centre piece on which the rotor blades are fastened (a hub with a pitch drive is furthermore also termed a “rotor head”, however in the following the term “hub” is used as the standard form), represents a region in which it is particularly difficult and risky for the service personnel to operate. By way of example here bolts which are used to fasten the rotor blades on the hub have to be regularly checked and/or retightened.
[0006] The said service works are nowadays normally carried out by a person who is secured by mobile frames and/or safety belts. The service workers thereby have to climb around at a mostly great drop height in the region of the open hub (i.e. provided with an access to the nacelle) in the end region of the rotor. Such procedures are very risky and furthermore complicated since the service workers have to be secured in the optimum possible way at all times.
SUMMARY OF INVENTION
[0007] Starting from the problem illustrated here an object of the invention is to provide the possibility for an improved safety of an operator for working in the hub region of a rotor. More particularly importance is to be placed on a simpler possibility for safety, and/or such safety, which is equipped with a higher safety standard.
[0008] This is achieved by a safety device and by a method according to the independent claims.
[0009] According to this a safety device of the type mentioned at the beginning comprises at least the following elements: a platform having a plurality of standing surfaces of which when the safety device is used as intended at least one lies substantially horizontal, fixing device for fixing the platform on a hub of the rotor and/or on an inside of a rotor housing of the rotor.
[0010] The invention offers the user an at least temporarily fixedly installed platform with several surfaces which are configured and measured so that he can stand on them on two legs. These surfaces are called “standing surfaces” within the scope of the invention. According to the invention in at least one position of the rotor one standing surface of the platform lies substantially horizontal. This position of the rotor is characterised as being specific for the use of the safety device. A horizontal surface offers the advantage that it minimizes the danger of the user slipping off.
[0011] Within the scope of the invention the term “rotor housing” is to mean the entirety of all the housing segments of the rotor which surround the hub and connecting flanges of rotor blades on the hub. The rotor housing comprises in particular also a nose or cap, i.e. a hood-like cover of the hub against the wind direction.
[0012] In order to configure the platform so that an operator can work safely thereon, it is fixed on the hub and/or on the inside of the rotor housing of the rotor by means of the fixing device. Thus in the installed state inside the rotor the platform is a part of the outermost end of the rotor.
[0013] A platform of this kind can be attached fixedly or detachably in the region of the hub of the rotor by means of the fixing device. With a solid fixing the platform is in the end a fixed constituent part of the rotor or hub. In the case of a detachable fixing the platform or the safety device can also be formed as an add-on solution or as a mountable and in turn demountable device. The fixing device can comprise by way of example a screw, rivet, bolt or adhesive connection.
[0014] By means of the platform which is fixed by the fixing device in the region of the hub of the rotor, in addition to a usually curved surface of the hub a number of standing surfaces are produced which provide the operator at any time with defined paths and handling regions during the intended use. The maintenance personnel are furthermore clearly better protected against a fall from a great height and can operate freely on the platform, more particularly unimpeded by security harnesses or corresponding security ropes. Drop paths are shortened since the platform also functions at the same time as a type of room divider of the interior space between the hub and the rotor housing. Overall maintenance and repair works are thereby easier in the region of the hub of the rotor, by way of example to renew a seal or to inspect and tighten bolts which fasten the rotor blades on the hub.
[0015] The invention furthermore comprises a rotor, more particularly a rotor of a wind turbine having a safety device according to the invention as well as a wind turbine having a safety device according to the invention.
[0016] The invention furthermore comprises a method of the type mentioned at the beginning wherein at least one standing surface of a platform of the safety device when the safety device is used as intended is positioned substantially horizontal wherein the platform is fixed on a hub of the rotor and/or on an inner side of a rotor housing of the rotor.
[0017] The method according to the invention can be achieved by means of the safety device according to the invention.
[0018] Further particularly advantageous configurations and developments of the invention are apparent from the dependent claims as well as from the following description wherein the independent claims of one claim category can also be developed analogously to the dependent claims of another claim category.
[0019] The platform can fundamentally be suspended or mounted floating on the hub or on the rotor housing so that it is aligned each time in the properly designated position for use. In this case at least one standing surface of the platform thus always stands horizontal. The platform can have by way of example a weight which draws it always into the horizontal position and an additional locking device so that it reliably remains in this position during maintenance work. According to a configuration the safety device is mounted fixed on the hub of the rotor and/or on the inside of the rotor housing. The platform thus automatically turns during a rotational movement of the rotor or hub and the rotor housing, i.e. in the right direction and angle. More advantageously standing surfaces of the platform are arranged at different angles to one another so that the safety device provides a horizontal standing surface not only in the case of one single position of the rotor.
[0020] According to an embodiment of the invention the platform is arranged relative to each two connecting flanges of rotor blades on the hub so that a standing surface on one side of the platform facing the rotor housing lies substantially parallel to a vertex face of the hub. By “vertex face” is meant a region of the curved surface of the hub which lies between two adjoining connecting flanges of the hub. With a rotation of the hub about the rotor axis the vertex faces arranged radially around the rotor axis are therefore aligned substantially horizontal alternately on a top side and an underneath side of the hub. “Substantially horizontal” hereby means that the curved vertex face stands symmetrical relative to a substantially flat standing surface. A three-vane rotor has by way of example three vertex faces.
[0021] The maintenance worker normally stands for a particularly long time on the vertex faces of the hub for example since in the event of a substantially horizontal alignment these faces represent a safe, because comparatively less precipitous, standing site and offer a comfortable access to the adjoining connecting flanges of the rotor blades. A substantially parallel position of the standing surfaces on the outsides of the platform relative to the respective corresponding vertex faces of the hub has proved particularly favourable since it clearly becomes easier for the operator to climb from one standing surface to the next vertex face. This then plays a role particularly when the operator sets up for example a mobile ladder on the standing surface and where applicable leans against an end face of the hub and then climbs up the ladder in the direction of the vertex face.
[0022] The platform of the safety device is advantageously arranged relative to the main extension directions of the rotor blades of a wind turbine so that a standing surface always lies substantially horizontal on an outer side of the platform when a rotor blade points downwards along a tower of a wind turbine towards a ground surface. This provides the possibility that a rotor blade mobile maintenance unit can be moved along the rotor blade between the hub and a rotor blade tip (for example for inspection and maintenance work) and at the same time an operator can carry out inspection and/or maintenance work inside the maintenance chamber between the hub and the rotor housing.
[0023] The safety device is particularly configured so that the platform divides a hollow chamber between the hub and the inside of the rotor housing into essentially at least two hollow chamber regions separated from one another. The rotor housing can stand at such a distance from the hub which is measured so that an operator can move by crawling, kneeling or semi-upright therein. The hollow chamber can be formed like a dish and is penetrated by at least three rotor blades which are fitted on the hub. The platform can extend between a surface on the outside of the hub and a surface on the inside of the rotor housing. Dividing up the hollow chamber has proved advantageous since the drop path of an operator when falling down or sliding down in the hollow chamber along the surface of the hub is significantly reduced. It is particularly advantageous if the platform is therefore designed so that it divides the hollow chamber into a plurality of separated hollow chamber regions.
[0024] Basically the platform of the safety device can have any shape, for example a polygonal or circular configuration. According to another embodiment the platform comprises three platform elements each with at least one standing surface to form a triangle. The platform elements can be formed circular or angular, e.g. rectangular or square. They can have the form of a frame, grid or scaffold, and be of the same or different size. The platform elements can form a triangle where they are connected to one another at the ends or at the edges running substantially parallel to the rotor axis. A chamber which is enclosed or defined by the insides of the platform elements directed towards the rotor axis is thus likewise triangular-shaped. It is called a “central chamber” within the scope of the invention. The platform elements of the triangle are particularly dimensioned sufficiently large so that the triangular-shaped central chamber can shelter an operator, e.g. a maintenance technician.
[0025] A triangular shape of the platform offers the advantage that an alignment of the standing surfaces can be coordinated particularly simply with a position of the rotor blades when the rotor of the wind turbines has three rotor blades. If the platform is formed as an equilateral triangle, then it can be positioned relative to the hub so that during a rotor rotation about 120° a change always takes place from a first standing surface in a horizontal position to a second standing surface in a horizontal position. The platform according to the invention thus reduces the dependency of the horizontal position of a standing surface on a position of the rotor blades.
[0026] Advantageously at least one of the platform elements comprises at least one opening as access for an operator. It is advantageous if all the platform elements comprise an opening. The opening(s) can advantageously have a dimension, or in the case of a circular opening, a diameter, which is large enough so that an operator can pass from any hollow chamber region through the opening into another hollow chamber region. The operator can pass from a chamber inside the hub into the hollow chamber between the hub and the rotor housing. He can then step from the chamber first into a region inside the triangular platform, the “central chamber”. From there the opening according to the invention in one or in each platform element allows access to one or any further hollow chamber region, wherein the access leads each time through a hollow chamber region inside the platform respectively to the “central chamber”.
[0027] In principle an opening in the platform element can be opened permanently during operation of the safety device. In particular the safety device comprises a closing element for closing the opening. The closing element can be a flap, a sliding door, or a roller shutter which allows an opened and a closed state of the opening. It can also be formed as a removable cover. An operator can cover the opening by means of the closing element after passing through. The closing element is particularly designed so that it can be loaded with a weight of the operator without opening automatically.
[0028] The further development according to the invention thus contributes to the safety of the operator. It reduces the risk of injury if the operator slides or falls down, for example starting from the vertex face.
[0029] According to a configuration of the safety device the platform comprises bridging elements which span the contact points of the platform elements on the inner sides of the platform elements facing a rotor axis. By “contact point” is meant a place or spatial area where the ends of two platform elements meet one another at an angle and are for example welded to one another. By “inner sides” of the platform elements are meant those sides which in the case of a three-dimensional shape of the platform face one another and at the same time towards the rotor axis. The bridging elements can be set up at any points of the inner sides. They can have the configuration of a frame, grid or scaffold, and can be of the same or different size. They can be fastened on the platform elements by means of screw connections, adhesive connections, bolts or rivets. The bridging elements may each comprise at least one standing surface on which an operator can stand. When fitting a for example triangular-shaped platform with for example three bridging elements according to the invention, at least one doubling of the standing surfaces on an inside of the platform to six standing surfaces can be achieved by the bridging elements. With a rotation of the rotor around 360° an operator can consequently use in six different positions of the rotor a horizontal standing surface in an inner hollow chamber region of the platform.
[0030] The bridging elements can basically each stand at any angle to the platform elements. The platform elements may stand on their inner sides facing the rotor axis at an angle of 120° to inner sides of each adjoining bridging elements likewise directed to the rotor axis. When the platform is designed as an equilateral triangle it results therefrom that each bridging element stands parallel to each opposite platform element. Thus with a rotation of a rotor about 120° in a starting and in an end position of the rotational movement, two parallel floors of the platform i.e. a platform and a bridging element, lie horizontal. Thus by way of example it becomes clearly easier to set up a ladder on a bridging element. The ladder can help the operator to pass from a space inside the triangular-shaped platform to an opening arranged above same, and then through it to a standing surface of a platform element lying parallel above same. Consequently during a rotation of the rotor about 60° a change takes place from one standing surface to an adjacent standing surface which then each lie horizontal and offer the operator a safe standing surface. The configuration according to the invention can significantly simplify the work of a maintenance technician in the hollow chamber, for example on the connecting flanges of the rotor blades.
[0031] In principle the platform can be fastened solely on the hub of the rotor. According to a configuration the safety device comprises strut elements as a fixing device which connect the platform at contact points of the platform elements to an inner side of the rotor housing. The strut elements can be placed at any points on the inside of the rotor housing. They can have the form of a frame, grid or scaffold, of the same or different size. Furthermore they can be fastened to the platform or on the inside of the rotor housing by means of screw connections, adhesive connections, bolts or rivets. The strut elements can furthermore be designed so that they divide the hollow chamber between the hub of the rotor and an inside of the rotor housing into separate hollow chamber regions.
[0032] The strut elements can basically be anchored at any points of the rotor housing which surrounds the hub and connecting flanges of the rotor blades on the hub. They are particularly fastened in the region of interfaces of segments of the rotor housing. The strut elements mounted on the platform thus connect the segments of the rotor housing to one another. The platform can serve by way of the strut elements as a reinforcement element of the rotor housing insofar as through its shape it absorbs the tensile forces acting on a housing segment of the rotor much more effectively than an adjacent housing segment. Fastening the strut elements on interfaces of the housing segments furthermore offers the advantage that fastening means, for example flat angle plates, are usually already provided at the interfaces which the strut elements can use for connection. Furthermore a single strut element can thereby be fitted at the ends of two housing segments of the rotor and stabilize them.
[0033] The platform is particularly likewise also mounted on the hub so that the segments of the rotor housing not only support one another, but ultimately are fastened on the hub of the rotor. The strut elements can thereby replace or support any other reinforcement elements which connect the hub, a rotor housing as well as a rotor hood, structurally to one another. The configuration according to the invention thus serves as a structural element of a rotor and stabilises the rotor housing which increases its resistance for example to acute wind loads. The safety device thus offers a valuable synergy effect.
[0034] The strut elements can run substantially parallel to a longitudinal axis of a blade of the rotor between interfaces of segments of the rotor housing and the platform. The safety device with the elements of the platform elements, the bridging elements and the strut elements can be constructed symmetrically, e.g. three-fold radially symmetrically. Such a design can enhance the working safety of the operator since the safety device has the same configuration each time in three different positions of the rotor. The operator is thus not forced to get used to or adapt to different forms and sizes of plates, standing surfaces, openings, which can take up part of his attention and in some circumstances can lead to a loss of time or accidents. Rather he discovers a uniformly configured working environment.
[0035] The platform elements, bridging elements and strut elements can basically each have a quite different shape. By way of example the platform elements can be designed flat, whilst the strut elements can on the other hand be grid-like structures. The platform elements and/or the bridging elements and/or the strut elements are particularly designed as flat plates. The flat plates can be by way of example metal plates, for example made of corrosion-resistant stainless steel or aluminium. Alternatively they can be made of plastics, e.g. of glass fibre reinforced plastics, of wood or of carbon fibre.
[0036] It is advantageous if the platform elements, bridging elements and strut elements are formed solely as plates. They each provide smooth standing surfaces which guarantee a particularly high working safety by not offering any engagement points for catching or clamping on an operator, which can lead for example to tripping and falling. The plates according to the invention can thereby provide the platform elements, bridging elements and strut elements with two standing surfaces lying parallel to one another on a front and a rear side.
[0037] The plates may extend continuously or substantially without any gaps between an outer side of the hub and an inner side of the rotor housing so that they pass through the entire hollow chamber. The plates thus ensure that an operator in the event of falling down, for example from a vertex face, does not unintentionally pass from one hollow chamber region into another hollow chamber region or becomes jammed in an interspace. The same advantage is produced for tools or spare parts which an operator may be carrying loose with him; should they become undesirably lost or dropped they are prevented from slipping through into another hollow chamber region and can be quickly found again by the operator.
[0038] Furthermore the plates offer the advantage that they can connect a rotor hood to the hub and can thus additionally strengthen a structure of the rotor housing. The plates therefore may have fastening elements for fastening the rotor hood on the platform. The fastening elements can comprise for example angle plates which are fixed on the plates or the rotor hood by means of rivets or screw connections.
[0039] According to a configuration of the safety device an extension of the platform elements in a direction substantially transversely or vertically to the rotor axis comprises at least 1 m, particularly at least 1.3 m and more particularly at least 1.5 m as well as at most 5 m, particularly at most 4 m and more particularly at most 3 m. This extension permits an optimum adaption of the safety device to rotors, more particularly of wind turbines which have a different size and power performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] The invention will now be explained below once more in further detail with reference to the accompanying drawings and using embodiments. The same components in the different figures are thereby provided with identical reference numerals. The drawings show:
[0041] FIG. 1 a perspective illustration with a partial section of a rotor housing according to the prior art;
[0042] FIG. 2 a perspective partial section from the right of a rotor housing with an embodiment of the safety device according to the invention;
[0043] FIG. 3 a side view from the right of the rotor of a wind turbine with the safety device;
[0044] FIG. 4 a front view of a rotor housing with the safety device; and
[0045] FIG. 5 a diagrammatic front sectional view of a rotor housing with the safety device.
DETAILED DESCRIPTION OF INVENTION
[0046] FIG. 1 shows a section of a rotor 1 of a wind turbine with a hub 3 which is surrounded by a rotor housing 12 . The rotor 1 is formed with three vanes, i.e. it has three rotor blades (not shown in FIG. 1 ) protruding radially from the hub 3 . Inside the hub 3 there is a tunnel-shaped hollow chamber (not shown) which serves as access from a tower (not shown) or a nacelle (not shown) of a wind turbine to connecting flanges 7 of the rotor blades 5 on the hub 3 . An exit 9 connects the tunnel to a dish-like maintenance chamber 21 between the hub 3 and the rotor housing 12 . Three two-prong ladder sections 10 protrude from an edge of the exit 9 . An operator 16 , e.g. a maintenance technician, climbs over an upper ladder section 10 in the direction of a vertex face 4 of the hub 3 . The vertex face 4 forms a region of the curved surface of the hub 3 which lies between the two circular connecting flanges 7 of the rotor blades 5 of the rotor 1 . In the illustrated position of the hub it offers a favourable, because substantially horizontally aligned, standing site for the operator 16 in order to inspect or tighten bolts for example by which the rotor blades 5 are mounted on the hub 3 . According to the prior art an operator 16 can rope himself by means of safety harness or belts onto security points which lie on an inner side 14 of the rotor housing 12 and/or on an outer surface of the hub 3 so that the operator 16 is protected against sliding or falling down.
[0047] FIG. 2 shows a safety device 19 according to the invention on the rotor 1 . A platform 20 is mounted at the front on the hub 3 of the rotor 1 and is supported by three feet as strut elements 28 or a fixing device on the inner side 14 of the rotor housing 12 . The platform 20 is fixed on the hub 3 so that it turns automatically during a rotational movement of the rotor 1 . The rotor housing 12 includes three housing segments 13 which enclose the hub 3 , the connecting flanges 7 of the rotor blades 5 and the platform 20 . The rotor housing 12 has a front circular opening which during operation of the rotor 1 is covered by a rotor hood (not shown). The strut elements 28 of the platform 20 connect at interfaces 17 between the housing segments 13 . The platform 20 and the strut elements 28 are made substantially of metal.
[0048] The platform 20 has three oblong platform elements 24 of identical length which are brought together in the form of an equilateral triangle. The platform elements 24 stand at internal angles α of 60° relative to one another. Each platform element 24 has an extension of 2 m in a direction perpendicular to a rotational axis R. At the inner sides 34 of the platform elements 24 facing the rotor axis R webs acting as bridging elements 26 span the tips of the triangle, i.e. the seam points between two adjoining platform elements 24 . The tips are formed from contact points 25 of the platform elements 24 . Each bridging element 26 thereby stands at an angle of 120° to an adjacent platform element 24 . Each bridging element 26 thereby also lies parallel to a platform element 24 which is opposite it on the other side of a central chamber 23 (as hollow chamber region). The platform elements 24 furthermore each have an opening 29 or an aperture which is covered here each time by a removable circular cover 30 as a closing element. The covers 30 have a diameter b which is large enough so that an operator can slip through the opening 29 . The platform 20 is measured so that the central chamber 23 is large enough so that an operator can stop and move about therein.
[0049] Whilst the bridging elements 26 offer an operator a standing surface 32 for standing up, the platform elements 24 each have two potential standing surfaces 32 . An inner one of these standing surfaces 32 thereby points towards the rotor axis R, an outer standing surface 32 points towards the rotor housing 12 . In the central chamber 23 of the platform 20 there are therefore six potential standing surfaces 32 . When any one standing surface 32 is located in a horizontal position each rotation of the rotor 1 around 60° causes a horizontal position of an adjacent standing surface 32 .
[0050] The strut elements 28 are seated on the outside at the tips of the triangle of the platform 20 . Each strut element 28 extends substantially parallel to a longitudinal axis L of an adjacent rotor blade 5 . Since the strut elements 28 are formed as flat plates they divide together with the platform elements 24 a maintenance chamber 21 between the hub 3 and the rotor housing 12 (as hollow chamber) into three outer partial chambers 22 (as hollow chamber regions) and a central chamber 23 (as hollow chamber region), which lies inside the platform 20 .
[0051] Several angle plates 38 are mounted on the platform elements 24 and fasten the platform 20 on one side on the hub 3 and on the other side on the rotor hood (not shown).
[0052] The platform 20 according to the invention offers the advantage that its in total nine potential standing surfaces 32 and its openings 29 provide an operator with defined paths and handling regions inside a maintenance chamber 21 . The triangular design of the platform 20 offers on its outer side during a rotor rotation about 120° a horizontally lying standing surface 32 , and even on its inner side facing the rotor axis R during a rotor rotation about 60°. It can thus assist or even replace a conventional safety fitting of an operator, such as safety harness and belts. The platform 20 furthermore considerably shortens the fall paths of an operator, e.g. from a vertex face (not shown) of the hub 3 starting in the direction of a connecting flange 7 of a rotor blade 5 which in this situation points directly downwards. The safety device 19 furthermore functions as a structural element of the rotor 1 and serves for a reinforcement and thus stabilizing of the rotor housing 12 with the rotor hood (not shown).
[0053] FIG. 3 shows, in contrast to FIG. 2 , an operator 16 , e.g. a maintenance technician who is moving forwards in an outer partial chamber 22 on a curved surface of the hub 3 in the direction of a vertex face 4 of the hub 3 . A horizontally aligned platform element 24 as well as the strut elements 28 which adjoin the ends of the platform element 24 and run inclined relative to the platform element 24 close off an upper outer partial chamber 22 from further partial chambers 22 , 23 . A fall path of the operator and his equipment, e.g. loosely carried spare parts and/or tools, is thereby clearly shortened. A continuous extension of the platform elements 24 and the strut elements 28 between the hub 3 and the rotor housing 12 reliably prevents the operator and smaller elements from becoming jammed or slipping through.
[0054] FIG. 4 shows, in contrast to FIGS. 2 and 3 , the safety device 19 according to the invention in a front view. The operator 16 stands facing the viewer on a horizontal standing surface 32 of a bridging element 26 and has in front of him a mobile ladder 40 which is likewise standing on the bridging element 26 . A spacing between the bridging element 26 and the platform element 24 is here greater than a body size of the operator 16 . The mobile ladder 40 extends up to an open opening 29 . The operator 16 when climbing up the ladder 40 can pass through the opening 29 . He can then move on a horizontal standing surface 32 of the platform element 24 . An opening of the rotor housing 12 released by the housing segments 13 is covered by a disc-like rotor hood 15 . The platform elements 24 have angle plates 38 which run along an extension of the platform elements 24 between the strut elements 28 , and fasten the platform 20 additionally on the hub 3 .
[0055] FIG. 5 shows, in contrast to FIG. 4 , more particularly the three-fold radially symmetrical construction of the safety device 19 according to the invention. Each of the three strut elements 28 aligns flush with a longitudinal axis L of one of the three rotor blades 5 or stands parallel to it. The platform 20 with its platform elements 24 forms an equilateral triangle. A longitudinal axis L of each rotor blade 5 stands perpendicular to an opposing platform element 24 . The strut elements 28 are mounted by means of bolts 18 as fixing device on interfaces 17 of the segments 13 of the rotor housing 12 .
[0056] It is finally pointed out once more that the devices described in detail above are only examples of embodiments which can be modified by one skilled in the art in the most varied of ways without departing from the scope of the invention. Furthermore the use of the indefinite article “a” and “an” does not rule out that the relevant features can also be present in several numbers.
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A safety device, for ensuring the safety of an operator, is arranged in a rotor, in particular of a wind turbine. The device has a platform with a number of standing surfaces, at least one of the standing surfaces being substantially horizontal when the safety device is used as intended, and also having a securing system for securing the platform to a hub of the rotor and/or to an inner face of a rotor housing of the rotor.
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CROSS-REFERENCE TO RELATED APPLICATION
Pursuant to 35 USC §120, this continuation application claims priority to and benefit of application Ser. No. 10/734,888, now U.S. Pat. No. 6,941,884, filed Dec. 15, 2003, on behalf of inventor Steven Clay Moore, entitled “Wake Control Mechanism”.
FIELD OF INVENTION
The invention relates to a plate, typically behind a boat's transom to increase wake size, and/or modify wake shape.
BACKGROUND
Because wakeboarders like big wakes, boats built for wakeboarding usually now have water tanks, called bladders installed near the back of the boat to increase boat weight or “displacement” and thus increase wake size. Patents cover various bladder configurations. One patent covers a totally different method of modifying a boat wake by placing a flat plate (called a “trim tab‘) at the bottom-center of the transom. This method can change the shape of the wake, but it is not intended or effective for increasing wake size, because trim tabs raise the back or “stern” of the boat and thus reduce wake size. Before I/O boat motor drives included automatic tilt controls, “trim tabs”, as shown in FIG. 1 , were often installed on the bottom outside edges of the transom, to adjust not only the “trim” or bow/stern angle but also the list or port/starboard tilt. Most trim tabs are hydraulically controlled so that the driver can adjust the tilt of the boat while underway with a toggle switch. At slower speeds, when the bow tends to ride too high, the tabs are lowered, thus deflecting the water leaving the back of the boat downward and so providing lift to the back of the boat and lowering bow or “trim.” If the boat is listing to one side, the trim tab on that side can be adjusted lower until there is no more sideways tilt. (Control mechanisms, typically hydraulic, for adjusting trim tabs have been in use for over 50 years and are not a part of this invention).
BRIEF SUMMARY OF THE INVENTION
The present invention achieves the same lowering of the boat rear that is achieved by a bladder, but without the added weight. The invention accomplishes this with one or more wake control plates, hereafter called plates, which look similar to normal trim tabs, but they have the opposite effect of trim tabs used so far, because: 1) the plates which are the subject of this patent are mounted so their front edge can be below the top surface of the flow of water beneath the hull of the boat versus normal trim tabs which are flush with the bottom of the hull, and 2) the plates are tilted up (back end higher than front edge) instead of down (back lower than front edge) so that the water can be scooped up instead of pushed down. This has the effect of forcing the back of the boat deeper into the water, just as added weight does, instead of lifting the stem as a normal trim tab does. The main advantages are: relatively little weight is added to the boat; more rapid adjustability; greater control of wake size; the plates can be adjusted to create different wake shapes compared to bladders which merely increase wake size; and the plates have dual use because they can be positioned so as to act like traditional trim tabs thus eliminating the need for normal trim tabs. No other inventions or designs found in patent searches describe plates or anything else designed to have negative lift by a water-scooping action.
The plates may be any size and may be connected to the stern and adjusted to various positions in a variety of ways, so that the front edge of the wake control plate(s) can be submersed in the water flowing past the boat, under the hull, behind the stern and/or to the sides of the stem, at an angle which provides a scooping action . . . the opposite of the lifting action of normal trim tabs. Additionally the plates may have walls allowing the water scooped up by the plates to accumulate above water level, thus increasing wake size by adding weight. It is the water scooping effect which is the object of this invention, regardless of what portion of the plates are in front, beside or behind the stern.
BRIEF DESCRIPTION OF THE DRAWINGS
Items in the drawings are labeled as follows:
“B” is a boat or watercraft; “T” is the transom (the back face of the boat); “P” is the plate or wake control mechanism; “A 1 ”, “A 2 ”, “A 3 ” are arms whose length can be adjusted; “JJ” is a joint which swivels on one axis of rotation; “J” is a joint which swivels on one axis of rotation and which can twist about the orthogonal axis up to approximately 20 degrees; “CL” is a control lever in the hydraulic system to activate adjustable arms; “V” is a vale in the hydraulic control system; “HP” is the hydraulic pump in the hydraulic control system; and elements whose label is predicated with an “S” are screw, clip, pin or other mechanical attachment points, that also are “JJ” joints.
FIG. 1 a side view of the prior art, is a boat equipped with trim tabs that are hinged at the front edge. The front edge is thus fixed to remain flush with the hull and the front edge cannot extend below the bottom of the boat.
FIG. 2A the preferred embodiment, is a side view of a watercraft with a flat wake control plate connected to the stern by three length adjustable arms. The two front arms labeled “A 1 ” and “A 2 ” are solidly attached to the transom so that the front of the plate can only move horizontally as the arms lengthen or shorten. Arms “A 1 ” and “A 2 ” are hinged where attached to the plate and arm “A 3 ” is hinged at both ends so that the bow/stem angle of the plate can be adjusted by varying the length of arm “A 3 .”
FIG. 2B is a stern view of the same configuration as FIG. 2A .
FIG. 2C is the same configuration as FIG. 2A with the plate in the closed/non-functioning position.
FIG. 2D is the top view of the same configuration as FIG. 2A .
FIG. 3 is the same configuration as FIG. 2A except that the plate is curved upwards.
FIG. 4 is the same configuration as FIG. 2A except that the plate has side and back walls to hold the water that is scooped up by the plate.
FIG. 5 is a stem view of a V-bottomed boat equipped with two wake control plates, which are shown, optionally, set at different tilt angles (by adjusting the same arms shown in FIG. 2A ). This configuration works for boats with outboard motors or I.O. drives that occupy the middle area of the transom.
FIG. 6A is a side view showing a plate connected to the stem by nonadjustable arms at the front and one adjustable arm.
FIG. 6B is a stern view of the same configuration as FIG. 6A .
FIG. 6C is the same configuration as FIG. 6A except with two plates.
FIG. 6D is the same configuration as FIG. 6A , FIG. 6B and FIG. 6C except that the front joints may be attached, by hand, at different places on the transom. The top attachment location (S 1 ) allows the plate to act as a normal trim tab because the front of the plate is flush with the bottom of the boat.
FIG. 7 shows a plate which has no motor powered adjustable arms. The plate is moved from the inactive/up position to the active/down position by manually changing the attachment points of arm “A 3 ” and/or by adjusting the length of arm A 3 .
FIG. 8 shows one means of hydraulic control for adjusting the length of the arms. This configuration is when “A 1 ” and “A 2 ” remain equal to each other in length.
FIG. 9 shows a means of hydraulic control where in addition to moving the front of the plate up and down, the plate can be tilted sideways by adjusting “A 1 ” and “A 2 ” to be different lengths.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the present invention is for boats that do not use an inboard-outboard or outboard engine and is depicted in FIG. 2A-FIG . 2 D. The wake control plate “P” is connected to the transom “T” of the boat “B” by adjustable arms “A 1 ”, “A 2 ” and “A 3 ”. Adjustable arms “A 1 ” and “A 2 ” are mounted rigidly on the Transom “T” and can only extend or contract vertically. “A 1 ”, “A 2 ” and “A 3 ” are connected to wake control plate “P” with a non-rigid joint “J”, where a non-rigid joint is a connection that allows the arm 360 degrees of angular flexibility in one plane and up to approximately 20 degrees of angular flexibility in the direction perpendicular to that plane. (An example of a non-rigid joint that rotates 360 degrees in one direction and up to 20 in the other is the rubber gasket joint typically used on the bottom end of automobile shock absorbers). Non-rigid joints give the wake control plate the flexibility to tilt about any axis as the length of the adjustable arms are independently adjusted, although the front two arms “A 1 ” and “A 2 ” are typically adjusted in concert. Adjustable arm “A 3 ” may be attached to the transom of the boat “T” by means of non-rigid or preferably rigid joint “JJ”. In the preferred embodiment, the front edge of the plate, when in the active position, is about 5 cm below the transom and tilted about 20 degrees upward from the plane of the hull and, in the inactive position, the front of the plate is raised to be flush with the hull. In the inactive position the plate may be tilted down, thus acting like a normal trim tab to raise the back of the boat. (for boats with outboard motors or IO drives, two separate plates on either side of the drive, as shown in FIG. 5 , or a single plate with a cutout may be used.)
Another embodiment or variation is to use a plate which has an upward curve as shown in FIG. 3 . Just as a curved wing is more efficient at creating lift with less drag, a curved plate is more efficient at producing negative lift with less drag. Two disadvantages of this variation are the added expense of manufacture and the optimum amount of curvature varies with boat speed. Optionally, additional efficiency improvement is achieved by also varying the thickness of the curved or flat plate, just like a wing varies in thickness.
Another variation is to have a fixed distance that the plate extends below the bottom edge of the transom. This variation, shown in FIG. 6A-6C , is lower cost because “A 1 ”, “A 2 ” and their associated control mechanisms are eliminated.
An even lower cost variation, as shown in FIG. 7 , is a plate which is held in position by arms which are not adjustable during use. In FIG. 7 , points “S 1 ” through “S 8 ” are positions where the arms can be snapped, hooked or screwed or otherwise connected to the transom. “S 1 ” is the inactive position and “S 2 ” through “S 8 ” are the active positions with varying amounts of water scooping/deflection action. This configuration is expected to be more popular when retrofitting existing boats, where the cost of installing hydraulics and control-panel switches is greater than when factory-installed. For the configurations shown in FIG. 6-FIG . 7 , the “fixed distance” that the plate extends below the hull is, of course, hand adjustable, for example by having different locations on a transom-plate where the hinges may be attached . . . including locations where the plate is flush with the hull bottom.
Arm “A 3 ” may be connected anywhere on the plate, except along a line between “A 1 ” and “A 2 ”, however somewhere between the middle and back edge provides the best combination of strength and lower manufacturing cost. Similarly arms “A 1 ”, “A 2 ” and “A 3 ” may be attached anywhere on or near the back of the boat, so long as the positions do not hinder movement of the plate. Also the plate(s) could be positioned so that part or all of the plate(s) is/are in front of the stern, either beneath or beside the transom.
FIG. 7 shows a plate which has no motor powered adjustable arms. The plate is moved from the inactive/up position to the active/down position by manually changing the attachment points of arm “A 3 ” and/or adjusting the length of arm A 3 .
FIG. 4 is the same configuration as FIG. 2A except that the plate has side and back walls to hold the water that is scooped up by the plate.
FIG. 5 is a more expensive embodiment for boats with V or U shaped hulls and for boats equipped with outboard or inboard-outboard engines. However the implementation shown in FIG. 5 also works with boats driven by inboard motors and provides more flexibility in creating different wake effects than a single plate implementation.
For any configuration shown, plates may be curved in the sideways direction to match the V, U or other shape of the bottom of the transom. When more than one plate is used, the controls may allow for separate adjustment of each plate or one or more plates may be simultaneously adjusted by a single control mechanism or, for any number of plates, each arm may be independently adjustable. Substitutions of elements from one described embodiment to another and logical amendments and appendages to each embodiment are also fully contemplated. It is also to be understood that the drawings or the aspects of each drawing are not necessarily drawn to scale, but are used to visualize the concepts covered herein.
Embodiments may include:
A wake control mechanism for watercraft wherein the one or more wake control plates are attached to the stern of the watercraft by one or more length adjustable rods such that the plate's front edge can be positioned below the transom; are inclined to a set or controllable angle so as to scoop water upward, or are alternately set in the traditional trim tab position; are of any size; and are either flat or curved upward.
The wake control mechanism for watercraft as described above wherein the said one or more length adjustable rods connect to any location on or near the stern of the watercraft and any location on the said one or more wake control plates except in a straight line, so as to hold the said one or more wake control plates in the desired position.
The wake control mechanism for watercraft as described above wherein the said one or more length adjustable rods are adjusted hydraulically or through another power assistance.
The wake control mechanism for watercraft as described above wherein the said one or more length adjustable rods are adjusted manually.
The wake control mechanism for watercraft as described above wherein the said one or more wake control plates are curved to conform to the bottom of the said watercraft.
The wake control mechanism for watercraft as described above wherein the said one or more wake control plates are equipped with sides, or sides and a back side, enabling it to hold scooped up water.
The wake control mechanism for watercraft as described above wherein the said one or more wake control plates is incorporated with a bait tank, swim platform, ladder, motor mount or other function.
Embodiments may further include:
A wake control mechanism for watercraft wherein the one or more wake control plates are attached to the stern of the watercraft through one or more length adjustable rods and one or more connections with fixed lengths; are of any shape and size; can be positioned in the water by the said one or more length adjustable rods; can be submersed under the stern of the watercraft; and can be controlled independently or dependently from the other one or more wake control plates.
The wake control mechanism for watercraft as described above wherein the said one or more length adjustable rods connect to non-rigid joints on both the wake control plate and the stern of the watercraft, where a said non-rigid joint is a connection that allows the said length adjustable rods approximately 180 degrees of angular displacement in one plane and approximately 30 degrees of angular displacement in the direction perpendicular to that plane.
The wake control mechanism for watercraft as described above wherein the said one or more connections with fixed lengths attach to non-rigid joints on the wake control plate and rotating joints on the stern of the watercraft, where a said non-rigid joint is a connection that allows the said rods with fixed lengths approximately 180 degrees of angular displacement in one plane and approximately 30 degrees of angular displacement in the direction perpendicular to that plane and a said rotating joint is a connection which lets the said rods with fixed lengths rotate approximately 180 degrees about the connection.
The wake control mechanism for watercraft as described in above wherein the said one or more length adjustable rods and the said rods with fixed lengths connect to any location on the stern of the watercraft and said one or more wake control plates, such that the said one or more wake control plates are held in the desired position.
The wake control mechanism for watercraft as described above wherein the said one or more length adjustable rods are adjusted hydraulically or through another power assistance.
The wake control mechanism for watercraft as described above wherein the said one or more length adjustable rods are adjusted manually.
The wake control mechanism for watercraft as described above wherein the said one or more wake control plates are curved to conform to the bottom of the said watercraft.
The wake control mechanism for watercraft as described above wherein the said one or more wake control plates are equipped with side wells, or side and back walls enabling it to hold water.
The wake control mechanism for watercraft as described above wherein the said one or more wake control plates is incorporated with a bait tank, swim platform, ladder, motor mount or other function.
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The present invention is a wake control mechanism for watercrafts comprising flat or upwardly curved wake control plate(s) which is/are connected to the stern in a variety of ways, either fixed or adjustable, such that the water passing beneath and/or beside the transom is scooped upward by the plate(s) and the watercraft is therefore pushed deeper into the water causing a larger wake. Additionally the plate(s) may have walls so that the scooped water is held above water level thus adding weight and further increasing wake size. Adjustments to the plate(s) position may be used to control the shape as well as the size of the wake.
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BACKGROUND OF THE INVENTION
This invention relates in general to the production of paper sheet products and is more particularly concerned with improvements in the production of non-laminated paper sheet products having regions of increased thickness for more economical use of the paper products and for conservation of wood pulp.
It has been customary in paper making to attempt to control the thickness of the web being formed to be as uniform as possible in thickness. Thus, sheets of paper cut from the web in either the wet or dry papermaking processes are usually of quite uniform thickness when the paper is viewed in its entirety. Upon much closer investigation, such as under microscopic viewing, differences in thickness are inherent since the pulp fibers cannot be so uniformly laid or dispersed during the papermaking processes so as to avoid any thickness variation on the microscopic level.
Various processing techniques are also known to the prior art to give uniform thickness sheet paper differing or modified characteristics. For example, softer texture can be imparted to relatively thin sheet paper by creping the paper, as by removing the paper from a calendar roll by a doctor. Such processing techniques after the paper has been formed have also been concerned with creating a finished product which has a generally uniform overall appearance.
Usage of paper, on the other hand, does not generally require that the paper be of entirely uniform thickness. For example, paper towels are more frequently used in the center portion than at the edges, especially in soaking up small spills and in drying one's hands. Similarly, in the printing industry, sheets of paper are printed primarily in the center portion such that the margins could be of reduced thickness to reduce the amount of wood pulp and other raw material utilized. Significant amounts of energy could also be conserved in the manufacture of paper of non-uniform thickness with additional energy savings gained in the transportation and further processing of such paper.
The concepts of the present invention could also be utilized to provide increased strength and support in the thicker portions of the paper sheet without the need for special or extra apparatus to add or inject high-strength fibers into the paper web as it is being formed. For example, it has been customary in the manufacture of heavy-duty paper bags suitable for containing and carrying groceries to manufacture such bags from multiple layers or plys of paper sheet stock, each sheet being of uniform thickness. There is, of course, a considerable waste of wood pulp in manufacturing these bags since the same paper thickness is not needed throughout the bag. With the present invention increased thicknesses of pulp can be provided along the areas or points of stress, such as along seams, creases and the top opening of the bag. The balance of the bag can be of reduced thickness of paper for considerable wood pulp savings.
Conversely, the present invention can be utilized to make paper thinner in desired areas by laying less pulp to provide other characteristics, such as increased flexibility along folded portions of the paper where the paper is otherwise of sufficient strength.
It is, therefore, a principal object of the present invention to provide novel and improved apparatus and methods for the manufacture of non-laminated paper sheet stock having regions of increased thickness to reduce the wood pulp requirements in manufacturing paper and thereby conserve wood pulp.
Another object of the invention is to increase the utilization of wood pulp by providing regions of extra thickness, strength and absorbability at those locations in paper sheet stock where the paper is most used.
A further object is to conserve energy by reducing the thickness and weight of the paper in those locations where the paper sheet is least used thereby requiring less energy to dry, transport or further process the paper.
Yet another object is to provide means for automatically depositing extra pulp in locations on the web being formed by either wet or dry papermaking machines such that the areas of increased thickness are an integral part of the paper web and the resultant paper sheet product does not substantially lose its inherent flexibility as in laminated paper products.
Another object of the invention is to provide means for automatically controlling the deposition of extra pulp being formed by the papermaking machine such that the web may be automatically cut into sheets or strips of paper with the areas of increased thickness registered in the desired positions.
SUMMARY OF THE INVENTION
These objects and advantages of the invention, and others, including those inherent in the invention, are accomplished by adding regions of extra pulp to the paper in the web forming area of a papermaking machine such that the regions of increased thickness become an integral part of the paper web, and hence, of the paper sheet products into which the web is cut or further processed. The areas of increased thickness are preferably sized and located in the areas of primary use for the particular paper sheet product such that the paper sheet products will be most efficiently utilized and wood pulp may be conserved. The areas of increased thickness can be formed in a conventional Fourdrinier wet papermaking machine including a head box for containing a quantity of pulp stock, an endless forming screen disposed below the head box and a slice formed in the head box adjacent the screen wherein the slice is provided with variations in thickness at spaced locations therealong such that corresponding variations in the thickness of pulp are deposited onto the forming screen to yield a paper sheet product having the desired regions of increased thickness. The variations in the thickness of the slice could be permanent, adjustable, or mechanically moveable as the paper is being formed. Alternatively, the additional pulp to create the thicker regions may be separately sprayed or otherwise deposited onto a continuous paper web of generally uniform thickness in the web-forming area of the papermaking machine in either the wet or dry papermaking processes. A plurality of sprayheads may be positioned at spaced locations above and across the width of the web, each adapted to spray additional quantities of pulp stock onto the paper web. Valves or other means in the sprayheads may periodically interrupt the deposition of additional pulp stock to form islands of increased thickness in the paper web. Web thickness sensing means, such as photo-electric devices, may be located downstream of the spraying heads to detect the regions of increased thickness in the paper to automatically interrupt deposition of the pulp stock by spraying heads.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel and patentable, are set forth with particularity in the appended claims. The invention together with the further advantages thereof, can best be understood by reference to the following description taken in conjunction with the accompanying drawings, and the several figures in which like reference numerals identify like elements, and in which:
FIG. 1 is a perspective view of the web-forming portion of a papermaking machine of the Fourdrinier type having an endless screen for forming of the paper web thereupon by flowing of pulp stock from the head box through a slice onto the screen and further illustrating the slice being of differing widths at spaced locations therealong for depositing corresponding thicknesses of pulp stock onto the screen to form a paper web having regions of increased thickness;
FIG. 2 is a front elevational view, partially in section, of the papermaking machine in FIG. 1 taken substantially along the line 2--2 to illustrate the regions of increased thickness in the paper web;
FIG. 3 is a perspective view of the web forming area of another papermaking machine illustrating spraying heads disposed above and across the width of the paper web for depositing extra thicknesses of pulp thereupon, with web thickness sensing means located downstream from the spraying heads, and further illustrating downstream rollers which are profiled to accommodate the regions of increased thickness in the web;
FIG. 4 is a top plan view of a strip of paper, such as toweling, substantially in sheet form and having centrally disposed rectangular regions of increased thickness;
FIG. 5 is a top plan view of another paper sheet product having a single generally circular region or island of increased thickness;
FIG. 6 is a top plan view of another type of paper sheet product having a plurality of increased thickness regions disposed in the sheets; and
FIG. 7 is a cross sectional view of the paper sheet product of FIG. 5 taken substantially along the line 5--5 and illustrating the increased thickness center region and reduced thickness edges or margins.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a web forming area of a conventional Fourdrinier papermaking machine, generally designated 10, adapted to produce a continuous paper web 11. A head box 12 is adapted to contain a quantity of wood pulp which is supplied to the head box 12 by a plurality of conduits 13 communicating therewith from a pulp storage tank (not shown) or other wood pulp source. Disposed immmediately below the head box 12, in the usual fashion, is an endless forming screen 14. A slice 15 defined in a lower portion of the head box 12 adjacent the screen 14 permits pulp from the head box 12 to flow through the slice 15 and onto the top surface of the screen 14 to begin formation of the paper web 11. The slice 15 is generally of narrow vertical width to limit and control the amount of pulp which flows out of the head box 12 onto the screen 14. However, the slice 15 is quite elongated and extends approximately the entire horizontal width of the web 11 or of the screen 14, as is best seen in FIG. 2.
The top portion of the screen 14 upon which the web 11 is formed is adapted to move forwardly from the slice 15 toward a couch roller 16. As the screen 14 begins to move downwardly about the couch roller 16 and thence back toward the head box 12, the web 11 is delivered from the screen 14 to a plurality of web-engaging rollers 18 which may comprise a part of the dryer section of the papermaking machine 10. While the web 11 is advancing on the screen 14 away from the slice 15, i.e. in the downstream direction, excess water is permitted to drip through the screen 14. The couch roller 16 may be adapted to remove additional water from the web 11 as by applying a vacuum through the screen 15 to the underside of the web 11.
In accordance with one aspect of the invention, the slice 15 varies in vertical width at spaced locations along the horizontal width of the web 11 such that additional quantities of pulp are permitted to flow through the slice 15 to form regions or continuous bands 20 of increased thickness in the web 11 as compared to the normal thickness portions 21. Since the increased thickness regions 20 are simultaneously formed with the normal thickness portions 21, the increased thickness regions 20 will be an integral part of the web 11. While FIGS. 1 and 2 illustrate the increased thickness regions 20 comprising a larger proportion of the web 11 than the normal thickness portions 21, it will be appreciated that the thicker regions 20 could comprise only a small percentage of the web 11, depending upon the end use of paper sheet products made from the web 11.
The slice 15, which is of generally uniform vertical width in a conventional papermaking machine, can be permanently altered in vertical height at spaced locations therealong, as illustrated in the preferred embodiment of the invention in FIGS. 1 and 2, to provide the web 11 with the increased thickness portions 20 and the normal thickness portions 21. On the other hand, it will be apparent to those skilled in the art that means, such as adjustable plates or the like, could be provided to selectively mask off portions of a uniform width slice to yield the desired arrangement of increased thickness regions 20 and normal thickness portions 21 in the web 11. Of course, the width of the slice could be controlled mechanically as by cams, electrically as by solenoids, or hydraulically. More elaborate controls, such as computers and programming thereof or various forms of numerical control known to the prior art, could be utilized to create more intricate patterns in the paper thickness, including embossing effects, by instantaneously controlling the width of the slice 15 at the desired spaced locations.
With reference to FIG. 3, there is shown another embodiment of a papermaking machine 23 which utilizes a slice 24 of uniform vertical width to form a web 25 of substantially uniform thickness on the screen 14. In accordance with another aspect of the invention, means are provided to deposit or lay additional amounts of wood pulp onto the uniform thickness paper web 25 in the web forming area of the machine 23 such that the additional amounts of pulp create regions or islands 26 of increased web thickness. The means for depositing the additional pulp onto the web 25 may include a plurality of spraying heads 27 disposed above the web 25 at spaced locations across the width of the web with the spraying heads 27 each connected to a source of pulp by the conduits 28. The spraying heads 27 may be arranged and operated to provide a variety of patterns of increased web thickness. The individual spraying patterns of each spraying head 27 may also contribute to different web thickness patterns. For example, if the heads 27 continuously deposit additional pulp onto the web 25, continuous bands as illustrated in FIGS. 1 and 2 may be added to the web in FIG. 3 or the spraying heads 27 may be operated in an on and off manner, as by valves contained in the spraying heads 27 or the conduits 28, to create isolated regions or islands 26 as illustrated in FIG. 3. If additional spraying heads are provided further away from the slice 24 than the spraying heads 27 illustrated in FIG. 3, additional thicknesses of wood pulp can be deposited onto the web 25, some of which may be in overlying relationship to the islands 26 formed by the heads 27. The pressure in the spraying heads 27 must be sufficient to move the pulp therethrough, but also must be sufficiently low so as not to puncture the web 25 when spraying the additional pulp thereon. Alternate on and off action of the spraying heads 27 may be controlled by conventional timing devices or by a photoelectric sensing device 29, located intermediate the spraying heads 27 and the couch roller 16, which provides an output signal indicative of the thickness of the web 25. The spraying heads 27 will be responsive to the output signal of the sensor 29 and thereby automatically repeat the pattern of regions of increased pulp thickness on the web 25. The output signal of the photoelectric sensor 29 or other control device which controls the sprayings heads 27 may also be utilized in controlling other processing operations, such as synchronous cutting of the web 25 into sheets or strips of paper with the islands 26 of increased web thickness thereby automatically positioned or registered in the sheet or strip.
In accordance with another aspect of the invention, at least some of the web engaging rollers 31 may be profiled to contain recessed areas 32 corresponding to the islands 26 in the web 25 such that the increased web thickness provided by the islands 26 is not unduly compressed by further processing of the web 25. Synchronization of the drive of the rollers 31 can be provided by the output signal of the photoelectric sensor 29 in a manner analogous to the control and registration of printing press rollers.
A wide variety of paper sheet products possessing increased regions of web thickness can be produced by the machines in FIGS. 1-3. As illustrated in FIG. 4, a continuous strip 34 of sheet paper may be cut or slit from the webs 11, 25 and perforated, as at 35, to define separate, but connected, sheets each having a central regions 36 of increased paper thickness with margins 37 of reduced paper thickness. The thickness of the center portion 36 is most advantageous in paper toweling, toilet tissue or the like where the center of the strip 34 is more frequently used than the thinner margins 37. This insures that the wood pulp comprising the strip 34 is most efficiently used and wood pulp is conserved. It will be readily apparent that other paper products, such as facial tissue and printing paper could be made in a manner similar to the strip 34. Printing processes could be synchronized with the increased thickness region 36, in a manner analogous to use of the photoelectric sensor 29 in depositing additional pulp on the web 25, to provide the desired thickness and opacity of the paper in the printed region and yet conserve pulp by making the marginal areas 37 of the page of reduced thickness.
Illustrated in FIGS. 5 and 6 are other arrangements of islands 26 of increased paper thickness, of generally circular configuration, surrounded by areas 38 of reduced thickness in the respective sheets 39, 40. As best seen in FIG. 7, typically the region of increased paper thickness 26 will blend or feather into the reduced thickness margins 38, rather than forming an abrupt change in thickness at the junction of the region 26 with the margins 38. The ratios of the thickness of the region 26 to the margins 38 can vary considerably depending on the end use of the paper sheet product. For example, the region 26 could be only a few percent thicker than the margins 38, or could be several times the thickness of the margins 38. Of course, the amount of pulp conserved by the invention will be dependent upon the difference in thickness between the increased thickness regions 26 to the margins 38 as well as the percentage of the web 25 occupied by the regions 26 to that occupied by the margins 38.
The advantages of the present invention can also be utilized to provide extra strength to the desired areas of the paper sheet product without the need for additional apparatus to add or inject higher strength fibers into the desired positions in the web formed by the papermaking machines 10, 23. Instead, the relative strength of portions of the paper sheet can be controlled by the thickness of pulp laid while forming the web, from which the sheet is later cut.
Yet another feature is the ability to deposit the additional pulp in a different color especially in the papermaking machine 23 wherein the pulp for the head box 12 and for the spraying heads 27 may come from different sources.
Since the additional pulp is laid or deposited in the web forming area of the machine, the additional pulp is formed with the web as an integral part thereof. Thus, the web and the paper sheet products made from the web maintain a high degree of flexibility and absorbability which is important in personal paper products, such as facial tissues, and in other paper sheet products such as paper toweling.
It is not expected that the packaging of paper products comprising regions of differing thickness in accordance with this invention will be troublesome, since the regions of increased thickness can be designed to aid in the packaging. For example, the regions of increased thickness can be staggered or stepped where the paper sheet product is packaged in a box, such as facial tissues. Similarly, rolling of strips of paper sheet products having differing areas of thickness will also result in staggered positioning of such thicker areas upon each other. Additionally, many paper products in rolls, such as paper toweling or toilet tissue are loosely rolled to avoid compression of the paper and to preserve the absorbability characteristics. Furthermore, in many paper products the difference in thickness between the narrower and thicker portions will not be so substantial as to cause packaging problems.
It will be understood that various changes and modifications may be made without departing from the spirit of the invention as defined in the following claims.
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A non-laminated paper sheet product characterized by regions or islands of increased thickness, usually located in the center of the sheet for more economical use of the paper product and for conservation of wood pulp. The regions of increased thickness are formed by depositing or laying additional pulp stock onto a generally uniform thickness paper web in the web-forming area of a paper machine in either wet or dry methods of paper production. Continuous regions of increased thickness in the web can be formed by corresponding variations in the width of the web or by spraying the additional pulp onto the forming web. Islands of increased web thickness can be formed by periodically interrupting pulp stock depositing sprayheads disposed at spaced locations across the width of the forming web, with timing devices or web thickness sensors controlling the sprayheads.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. §119 of Mexican Patent Application No. MX/a/2009/008597, filed Aug. 12, 2009, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD OF THE INVENTION
The present invention is concerned with a system for tracers detection which emits gamma radiation at the head of production wells, in order to monitor in real-time concentration values of tracer activity, and that it will be able to operate autonomously according to a monitoring established program, and in this manner to be able to collect more data, which contributes to reduce the uncertainty level and to increase analysis efficiency and interpretation of the results of tracer tests.
BACKGROUND OF THE INVENTION
The main goal during the exploitation phase of an oil reservoir, from a technical-economic point of view, is to obtain the optimal hydrocarbons recovery, so that it remains the least amount of residual oil in the reservoir. In order to increase the amount of oil, it is used the secondary and/or enhanced recovery processes, which mainly consist in injecting fluid for providing additional energy to the reservoir, taking advantage of this energy in the displacement of hydrocarbons towards production wells.
The tracer tests among wells are a widely used tool in the recovery processes, in order to determine the flow trajectories of injection fluids, as well as to detect high permeability zones or drainages that cause a disproportionate distribution of injected fluids, which can be reflected on an efficiency process reduction.
In documents found in tracer tests literature, the sampling test is performed through a visit to the field of selected production wells, by trained technical staff, this task is carried out according to a previously established sampling test program during the design stage of the activities for the tracers injection to the reservoir. This program usually takes into account a high sampling test frequency the days immediately after the tracer injection, so that going down its frequency as long as the time passes through. The reason of high frequency at the beginning is the possibility of the presence of tracer due to drainage which breakthrough the tracer in the production well very quickly. This matter produces a very short tracer response but at the same time of great magnitude so that it can be only possible to reconstituted if it is possible to have a sufficient number of sampling tests. Otherwise, when there is not drainages, the tracer flow more slowly in the porous media, so the scheduling of sampling tests collection is at least one year, and then to accomplish that the tracer response more closely reflect what happens in the reservoir. Taking into account the above description, the cost of the sampling test of a tracers test rises sharply, due to the large amount of sampling tests. It is worth to say that a substantive part of the cost of a tracer project corresponds to the analysis of sampling tests, and often it is sacrificed the number of sampling tests in order to reduce the project costs. However, the information obtained from tracer tests is directly proportional to the number of analyzed sampling tests.
One of the main problems that arise when interpreting a tracers test results, and even, reaching some failure cases, is caused by a poor and/or insufficient monitoring program. This may be due to several factors, mainly to an inadequate program design of the sampling test, or it could also be due to other causes, such as, difficulty of moving through long distances for carrying out the sampling tests, impossibility to perform the sampling tests due to affectations caused by farmers who did not allow access to the wells, remote offshore platforms, or it could also be due to the lack of available resources (human, economics) for sampling tests:
The main advantage that represents the radioactive tracers is the possibility of working with small volumes for its injection and in many cases, especially for gamma emitters, its facility for being detected in-situ. However, the radiation measurements for radioactive isotopes of low energy beta emitters such as tritium (18 keV maximum beta energy) and carbon-14 (155 KeV) are not carried out in the field, because their analysis is carried out with special low level count equipment, therefore all samples are sent for their analysis to specialized laboratories that have liquid scintillation counters equipments. In another case, the use of radioactive isotope tracers that emit gamma radiation, such as: 57 Co, 58 Co and 60 Co, 192 Ir or 131 I, they make much easier their detection, which can be achieved through scintillation crystals. The sodium iodide detectors activated with thallium, NaI (TI), are widely used for the detection of gamma radiation, which given its characteristics make possible that they can be used in the field, which allows it become unnecessary to perform a sampling test and then to send it to the laboratory for radio-chemical analysis.
Currently, for measuring gamma radiation, there are a several commercial laptops, however, its use is focused on general applications, among these kind of commercial mobile computers it can be mentioned the following models: 1000 Inspector, Inspector 2000 Canberra brand, and others from the Ortec brand.
It is important to mention that if commercial equipment are intended to be used for detecting radioactive tracers in a intrusive way, which is known by the
term of “on-line detection,” in the head of production wells, these equipments would present serious disadvantages in compared with the system developed in this invention, such as:
1. Non-intrusive measuring drill. They cannot directly measure the radiation contained in fluid from of the reservoir.
2. They are portable, but with battery life which last from 3 to 10 hrs. which does not allow us to connect them to the wells permanently.
3. They do not have data storage capacity for testing lasting long periods of time (months).
4. Temperature operation is very limited (maximum 55° C.).
5. They do not operate on a autonomous manner, i.e. they require the permanent presence of an operator.
It is worth to say that it have been reported (Zemel, 1995) applications in tracer tests, where it is mentioned that radioactive tracers measurements can be performed in-situ by using detectors NaI (TI), however, features of the measurement system are not specified and even less if they are commercially available equipment, or having similar characteristics to the system of the present invention.
There are also commercial tools or systems (Spectral Gamma Ray Tool, TracerScan, etc.) from different companies like Halliburton, Schlumberger, International Protechnics, etc., whose application is the natural gamma radiation log test, or also gamma spectroscopy applications, within oil wells, these tools are used to characterize the stratums, and they operate at conditions of high temperature and pressure. However, these tools are designed to operate inside the wells, so they do not meet all the features and operating purposes of the measurement system that is result of this invention.
Likewise, with regarding to the above they are published large number of patents relating to tools and systems to make profiles of gamma radiation inside the wells, focusing to different applications. For example, in U.S. Pat. No. 4,007,366, relate equally to systems and apparatus for take a radiation intensity profile of tracer in different runs that are performed inside the wells. The arrangements consists of a background tool (drill), which has two types of radiation detectors Geiger Müller, a device for injecting a tracer charge inside the well, a telemetry module to transmit data between the drill and the surface equipment. The pulses generated by detectors, are sent to the surface equipment through a cable record. The unit on the surface, has all the postcards for the management of the pulses from the background tool, electronic arrangements for corrections of the readings, discrimination circuits, counters, power supplies to provide the energy needed to power electronic circuits in the equipment fund, etc. Given the characteristics of the detectors used, this system can not differentiate between two or more tracers used, nor can operate autonomously.
Other patents mentioned techniques developed for specific applications related tools also for operate in the interior of the wells, such is the case of U.S. Pat. No. 4,481,597, which refers to an analog to digital converter or spectrum analyzer for use in a drill for making logs of spectrum gamma ray within the wells. The system converts analogics pulses generated by the photomultiplier tube in a digital representation or digital word. This digital representation has the form of numbers representing the energy of gamma rays or other types of nuclear radiation that produces scintillations in the crystal detector, which is optimally coupled to the photomultiplier tube. The digitized value is transmitted by the drill to the surface through cable record.
Also there are published other developments related to the sampling of fluids in wells, as mentioned in the reference U.S. Pat. No. 4,454,772, which describes a new method for automated fluid sampling wells. This method is basically of a series of solenoid valves to inject fluid from the well to a number of sample containers are filled one after another, through the valves that are electrically driven by a programmable switch. Later, with the series of containers collected samples are sent for laboratory analysis. The novelty of the method of the present invention is to automate the sampling of fluid from the wells, thus avoiding moving staff to the sampling points.
The references mentioned above were created for entirely different applications of the present invention, by virtue of this we have implemented an online measurement system of radioactive tracers in the wellhead in an offshore producer of oil, which allows continuously monitor the presence or not presence of three different tracers, above to determine with greater precision the times of arrival of the tracer, while eliminating the need to allocate staff to carry out sampling operations, with all advantages that this represents.
Therefore, one of the objects and advantages of the present invention is to provide a measurement system that allows online monitoring and permanent values of tracer concentration, and is able to operate autonomously according to a program monitoring previously established based on the design and objectives of the injection of tracer to the site, and thus have more data from the tracer activity, which reproduce the response curves of tracer, which contribute to reduce the level of uncertainty and increase efficiency in the analysis and interpretation of results.
BRIEF DESCRIPTION OF THE DRAWINGS OF THE INVENTION
It provide the following FIGS. 1 , 2 and 3 , in order to understand clearly the online measurement system of radioactive tracer activity in oil fields, and serve as a reference in the application example provided in the following paragraphs. Although the figures illustrate specific provisions of equipment, with which are can go to the practice the present invention, should not be understood as limited to a specific computer.
FIG. 1 illustrates a block diagram which shows the parts that make up the online measurement of activity of radioactive tracer in the head in production wells of oil fields, cause for complaint as an innovative system.
FIG. 2 shows a schematic diagram of the measurement system on-line radioactive tracer, installed between the tubing (before the choke) and Oil Pipe Line (after the choke) in a well in production, at a oil reservoir.
FIG. 3 shows a schematic representation in a greater detail of the measurement system and arrangement of connections required for operation through a bypass flow between the production pipeline and the Oil Pipe Line.
DETAILED DESCRIPTION OF THE INVENTION
This system object of the present invention was developed with the aim of satisfying the requirements of detection and measurement of the arrival of radioactive tracers that emit gamma radiation, in the head of production wells of oil fields.
In accordance with FIG. 1 , the system basically consists of four parts:
I. The radiation detector. II. The power plant. III. Laptop. IV. Data Acquisition Equipment.
The following describes each of the different blocks and their interrelation.
I. Radiation Detector (blocks 1 to 3 of FIG. 1 ).—This device, as shown in FIG. 1 , consists of three elements: the scintillation crystal NaI (TI) and photomultiplier tube (block 2 ) the high-voltage source (block 1 ) and an amplifier (block 3 ). The radiation emitted by the fluid (tracer) from the field, which flows through the container type Marinelli, strike the scintillation crystal, producing flashes to be connected to the photomultiplier tube, is generated out of this a proportional electrical signals the energy of the incident radiation, these pulses generated finally enter the stage of signal amplification. A brief description of each of the three components of the radiation detector:
1) High voltage source (block 1 in FIG. 1 ).—This is a switching power supply delivering between 1200 and 1500 Volts needed to polarize the photomultiplier tube through a resistive-capacitive arrangement. This source of high-voltage bias required for a direct-current power supply +/−+/−15 Volts, which is provided by a converter AC/DC powered in turn by the solar plant (converters AC/DC). 2) Scintillation crystal and photomultiplier tube (block 2 in FIG. 1 ).—It is the primary element radiation detector. It is sodium iodide activated with thallium NaI (TI). Cylindrical geometry has a diameter of 2 inches×4 inches long. It chose this type of detector, for the ability to distinguish different energies of radiation, which allows us to differentiate the arrival of several tracers simultaneously. The function of the scintillation crystal is to make the conversion of gamma radiation incident visible electromagnetic energy. The scintillation crystal is coupled photomultiplier tube (PMT), whose function is to convert the electromagnetic energy in the visible region that delivers the scintillation crystal, in pulses of electrical energy. Model was selected photomultiplier used to achieve the coupling of the whole energy range of incident gamma radiation, measurement of 50-2000 keV. 3) Amplifier (block 3 in FIG. 1 ).—By this module, the pulses are amplified signal from the photomultiplier (PMT). This module is also powered with +/−15 Volts CD.
Features and specifications of the radiation detector, Model: Brand 2GR4/2L-XM Saint-Gobain Crystals:
Dimensions complete radiation detector: 2.37×15.59 inches. Detector comprising a scintillation crystal, photomultiplier tube, high voltage source and signal amplifier. Scintillation crystal dimensions: 2×4 inches (diameter, length). Radiation to be measured: Gamma. Detection range: 50-2000 keV. Operating Temperature: 150° C. Pulse Height Resolution: 7.5% Cs-137. Material from the cover: Stainless steel.
It is important to mention that the radiation detector was specially designed and built by Saint-Gobain Crystals, according to design specifications and parameters provided by the Tracer Technology Area of the Instituto Mexicano del Petroleo (IMP).
Container radiation detector (represented by number 5 in FIG. 2 ).—
To increase the efficiency of detection module, we designed a Marinelli container type, stainless steel with an effective volume of 2.3 liters of fluid to reduce undesirable background radiation from the environment, covered container with lead shielding ½ ″thick, which allows increasing the minimum level of detection. The container detection module was designed and built to withstand a maximum pressure of 1,600 psi, which is invention is not limited to operate at pressures above this value. This container was designed only for the radiation of Saint-Gobain crystal, which is described here.
II. Power plant (block 4 in FIG. 1 ). This module is only one component, described below.
4) Power source of the entire system, consisting of a photovoltaic panel, a bank of two batteries, a controller and an inverter DC/AC. With this inverter are generated at 60 Hz 127 volts to power converters, AC/DC Voltage with outputs of +/−15 V, +12 V and +5 V direct current necessary to energize both the radiation detector as other electronic circuitry in the data acquisition module.
The elements that make the solar plant, were selected to allow energy supply to the measuring system, up to 72 hours on days of total darkness. The power supply is permanent on a sunny day or a little sun. Other characteristics of the elements that make up this block are:
Monocrystalline photovoltaic module, is 75 Watts. PV controller 2 Batteries 100 Amp/hr. Investor of current. Converter AC/DC +/−15 Volts and 0.50 Amps output. Converter AC/DC +5 Volts and 3 Amps output.
III. Laptop (block 5 of FIG. 1 ). This module has only one component, described below.
5) For programming and retrieval of data acquired during or at the end of the field test carried out. Communication between the device and measuring system, is effected by the protocol via RS-232 serial port at 9600 baud. Similarly, the data processing is performed on this computer. To this end, it was a program in Visual Basic within Excel tool for Microsoft Office.
Through line A in FIG. 1 , is performed signal coupling between the power amplifier radiation detector and the entrance to the stage of signal conditioning in data acquisition. Through the communication represented by line B in the figure, power is provided throughout the system, and reading of data stored in the system is done via a laptop computer through a communication port RS-232 (represented by line C of FIG. 1 ).
IV.—Data Acquisition Equipment (block 6 to 12 in FIG. 1 ).—Using this equipment, process the pulses from the detection module, has the electronic circuits: signal coupling through a simple differentiating circuit, discrimination pulses with voltage thresholds and timing, a monostable multivibrator and a signal conditioning stage, later entering the counter circuit based on a preset time window, then the data is stored in memory according to the monitoring program established. The information is continuously displayed on a display numbers and as additional support, the information displayed on screen prints.
Here are the main functions of each of the stages that compose the programmable data acquisition equipment and the relation among them, corresponding to blocks 6 to 12 , according to FIG. 1 :
6) Phase comparison and signal conditioning (block 6 of FIG. 1 ).—This stage consists of three channels of comparison, earlier in order to be able to detect up to three different radioactive tracer. Each of the comparators is set to an adjustable reference voltage, which corresponds to a detection threshold of the energy of the radiation emitted by the tracer detection is required. Following this section is a monostable multivibrator designed to standardize the width of the pulses to 0.8 us. The purpose of the above, is to avoid problems of overlapping pulses, resulting in erroneous reading would count them. As a protection against noise, which similarly could cause false triggering, the output signal of the previous stage, is coupled through an RC circuit and a gate array to the next stage: the counting of pulses. 7) Step counting of pulses (block 7 of FIG. 1 ).—As the name implies, this stage is done counting the pulses from the phase comparison and signal conditioning. This has an adjustable time base, allowing count pulses at a frequency of 3.66 msec each to each 8:32 pm. The measuring window was prefixed in 1 minute may count up to 224 pulses, ie 16.78×106 pulses per minute to the time window selected. 8) 16-bit microcontroller (block 8 of FIG. 1 ).—The integrated microcontroller is used in a development board. Through this device, it performs the function of programming and control, data read from the stage of counting and writing them in memory, as well as the results displayed on screen and printing of the thermal paper. The electronic card microcontroller with a bank of read-only memory (RAM)256 Kbytes, which added to 256 KBytes of internal flash memory that holds the microcontroller, provides a total of 512 Kbytes of user memory that can store approximately 174.000 data. Another feature of the microcontroller, it has ports for 12 C and SPI communication. The latter allow you to link serial devices such as memory, allowing larger data storage capacity of the system to 840.000 or more, if they require the application.
We developed a software in C language, which was compiled, by which the microcontroller performs all control tasks of acquisition, storage and information management.
9) Output interface for the user.—Communication between the user and the microcontroller is done through a keyboard (block 9 of FIG. 1 ), by which all values are entered the required parameters for programming measurement (frequency counting). As a means of display, it has a liquid crystal display, LCD, and has a thermal printer, as a means of additional support for the information.
The alphanumeric keyboard is 4 columns×4 rows. The display or LCD screen is 4 rows and 16 alphanumeric characters per line. The keyboard is connected to the microcontroller through port H of the microcontroller. This port is configured as input/output (I/O) and LCD display communicates via SPI port.
10) Printer (block 10 of FIG. 1 ).—As mentioned earlier, to have additional support from the acquired data, joined to the measuring system, a thermal paper printer. Communication between the microcontroller and the thermal printer is done via the serial port at a speed of 9600 baud. 11) Report of data (block 11 of FIG. 1 ).—This consists of a bank of read-only memory (RAM) 256 Kbytes, which added to 256 KBytes of internal flash memory that holds the microcontroller, gives a total 512 Kbytes of user memory, allowing us to store approximately 174.000 data. The programming is done in the same way paged. 12) The keyboard (block 12 of FIG. 1 ) is alphanumeric.—4 columns×4 rows. The keyboard is connected to the microcontroller through port H of the microcontroller. This port is configured as input/output (I/O).
Finally, it is noteworthy that the electronic equipment buyer, is contained within a NEMA that protects it from adverse environmental conditions. We should also mention that this computer is powered by alternating current (AC) of 127 Volts and 60 Hz, from the solar plant. This alternating current is converted to direct current of +/−12 Volts and 5 Volts, needed to operate the electronic circuitry above and to polarize the radiation detector. To move from this alternating current to direct current converters used the following AC/DC:
Lambda Converter KWD10-1212 model of +/−12 Volts and 0.45 Amps output. Converter KWS15 model Lambda-5 +5 Volts and 3 Amps output.
Finally, it is noteworthy that the electronic acquisition equipment, is contained within a NEMA 4 box, which protects it from harsh environmental conditions which must operate. We should also mention that this computer is powered by alternating current (AC) of 127 Volts and 60 Hz, from the solar plant. This alternating current is converted to direct current of +/−15 V, +12 V, needed to operate the electronic circuits mentioned above, as well as providing energy to the detection module. To move from this alternating current to direct current used the following sources of DC power (converters AC/DC) of +/−15 Volts and 0.5 Amps output to +5 Volts, 3 Amps output.
Description of the procedure used for installation and operation measurement system radioactive tracers online at the head of production wells. FIG. 2 and FIG. 3 (Detail A), shows the elements needed to install the equipment on the premises of the production wells in the field under study.
As shown in Detail “A”, FIG. 3 , the data acquisition system ( 8 ), container ( 5 ) together with the sensor ( 12 ), the battery module ( 9 ) and the solar cell ( 7 ) are installed on a pipe or pole ( 23 ). The container is arranged for coupling mechanical connections and stainless steel tubing or reinforced hose for fluid entry and exit of the container, both the tubing and in which case the hose must withstand the operating pressure and temperature of the well, in one of the wells in which validated the computer, the operating pressure at the well head was 900 psi and the temperature in the head of 119° C. FIG. 2 shows the connection lines ( 21 and 22 ), one of them taking well fluid ( 21 ), connects before the choke ( 2 ), and is fed to the container ( 5 ) Valve ( 4 ) regulates the flow into the container. The output of the fluid is made by connecting the line ( 22 ) to the Oil Pipe Line ( 3 ) is tied with the head of the oil collection leading to the separation station. The connection of the line ( 22 ) must be made to a valve ( 10 ) whether or regulatory step. Normally the valves 4 and 10 are part of an array of valves that are installed on the operating lines of the well and is used for oil sampling and measuring the pressure through mammography manometers installed that monitor operating conditions of both the wellhead and the Oil Pipe Line. In the event that these valves do not exist in this way, you need to install to ensure proper system operation. The container must have installed a valve ( 11 ) and a hose for venting and depressurization of the system.
In the implementation phase, first of all must make sure that the solar cell ( 7 ), the data acquisition system ( 8 ) and all electrical components, are operating properly. You should also ensure that the data acquisition program is scheduled properly considering the duration of the operation. To ensure that the fluid flow on the system of tubing and container must be a difference in pressure between the pressure and the pressure of the Oil Pipe Line. Obviously the pressure at the wellhead must be greater than the pressure of the Oil Pipe Line, on the operational phase it must kept this difference of pressures.
Once installed to the computer as shown in the diagram in FIG. 2 , opens the valve ( 4 ) to regulate the proper flow, vented in the first instance by the valve ( 11 ), having confirmed the flow, closes the valve ( 11 ) and opens the valve ( 10 ), which the oil is flowed into the system. You should keep a manual record of the variation of pressure from the wellhead and the Oil Pipe Line and if possible the container.
According to FIG. 2 , the output interface for the user (Display), communication between the user and the microcontroller is done through a keyboard ( 16 ), in which all values are entered the required parameters for the programming of the measurement (frequency count). As a means of display, it has a liquid crystal display, LCD ( 15 ), and a thermal printer ( 17 ) as a means of additional support information.
As mentioned previously, to have additional support from the acquired data was integrated to the system of measurement, thermal paper printer ( 17 ). Communication between the microcontroller and the thermal printer is done via the serial port at a speed of 9600 baud.
Finally, it is noteworthy that the electronic acquisition equipment is contained within a NEMA 4 ( 8 ), which protects it from harsh environmental conditions which must operate. We should also mention that this computer is powered by alternating current (AC) of 127 Volts and 60 Hz, from the solar plant.
EXAMPLE
The following example is presented to illustrate the operation of the online measurement system of radioactive tracers in oil well head. This example should not be considered as limiting the claims here, but simply describes the procedure whereby operation tests were performed measuring system online source of this invention, in one of the tests conducted in oil production wells.
We describe useful framework and requirements to which the computer responds developed, and also, a brief description of the measurement system and its main components, the wiring diagram required for testing for the equipment. Referring to FIGS. 2 and 3 , have the following:
Description of specialized valves of valves used:
1.) Needle valve ½″—NPT ( 4 ) to control the container flow 2.) Needle valve ½″—NPT ( 10 ), Security outflow towards the Oil Pipe Line. 3.) Ball valve ½″—NPT (11th) for phase lock control flow. 4.) Needle valve ½″—NPT ( 11 ), to purge and depressurization of the system.
Description of operations needed to establish the flow measurement device line tracers: Once installed the system as shown in FIG. 2 and as specified above, the system must be connected before the choke, the will be making fluid and the fluid outlet must be connected to a choke point after on the same line where you have a pressure difference, it is the Oil Pipe Line that reaches the head of collection. Then, it performs the following procedure to enable the operation of the system for online detection of tracers.
FIG. 3 shows the components of the detection system used for the development of operations in the procedure.
Operation 1.—Establishment of Flow
Step 1.—Check that all valves 4 , 10 , 11 a , 11 are fully closed.
Step 2.—Check that hose is placed a valve 11 to a storage container vent fluids.
Step 3.—Verify is an instrument for measuring pressure at points of connection, this may be gauge or manografo, in which case you need to install this device.
Step 5.—Manipulating the valve 4 , gradually opening it up to a quarter turn around, just as you open the valve 11 regulating the flow slowly to ¼ turn. The valve 11 a and valve 10 remain closed, maintaining the flow for a term May to 15 seconds, checking the level of container harvesting should be noted that this container will only be used at this stage and in full operation should not be present.
Step 6.—Valve 11 is closed and fully open the valve 11 a , the valves remain closed 10 , which is the conjunction with the Oil Pipe Line of the well. In this step it is suggested to maintain a pressure monitoring system throughout the entire process. In the same manner, it is recommended to verify the existence of unions and fix leaks in such case before making the oil flow on the system.
Step 7.—Gradually opened fully the valve 10 , permitting the flow connection to the flow system of the Oil Pipe Line. Establishing the flow and pressure is monitored over a period of time.
Operation 2. Flow Regulation on the Line Feeding the Container
Once flow is established and verified that no leak in the connections necessary to regulate the flow to ensure the movement of fluid in the line and the container.
Step 1.—Check that hose is installed in the valve 11 and it is within the container for collecting fluids from the well. Step 2.—Check that the valve 11 is closed. Step 3.—Fully close the valve 11 a. Step 4.—Close the valve 4 and then open it slowly to regulate the flow line from the container to the desired flow, making flow measurements over time. Step 5.—Open slowly until all the valve 11 . Step 6.—Check the volume of container that stores the vent fluid, taking care not to spill. Step 7.—Verify at any time pressures on the gauges. In this operation, as a first test, the flow was regulated at a cost of 1 liter in 25 seconds; it is noteworthy that output regulation is done at atmospheric pressure where the pressure difference is very high, making the oil flow on the new line of low pressure difference by reducing fluid volume. Once adjusted the flow proceeds to perform the following steps. Step 8.—Close valve 11 . Step 9.—Check gauge pressure at the head and the Oil Pipe Line. Step 10.—Open slowly and in full the valve 11 a , to establish the flow. Step 11.—Check the setting on the system flow is necessary to consider the motion of fluid in all items of equipment.
Once adjusted, the flow goes to work the system and monitor the pressure data. Table 1 shows an example of data taken in a well where test runs were conducted.
Moreover, it is important to note that the data acquisition system must be programmed to acquire data for as long as the rest of the procedure, and only need to verify that the power supply to work properly, since it depends on energy solar. At this stage of operation, the acquisition system records the energy intensity of the radioactive tracer that is used and is blended in the aqueous phase in the production of hydrocarbon reservoir.
TABLE 1 Pressure data with a regulated flow lt/25 seconds Pressure Pressure Oil Pressure on gauge 2 Pipe Line the wellhead (Container) connection Time Psi Psi Psi 13:50 890 440 430 13:55 890 440 430 14:00 890 435 430 17:46 890 420 430 17:50 890 450 430
Operation 3. Depressurization and Purging of the Measuring Equipment
After completing the operations for the detection and measurement of tracer in line at the wellhead, we proceed to disconnect the computer by using the following procedure:
Purge and Depressurization of the System
Step 1.—Check that the valves 4 , 10 , 11 a are operating efficiently, the valve 11 must be closed.
Step 2.—Check that the valve 11 hose is placed to a storage container vent fluids.
Step 3.—Manipulating the valve 4 , closing gradually until full.
Step 4.—Manipulating the valve 10 , closing gradually until full.
Step 5.—Check that the pressure of the wellhead and the Oil Pile Line was reintroduced in its original condition.
Step 6.—11th valve is closed and fully open the valve 11 , the remaining fluid should go into the collection container, avoiding spills on the floor. This step is depressurized the line between the wellhead and the container.
Step 7.—Slowly opens in full the valve 11 a , now allowing the container and the line that goes to the Oil Pipe Line lose pressure.
Step 8.—Verify that the remaining fluid was being removed from the entire system.
Step 9.—Check again that the valves 4 and 10 are closed.
Step 10.—Proceed to disconnect from the production facilities if necessary.
Comments
As part of the results of tests conducted in a well in production, you can mention the following:
The system operates satisfactorily to the conditions of temperature and pressure of 880 psi and 115° C., respectively. It is noted that these conditions are high. Similarly the system is expected to work well under pressure conditions and temperature. Therefore, one can say that the system was tested under extreme conditions. The system was operating and recording data for a total 53 hours, of which, 15 hrs operated without fluid flow flowing through the container, and 38 hrs from spending registered site. The different conditions for the tests, without fluids, namely, operating at room temperature, at different costs, allowed to observe and evaluate performance at different operating temperatures.
Conclusions
A summary of some points of tests the equipment:
It was possible to measure the radioactivity (gamma emission) contained in the fluid from the reservoir, connecting such a system between the production tubing Oil Pipe Line and production, i.e., measuring the flow production line and in real time, with a window measuring 1 minus. The system works perfectly with the operating conditions of the well, the pressure in one case was approximately 900 psi and 450 psi the Oil Pipe Line. Maximum working pressure is by design: 1,600 psi. The system works fine with the production fluid to a temperature of 115° C. The design is made to withstand a maximum fluid temperature of 150° C. Autonomy was validated in the measuring system, as to supply its own energy through solar panel and battery assembly. This system is designed to operate continuously and indefinitely. The system operate continuously 53 hours, is designed to operate on long tests (6 months or more) in terms of data storage capacity is concerned. Was validated in the field supported by the findings obtained in printed form as well as communication with PC and output data via RS-232 serial port. The study validated robust heavy duty design capable of withstanding the temperature of the fluid from the reservoir, and environmental conditions of operation of the online measurement system.
It can be highlighted the usefulness of the system of the present invention, in terms of on-line measurement of tracer activity emission range, since this system is not necessary to take samples in the wells to be sent to the laboratory for analysis. The main reason for implementing the system of this invention, it is precisely on-line measuring radioactivity in the fluids from the reservoir, therefore, significantly reduced costs and in particular will more closely in terms of the tracer response curves therefore will increase the reliability of the results of tracer tests also achieved a significant reduction in the costs are normally in the sampling and radiochemical analysis laboratory in a conventional test tracers in oil field.
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The online measurement system of radioactive tracers in oil wells head, object of this invention, is characterized by the use of new technology to measure concentrations of tracer activity in real time, using a radiation detector NaI (TI), with features that make it possible to detect up to three different tracers and be able to operate in temperature conditions up to 150° C., which allows to be immersed in a container with fluid coming from the flow stream, achieving with this to increase the sensitivity of the measurements. This system of measurement in the head of production wells will allow having much more data of the tracer activity, avoiding having to transport the operational staff to production wells to carry out sampling test, with all the advantages that this represents.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved method and apparatus for automatically attaching a collarette, display, and label to a garment body by synchronized sewing and material feeding.
2. Description of the Prior Art
Garments such as shirts or blouses are typically manufactured using manual labor. Garment pieces are cut out of stock material, trimmed to proper dimensions, and then sewn together on a sewing machine by a sewing machine operator.
Often in garment manufacturing, a piece of material, known in the art as a "collarette", is folded and sewn around the garment neck to form a continuous collar. The conventional method of sewing a collarette to a garment neck is performed by a sewing machine operator in the following manner. First, the collarette is cut to a size slightly shorter than the garment neck edge where the collarette is to be sewn. Then, the operator positions the collarette on top of the garment body, places the material under a sewing machine and starts sewing. While sewing, the operator must continually maintain the alignment of the collarette and garment body to obtain an evenly manufactured finished product. Additionally, the operator must pull and stretch the collarette during the sewing operation. Stretching the collarette in such a manner will cause the completed garment and collarette to lie flat and have no wrinkles or gathers around the neck when worn.
The operator may also be required to attached a label (e.g. a manufacturer's identifier having the manufacturer's name and product information) to the garment with the same stitch being used to attach the collarette to the garment. To perform this operation, the operator must carefully position and hold the label in the desired location while sewing.
Additionally, the operator may be required to sew a small strip of material, known in the art as a "display", to the inside of the garment neck to flatten and cover the seam joining the collarette and label to the garment body (the "joining seam"). The display is used to cover the area inside the garment where the joining seam would be partially visible after the garment is packaged for sale, i.e., on the inside back portion of the garment neck. To sew a display the operator must carefully position the display on top of the collarette and garment body and hold the display in position while sewing.
Further complications to the above-described conventional sewing operation are encountered when the joining seam is to be hidden from view from the outside of the garment (i.e. the side of the garment away from the body of the wearer). To hide the joining seam, an operator must layer the collarette, display, and label on top of the garment body and use an "overedge stitch" to join the pieces together. The resulting "overedge seam" is then hidden from the outside of the finished garment. To sew a collarette, label, and display to a garment body with an overedge stitch an operator must first manually arrange and layer the materials one on top of the other as follows: garment body, collarette, display, and label. The operator then passes the layered materials through the sewing machine, maintaining them in constant alignment while stretching the collarette as described above. If desired, a second sewing operation is then performed to attach the loose edge of the display to garment body with a top stitch to assure that the display covers the overedge seam and a portion of the label.
The manual process of sewing a collarette, display, and label to a garment body is difficult and tedious. The quality of the finished product is often variable and is largely dependent on the experience and skill of the sewing machine operator. Moreover, the conventional process is time consuming due to the need to precisely arrange and sew the materials together.
One solution to the above-identified problems is disclosed in co-pending U.S. patent application U.S. Ser. No. 07/711,659 (Attorney Docket No. 1718-4053), filed Jun. 6, 1991 for A METHOD AND APPARATUS FOR AUTOMATICALLY ATTACHING A COLLARETTE, DISPLAY, AND LABEL TO A GARMENT BODY, commonly assigned to Union Special Corporation, the disclosure of which is hereby incorporated by reference herein. U.S. Ser. No. 07/711,659 (Attorney Docket No. 1718-4053) discloses a method and apparatus for automatically attaching a collarette, display, and label to a garment body using, inter alia, a collarette feed means, display feed means, label feed means and a controller means. As disclosed therein, the controller means counts the total number of stitches since the start of a sewing operation. When the total stitch count equals certain predetermined stitch counts, the controller means commands the display feed means and label feed means to feed their respective material under a sewing head.
Variations in garment body dimensions often occur within a garment body size. For example, a garment neck edge can vary in length from garment to garment within a garment size by as much as plus or minus one inch (+/- 1") resulting in an overall edge length variation of four inches (4"). The use of predetermined total stitch count values based on the start of a sewing operation to command display and label feeding cannot account for the above described length variations that exist from garment to garment within a garment size. As a result, inconsistent placement of display and label can occur.
Additionally, using a motor to drive the label feed means independently from, i.e. not synchronized with, the motor driving the sewing head can cause the label to be misaligned when placed under the sewing head and cause the label to skew.
Further, feeding the collarette and display material on top of the garment body can obstruct the field of view of the sewing head making it difficult for an operator to assure the sewing operation is being performed properly.
Further, the layering from bottom to top of garment body, collarette, display, and label can complicate the automation of the subsequent operation of sewing the loose edge of the display over the overedge seam with a top stitch. Specifically, automating the second sewing operating when the display and collarette is placed on top of the garment body would require an apparatus to be able to fold the display underneath the garment body and collarette and to sew the display "blind" through the garment body and collarette. Such an apparatus would be difficult to construct and operate and would prevent the operator from being able to visually check whether the display has been folded and sewn properly in the second sewing operation until after the operation is complete.
It is therefore an object of the present invention to provide a new and improved method and apparatus for automatically attaching a collarette and other materials to a garment body.
Another object of the present invention is to provide a new and improved method and apparatus capable of attaching a collarette, display, and label to a garment body in an efficient and precise manner without the need of manual assistance to feed and maintain alignment of the materials during the sewing operation.
It is still a further object of the present invention to provide a new and improved method and apparatus capable of attaching a collarette, display, and label to a garment body such that the resulting product is of a consistently high quality, but manufactured using less time and manpower.
It is still a further object of the present invention to provide a new and improved method and apparatus for accurately placing a display and label on a garment body.
It is still a further object of the present invention to provide a new and improved method and apparatus for preventing a label from becoming skewed while being sewn to a garment body.
It is still another object of the present invention to provide a new and improved method and apparatus for feeding a collarette, display, and label to a sewing head without obstructing the field of view of the sewing head.
It is still a further object of the present invention to provide a new and improved method and apparatus for simplifying a second automated sewing operation to sew the loose edge of the display over an overedge seam with a top stitch.
SUMMARY OF THE INVENTION
The above-described and other objects of the invention are met by providing an apparatus for attaching a collarette, display, and label to a garment body preferrably incorporating a sewing machine having a sewing head, a collarette feed means, a display feed means, a label feed means synchronized with the sewing head, a seam deflector means, a seam detector means, a label deflector means, a garment detector means, a stitch count means, and a controller means to control each device and perform necessary calculations.
In a preferred embodiment, an operator places a garment body on the sewing machine and presses a foot switch to activate same. If a garment is detected by the garment detector means, the sewing machine is activated and sewing starts. As the garment is being fed through the sewing machine, collarette material is stretched and automatically fed and sewn under the garment body by the collarette feed means. Additionally, the controller means in combination with the stitch count means counts the total number of stitches (N) sewn.
When a first total stitch count (N 1 ) from the start of the sewing operation equals a predetermined stitch count for seam detection (N 1 =n s ), the controller means commands the seam deflector means to lower into the sewing area and activates the seam detector means. When the garment body shoulder seam advances towards the sewing area, the seam deflector presses the shoulder seam down so as to help the seam detector means detect the presence of the shoulder seam. The seam detector is only activated when the seam deflector is in position so that wrinkles and folds, characteristic of soft cloth, do not create false seam detection signals. When the seam detector means detects the presence of the shoulder seam, the controller means commands the display feed means within a predetermined number of stitch counts to move into the sewing area and begin feeding the display material under the sewing head. By using the detection of each garment body shoulder seam to command the commencement of display feeding, accurate placement of display material relative to each garment body is achieved.
The controller means then determines the number of stitches to count before inserting a label (n sl ). By using the first total stitch count (N 1 ) from the start of the sewing operation to shoulder seam detection for each garment body being sewn and multiplying same by a ratio factor (R) the method and apparatus of the present invention can accurately determine the center label position for each garment body being sewn. Referring to FIG. 2, the preferred ratio factor (R) is based on garment body size and is calculated by dividing half the distance from the shoulder seam to the trailing neck garment edge (d e ) by the distance from the leading neck garment edge to the shoulder seam (d s ) ##EQU1##
The controller means then determines the number of stitches to the center of the label (n cl ) by multiplying the first total stitch count (N 1 ) from the start of the sewing operation to seam detection by the preferred ratio factor (n cl =N 1 ×R). The controller means then subtracts one half the number of stitches required to sew the width of the label (n wl ) to determine the number of stitches to count before inserting the label (n sl =n cl -0.5×n wl ).
After seam detection, the controller means maintains a second total stitch count (N 2 ) from seam detection and when the second total stitch count equals the number of stitches to count before inserting the label (N 2 =n sl ), the controller means commands the label feed means to automatically feed a label to the sewing area. The label feed means is synchronized with the sewing head causing the label to be fed evenly under the sewing head thereby preventing the label from skewing while being sewn to the garment body.
When the garment detector means detects the end of the garment body the controller means, after a predetermined number of stitches, commands the display feed means to move away from the sewing area and terminate the sewing of the display material. Finally, when the garment detector means fails to detect the presence of another garment, the sewing machine stops sewing after a predetermined number of stitches. The last predetermined stitch count controls the spacing of the garments being sewn through the apparatus of the present invention.
By using the detection of a garment body shoulder seam as a reference point for display and label feeding and maintaining a total stitch count during the sewing operation, the present invention is able to accurately determine the commencement and termination of the mechanical feeding of a display and label for the particular dimensions of each garment body being sewn. As a result, the present invention is able to achieve a consistently even manufactured product in less time using less manpower.
Additionally, by synchronizing label feeding with the overall sewing operation the present invention is able to prevent label skewing.
Further, by feeding the collarette and display material underneath the garment body during the sewing operation the present invention allows an operator to have a clear field of view of the sewing head during a sewing operation and simplifies the automation of the second sewing operation by enabling the display material to be folded from underneath to on top of the garment body to allow an operator a clear field of view of a second sewing operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in greater detail below by use of reference to the accompanying drawings, wherein:
FIG. 1 is of a completed garment having a collarette, display, and label;
FIG. 2 is a planar view of the layered arrangement of garment body, collarette, display and label as they are sewn together using an overedge stitch;
FIG. 3 is a side view of the layered arrangement of FIG. 2;
FIG. 4 is a left side view of an embodiment according to the present invention;
FIG. 5 is a top view of the embodiment of FIG. 4;
FIG. 6 is a front view of the embodiment of FIG. 4;
FIG. 7 is a three dimensional view of the embodiment of FIGS. 4, 5 and 6.
FIGS. 8A and 8B are close-up side views of the seam and label deflectors respectively.
FIGS. 9A and 9B are a flow chart of the operation of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, FIG. 1 is an illustration of the components of a completed garment having a collarette 22, display 24, and label 26 fashioned from known materials used for shirts, blouses, or the like. The dimensions of the various pieces are based on the desired size of the finished product. For example, in an average T-shirt, the width of collarette 22 is typically in the range of 1 3/16" to 1 7/16" and the width of display 24 is typically 7/16" to 1/2" wide. As will become readily apparent to those skilled in the art, the widths of the collarette and display can be easily varied.
Label 26, which provides the purchaser or wearer with information concerning the garment (e.g., size, manufacturer, washing instructions), may be made from various known materials such as nylon, cloth, or the like. The size of label 26 is usually dependent on the amount and the size of the writing present.
As shown in FIG. 1, display 24 and label 26 are affixed in a position such that display 24 covers the overedge seam (not shown) which would be visible along the inside the garment neck when the garment is placed on its back. Also shown is top stitch 33 used in a second sewing operation to sew the loose end of the display over the overedge seam.
FIG. 2 is a planar view illustration of the layering of display 24, collarette 22, garment body 20, and label 26 as fed through the apparatus of the present invention. The layering allows the display, collarette, garment body, and label to be sewn together with a single overedge stitch. The overedge stitch, known in the art as a 504 SSa-1 stitch, forms an overedge seam 28. To assure proper placement of display 24, the display is preferrably sewn so as to overlap shoulder seam 32 by approximately 3/4" of an inch. As will become readily apparent to those skilled in the art, the overlap distance can be varied as desired. Line of feed ("L.O.F.") arrow 1 indicates the direction the display, collarette, garment body, and label are fed through the sewing apparatus of the present invention.
FIG. 3 is a side view illustration of the layering of FIG. 2 as fed through the sewing apparatus of the present invention. The display 24 and collarette 22 are placed under garment body 20 and label 26 is placed on top of garment body 20. The layering of these materials as shown in FIG. 3 has several advantages. First, positioning the collarette and display material as illustrated allows the materials to be fed under the garment body. Accordingly, an operator is afforded a clear unobstructed view of the sewing head during a sewing operation. Additionally, the layering of the display and collarette underneath the garment body simplifies the automation of the second sewing operation wherein the loose end of the display is sewn over the overedge seam with a top stitch. Specifically, the display material can be folded from under the garment body to a top thereof to allow a second sewing operation to be performed in clear view of the operator.
A preferred embodiment of the present invention is illustrated in the side, top, and front views of FIGS. 4, 5, and 6 respectively as well as the three dimensional view of FIG. 7 and the close-up side views of FIGS. 8A and 8B.
Frame 34 is used to support the various elements of the present invention. Controller 36 having a control panel 37 is attached to the front of frame 34 as shown. In the preferred embodiment, a Union Special C.P.U. Design is used as controller 36. Control panel 37 is used to allow an operator to input to the controller certain predetermined garment parameters such as size and style (e.g. distance to shoulder seam label width overlap distance and the like). Motor 38 is used to drive sewing machine 39 having a sewing head 40. In a preferred embodiment, a 39500 series sewing machine, manufactured by Union Special Corporation of Chicago, Ill., is used. Stitch counter 90 is used to count each revolution, which represents one stitch, of sewing head 40 and signals same to controller 36 which maintains a total stitch count for each sewing operation.
Rolls 56, 58 and 60 are used to provide a continuous supply of collarette 22, label 26, and display material 24 respectively. As will become readily apparent to those skilled in the art, the supply of these materials may be from flat continuous strips of folded material, commonly called festooning. The size and dimension of supply rolls 56, 58 and 60 are dependent on the materials used. Additionally, thread supply spools 102, 104 and 106 are used to supply thread to sewing head 40 in a known manner.
Collarette feed motor 62 drives collarette feed rollers 63 which are used to maintain the collarette in tension between the rollers 63 and the sewing head 40. The tension created effectively stretches the collarette material as it is being sewn to the garment body so that the completed garment and collarette will lie flat and have no wrinkles or gathers around the neck when worn. As shown, the collarette material is fed underneath the garment body. Accordingly, when an operator sews the collarette to the garment body, the operator is afforded a clear unobstructed view of the sewing head 40.
Display feeder 65 is used to fold the display material and to guide same into the sewing area so as feed the display material 24 underneath collarette material 22 and under presser foot 80 and sewing head 40. The resulting adhesion between the collarette 22 and the display 24 while under sewing head 40 causes the display material to unroll from display supply roll 60 and feed under the sewing head 40. Pneumatic display feed inserter 64 is used to move display feeder 65 into and out of the sewing area on command from the controller 36. As with the feeding of the collarette material, the display material is fed under the garment body allowing an operator to have an unobstructed view of the sewing head 40 during the sewing operation. Plate 67 is used to help guide the collarette material over the display feeder 65 and under presser foot 80.
Label feeder 70 is used to cut labels from supply roll 58 and feed same to sewing head 40. The label feeder comprises a stepper motor 71 to drive label arm 72, a pneumatic gripper 74 for gripping a label 26, and a hot wire knife 76 for cutting labels from the label supply roll 58. On command from controller 36, the label arm 72 and gripper 74 grab a label 26 from the hot wire knife 76 and delivers same under presser foot 80 to sewing head 40. The cycle of movement of the output shaft of the label stepper motor 71 is synchronized with the cycle of movement of the motor driving sewing head 40 so as to synchronize the label feeding operation with the overall sewing operation. Synchronizing the cycle of movement of the output shaft of the label feeder stepper motor with the cycle of movement of the motor in the sewing head allows the gripper 74 to hold on to the label as it is being sewn to the garment body under sewing head 40 effectively preventing the label from skewing during the sewing operation.
As shown in detail in FIG. 8A, pneumatic label guide 78 is used to help guide the label under the presser foot 80 and sewing head 40. On command from the controller 36, the label guide 78 lowers into the sewing area to be in alignment with the label feeder to help guide each label under presser foot 80 and sewing head 40. Also shown are feed dogs 92.
A garment detector 82 comprising a light emitting diode ("LED") and a photodetector, is used to detect the presence of a garment body in the sewing area. Specifically, light from the LED is directed downward to the sewing area and reflected back to the photodetector by reflective patch 94. When a garment is place in a sewing area and top of the reflecting patch 94, the light being reflected from the LED is blocked and therefore not detected by the photodetector causing the garment detector to signal to the control means a "garment present" signal. As will become readily apparent to those skilled in the art, a through-beam photodetector similar to the seam detector described below can also be used as a garment dector.
A through-beam seam detector 83, comprising LED 83a and photodetector 83b, is used to detect the garment body shoulder seam during a sewing operation. In a preferred embodiment, the LED 83a is placed under plate 67 and emits light vertically through a hole 68 in plate 67. The light is detected by photodetector 83b placed atop thereof. The LED must emit sufficient light so as to allow the photodetector to detect same when a garment body is placed on top of the LED. Accordingly, when a shoulder seam passes over the LED, the light being detected by the photodetector will be blocked by the seam causing the seam detector to signal a "seam present" signal to the controller. Referring to FIG. 8B, a pneumatic seam deflector 79 is used to deflect a garment body shoulder seam to create a wider sensing window so as to help the seam detector detect same. Specifically, the seam deflector will, on command from the controller 36, lower into the sewing area and press the shoulder seam 32 down to effectively block the light emitted from LED 83a. Preferably, seam detector 83 is activated by the controller 36 only when the seam deflector is lowered into the sewing area so as to avoid false seam detection signals caused by wrinkles and folds characteristic in garments made of soft cloth.
In the preferred embodiment, all motors, pneumatic devices, and sensors are digital devices. Nevertheless, as will become readily apparent to those skilled in the art, analog devices can be used for some or all of the devices.
Once a device is configured as described above, the sewing method of the present invention can be performed as described below.
To begin, an operator feeds the collarette and display material through their respective feed mechanisms to effectively prime the apparatus for commencement of a sewing operation.
Referring to FIG. 2, the operator then measures in inches the approximate distance (d s ) from the leading garment body edge to the shoulder seam (d s ) for the particular garment size, e.g. small, medium, large, extra large and the like. The operator then converts the distance value to stitch counts (n s ) by equation: n s =d s ×s, where s is the number of stitches per inch the sewing head 40 performs. In a preferred embodiment, s has the value of approximately 12 stitches per inch (s=12). The resulting value (n s ) represents the number of stitches to count before a seam can be detected. Additionally, the operator measures the width of the label (d wl ) and using the above described equation converts the width to stitch counts (n wl ).
To determine the preferred ratio factor (R) for a particular garment size, the operator measures the distance from the shoulder seam to the trailing garment body edge (d e ). The ratio factor (R) is then determined by the following equation: ##EQU2##
It has been found that for most T-shirts, R has a preferred value of 32% (R=0.32).
The operator then activates the controller via the control panel to start a sewing operation. Referring to the flow chart of FIGS. 9A and 9B, the controller executes the series of steps illustrated therein and described as follows. The controller begins at step 201 where the operator inputs via control panel 37 the predetermined values the distance in stitches counts from the leading garment body edge to the shoulder seam (n s ), the label width in stitch counts (n wl ), the ratio factor (R), and the garment spacing in stitch counts (n gs ).
The controller then advances to step 203 where it waits for a garment to be detected, i.e. loaded on to the sewing machine 39. The operator then manually loads the garment body 20 until its leading edge is under presser foot 80. It will be apparent to those skilled in the art that the loading of the garment body may be accomplished by manual or automated mechanisms. As described above, when the garment body 20 and collarette 22 are maneuvered under presser foot 80, material present sensor 82 signals to the controller 36 that a garment is present. The controller then advances to step 205 where the controller directs sewing head 40 to lower the presser foot 80 and start sewing the collarette 22 to the garment body 20. In preferred embodiments, sewing operation does not actually begin until the operator presses on a foot switch (not shown). The foot switch acts as a separate safety feature and control mechanism. Alternatively, a highly trained operator could have the option of using an "auto start" mode where, once the garment is detected and after an adjustable time delay, sewing would start automatically without use of the foot switch.
Once sewing starts, both the garment body and collarette are urged under presser foot 80 by forces generated by feed dogs 92 under the garment body material. The frictional interference between the collarette material 22 and the garment body 20 also assists in maintaining the position of the collarette under presser foot 80. Additionally, as described above, collarette feed rollers 63 maintain the collarette material in tension between the rollers 63 and the sewing head 40.
The controller then advances to step 207 where a first total stitch count (N 1 ) from the start of a sewing operation is determined by controller 36 by adding each stitch count signal from stitch counter 90. Next, a determination is made at step 209 as to whether the first total stitch count (N 1 ) is greater than or equal to the predetermined number of stitches to count before detecting the shoulder seam (N≧n s ). If false, the controller returns to step 207 to continue counting stitches. If true, the controller advances to step 211 where it activates the seam detector 83 and commands the seam deflector 79 and label guide 78 to move down into the sewing area. The controller then advances to step 213 where its checks whether the garment body shoulder seam has been detected by the seam detector means. If no seam is detected, the system returns to step 207 to continue counting stitches. In a preferred embodiment, the value of n s is reduced by a predetermined value to allow the seam deflector time to advance into the sewing area and to create a "window" of time for seam detection. Once the seam is detected, the controller advances to step 215 where the it deactivates the seam detector and it commands the seam deflector to raise up from the sewing area. The controller then advances to step 217 where, after a predetermined number of stitches based on desired seam overlap, it commands the display inserter 64 to move the display feeder 65 into the sewing area as described above. The friction interference between the collarette 22 and display 24 causes the display to be drawn under presser foot 80 to be sewn to the collarette 22 and the garment body 20. The controller then advances to step 219.
At step 219, the controller determines the number of stitches to count to the center of label (n cl ). In a preferred embodiment, the number of stitches to the center of label is equal to the total number of stitches counted from the start of the sewing operation to seam detection (N 1 ) multiplied by the preferred ratio factor (n cl =N 1 ×R). The controller then advances to step 221 where it determines the number of stitches to count from seam detection to start of label feeding (n sl ). In a preferred embodiment, the number of stitches to count for the start of label is equal to the number of stitches to the center of label less one half the label width in stitch counts (n sl =n cl -n wl ×0.5). The controller then advances to step 223 where it maintains a second total stitch count (N 2 ) which represents the total number of stitches sewn from seam detection.
The controller then advances to step 225 where it checks whether the total number of stitches counted from seam detection (N 2 ) is greater than or equal to the predetermined number of stitches to count to the start of label feeding (N 2 ≧n sl ). If false, the controller returns to step 223 to continue counting stitches. If true, the controller advances to step 227 where it commands the label feeder 70 to feed a label. At this time, the label feed arm 72 brings a pre-cut label 26 into the sewing area and positions same on top of the display 24 and under the presser foot 40. After the label has been almost completely sewn, the label grippers 74 open up to release the label and the label arm 72 continues moving in synchronization with the sewing so as not to disturb completion of the label sewing cycle. Once the label is sewn, the system advances to step 229 where the label guide is raised and label arm 72 returns to its vertical position to grab another label 26 with grippers 74 from hot wire knife 76. Label arm 72 then moves down to a position just above sewing head 40 to await the next label insertion command from controller 36.
The controller than advances to step 231 where it checks whether the end of the garment has been detected by the garment detector 82. If false, sewing continues. If true, the controller advances to step 232 where, after a predetermined number of stitches, the controller commands the display feed means to end feeding display material from the sewing area. The controller then advances to step 235 where the controller maintains a third total stitch count (N 3 ). The controller then advances to step 237 where it checks whether the third total stitch count equals the garment spacing stitch count (N 3 =n gs ). If false, the controller returns to step 235 to continue counting stitches. If true, the controller advances to step 239 where the presser foot 80 is raised, and if the garment detector still detects no other garment body, sewing head 40 is turned off and sewing is completed.
The varying of the predetermined stitch count after sensing the end of the garment (n gs ) controls the spacing between garments. It has been found that a close spacing saves expensive collarette material and increases garment output.
As will become readily apparent to those skilled in the art, the display feeder and label feeder can be deactivated to vary the finished product. For example, the label feeder 70 can be deactivated so that when the apparatus is operated, only a collarette and display will be sewn to the garment body. Similarly, the display feeder can be deactivated such that only a collarette and label will be sewn to the garment body.
Additionally, as will become apparent to those skilled in the art, the synchronization of inserting the display and label need not be dependant on stitch count. For example, timed synchronization can be used to command the display feeder and label feeder at the appropriate times.
Furthermore, as will become readily apparent to those skilled in the art, a second sewing operation on the garment can be performed to sew the loose end of the display down over the overedge seam 32 with a top stitch 33.
Although illustrative preferred embodiments have thus been described herein in detail, it should be noted and will be appreciated by those skilled in the art that numerous variations may be made within the scope of this invention without departing from the principle of the invention and without sacrificing its advantages. The terms and expressions have been used as terms of description and not terms of limitation. There is no intention to use the terms or expressions to exclude any equivalents of features shown and described or portions thereof and the invention should be interpreted in accordance with the claims which follow.
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An improved method and apparatus for attaching a collarette, display, and label incorporating the use of a sewing machine having a sewing head a collarette feeder, a display feeder, a label feeder synchronized with the sewing head, a garment detector, a seam detector, a stitch counter, and a controller to control each device and perform necessary calculations is disclosed.
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FIELD OF THE INVENTION
This invention relates to a cushioned floor covering article wherein the mat includes a tufted carpet placed on the top side of a foam rubber sheet and at least one foam rubber protrusion integrated within at least a portion of the bottom side of the foam rubber sheet. Such an article provides effective removal of moisture, dirt, and debris from the footwear of pedestrians through the utilization of a carpet pile component. Furthermore, the utilization of a foam rubber backing also allows for either periodic heavy duty industrial-scale laundering in such standard washing machines or periodic washing and drying in standard in-home machines, both without appreciably damaging the inventive floor covering article, such as a floor mat. Additionally, the presence of integrated foam rubber protrusions within the mat structure provides an effective cushioning effect for pedestrian comfort as well as a means to prevent slippage of the article from its contacted surface. A method of producing such an inventive cushioned floor covering article is also provided.
DISCUSSION OF THE PRIOR ART
All U.S. patent cited herein are hereby fully incorporated by reference.
Floor mats have long been utilized to facilitate the cleaning of the bottoms of people's shoes, particularly in areas of high pedestrian traffic such as doorways. Moisture, dirt, and debris from out of doors easily adhere to such footwear, particularly in inclement weather and particularly in areas of grass or mud or the like. Such unwanted and potentially floor staining or dirtying articles need to be removed from a person's footwear prior to entry indoors. As will be appreciated, such outdoor mats by their nature must undergo frequent repeated washings and dryings so as to remove the dirt and debris deposited thereon during use. These mats are generally rented from service entities which retrieve the soiled mats from the user and provide clean replacement mats on a frequent basis. The soiled mats are thereafter cleaned and dried in an industrial laundering process (such as within rotary washing and drying machines, for example) and then sent to another user in replacement of newly soiled mats. Furthermore, it is generally necessary from a health standpoint to produce floor coverings on which persons may stand for appreciable amounts of time which will provide comfort to such persons to substantially lower the potential for fatigue of such persons by reducing the stress on feet and leg joints through cushioning.
Typical carpeted dust control mats comprise solid and/or foam rubber backing sheets which must be cleated in some manner to prevent slippage of the mat from its designated area. Such cleats are formed during a vulcanization step and have required a time-consuming procedure of placing the green (unvulcanized) rubber sheet on a molded silicone pad and then removing the same after vulcanization. Also, the thicknesses of such dust control rubber backing sheets are generally quite low and thus permit the placement of a pedestrian's foot relatively close to the covered floor or ground when he steps on such a mat. As a result, and particularly if the covered area is hard, the mat does not appreciably cushion the pedestrian's foot. With a general shift toward providing protection to pedestrians, particularly outside entryways of stores, where a cushioned, non-slip dust control mat will provide a safe, comfortable floor covering on which a customer may clean his footwear, and workplaces, where a person may be required to be mobile for an appreciable amount of time during the workday and thus a non-slip, cushioned floor covering provides a certain degree of safety to a user, there is a recognized need to provide non-slip floor and/or ground coverings which can potentially reduce the stress of a pedestrian's leg and foot joints through the benefit of cushioning characteristics. There have been a few advancements within the prior art for providing cushioning within dust control mats, such as U.S. Pat. No. 5,645,914 to Horowitz. Generally, such cushioning benefits are provided in either only all-rubber mats, as in U.S. Pat. No. 3,016,317 to Brunner, or solely provide such cushioning benefits within or on the top side of the mat, as in U.S. Pat. No. 4,262,048 to Mitchell. Also, cleated backings have been produced in the past to provide non-slip characteristics, such as in U.S. Pat. No. 4,741,065 to Parkins. Such mats do not also provide cushioning characteristics with the same non-slip components, however. As such, there still exists a need to reduce cost for producing overall dust control mat products through a process wherein the cushioning characteristics are simultaneously provided by the same non-slip mechanism. To date, the prior art has neither taught nor fairly suggested such a combination of elements in a cushioned carpeted floor covering article.
DESCRIPTION OF THE INVENTION
It is thus an object of this invention to provide a non-slip, cushioned, anti-fatigue carpeted floor covering article which permits cleaning of a pedestrian's footwear. Furthermore, it is an object of the invention to provide a carpeted floor covering article for which the portion which provides the cushioning characteristics simultaneously provides non-slip benefits. An additional object of this invention is to provide a non-slip, cushioned, antifatigue carpeted floor covering article in which the cushioning aspects are provided by at least one integrated rubber protrusion produced during the necessary vulcanization process. Still a further object of the invention is to provide a non-slip, cushioned carpeted floor covering article which possesses sufficient flexibility to withstand periodical laundering in industrial washing and drying machines. Yet another object of this invention is to provide a floor covering article which can substantially reduce a person's fatigue after standing on such an article for appreciable periods of time as compared with other standard floor covering articles.
Accordingly, this invention encompasses a cushioned floor covering article comprising
a carrier fabric;
a pile material tufted into the carrier fabric which forms a pile surface on one side of the carrier fabric; and
a vulcanized expanded backing sheet of rubber attached to the other side of the carrier fabric, wherein at least one protrusion integrated within said backing sheet is present on the side of the backing opposite the side to which the carrier fabric is attached. Also, this invention encompasses a method of forming a cushioned floor covering article comprising the steps of
(a) placing a sheet of rubber over a die having at least a first and second side, wherein said rubber optionally comprises a blowing agent to form a closed-cell foam rubber structure upon vulcanization, wherein said die has portions thereof removed to allow for the entry of molten rubber, and wherein said die is comprised of a material which can withstand vulcanization temperatures and pressures;
(b) tufting a pile material into a carrier fabric to form a tufted pile surface extending from one side of the carrier fabric;
(c) laying the carrier fabric with tufted pile onto the rubber sheet of step “a”;
(d) optionally, placing solid rubber reinforcing strips around at least one of the border edges of the rubber sheet; and
(e) subjecting the composite comprising the rubber sheet, the die, the carrier fabric, the carpet pile, and the optional reinforcing strips to vulcanization temperatures and pressures to (1) attach the rubber sheet to the side of the carrier fabric from which the pile surface does not extend, and (2) to form rubber protrusions through the removed portions of the die.
The inventive dust control mat generally comprises any type of standard carpet pile fibers tufted through any standard type of carrier fabric. Such carpet fibers may be natural or synthetic, including, without limitation, cotton, ramie, wool, polyester, nylon, polypropylene, and the like, as well as blends of such fibers (all as merely examples). The fibers may be coarse or fine in structure as well. Such fiber structures are represented in dust control mats within U.S. Pat. No. 1,008,618, to Skowronski et al., U.S. Pat. No. 4,045,605, to Breens et al., and U.S. Pat. No. 4,353,944, to Tarui, U.S. Pat. Nos. 4,820,566 and 5,055,333, both to Heine et al., as well as within French Patent No. 1,211,755, assigned to Cosyntex (S.A.), and PCT Application 95/30040, assigned to Kleen-Tex Industries, Inc. Of particular interest in this invention, however, are 100% solution dyed nylon fibers. Such pile fibers provide the best pile surface for overprinting with different dyes in order to provide the most aesthetically pleasing colorations and shades on the floor mat pile surface. The carrier fabric may thus be of any construction, such as woven, non-woven, knit, and the like. Preferably, a woven or non-woven substrate is utilized. The carpet pile is tufted through the carrier fabric in a standard tufting process for further placement on and attachment during vulcanization to the top side of the rubber backing sheet.
The carpet fibers may be colored or dyed through any acceptable method so as to produce aesthetically pleasing designs within the carpet pile portion of the inventive mat. Of particular importance, however, is the utilization of an overprinting procedure of 100% solution dyed nylon fibers. Such nylon is acid-dyeable and available from Cookson Fibers. As noted above, such pile fibers allow for the most pleasing and long-lasting colorations and shades of color to be applied and retained on the pile surface through the utilization of acid dyes. With such fibers, any design or configuration may be produced (as well as logos, pictures, and the like) on the pile surface, again in order to provide a long-lasting aesthetically pleasing floor mat for the consumer. Furthermore, the inventive article itself can be made in any shape, with rectangular or square configurations being preferred.
In actuality, the attachment of the rubber sheet component to the carpet pile fibers may be accomplished either during the actual vulcanization step, as taught in Nagahama, for example, above, or through the use of an adhesive layer, preferably a polyolefin adhesive, between the carpet pile and the rubber sheet, as disclosed in copending U.S. patent application Ser. No. 08/732,866, to Kerr, hereby entirely incorporated by reference, or any other like procedure.
The rubber backing sheet may be comprised of any standard rubber composition, including, but not limited to, acrylonitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), ethylene--propylene-diene comonomer rubber (EPDM), carboxylated NBR, carboxylated SBR, chlorinated rubber, silicon-containing rubber, and the like. For cost purposes, the preferred rubbers are NBR, SBR, EPDM and blends thereof.
The rubber composition may be of solid or foam construction or there may be layers of both present on the inventive mat. Preferably, the majority of the rubber composition within the backing sheet is of foam construction (which requires the presence of a blowing agent to form closed-cell structures within the rubber upon vulcanization, such as in U.S. Pat. No. 5,305,565 to Nagahama et al.). The target thickness for such a rubber sheet is from about 5 to about 500 mils, preferably from about 25 to about 400 mils, more preferably from about 40 to about 250 mils, and most preferably from about 75 to about 200 mils.
Floor mats and other like floor covering articles have exhibited general problems arising from frequent washings and harsh environments of use. First, the energy required to wash and dry a typical floor mat is significant due to the overall mass of the mats. This overall mass is made up of the mass of the mat pile, the mass of the carrier fabric into which the mat pile is tufted, and most significantly, the mass of the rubber backing sheet which is integrated to the carrier fabric under heat and pressure. As will be appreciated, a reduction in the overall mass of the floor mat will result in a reduced energy requirement in washing and drying the mat. Moreover, a relative reduction in the mass of the rubber backing sheet (i.e. the heaviest component) will provide the most substantial benefit. Thus, the utilization of a lighter weight rubber composition, such as foam rubber, in at least a portion of the dust control mat of the present invention includes a rubber backing sheet which may possess a specific gravity which is approximately 25-35 percent less then the solid rubber sheets of typical prior floor mats. Accordingly, a foam rubber is preferable, though not required, as the rubber structure of the inventive mat's rubber backing sheet. This lighter weight thus translates into a reduced possibility of the mat harming either the washing or drying machine in which the mat is cleaned, or the mat being harmed itself during such rigorous procedures. Although the inventive floor mat must withstand the rigors of industrial machine washing, hand washing and any other manner of cleaning may also be utilized. Overall, the inventive floor mat provides an article which will retain its aesthetically pleasing characteristics over a long period of time and which thereby translates into reduced costs for the consumer.
Solid rubber reinforcement strips may also be added around the borders of the mat, either by hand or in an in-line process, such as in Patent Cooperation Treaty Application 96/38298, to Milliken Research Corporation. Such strips must either possess roughly the same shrinkage rate factor as the carpet pile substrate and the foam rubber backing sheet or they must possess roughly the same modulus strength of the solid rubber backing sheet, all in order to ensure the probability of rippling (or curling) of the mat will be minimal. Such strips may be comprised of any type of butadiene rubber, such as acrylonitrile-butadiene (NBR) or styrene-butadiene (SBR), or carboxylated derivatives of such butadienes, merely as examples. Preferably, the strips are comprised of NBR as carboxylated NBR is cost prohibitive. Such strips can be of any general width and as long as the specific side upon which they are attached on the backing sheet. The target thickness for such strips second layer is from about 2 to about 50 mils, preferably from about 4 to about 40 mils, more preferably from about 5 to about 35 mils, and most preferably from about 5 to about 25 mils. Furthermore, if such strips are applied, they should be placed on top of the backing sheet prior to the placement of the carpet pile if the width of such strips, as measured from the border of the sheet, is greater then the width of the area from the border to the carpet pile, in order to permit overlap of the strips and the carpet pile while simultaneously permitting adhesion of the strips to the sheet.
Furthermore, a significant problem exists within this field concerning the deterioration of the carbon-carbon double bonds in the matrix of the rubber backing sheet due to the exposure of the sheets to an oxidizing environment during use and cleaning. Specifically, the exposure of the mats to oxidizing agents during the washing and drying process tends to cleave the carbon-carbon double bonds of the rubber sheet thereby substantially embrittling the rubber which leads to cracking under the stress of use. In addition to the laundering process, the exposure of the mats to oxygen and ozone, either atmospheric or generated, during storage and use leads to cracking over time. The mat of the present invention may thus include an ozone-resistance additive, such as ethylene-propylene-diene monomer rubber (EPDM), as taught within U.S. Pat. No. 5,902,662, to Kerr, which provides enhanced protection to the rubber backing sheet against oxygen in order to substantially prolong the useful life of the mat. Such an additive also appears to provide a reduction in staining ability of such rubber backed mats upon contact with various surfaces, such as concrete, wood, and a handler's skin, just to name a few, as discussed in U.S. patent application Ser. No. 09/113,842 to Rockwell, Jr.
U.S. Pat. No. 5,305,565, to Nagahama et al., previously entirely incorporated by reference, shows the usual manner of producing floor mats comprising carpet pile fibers, a carpet pile substrate, and a rubber backing sheet. This reference, however, makes no mention as to the production of at least one integrated rubber protrusion from the side of the backing sheet opposite the carpet pile component. The term “integrated rubber protrusion” is intended to encompass any type of protrusion from the rubber backing sheet which is formed from the same backing sheet composition and is not attached in any manner to the resultant backing sheet after vulcanization. Thus, such a protrusion would be produced through the flowing of the rubber composition during vulcanization and allowing molten rubber to form around a die mold in a position in which it remains until it cures and sets. The shape of such a protrusion is virtually limitless, and may be of any size. Furthermore, it is possible to construct sheet wherein the body of the structure comprises a blowing agent (to produce a foam rubber) and a second layer of solid rubber covers the body portion. In such a manner, the protrusions could be formed with a core of foam rubber and a cap of solid rubber (upon vulcanization through a die-mold, for example). As such, preferably the protrusion or protrusions are formed from all foam rubber (which provides better cushioning). The separate protrusions thus provide discrete areas of relaxed stress within the inventive mat which thus provides a cushioning effect to a pedestrian, greater than for an overall flat foam rubber structure.
As noted previously, since the protrusion or protrusions are both located on the bottom side of the backing sheet and extend from the sheet itself, such a protrusion or protrusions provides a non-slip character to the overall mat structure. Since the length of the protrusions cannot be greater than the depth of the backing sheet itself (since it is vulcanized on a solid surface, the resultant protrusions are formed through the embedding of the die-mold within the backing sheet during vulcanization; removed portions of the die provide the holes in which the protrusions are ultimately formed from molten, then cooled rubber), such protrusions, being separate from the body of the mat through some type of shaft (again of any size and shape), form “feet” which can grip the surface on which the mat is placed and create difficulty in moving the mat through a pushing motion parallel to such a surface. Thus, the protrusions also provide a non-slip characteristic to the inventive mat. Again, as noted above, there has been no teaching or fair suggestion of such an advantage (in cost, at least) for an aesthetically pleasing carpeted dust control mat.
With regard to the die, it may be constructed of any material which can withstand vulcanization temperatures (i.e., between about 250° F. and about 350° F.) and pressures (i.e., between about 15 psi and 50 psi, generally). Thus, any metal may be utilized, certain plastics, such as Teflon®, for example, silicon molds, and the like. Preferably, the die is made of steel, is generally square or rectangular in shape (although any shape may be utilized), and comprises holes throughout to ultimately form the desired protrusions. Preferably, such holes are circular in shape (at the die surface) and cylindrical as well (i.e., circular on both surfaces with the same shape throughout the die from one surface to the other). Furthermore, such a die may also be utilized in an in-line process wherein there is no need to hand place the backing sheet over the die itself. The preferred procedure is outlined more particularly below.
The inventive mat provides a long-lasting non-slip, cushioned carpeted article which provides comfort to users as well as significantly reduced chances of slipping, all in a one-step procedure. All of this translates into reduced cost for the consumer as costs to produce are lower and possible medical and insurance costs may also be reduced with the utilization of such specific mats which also work to remove dirt and moisture from pedestrians' footwear.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a floor mat manufacturing machine with the inventive process ongoing.
FIG. 2 is an aerial view of the components of the inventive dust control mat placed together prior to vulcanization.
FIG. 3 is an aerial view of the preferred die.
FIG. 4 is a cross-sectional view of the inventive dust control mat after vulcanization.
DETAILED DESCRIPTION OF THE DRAWINGS
While the invention will be described in connection with certain preferred embodiments and practices, it is to be understood that it is not intended to in any way limit the invention to such embodiments and practices. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
Turning now to the drawings wherein like elements are designated by like reference numerals in the various views, FIG. 1 shows a floor mat manufacturing machine 10 for producing the inventive dust control mat 24 . The machine 10 comprises a conveyor belt 11 which carries the mat components 14 , 16 , 18 , 20 from an initial placement area 12 (where each component is placed in sequence) through a vulcanization chamber 22 and to a removal area 26 . Thus, a die 14 is first placed on the belt 11 . On top of the die 14 is then placed a rubber sheet 16 which includes a blowing agent (preferably), followed by solid rubber strips 18 placed around the perimeter of the first rubber sheet 16 . These strips are the same length as each of the sides of the first rubber sheet 16 and are each preferably about 2 to 4 inches in width. The first rubber sheet 16 has a thickness of about 40 mils and the solid rubber strips 18 , being much thinner, has a thickness of about 2.5 mils. To this die/rubber composite 13 is then placed a carpet pile through a carrier fabric 20 . The resultant combination is then moved into the vulcanization chamber 22 , which includes a heated press (not illustrated) to subject the mat components to a temperature of about 290° C. and a pressure of about 30 psi. After vulcanization, the finished mat 24 is allowed to cool and can then be removed from the die 14 . This entire procedure or only portions thereof may be performed in an in-line process, such as in U.S. Pat. Nos. 5,928,446 and 5,932,317, both to Kerr et al.
FIG. 2 gives a greater detailed view of the die/rubber composite 13 as well as a cut-away view of the carpet pile 20 added on top of the composite 13 . On top of the die 14 is placed the first rubber sheet 16 (including a blowing agent to form a foam rubber ultimately). The solid rubber strips 18 are placed around the perimeter of the first rubber sheet 16 , leaving some overlap of the carpet pile 20 once that component is placed on top of the first rubber sheet 16 and a portion of the rubber strips 18 .
The preferred die 14 is more thoroughly depicted in FIG. 3 . The die is preferably about 2 inches tall and made of steel. Any material may be used for this die 14 as long as it can withstand vulcanization temperatures and pressures without distorting its shape or permanently adhering to the mat product ( 24 of FIG. 1) (such as, as merely examples, other metals like titanium, aluminum, and the like; fibers, such as polyaramid structures, and the like; silicon molds; and ceramics). The preferred die 14 comprises a plurality of cut-outs 28 which are, again preferably, circular in shape, and thus cylindrical in configuration, having a diameter of about 1 inch and a depth of 2 inches. It is through these holes 28 that the rubber composition of the first rubber sheet ( 16 of FIG. 2) is pressed to ultimately form the desired protrusions ( 34 of FIG. 4) on the bottom side of the preferred mat ( 24 of FIG. 1 ).
FIG. 4 thus shows a cross-section of a portion of the finished inventive dust control mat 24 . Protrusions 34 have been formed comprising foam rubber from the first rubber sheet 16 . The rubber strip 18 has been adhered to the first rubber sheet 16 and the carpet pile component 20 , comprised of cut pile fibers 32 and a carrier fabric 30 , have become adhered to both the first rubber sheet 16 and the rubber strip 18 . The resultant preferred protrusions 34 are each about 1 inch in diameter and about 2 inches in length.
DETAILED DESCRIPTION OF THE INVENTION
As previously indicated, in the preferred embodiment of the present invention the base material for the first rubber backing sheet is acrylonitrile-butadiene rubber (NBR) or styrene-butadiene rubber (SBR). Other materials which may also be used include, by way of example, hydrogenated NBR, carboxylated NBR, EPDM, and generally any other standard types of rubbers which may be formed in a foam state. As will be appreciated, the use of NBR or SBR is desirable from a cost perspective.
The present invention makes use of the addition of chemical blowing agents to the rubber materials ultimately yielding a lighter rubber sheet. Specifically, in the preferred embodiment, the rubber backing sheet of the present invention comprises either NBR or SBR or both mixed with a blowing agent. The rubber/blowing agent mixture is thereafter calendared as a solid sheet of unvulcanized material which is used in the manufacture of the floor covering article in the process as described above. In practice, the raw NBR is believed to be available from Miles Inc. Rubber Division in Akron, Ohio. The SBR may be purchased from Goodyear Tire and Rubber Company in Akron, Ohio. EPDM may also be added in a preferred embodiment to provide ozone resistance.
In the preferred practice of the present invention, a masterbatch of the polymer components is first prepared by mixing the base rubber (either NBR or SBR) with the additive ozone resistant polymer (EPDM) in the desired ratio along with various stabilizers and processing agents. Exemplary compositions of the masterbatch for various additive ratios wherein EPDM is mixed with NBR are provided in Table 1A for ratios of NBR to the additive polymer of 9.0 (Column a), 2.3 (Column b) and 1.2 (Column c).
TABLE 1A
PARTS BY WEIGHT
MATERIAL
a
b
c
Rubber (NBR)
40
25
50
Additive Rubber (EPDM)
60
75
50
Plasticizer
10
5
15
Stabilizer
2
2
2
Processing Aid
1.75
1.75
1.75
Antioxidant
1.2
1.2
1.2
In the preferred practice the plasticizer which is used is diisononylphthalate. The stabilizer is trinonylphenolphosphate available from Uniroyal Chemical under the trade designation Polyguard™. The processing aid is purchased from the R.T. Vanderbilt Company in Norwalk Conn. under the trade designation Vanfree™ AP-2. The antioxidant is purchased from Uniroyal Chemical under the trade designation Octamine™.
Following the mixing of the masterbatch, curative agents are added in a second stage mixing process for formation of the raw rubber compound which forms the backing sheet of the floor covering article of the present invention. An exemplary composition of the raw rubber compound formed in this second stage mixing process is provided in Table 1B.
TABLE 1B
MATERIAL
PARTS BY WEIGHT
Masterbatch Blend
100
Sulfur
1.25
Stearic Acid
1
Carbon Black N-550
40
Vulkacit Thiaram MS (TMTM)
0.5
Zinc Oxide
5
Blowing Agent
2.5
Exemplary compositions of the masterbatch for various additive ratios of SBR to EPDM are provided in Table 2A in a manner similar to that of Table 1A.
TABLE 2A
PARTS BY WEIGHT
MATERIAL
a
b
c
Rubber (SBR)
40
25
50
Additive Polymer (EPDM)
60
75
50
Stearic Acid
1
1
1
Sunolite 240
2
2
2
Zinc Oxide
5
5
5
Carbon Black N-550
30
30
30
Carbon Black N-224
60
60
60
Calcium Carbonate
35
35
35
Talc
30
30
30
Supar 2280
80
80
80
After mixing of the SBR masterbatch, curative agents are preferably added in a second stage mixing process for formation of the raw rubber compound which forms the backing sheet of the floor covering article of the present invention. An exemplary composition of the raw rubber compound formed in this second stage mixing process is provided in Table 2B.
TABLE 2B
MATERIAL
PARTS BY WEIGHT
Masterbatch Blend
100
Sulfur
2
Methyl Zimate
1.25
Butyl Zimate
1.25
Dibutyl Thiurea
2.50
Tellurium Diethyldithiocarbanate
1
Blowing Agent
2.0
As previously indicated and shown above, the rubber backing sheet includes a blowing agent to effectuate the formation of closed gas cells in the rubber during vulcanization. The blowing agent which is preferably used is a nitrogen compound organic type agent which is stable at normal storage and mixing temperatures but which undergoes controllable gas evolution at reasonably well defined decomposition temperatures. By way of example only and not limitation, blowing agents which may be used include: azodicarbonamide (Celogen™ AZ-type blowing agents) available from Uniroyal Chemical Inc. in Middlebury Conn. and modified azodicarbonamide available from Miles Chemical in Akron, Ohio under the trade designation Porofor™ ADC-K.
It has been found that the addition of such blowing agents at a level of between about 1 and about 5 parts by weight in the raw rubber composition yields a rubber sheet having an expansion factor of between about 50 and 200 percent. After the fluxing processes are completed, the uncured rubber compound containing EPDM and the blowing agent is assembled with the pile yarns and carrier layer as previously described. The vulcanization of the rubber backing sheet is then at least partially effected within the press molding apparatus wherein the applied pressure is between 20 and 40 psi. Under the high temperatures and pressure, the nitrogen which is formed by the blowing agent partly dissolves in the rubber. Due to the high internal gas pressure, small closed gas cells are formed within the structure as the pressure is relieved upon exit from the press molding apparatus. In an alternative practice a post cure oven may be used to complete the vulcanization of the mat and provide additional stability to the resulting product.
EXAMPLE
A rubber sheet material was produced by fluxing together the materials as set forth in Table 1A in a standard rubber internal mixer at a temperature of about 280° F. to 300° F. for a period of one to two minutes. EPDM additions were varied as shown in Table 1A to yield ratios of EPDM to NBR of 3.0 (75 parts EPDM to 25 parts NBR); 1.5 (60 parts EPDM to 40 parts NBR); and 1.0 (50 parts EPDM to 50 parts NBR). Additions of curative agents as provided in Table 1B were then made. An Uncured sheet of the fluxed rubber compounds was then calendared, placed over a die mold having a plurality of cylindrically configured openings, covered partially with a pile fabric component (attached to a carrier fabric) and cured at a temperature of about 290° F. for five (5) minutes under a pressure of about 40 psi and post cured at a temperature of about 290° F. at atmospheric pressure for a period of five (5) minutes. The resultant floor covering article provided a significant amount of increased cushioning as compared to a sample article prepared without the utilization of the die mold but with the same rubber composition and pile fabric covering and under the same conditions as the inventive mat. Furthermore, the inventive mat, when placed on a floor with the resultant foam rubber protrusions in contact with the floor exhibited a substantial reduction in slip capability as compared with the standard non-cleated foam rubber sample produced without the use of the die molding vessel did not exhibit any appreciable carbon staining from the rubber backing sheet.
While the invention has been described and disclosed in connection with certain preferred embodiments and procedures, these have by no means been intended to limit the invention to such specific embodiments and procedures. Rather, the invention is intended to cover all such alternative embodiments, procedures, and modifications thereto as may fall within the true spirit and scope of the invention as defined and limited only by the appended claims.
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This invention relates to a cushioned floor covering article wherein the mat includes a tufted carpet placed on the top side of a foam rubber sheet and at least one foam rubber protrusion integrated within at least a portion of the bottom side of the foam rubber sheet. Such an article provides effective removal of moisture, dirt, and debris from the footwear of pedestrians through the utilization of a carpet pile component. Furthermore, the utilization of a foam rubber backing also allows for either periodic heavy duty industrial-scale laundering in such standard washing machines or periodic washing and drying in standard in-home machines, both without appreciably damaging the inventive floor covering article, such as a floor mat. Additionally, the presence of integrated foam rubber protrusions within the mat structure provides an effective cushioning effect for pedestrian comfort as well as a means to prevent slippage of the article from its contacted surface. A method of producing such an inventive cushioned floor covering article is also provided.
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The present application claims priority to, under 35 U.S.C. 119(e), U.S. Provisional Patent Application 60/357,071, filed Feb. 12, 2002, which is incorporated herein by reference.
BRIEF DESCRIPTION OF THE INVENTION
The present invention relates generally to cable television systems (CATV). More specifically, the present invention pertains to a method and system for lowering the data rate of digital return path links for a CATV hybrid fiber coax system.
BACKGROUND OF THE INVENTION
Cable television systems (CATV) were initially deployed so that remotely located communities were allowed to place a receiver on a hilltop and to use coaxial cable and amplifiers to distribute received signals down to the town that otherwise had poor signal reception. These early systems brought the signal down from the antennas to a “head end” and then distributed the signals out from this point. Since the purpose was to distribute television channels throughout a community, the systems were designed to be one-way and did not have the capability to take information back from subscribers to the head end.
Over time, it was realized that the basic system infrastructure could be made to operate two-way with the addition of some new components. Two-way CATV was used for many years to carry back some locally generated video programming to the head end where it could be up-converted to a carrier frequency compatible with the normal television channels.
Definitions for CATV systems today call the normal broadcast direction from the head end to the subscribers the “forward path” and the direction from the subscribers back to the head end the “return path.” A good review of much of today's existing return path technology is contained in the book entitled Return Systems for Hybrid Fiber Coax Cable TV Networks by Donald Raskin and Dean Stoneback, hereby incorporated by reference as background information.
One innovation, which has become pervasive throughout the CATV industry over the past decade, is the introduction of fiber optics technology. Optical links have been used to break up the original tree and branch architecture of most CATV systems and to replace that with an architecture labeled Hybrid Fiber/Coax (HFC). In this approach, optical fibers connect the head end of the system to neighborhood nodes, and then coaxial cable is used to connect the neighborhood nodes to homes, businesses and the like in a small geographical area.
FIG. 1 shows the architecture of a HFC cable television system. Television programming and data from external sources are sent to the customers over the “forward path.” Television signals and data are sent from a head end 10 to multiple hubs 12 over optical link 11 . At each hub 12 , data is sent to multiple nodes 14 over optical links 13 . At each node 14 , the optical signals are converted to electrical signals and sent to customers over a coaxial cable 15 . In the United States, the frequency range of these signals is between 55 to 850 MHz.
Data or television programming from the customer to external destinations, also known as return signals or return data, are sent over the “return path.” From the customers to the nodes 14 , return signals are sent over the coaxial cables 15 . In the United States, the frequency range of the return signals is between 5 to 42 MHz. At the nodes 14 , the return signals are converted to optical signals and sent to the hub 12 . The hub combines signals from multiple nodes 14 and sends the combined signals to the head end 10 .
FIG. 2 is a block diagram of a digital return path 100 of a prior art HFC cable television system that uses conventional return path optical fiber links. As shown, analog return signals, which include signals generated by cable modems and set top boxes, are present on the coaxial cable 102 returning from the customer. The coaxial cable 102 is terminated at a node 14 where the analog return signals are converted to a digital representation by an A/D converter 112 . The digital signal is used to modulate a optical data transmitter 114 and the resulting optical signal is sent over an optical fiber 106 to an intermediate or head end hub 12 . At the hub 12 , the optical signal is detected by an optical receiver 122 , and the detected digital signal is used to drive a D/A converter 124 whose output is the recovered analog return signals.
The analog return signals present on the coaxial cable 102 are typically a collection of independent signals. In the United States, because the analog return signals are in the frequency range of 5 to 42 MHz, the sampling rate of the A/D converter is about 100 MHz, slightly more than twice the highest frequency in the band. A 10-bit A/D converter operating at a sampling rate of 100 MHz is typically used for digitizing the return signals. As a result, data will be output from the A/D converter 112 at a rate of about 1 Gbps. Further, the optical data transmitter 114 and the optical data receiver 122 must be capable of transmitting and receiving optical signals at a rate of 1 Gbps or higher. The high transmission data rate requires the use of expensive equipment, or short transmission distances, or both. Bandwidth limitations of the data transmission equipment also limits the number of analog return signals that can be aggregated for transmission on the same optical fiber.
Accordingly, there exists a need for a method of and system for lowering the data rate in the return path of a CATV system.
SUMMARY OF THE INVENTION
An embodiment of the present invention is an apparatus for and a method of transmitting analog return signals in a digital return path of a cable television system (CATV). In this embodiment, at a node of the CATV system, an analog CATV return signal is converted to a stream of digital samples at approximately 100 MHz. Signals outside of a desired frequency band are removed with a digital filter having predetermined filter coefficients. The resulting stream of digital samples is up-sampled to generate another stream of digital samples at a rate that is four times the center frequency of a predetermined frequency band. The resulting stream is then punctured to generate yet another stream with a data rate that is lower than 100 MHz. Zero samples (i.e., sample having a value of zero) are removed, and the remaining digital samples are serialized and converted to optical signals for transmission via an optical medium of the CATV return path. In one particular embodiment, the transported data stream has a data rate that is less than half of the 100 MHz data rate.
In furtherance of the present embodiment, at a hub or head end of the CATV system, the optical signals are converted to electrical signals and deserialized to form a stream of digital samples. Zeros samples are reinserted, and the resulting stream is filtered by a digital filter that has the same filter coefficients as the filter in the node of the CATV system. The filtered stream of digital samples are then up-sampled to a rate of approximately 100 MHz. The up-sampled stream is converted by a digital-to-analog converter to restore the signals in the desired frequency band.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages and aspects of the present invention will be more readily apparent from the following description and appended claims when taken in conjunction with the accompanying drawings, in which:
FIG. 1 shows the architecture of a cable television system;
FIG. 2 is a block diagram of a cable television (CATV) digital return path of the prior art;
FIG. 3 is a block diagram of a CATV return path according to one embodiment of the present invention;
FIG. 4 illustrates a relationship between spectral energy and frequency of signals carried by a conventional CATV digital return path and a desired frequency band that is carried by a CATV digital return path of FIG. 3 ;
FIG. 5 illustrates an encoder that can be used in the CATV digital return path of FIG. 3 ;
FIG. 6 illustrates a decoder that can be used in the CATV digital return path of FIG. 3 ;
FIG. 7 illustrates samples of a 35.3 MHz sinusoidal waveform sampled at a 100 MHz rate;
FIG. 8 illustrates the coefficients of the bandpass interpolation filter of FIG. 5 according to one embodiment of the present invention;
FIG. 9 illustrates the frequency response of the bandpass interpolation filter of FIG. 5 according to one embodiment of the present invention;
FIG. 10 illustrates the output of the bandpass interpolation filter of FIG. 5 when interpolated 48/34 times the input frequency or approximately 141.176 MHz;
FIG. 11 illustrates the result of puncturing the output of the bandpass interpolation filter FIG. 5 according to one embodiment of the present invention;
FIG. 12 illustrates the result of interpolating the filter output of the bandpass filter of FIG. 6 to the full rate of approximately 100 MHz according to one embodiment of the present invention; and
FIG. 13 illustrates the result of converting the output of the bandpass interpolation filter of FIG. 6 and low-pass filtering the analog signal according to one embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 is a block diagram depicting a CATV return path 200 according to one embodiment of the present invention. At the CATV return path transmitter 210 , an A/D converter 112 receives an analog return signal from a co-axial cable 201 and generates a stream of data at a full sampling rate (e.g., 100 MHz). A signal encoder 213 encodes the output of the A/D converter 112 and generates another stream of data at a lower data rate. The low data rate output of the signal encoder 213 is provided to the optical data transmitter 114 for transmission to a hub 220 as optical signals. According to the present invention, the hub 220 can be an intermediate hub or a head end hub.
At the hub 220 , an optical data receiver 122 receives the optical signals from the transmitter 210 and converts the signals to a low data rate data stream that is a replica of the data stream generated by the signal encoder 213 . More specifically, the optical data receiver 122 preferably includes an optoelectronic receiver that receives the optical signals and converts the optical signals into a serial bit stream, and a deserializer for converting the serial bit stream into a stream of multiple-bit digital values (sometimes called samples). A signal decoder 223 receives and decodes the output of the optical data receiver 122 and generates a stream of data at a full sampling rate. The output of the decoder 223 is provided to the D/A converter 124 for conversion into analog signals. In this embodiment, the signal encoder 213 and signal decoder 223 enable digital data to be transmitted across the optical link at a lower rate than N*F bits per second (where N is the number of bits and F is the sampling frequency of the A/D converter 112 ). The entire spectrum of the analog return signal originally present on cable 201 , however, is not recreated at the output of the hub 220 . Only frequencies within a desired frequency band of the analog return signal are recovered at the hub 220 .
The analog return signal carried by the co-axial cable 201 is an analog signal with signal components from 5 to 42 MHz. FIG. 4 illustrates the spectral density of the signal components of a typical analog return signal. In prior art CATV systems, most or all of the signal components from 5 to 42 MHz are communicated via the return path to the head end. A typical sampling rate of the analog return signal is 100 MHz, which is higher than twice the highest frequency transmitted in the return path. In some CATV systems, users of the CATV return path only use specific portions of the return path spectrum. Thus, in those systems, only those portions of the return path spectrum carrying useful information need be transmitted from the node 210 to the hub 220 . Other portions of the return path spectrum can be filtered out. In one particular embodiment as shown in FIG. 4 , the desired signal is only in a portion of the return path spectrum approximately between 34 MHz and 40 MHz with a total bandwidth of approximately 6 MHz. When only a specific portion of the return path spectrum is transmitted, (e.g., the spectrum between 34 MHz and 40 MHz) the data rate of the optical link can be significantly reduced.
According to one embodiment of the present invention, logic for transmitting a signal that embodies a specific portion of the return path spectrum is implemented in the signal encoder 213 . One implementation of the signal encoder 213 is shown in FIG. 5 . As shown, a stream of A/ID samples at the Full Rate of 100 MHz is first filtered by a digital FIR (Finite Impulse Response) band-pass interpolation filter 510 to form a band-limited data stream. The filter rate of the bandpass interpolation filter 510 is chosen as the least common multiple of the Full Rate and an integer multiple (e.g. four times) of Center Frequency. As used herein, Center Frequency refers to the frequency approximately at the center of the frequency band to be retained. For example, if the frequency band to be retained is the band between 32-38 MHz, the Center Frequency will be approximately 35 MHz. The Center Frequency is preferably less than one half the Full Rate.
In the present embodiment, A/D samples enter the filter at the Full Rate (e.g., 100 MHz), and samples are read from the multiple phase taps of band-pass interpolation filter 510 at a rate that is four times (and more generally an integer multiple of) the Center Frequency to form another stream of samples. If the Center Frequency is 35 MHz, then samples are read from the band-pass interpolation filter 510 at a rate of 140 MHz, and the filter rate will be 700 MHz. In the present embodiment, the data rate at which samples are read from the output phase taps of the bandpass interpolation filter 510 is set by an NCO (Numerically Controlled Oscillator) 512 .
With reference again to FIG. 5 , the interpolated samples are then punctured at an odd integer rate by logic circuits 514 . That is, samples are punctured at a rate of Center Frequency*4/k; where k is an odd integer. The value of k can be chosen as any odd number as long as the resulting sampling rate is less than twice the desired bandwidth (i.e., of the desired signal band). For a ⅓ puncture rate, only every third sample is retained. The other 2 of 3 of the samples are replaced by zeros. The retained samples are the Transport Samples. In the present embodiment, only the Transport Samples are sent to the optical data transmitter 114 . The samples that are replaced by zeros (or, “punctured”) are not sent over the optical link 11 to the hub 12 or head end 10 .
Attention now turns to FIG. 6 , which is a block diagram depicting an implementation of signal decoder 223 in accordance with an embodiment of the present invention. The signal decoder 223 is coupled to SERDES circuits of the optical data receiver 122 to receive the transport stream generated by node 210 . As described above, the transport stream consists of punctured samples. That is, certain samples were replaced with zeros and were not transported. Thus, in the present embodiment, the zero-insertion logic 624 of the signal decoder 223 reinserts the zero samples in the transport stream to generate a “depunctured” or “restored” stream. The “depunctured” stream is filtered by a bandpass interpolation filter 626 , and the output phase taps of the interpolation filter 626 are read (by a multiplexer or similar apparatus 628 ) at the Full Rate of 100 MHz to form an output data stream. The samples of the output data stream are then sent to the D/A converter 124 ( FIG. 3 ) and an analog low pass output filter 230 , which reconstruct the desired analog waveform. The low pass output filter preferably filters out signals significantly above the desired band of signals, so as to reduce or eliminate high frequency noise generated by the reconstruction of the desired signal from digital samples. For example, with a desired signal band of 34 to 40 MHz, the low pass output filter would preferably filter out signal above approximately 50 MHz.
Example Implementation
Attention now turns to an example implementation that illustrates the principles of an embodiment of the present invention. In this example, a 35.3 MHz sinusoidal waveform sampled at a 100 MHz rate is used as the input signal. FIG. 7 shows the samples of the 35.3 MHz sinusoidal input signal sampled at a 100 MHz rate.
Further, in this example, the bandpass interpolation filter 510 of the signal encoder has thirty-four active taps with forty-eight phases. FIG. 8 shows the coefficients of the bandpass interpolation filter 510 in this particular example. The frequency response of the filter 510 in this particular example is shown in FIG. 9 . The bandpass interpolation filter 510 processes the input signal allowing only the desired signals to pass. In this example, the 35.3 MHz sinusoidal input signal falls within the range of desired signals that are allowed to pass. (35.3 MHz corresponds to 112.96 on the horizontal scale of FIG. 9 , and thus falls near the center of the region have 0 dB in amplitude attenuation.)
In the present example the output of the filter 510 is interpolated 48/34 times the (100 MHz) input frequency or approximately 141.18 MHz (which is approximately four times the center frequency of 35.3 MHz (35.3 MHz*4=141.2 MHz)), resulting in the interpolated samples of FIG. 10 . The interpolated samples are then punctured to ⅓ the sample rate of 141.18 MHz or 47.06 MHz. FIG. 11 shows the samples after puncturing. The punctured samples are set to zero in the FIG. 11 . Only the non-zero samples are transported to the receiver. Thus, the transport data rate is reduced from 100 MHz to approximately 47.06 MHz.
At the receiver, the zeros in the punctured data stream are reinserted. The resulting data stream is filtered in the bandpass interpolation filter 626 , which has the same filter coefficients as the bandpass interpolation filter 510 . The bandpass interpolation filter 626 , however, is used with forty-eight active taps and thirty-four phases. The filter output is computed at the full rate of 100 MHz resulting in the samples shown in FIG. 12 . The resulting samples are similar to the input samples ( FIG. 7 ) with only the phase shift of the system components.
The output of the bandpass interpolation filter 626 is passed to the D/A converter 124 ( FIG. 3 ) and filtered by an analog low pass filter 230 ( FIG. 3 ), resulting in the output of FIG. 13 .
Preferred embodiments of the present invention and best modes for carrying out the invention have thus been disclosed. While the present invention has been described with reference to a few specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications may occur to those skilled in the art without departing from the true spirit and scope of the invention. It should also be noted that some embodiments of the present invention described above can be implemented by hardware logic (e.g., Field Programmable Gate Array(s)). In addition, a person skilled in the art would realize upon reading the present disclosure that portions of the present invention can be implemented as computer executable programs executable by a digital signal processor. Further, although the embodiments described above use finite impulse response (FIR) digital filters for rate conversion, a person skilled in the art would realize upon reading the present disclosure that other embodiments of the invention can use infinite impulse response digital filters and variable time update periods.
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An apparatus for and a method of transmitting analog return signals in a digital return path of a cable television system (CATV) is disclosed. In one embodiment, at a node of the CATV system, an analog CATV return signal is converted to a stream of digital samples at approximately 100 MHz. Signals outside of a desired frequency band are removed with a digital filter having predetermined filter coefficients. The resulting stream of digital samples is up-sampled to generate another stream of digital samples at a rate that is four times the center frequency of a predetermined frequency band. The resulting stream is then punctured to generate yet another stream with a data rate that is lower than 100 MHz. Zero samples are removed, and the remaining digital samples are serialized and converted to optical signals for transmission via an optical medium of the CATV return path. A reverse process at a hub or head end of the CATV return system restores the signals of the desired frequency band.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority of Korean Patent Application Number 10-2009-0076922 filed Aug. 19, 2009, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present disclosure relates to a vehicle door locking system. More particularly, it relates to a vehicle door locking system, in which an inside handle is pushed to lock a door.
[0004] 2. Description of Related Art
[0005] In general, the door of a vehicle is equipped with an inside handle connected with a latch on the inner side thereof so as to be able to unlock or lock the door.
[0006] FIG. 1 is a schematic perspective view illustrating a conventional vehicle door locking system.
[0007] Referring to FIG. 1 , a door inside handle 10 includes a lock release lever 20 pulled to open a door, and a safety lock knob 40 installed on the same axis as the lock release lever 20 and adjusting the operation of a safety lock.
[0008] The lock release lever 20 is connected to a latch 70 via a lock release cable 30 , and the safety lock knob 40 is connected to the latch 70 via a safety lock cable 50 .
[0009] At this time, when the safety lock knob 40 protrudes toward the passenger compartment, the lock release lever 20 is pulled to open the door. On the other hand, when the safety lock knob 40 is pushed away from the passenger compartment, i.e. does not protrude toward the passenger compartment, the door will not open although the lock release lever 20 is pulled.
[0010] However, the door locking system facilitates the convenience of a user by installing the safety lock knob, the lock release lever, the two cables, and the latch assembly for a door locks in the vehicle door. The safety lock knob and the lock release lever are connected to and operated with the latch assembly through respective cables, so that the number of parts and the number of assembling steps are increased, which is attributed to increasing the cost of production.
[0011] The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention has been made in an effort to solve the above-described problems associated with the prior art. The present invention is directed toward providing a vehicle door locking system, in which a push lock function is added to an existing lock release lever, thereby integrating the function of an existing safety lock knob into a single lever to thereby permit the number of parts and the cost of production to be reduced.
[0013] In one aspect, the present invention provides a vehicle door locking system which includes a door latch assembly installed on one side of a door, an integrated lever operating the door latch assembly, and a cable connecting the integrated lever with the door latch assembly. The state of the door changes to an open state when the integrated lever is pulled, an unlocked state when the integrated lever is neutral, and a safety locked state when the integrated lever is pushed in.
[0014] According to the present invention, the vehicle door locking system has the following advantages and effects.
[0015] First, in the case of a conventional inside handle, a lock release lever and a safety lock knob are separately installed to facilitate the convenience of a passenger. On the contrary, in the case of the inventive inside handle, a push function is added to a lock release lever, thereby integrating the function of the safety lock knob. As a result, the parts associated with the function of the safety lock knob are eliminated to be able to reduce the number of parts and the cost of production.
[0016] Second, the end of a cable is coupled to a safety lock link using a ball joint, and a latch release link is rotated by a hook connected to the end of the cable, so that a lock release function and a safety lock function can be simultaneously realized using a single integrated lever.
[0017] Other aspects and other embodiments of the invention are discussed infra.
[0018] It is understood that the term “vehicle” or “vehicular” or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like, and includes hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other alternative fuel vehicles (e.g. fuels derived from resources other than petroleum). As referred to herein, a hybrid vehicle is a vehicle that has two or more sources of power, for example a vehicle which is both gasoline- and electric-powered.
[0019] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic perspective view illustrating a conventional vehicle door locking system.
[0021] FIG. 2 is a schematic view illustrating a vehicle door locking system according to an embodiment of the present invention.
[0022] FIG. 3 illustrates the operation of each component at the time of performing the door lock operation in accordance with an embodiment of the present invention.
[0023] FIG. 4 illustrates the operation of each component at the time of performing the door unlock operation in accordance with an embodiment of the present invention.
[0024] FIG. 5 illustrates the operation of each component at the time of performing the door open operation in accordance with an embodiment of the present invention.
[0025] FIG. 6 illustrates the operation of a safety lock link at the time of performing each door operation in accordance with an embodiment of the present invention.
[0026] It should be understood that the appended drawings are not necessarily to scale and present a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0028] FIG. 2 is a schematic view illustrating a vehicle door locking system according to an embodiment of the present invention.
[0029] The present invention is directed to a vehicle door locking system, which adds the function of a safety lock knob to a lock release lever, instead of removing the safety lock knob installed on an existing inside handle.
[0030] An existing lock release lever for opening a door is a device which is required to perform only a pull operation, and thus uses no push operation.
[0031] However, the present invention is configured to apply a locking function to the pushing function of the lock release lever.
[0032] The vehicle door locking system according to an embodiment of the present invention includes an integrated lever 100 , a cable 110 , and a door latch assembly.
[0033] The integrated lever 100 operates the door latch assembly to open, unlock, or lock the door.
[0034] The integrated lever 100 makes it possible to perform pull, neutral and push operations. The push operation is added to the existing lock release lever, so that a locking function can be implemented by the existing lock release lever.
[0035] Here, the neutral operation of the integrated lever 100 refers to the state where the pull operation of the integrated lever 100 is released, i.e. the state where the integrated lever 100 is not pulled toward the passenger compartment and is not pushed away from the passenger compartment.
[0036] The integrated lever 100 is connected with the door latch assembly. Thus, when the integrated lever 100 is pulled, the door is opened. When the integrated lever 100 is released from being pulled, the door is unlocked. When the integrated lever 100 is pushed, the door is locked.
[0037] The cable 110 connects the integrated lever 100 with the door latch assembly, and thus serves to transmit the operation of the integrated lever 100 to the door latch assembly.
[0038] The door latch assembly is mounted on an inner panel of the door, and includes a housing 121 , an end of the cable 110 , and first to fourth links 122 , 126 , 127 and 125 .
[0039] The housing 121 holds the end of the cable 110 and the first to fourth links 122 , 126 , 127 and 125 , and serves to protect them from an external force.
[0040] The cable 110 is connected to a first end of the housing 121 . The end of the cable 110 , which is connected so as to integrally move with the cable 110 , is inserted into the first end of the housing 121 . The end of the cable 110 is provided with a ball end 111 having the shape of a ball.
[0041] At this time, the ball end 111 has a connecting cable 123 of a small diameter, which extends along the same axis as the cable 110 . A hook 124 is attached to an end of the connecting cable 123 . The hook 124 is connected with the fourth link 125 , which will be described below.
[0042] The first link 122 includes a ball socket 122 a formed to retain the ball end 111 of the end of the cable. Thus, the first link 122 continues to be coupled with the ball end 111 of the end of the cable 110 in locking and unlocking functions when the ball socket 122 a retains the ball end 111 of the end of the cable 110 , and continues to be decoupled from the ball end 111 of the end of the cable 110 in a releasing (opening) function.
[0043] The first link 122 is rotatably supported on one side of the housing 121 at one end thereof, and is rotatably hinged with one end of the second link 126 at the other end thereof. The other end of the second link 126 is connected with one end of the third link 127 . The third link 127 is installed in the housing 121 so as to be movable left and right.
[0044] The second link 126 is provided with a hinge part 126 a , which is hinged to an upper end of the third link 127 , and a slide part 126 b , which is slidably coupled to a lower portion of the third link 127 , at the other end thereof.
[0045] The third link 127 is formed with a slide groove in one end thereof, so that the slide part 126 b of the second link 126 can move left and right along the slide groove of the third link 127 .
[0046] The fourth link 125 is rotatably installed on a lower side of the housing 121 , and is provided with a hooking slot in one end thereof, so that the hook 124 is slidably coupled in the hooking slot of the fourth link 125 . As the end of the cable is pulled or pushed, the fourth link 125 is rotated, so that the open or lock/unlock operation is carried out.
[0047] Further, the housing 121 is provided with a guide protrusion at an upper end thereof. The guide protrusion serves to guide the ball end 111 to be coupled to the ball socket 122 a of the first link 122 when the ball end 111 of the end of the cable 110 moves up and down.
[0048] The hook 124 is coupled in the hooking slot so as to be movable up and down. Thus, the hook 124 moves toward a lower end of the hooking slot in a door locked state, and toward an upper end of the hooking slot in a door unlocked state.
[0049] An operation of the vehicle door locking system having this configuration in accordance with an embodiment of the present invention will be described below.
[0050] FIG. 3 illustrates the operation of each component at the time of performing the door lock operation in accordance with an embodiment of the present invention. FIG. 4 illustrates the operation of each component at the time of performing the door unlock operation in accordance with an embodiment of the present invention. FIG. 5 illustrates the operation of each component at the time of performing the door open operation in accordance with an embodiment of the present invention. FIG. 6 illustrates the operation of a safety lock link at the time of performing each door operation in accordance with an embodiment of the present invention.
[0051] 1. Door Safety Lock
[0052] The integrated lever 100 is pushed away from the passenger compartment, thereby keeping the door latch assembly locked through the cable 110 .
[0053] Here, when the integrated lever 100 is pushed, the end of the cable moves downwards, and thus the ball end 111 of the end of the cable pushes and rotates the ball socket 122 a of the first link 122 . Thereby, the ball end 111 is surrounded by the ball socket 122 a , so that the door is put into a safety locked state.
[0054] At this time, the second link 126 is rotated in a direction opposite the direction where the first link 122 is rotated, thereby pulling the third link 127 in a rightward direction. The slide part 126 b of the second link 126 moves into the slide groove of the third link 127 , and the hook 124 connected with the end of the cable moves toward the lower end of the hooking slot.
[0055] Here, the fourth link 125 is rotated in a downward direction, and the user feels the operation caused by the coupling of the ball end 111 with the ball socket 122 a . When the integrated lever 100 is pulled with force enough to decouple the ball end 111 from the ball socket 122 a , the safety lock of the door can be released.
[0056] Accordingly, the integrated lever 100 is allowed to perform the function of the safety lock knob.
[0057] 2. Door Unlock
[0058] The integrated lever 100 is put in a neutral state, thereby keeping the door latch assembly unlocked through the cable 110 .
[0059] Here, when the integrated lever 100 is put in the neutral state, the end of the cable is pulled, and thus the ball end 111 of the end of the cable pulls up and rotates the first link 122 . Thereby, the ball end 111 comes out of the ball socket 122 a , so that the door is put in an unlocked state. As the first link 122 is rotated and returns to its original state, the second link 126 is rotated in a direction opposite the direction where the first link 122 is rotated, thereby pushing the third link 127 in a leftward direction. The slide part 126 b of the second link 126 moves out of the slide groove of the third link 127 .
[0060] The hook 124 connected with the end of the cable moves toward the upper end of the hooking slot.
[0061] 3. Door Open
[0062] The integrated lever 100 is pulled from the passenger compartment, thereby keeping the door latch assembly opened thanks to the cable 110 .
[0063] Here, when the integrated lever 100 is pulled, the end of the cable moves upwards, and thus the ball end 111 of the end of the cable is completely decoupled from the ball socket 122 a of the first link 122 in an upward direction. As the hook 124 connected with the end of the cable pulls up and rotates the fourth link 125 , the door is put in an open state.
[0064] Here, the first, second and third links 122 , 126 and 127 take part in the lock/unlock operation of the door, whereas the first link 122 and the fourth link 125 take part in the open operation of the door.
[0065] For convenience in explanation and accurate definition in the appended claims, the terms “upper” or “lower”, and etc. are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
[0066] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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A vehicle door locking system, in which a push lock function is added to the door lock release lever of an existing vehicle, integrates a lock release function and a safety lock function into a single integrated lever to thereby permit the number of parts and the cost of production to be reduced. To this end, the vehicle door locking system includes a door latch assembly installed on one side of a door, an integrated lever operating the door latch assembly, and a cable connecting the integrated lever with the door latch assembly. The door is put in an open state when the integrated lever is pulled, an unlocked state when the integrated lever is in a neutral state, and a safety locked state when the integrated lever is pushed.
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BACKGROUND OF THE INVENTION
1. Introduction
This invention relates to a process and apparatus for generating permanganate through electrolytic oxidation. In particular, the invention relates to electrolytic regeneration of permanganate etchant baths.
2. Description of the prior art
Electroless metal plating of plastic substrates is employed to produce a variety of items such as printed electronic circuit boards and electromagnetic interference shielding. Prior to metal deposition, the plastic substrate is etched by an oxidant to enhance adhesion of the metal. This is often an essential step to a successful plating sequence. For example, conductive through-holes of printed circuit boards have posed persistent problems to metal plating which have been addressed through an oxidative etching process, as described in U.S. Pat. No. 4,515,829, incorporated herein by reference.
A variety of oxidant etching agents have been employed. Chromium compounds and concentrated sulfuric acid are less favored due to problems associated with application, safety and disposal. Much more convenient are the widely used permanganate solutions, particularly alkaline permanganate solutions.
The operating life of a permanganate etchant bath can be relatively limited as permanganate ions are reduced during the etching process to manganese species of lower oxidative states, such as manages dioxide and manganate. This reduction results directly from the etching process as well as from the etchant bath conditions; for instance, the alkaline bath promotes permanganate disproportionation to yield manganate. As it is permanganate rather than the lower oxidative state manganese species which exhibit polymer etching properties, to maintain etchant activity the bath must either be regularly replaced with fresh permangante solution or supplemented with additional permanganate ions. Preferably, permanganate concentration is maintained by oxidation of reduced manganese species present in the bath as addition of new permanganate to an existing bath or bath replacement are both expensive and burdensome.
A convenient means of permanganate regeneration is oxidative electrolysis, as generally described in U.S. Pat. No. 4,859,300, incorporated herein by reference. The efficiency of such electrolysis has been limited by reduction reactions occurring at the cathode, specifically the reduction of permanganate and lower oxidative state manganese compounds. Reduction yielding manganese dioxide particularly limits cell efficiency. Manganese dioxide is extremely insoluble in typical etching solutions and thus, once formed, cannot be oxidized at the anode to permanganate.
This problem is commonly addressed by use of a high anode surface area to cathode surface area ratio. However, a high electrode surface area ratio only limits, and does not eliminate, cathode reduction reactions. Furthermore, use of a high electrode surface area ratio can be burdensome where a relatively compact cell is required, for example if permanganate regeneration is performed in situ by placement of the cell within the etchant bath vessel.
A separated-type cell also has been employed to limit undesirable cathode reduction reactions. In this type of cell the cathode is separated from the anode by a porous membrane which restricts migration of permanganate ions to the cathode. However this system tends to be inconvenient. Manganese dioxide is produced through permanganate decay in the solution and as noted is virtually insoluble in the etchant solution. The insoluble manganese dioxide collects throughout the separated cell and particularly on the porous membrane separating the anode and cathode. The membrane consequently becomes blocked, preventing electricity flow through the cell. Regular cell disassembly and cleaning are required to maintain cell efficiency.
SUMMARY OF THE INVENTION
The present invention comprises an improved method and apparatus for electrolytic generation of permanganate. The invention provides more efficient and convenient permanganate generation than afforded by prior systems. Although generally discussed in the context of permanganate generation, and specifically regeneration of permanganate etchant solutions, the present invention should be applicable to electrolytic oxidation in other technologies and particularly other technologies employing permanganate solutions.
In one embodiment, the invention is a process for permanganate generation through electrolytic oxidation of one or more manganese compounds in an aqueous solution, comprising the steps of contacting an anode and a cathode with the aqueous solution and subjecting the solution to electrolysis. The cathode may be of a variety of conductive materials and has a surface deposit that is adherent to manganese dioxide during electrolysis covering at least a portion of the cathode surface. During electrolysis manganese dioxide in the solution adheres to the cathode surface deposit forming a film thereon. This manganese dioxide film completely or at least virtually eliminates undesired reduction reactions at the cathode and thereby substantially increases permanganate generation efficiency.
In another embodiment, the invention is an electrolytic cell for permanganate generation by electrolytic oxidation of one or more manganese compounds in a aqueous solution. The cell comprises an anode and cathode of the above-described type. During electrolysis of a permanganate etchant solution, a manganese dioxide film forms on the cathode surface deposit affording the noted advantages thereof.
BRIEF DESCRIPTION OF THE DRAWING
A more complete understanding of the invention may be provided by reference to the accompanying drawing wherein:
The FIGURE is a cross-sectional representation of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The anode electrode of the present invention can be of any suitable conductive and corrosion resistant material and preferably is nickel or a nickel alloy, such as the nickel-copper alloy Monel. The anode preferably has an electrical conductivity of at least about 51 microohms/cm. at 20° C., and is constructed of expanded metal plate with some type of punched holes or other openings to maximize the electrode's surface area. A preferred material of construction is Monel mesh of thickness between 0.5 and 1.0 mm. and mesh openings of between 1.5 to 4.0 mm.
The cathode electrode comprises a conductive metal on which is deposited a composition that is adherent to manganese dioxide during electrolysis. The cathode conductive metal core may be any suitable conductive material such as copper, stainless steel or titanium, with copper being preferred for its conductivity. Nickel is preferably used as the composition adherent to mangenese dioxide. It is believed that other conductive compounds could serve as suitable manganese dioxide adherent compositions. The cathode deposit is applied by either electroless deposition or bright nickel electroplating using standard procedures, for example those procedures described in L. J. Durney, Electroplating Engineering Handbook, pp. 174-184 and 453 (4th ed. 1984); and The Canning Handbook of Surface Finishing Technology, ch. 13 (23rd ed., E & F N Spon), both incorporated herein by reference.
Nickel is deposited on the cathode to a thickness of between about 3 to 30 microns, preferably between about 5 to 15 microns. This cathode deposit preferably covers the entire surface of the cathode that contacts the etchant bath. However, significant increases in permanganate generation efficiency also should be realized where a lesser amount of the cathode is covered with the manganese dioxide adherent surface deposit, for example where at least about 25 percent of the cathode surface contacting the etchant bath is covered by the surface deposit.
During electrolysis of a permanganate etchant solution, manganese dioxide adheres to the cathode surface deposit providing a manganese dioxide film thereon of thickness of between about 0.5 to 5.0 mm. It has been found that this manganese dioxide layer completely or at least virtually eliminates undesired reduction reactions occurring at the cathode and thereby substantially increases permanganate yields. As the only MnO 2 produced is through permanganate decay in the alkaline solution, the present invention produces much less MnO 2 than a similar system that lacks a manganese dioxide adherent cathode surface deposit. Additionally, unlike separation-type cells having membranes that readily clog with manganese dioxide, the presence of MnO 2 does not disrupt the operation of the cell of the present invention.
While the manganese dioxide layer does not appreciably impede oxidation reactions occuring at the anode, cell voltage may be increased during the course of the electrolysis. If a portion of the manganese dioxide coating is for any reason dislodged from the cathode surface, it is immediately replaced through adherance of manganese dioxide present in the solution or generated through permanganate reduction.
Though not wishing to be bound by theory, it is believed the adhesion of manganese dioxide to the nickel plated cathode is due at least in part to the cleaning of the nickel surface by hydrogen liberated through H 2 O reduction.
The etchant solution is an aqueous solution having a permanganate concentration of between about 10 to 100 grams per liter and preferably between about 20 and 50 grams per liter, and a hydroxide concentration to provide a pH of at least about 10, and preferably a hydroxide concentration of about 1.2 normal in hydroxide to provide a pH of at least about 13. Any metal salt of permanganate that is sufficiently stable and soluble can be used, but preferred are alkali metal salts such as sodium, potassium, litium or cesium, or an alkaline earth metal salt, for example a salt of calcium. Especially preferred are sodium and potassium permanganates because of availability and relatively low costs. Similarly, a variety of hydroxide salts may be employed, but sodium and potassium hydroxide are preferred for reasons of availability and cost. The etchant solution may also include suitable buffers to increase peel strength such as phosphates, borates and carbonates as well as wetting agents to improve the wettability of the etchant solution.
The etchant bath is agitated in the etchant bath vessel during use to avoid layering. In the case of an in situ cell system, agitation of the etchant bath also ensures flow of reduced manganese species to the anode. Any suitable means of agitation may be employed such as one or more air pumps or mechanical stirrers. In the external cell system depicted in the FIGURE, the solution flow through the cell ensures reduced manganese species will contact the anode. The temperature of the etchant bath is generally maintained at 65° to 90° C., preferably at 80° to 85° C. However, temperatures above and below those ranges may be employed.
Cell voltage at which the etchant solution is electrolytically oxidized may vary widely and is generally between about 1 to 20 volts, and preferably is between about 4 to 5 volts. If voltage is increased during cell operation, it is generally increased between about 0.1 and 0.5 volts. Anode current densities are generally between about 212 and 850 amps per square meter, and preferably between about 425 and 640 amps per square meter. Cathode current densities are generally between about 2,000 and 8,000 amps per square meter, and preferably between about 4,000 and 6,000 amps per square meter.
The flow of the etchant solution past the cathode is preferably less than a rate where the manganese dioxide coating is regularly dislodged from the cathode surface by the force of the moving solution. If the solution flow is of a higher rate, permanganate could be reduced at the cathode until additional manganese dioxide adhered to the dislodged portion. In the cell depicted in the FIGURE, the solution flow rate through the cell is generally less than about 2.0 liters per minute, preferably is less than about 1.5 liters per minute, and most preferably about 1.0 liters per minute, although it is clear that acceptable flow rates will vary with cell design.
The present invention is advantageously employed in the manufacturing process of printed circuit boards. Such a manufacturing process is generally described in U.S. Pat. No. 4,515,829, incorporated herein by reference. The present invention can be used directly within a vessel containing etchant bath to provide in situ regeneration or can be used externally to the etchant bath vessel as depicted in the FIGURE.
Referring now to the FIGURE, which shows the present invention as utilized in a preferred fashion to etch printed circuit boards, a etchant solution tank 10 contains etchant solution 12 which is agitated by pump 14. Printed circuit boards (not shown) are immersed in tank 10 for etching. Tank 10 communicates with external electrolytic cell unit 16 by inlet pipe 18 and outlet pipe 20. Unit 16 comprises cell housing 22 within which anode electrode 24 and cathode electrode 26 are positioned. Cell housing 22 has an inlet opening 28 at one end communicating with pipe 18 and an outlet opening 30 at the other end communicating with outlet pipe 20. Anode 24 is a cylindrical tube extending the length of cell housing 22. Cathode 26 is concentrically positioned along the axis of anode 24. To generate permanganate, solution 12 is introduced to the cell by means of a circulating pump (not shown) through pipe 18, passed through the cell and subjected to electrolysis therein, and then returned to tank 10 by outlet pipe 20. Oxidation may be conducted while circuit boards are being etched in vessel 10 or at any other time.
The invention will be better understood by reference to the following examples. As shown by the superior permanganate yield realized in Example 2 relative to the yield of Example 3, the present invention provides a substantially more efficient means of permanganate generation than afforded by prior systems.
EXAMPLE 1
A copper cathode of 50 cm. length and 1 cm. diameter was cleaned in a 10% aqueous solution of Neutraclean 68 (Shipley Company) at 50° C. for 5 minutes. The cathode was rinsed in deionized water and then etched using Preposit etch 748 (Shipley Company) at room temperature for 2 minutes. After etching, the cathode was rinsed in deionized water and then completely immersed in a Niposit 65 electroless nickel plating bath (Shipley Company) heated to 90° C. The cathode was contacted with a steel bar to initiate deposition. After 1 hour, the cathode was removed from the bath having a nickel surface deposit thereon of approximately 10 microns.
EXAMPLE 2
A stainless steel tank was charged with 45 liters of deionized water containing 65 g/l KMnO 4 and 40 g/l NaOH. The solution was circulated in the tank with an air pump and heated to 80° C. An electrolytic cell unit of the type depicted in the FIGURE was connected to the tank by stainless steel piping. The cell unit included a cell housing of 50 cm. length and 11 cm. diameter. The cell housing had an inlet opening at one end and an outlet opening at another end to provide means for passing the alkaline solution through the cell. Within the cell housing was placed a cylindrical Monel mesh anode electrode of 50 cm. length and 8 cm. diameter. The Monel mesh was of mesh size no. 12, i.e. 12 holes per inch. A tubular copper cathode electrode of 50 cm. length and 1 cm. diameter was concentrically placed along the axis of the anode. The copper cathode had a nickel surface deposit applied by the procedure of Example 1.
For a two hour period, the heated alkaline solution was continuously withdrawn from the tank with a circulating pump, passed through the electrolytic cell at a rate of 1.0 liters per minute with the cell operated at 50 amps and 4.5 volts. Formation of a manganese dioxide film on the cathode was observed immediately upon the start of electrolysis. At the end of the two hour period, the manganese dioxide film increased to a thickness of 1 mm. and completely covered the cathode surface.
Solution flow through the cell was terminated after this two hour period, and 3 ml/l of a glycol ether was added to the solution to reduce a portion of the KMnO 4 . After thorough mixing, a sample of the alkaline solution was removed and spectrophotometric analysis showed concentrations of 15 g/l KMnO 4 and 50 g/l K 2 MnO 4 . The solution was then again passed through the external cell at a rate of 1.0 liters per minute and subjected to electrolysis at 50 amps and 4.5 volts for six hours. At the end of this six hour period, spectrophotometric analysis of a sample of the alkaline solution showed concentrations of 45 g/l KMnO 4 and 20 g/l K 2 MnO 4 . This represents a 61% Faradiac efficiency based on the reaction:
K.sub.2 MnO.sub.4 →KMnO.sub.4 +K.sup.+ +e.sup.- (I)
This yield does not reflect the decay of potassium permanganate which takes place at the solution operating temperature.
EXAMPLE 3
The procedure of Example 2 was repeated, but the cathode did not have a manganese adherent surface deposit. Spectrophotometric analysis of a sample of the alkaline solution at the end of the six hour period of electrolysis showed a 45% Faradiac efficiency based on the above-noted reaction (I) of manganate to permanganate.
The foregoing description of the present invention is merely illustrative thereof, and it is understood that variations and modifications can be effected without departing from the spirit or scope of the invention as set forth in the following claims.
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Method and apparatus for electrolytic generation of permanganate. The invention includes a manganese dioxide adherent cathode surface which eliminates undesirable reduction reactions at the cathode during electrolysis thereby increasing permanganate generation efficiency.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The present disclosure relates to a system for cooling an electrical machine. More particularly, the present disclosure relates to a system for cooling stator laminations and coils of the electrical machine.
[0003] 2. Description of the Related Art
[0004] Electrical machines, including motors and generators, operate by rotating a rotor relative to a stator that surrounds the rotor. Electrical machines generate heat during operation that flows radially outward from the rotor to the stator to an exterior housing. To cool the electrical machine, air or a liquid coolant may be directed through channels located in the exterior housing, through apertures located in sealed laminations of the stator, or through channels located between coils of the stator, for example.
SUMMARY
[0005] The present disclosure provides a system for cooling an electrical machine. The electrical machine includes a rotor, a stator, and at least one cooling tube extending through the stator. During operation of the electrical machine, fluid flows through the tube and carries away heat generated by the machine.
[0006] According to an embodiment of the present disclosure, an electrical machine is provided including: a rotor; and a stator. The stator including a lamination stack that includes a plurality of laminations aligned coaxially, the lamination stack defining a central bore sized to receive the rotor and defining at least one cooling bore, the lamination stack defining a first end and a second end, a fluid input plate disposed within the lamination stack and spaced apart from the first end and second end; and a cooling fluid positioned in the at least one cooling bore.
[0007] According to another embodiment of the present disclosure, an electrical machine fluid transport device is provided. The device including a body having a first side and a second side; a fluid input defined in the body; an internal passageway defined in the body and fluidly linked to the input; a first output defined in the first side and fluidly linked to the internal passageway; and a second output defined in the second side and fluidly linked to the internal passageway.
[0008] According to yet another embodiment of the present disclosure, a plate for use with a motor stator is provided. The plate includes a body sized and shaped to abut a lamination of a stack of laminations of the motor stator. The body including: a first output orifice positioned to align with a fluid conduit of the lamination, and a first facet positioned adjacent the first output orifice to receive fluid from the first output orifice, the first facet including a first facet output, the first facet sized and shaped and located such that fluid exiting the first facet via the first facet output is directed onto a winding of the motor stator.
[0009] According to yet another embodiment of the present disclosure, an electrical machine is provided. The machine includes a rotor and a stator. The stator including at least one coil; a lamination stack that includes a plurality of laminations aligned coaxially, the lamination stack defining a central bore sized to receive the rotor and defining at least one cooling bore, the lamination stack defining a first end and a second end; and an end piece having at least one fluid outlet defined therein, the at least one fluid outlet including spray nozzles that receive fluid from within the lamination stack and direct the fluid onto the at least one coil.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above-mentioned and other features of the present disclosure will become more apparent and the present disclosure itself will be better understood by reference to the following description of embodiments of the present disclosure taken in conjunction with the accompanying drawings, wherein:
[0011] FIG. 1 is a perspective view of an embodiment of a motor including a rotor and a stator with cooling pathways extending therethrough;
[0012] FIG. 2 is a top plan view of the stator of FIG. 1 shown with a stator end cap in place;
[0013] FIG. 3 is a top plan view of the stator of FIG. 1 shown with a stator end cap removed;
[0014] FIG. 4 is a schematic illustration of cross-section of the stator of FIG. 1 ;
[0015] FIG. 5 is a schematic illustration of cross-section of the stator of FIG. 1 showing fluid travel therein; and
[0016] FIG. 6 is a top plan view of the input plate of the stator of FIG. 1 .
[0017] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION
[0018] FIG. 1 provides an illustrative electrical machine in the form of motor 10 . Although the electrical machine is illustrated and described herein as motor 10 , machines of the present disclosure may also include generators, for example. Motor 10 includes rotor 12 , stator 14 , and, optionally, housing (not shown) surrounding stator 14 . In operation, power is supplied to motor 10 to rotate rotor 12 relative to the surrounding stator 14 .
[0019] Stator 14 includes lamination stack 20 and coils 22 . Lamination stack 20 includes a plurality of individual laminations 24 layered and secured together axially. Lamination stack 20 further includes input plates 44 and end caps 16 therein. Adjacent laminations 24 , input plates 44 , and end caps 16 may be secured together by welding, with a bonding agent, with a fastening device, or by another suitable technique.
[0020] As shown in FIG. 3 , each lamination 24 is a disk-shaped body constructed of electrical steel or another suitable ferromagnetic material. Lamination 24 includes an outer periphery 26 and an inner periphery 28 that defines a central aperture 30 . When laminations 24 are layered together, adjacent central apertures 30 align to form a central bore 32 that extends axially through lamination stack 20 . Central bore 32 is sized to receive rotor 12 ( FIG. 1 ). Inner periphery 28 of lamination 24 also includes a plurality of radially-spaced winding teeth 40 . Adjacent winding teeth 40 define winding slots 42 therebetween.
[0021] As shown in FIG. 2 , each end of lamination stack 20 includes an end cap 16 . End cap 16 is a non-ferromagnetic disk-shaped piece that is substantially similarly dimensioned to laminations 24 . End caps 16 thus have winding slots 42 that align with winding slots 42 of lamination stack 20 . Additional features of end caps 16 are discussed below.
[0022] When laminations 24 are layered together with end caps 16 , wires, such as insulated copper wires, extend through winding slots 42 and wrap around winding teeth 40 to form coils 22 . Outer periphery 26 of lamination 24 may include any number of alignment features (not shown), such as indentations, protrusions, and/or markings, to indicate when adjacent laminations 24 are properly aligned.
[0023] Referring still to FIG. 3 , each lamination 24 also includes a plurality of flow apertures 50 . Flow apertures 50 are positioned to be between adjacent coils 22 of stator 14 , as shown in FIG. 3 . In FIG. 3 , endcap 16 is removed to show flow apertures 50 . Placing flow apertures 50 between adjacent coils 22 cools the coils 22 directly, rather than indirectly through lamination stack 20 . In addition to apertures 50 , cooling tubes 60 may be inserted therein between adjacent coils 22 and hydroformed against coils 22 as described with respect to cooling bores 52 of lamination stack 20 in U.S. patent application Ser. No. 12/262,721 (METHOD OF MANUFACTURING COOLING CHANNELS IN STATOR LAMINATIONS, filed Oct. 31, 2008) which is expressly incorporated herein by reference.
[0024] Flow apertures 50 may be formed in laminations 24 by any suitable method. For example, after (or while) lamination 24 is stamped from a metal sheet, flow apertures 50 may be formed by cutting or punching holes into the metal sheet. As another example, flow apertures 50 may be formed during a molding process. Flow apertures 50 may be circular, oval, triangular, or another suitable shape. The illustrated embodiment includes triangular apertures 50 . When laminations 24 are layered together, adjacent apertures 50 cooperate to form a plurality of cooling bores 52 that extend through lamination stack 20 . In an embodiment, cooling bores 52 extend through lamination stack 20 in a direction essentially parallel to central bore 32 . This parallel arrangement may be achieved by aligning adjacent flow apertures 50 directly on top of one another.
[0025] While the specification has described flow apertures 50 as being defined by laminations 24 , cooling tubes (not shown) may also be placed within flow apertures 50 to define cooling bores 52 . Cooling tubes may be constructed of a thermally conductive material, such as copper, a copper alloy, aluminum, or an aluminum alloy, or another suitable material, such as steel or a steel alloy. Embodiments are also envisioned where cooling tubes are non-ferrous but still thermally conductive.
[0026] In addition to laminations 24 , stator 14 also includes one or more input plates 44 , FIG. 6 . In the illustrated embodiment of FIGS. 4 & 6 , input plate 44 is similarly sized to lamination 24 with respect to outer and inner periphery 26 , 28 . However, input plate 44 is thick enough such that input aperture 46 is defined therein and is non-ferrromagnetic. Additionally, input plates 44 are envisioned having a greater diameter than laminations 24 . Input aperture 46 is a multi-diametered aperture that extends from outer periphery 26 to portion 48 of cooling bore 52 . Portion 48 forms a “T” with input aperture 46 . In one embodiment, an input aperture 46 is provided for each cooling bore 52 . In another embodiment, shown in FIG. 6 , a single input aperture 46 is provided and input plate 44 includes a circumferential passageway 54 therein that link input aperture 46 to all cooling bores 52 . Furthermore, it should be appreciated that embodiments are envisioned where multiple input apertures 46 are provided and each is coupled to more than one but less than all cooling bore 52 . In the embodiments where a single input aperture 46 serves more than one cooling bore 52 , circumferential pathways 54 are provided within input plates 44 . Outer portion 47 of input aperture 46 is sized to receive a hose or other conduit that seals to outer portion 47 to supply cooling oil thereto. While FIGS. 4 and 5 show stator 14 having a single input plate 46 , embodiments are envisioned where more than one input plate is disposed within lamination stack 20 . Additionally, while FIG. 6 shows one side of input plate 44 with portions of cooling bores 52 defined therein, it should be appreciated that the opposing side also contains portions of cooling bores 52 defined therein.
[0027] As previously noted, endplates 16 are similarly dimensioned to laminations 24 . Endplates have distribution facets 72 and output metering apertures 74 . Output metering apertures 74 are aligned with cooling bores 52 . The sizing of output metering apertures 74 is customized to provide desired flow characteristics for the particular location on stator 14 where the aperture is located. Distribution facets 72 are areas of increased thickness sized to fit between adjacent coils end windings of coils 22 . Distribution facets 72 are sized and shaped to receive cooling oil from output metering apertures 74 and direct it to adjacent end windings of coils 22 . Motor 10 , in operation, has a defined orientation relative to gravity. Accordingly, distribution facets 72 are each customized in recognition that each output metering aperture 74 can assume a unique relation to adjacent end windings for coils 22 and gravity.
[0028] The cooling fluid may include, for example, oil, water, a mixture of water and ethylene glycol, a mixture of water and propylene glycol, or another suitable heat transfer fluid. Exemplary cooling fluids are capable of removing more heat from motor 10 than air, for example. As illustrated schematically in FIG. 5 , the cooling fluid travels from source tank S, into input aperture 46 of input plate 44 (via pump 71 and a filter), inward to portion 48 , laterally through cooling tube 60 (where present) through lamination stack 20 , out of output metering apertures 74 , into distribution facets 72 , along end windings of coil 22 (adjacent to facets 72 and not shown in FIG. 5 ), and ultimately to destination tank D. The direction of fluid flow is indicated by arrow F. Heat generated by motor 10 is transferred from lamination stack 20 , through the walls of cooling tubes 60 (where present), and into the cooling fluid flowing therein. The direction of heat flow is indicated by arrow H. The heated fluid that is delivered to destination tank D may be cooled and recycled back to source tank S.
[0029] Referring still to FIG. 5 , input aperture 46 of input plate 44 is coupled to fluid lines 70 . Fluid lines 70 may be constructed of flexible rubber tubing, for example. As illustrated schematically in FIG. 5 , fluid lines 70 direct the cooling fluid from source tank S to input aperture 46 of input plate 44 via pump 71 . According to an exemplary embodiment of the present disclosure, fluid lines 70 are also coupled to a housing in which motor 10 is located. The housing contains the fluid that is output from apertures 74 and flowed across the end windings of coils 22 ( FIG. 2 ).
[0030] To promote even cooling of lamination stack 20 , substantially equal flow is desired in all cooling bores 52 . However, it will be appreciated that gravity operates on motor 10 and the fluid. For embodiments where a single inlet aperture 46 is coupled to more than one cooling bore 52 , the cooling bores 52 are potentially located at different heights (due to the differing radial locations). For this reason, or any other reason tending to cause uneven distribution, the sizing of output metering apertures 74 is customized. For any cooling bore 52 that would naturally tend to collect an increased amount of fluid therein, such cooling bore 52 is provided with a smaller output metering aperture 74 to equalize the flow experienced by that cooling bore 52 with other cooling bores 52 . Furthermore, output metering apertures 74 are sized such that the collective output of all output metering apertures 74 for a given input aperture 46 is equal to the supply of fluid being input to the input aperture 46 that serves the one or more output metering apertures 74 . Accordingly, the situation does not arise where certain cooling bores 52 are receiving adequate cooling fluid while other cooling bores 52 receive less than necessary amounts.
[0031] While the above customization has been described as seeking uniform flow and uniform cooling. It should be appreciated that the flow characteristics can be adjusted to non-uniform flow if operational designs and parameters result in non-uniform heat production in motor 10 .
[0032] Once the cooling fluid is expelled from output metering apertures, the fluid encounters distribution facets 72 . Distribution facets 72 define pooling vessels 73 each having a lip 75 . Pooling vessels 73 each fill up and ultimately overflow with fluid, similarly to that often seen in water fountains. Distribution facets 72 are sized and shaped to direct fluid onto adjacent end windings of coils 22 . In that the orientation of the various facets 72 relative to gravity is known, facets 72 are sized and shaped differently to direct fluid to adjacent end windings of coils 22 . As shown most clearly in FIG. 2 , facets 72 on either side of vertical centerline 76 are mirror images of each other. Facets 72 a, on either side of the top center coil 22 are shaped such that fluid overflows onto both adjacent coils 22 . The balance of the facets 72 are shaped such that fluid overflows proximate the higher end of the lower adjacent coil 22 . This results in gravity causing increased flow over a greater portion of the end windings of coils 22 .
[0033] While facets 72 are shown and described as defining a pooling vessels 73 , embodiments are envisioned where facets 72 provide sprays that, via pressurization of the fluid, can eject the fluid to be sprayed onto adjacent coils 22 . In such embodiments, spray can be applied to both adjacent coils rather than just those for which gravity would allow the fluid to fall downwardly onto.
[0034] While this invention has been described as having preferred designs, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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A system for cooling an electrical machine is disclosed. The electrical machine includes a rotor, a stator, and at least one cooling pathway extending through the stator. During operation of the electrical machine, fluid flows through the pathway and carries away heat generated by the electrical machine.
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RELATED APPLICATIONS
This application is related to U.S. application Ser. No. 948,092, filing concurrently herewith by the same inventors, the disclosure of which is incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to an injection device for fluid propellants for guns, with the injection device including a pump chamber for accommodating the propellant, a pump piston axially movable therein as well as a slide for opening and closing apertures in an injector surface which at least partially surrounds a combustion chamber and which is oriented approximately radially with respect to the direction of projectile ejection, and to a fluid propellant gun having at least one of these injection devices.
Such an arrangement is disclosed in German Patent No. 2,226,175 and corresponding U.S. Pat. No. 3,763,739 to Douglas P. Tassie which relates to a valve for controlling the propellant supply into the combustion chamber of an automatic weapon. The weapon here includes a weapon housing in which a barrel having a bore is rigidly fixed. The rear end of the bore is subdivided into chambers so as to accommodate a projectile and to form a combustion chamber whose end opposite the projectile is sealed by a breechblock. The circumferential face of the combustion chamber between the projectile chamber and the breechblock is partially designed as an injector surface. The term "injector surface" is to be understood herein to mean a surface provided with a plurality of apertures (injection nozzles) through which the fluid propellant is injected into the combustion chamber.
A control slide rigidly fastened to a pump piston and movable thereby makes it possible to expose, the influx opening cross section of the injector surface by appropriate displacement. The displacement results from a cam arrangement and is defined to that extent.
German Patent No. 1,728,077 discloses a differential pressure piston combustion chamber system for generating propellant gases, particularly for firearms. The propellant and the oxygen or, more precisely, the oxygen carrier are injected into the combustion chamber axially with respect to the direction of projectile ejection by way of corresponding intake conduits and chambers. The partial quantities of the two propellant components injected into the combustion chamber react hypergolically. With initiation of the combustion process, the pressure in the combustion chamber increases and drives the differential piston back, thus causing further injection of the further quantity of the two propellant components stored in the dosaging chambers.
German Offenlegunsschrift [laid open patent application] 2,725,925 and corresponding U.S. Pat. No. 4,023,463 to Douglas P. Tassie disclose a pumping device for a gun operated with a fluid propellant. The propellant introduced into a pump chamber is injected axially into the combustion chamber by way of channels disposed in the head section of a pump piston. A displaceable sleeve arranged coaxially with the pump piston has an enlarged head which serves to control the flow and quantity of the propellant.
All of the above prior art arrangements are relatively complicated in their structural design and in the association of the individual components as well as their sequences of movement. A particular drawback, however, is that the quantity of propellant can be measured out, if at all, only within limits and in a complicated manner. Emptying of the pump chamber, for example in the arrangement disclosed in German Patent No. 2,226,175 and corresponding U.S. Pat. No. 3,763,739, is also limited. Moreover, the mechanically moved parts permit displacement only within narrow geometric limits.
Different projectiles require different propellant supplies and control possibilities for propellant injection and these can also not be provided by the prior art arrangements. The case is similar with respect to variability of the projectile ejection velocity and temperature influences, for example, as a result of so-called "warming up" of the gun barrel.
Additionally, in some prior art arrangements the introduction of the projectiles is relatively complicated as disclosed in, for example, German Patent No. 1,728,077.
In an arrangement disclosed, for example, in German Patent No. 2,226,175 and corresponding U.S. Pat. No. 3,763,739, there exists an additional drawback in that damping of components sometimes charged with high velocities is possible only conditionally, which sometimes brings about considerable and undesirable excess material stresses and interferes with the resistance to malfunctions of a gun, particularly during continuous operation.
SUMMARY OF THE INVENTION
It is an object of the invention to eliminate the above-described drawbacks as much as possible. In particular, an injection device is to be made available which is simple in configuration, reliable in operation and easily manipulated. Additionally, this device is to be accessible to monoergolic and diergolic, hypergolic propellants and to permit easy insertion of the projectiles and easy dosaging of the propellant quantity required.
The present invention is based on the realization that optimized propellant injection and thus combustion can be realized by a change in the structural design and association of individual components of the injection device while simultaneously permitting quantitative control of the combustion process.
Accordingly, the present invention provides that, in an injection device of the above-mentioned type, slide and pump piston are designed as mutually freely movable components, and a means for developing a pressure is provided for displacing the slide by such pressure, preferably such means including means for using a separate priming charge, the propellant and/or the pump piston. It is important in this connection that this invention does not propose a mechanical injection control with the above-described drawbacks but, as provided in a preferred embodiment, that the pressure released by a priming charge serves to cause the components to be displaced and, in particular, to open the injection nozzles in the injector surface.
The inventive idea can be realized by various concrete embodiments.
One advantageous embodiment of the invention provides that the pump piston is configured as a component which passes around or behind the slide so that, the space enclosed by the pump piston simultaneously defines the pump chamber. The frontal face of the slide is then preferably configured such that it is spaced at least in part from the outer section of the corresponding surface of the pump piston. In a particularly preferred embodiment, this may be realized by an annular seal projecting approximately centrally in the region of the frontal face of the slide.
If then, as provided in a further advantageous embodiment of the invention, a priming charge is fired in a pressure chamber disposed behind the pump piston, the pressure generated thereby will initially push the pump piston forward and create excess pressure in the pump chamber. This hydraulic pressure then acts on the corresponding differential face of the slide and presses it forward at high speed, simultaneously exposing the injector surface. A further feature of the invention provides that the slide and/or the pump piston are mounted, in the direction of movement, against a prestressed or biasing device, preferably a spring bearing. The force of a spring thus presses the control slide over the injector surface.
The pressure which continues to act on the frontal face of the pump piston likewise pushes the pump piston forward; however, this occurs at a somewhat slower speed than the slide and thus causes more propellant to be injected into the combustion chambers through the openings in the injector surface in that the pump chamber volume is constantly reduced.
An alternative embodiment provides that the pressure of the priming charge acts not only on the pump piston but, via an appropriate channel arrangement, also on the frontal face of the slide itself so that the latter is pressed over the injector surface directly by the generated gas pressure.
It is then of particular advantage for the pressure chamber to be connected with the combustion chamber by means of a connecting conduit. In that case, the priming charge can be effected pyrotechnically by way of an additional charge fastened to the projectile. It is also possible, however to fire the priming charge by injecting a partial quantity of propellant with extraneous energy branched off and stored, for example, by tensioning a spring when the breechblock is opened.
The device according to the invention permits a rotationally symmetrical arrangement of the components around a cylindrical combustion chamber, in which case the slide has the shape of a sleeve, and the pump chamber is annular as is the pump piston. An arrangement is also possible in which a plurality of pump chambers are disposed around the combustion chamber, with each pump chamber then having its own arrangement of pump piston and slide for the respective injector surface.
The arrangement according to the invention makes it possible in a particularly simple and advantageous manner to provide a device for controlling the movement of the pump piston during the introduction of the propellant and to thus provide a device for dosaging the quantity of propellant to be introduced into the respective pump chamber.
Preferably, the device may also include an abutment which can be adjusted along the path of movement, and/or of a guide member, particularly a guide piston. For example, a simple limitation of the displacement of the pump piston makes it possible to set the volume in the pump chamber and thus the quantity of propellant employed in practically infinite variations.
In a further advantageous embodiment of the invention, a valve is provided which connects a propellant conduit with the pump chamber. Together with the above-mentioned guide member, this valve can then not only be used to supply the pump chamber but also to empty it, for example upon termination of firing.
There are many additional advantages of the arrangement according to the invention. In particular, no mechanical adjustment members are required; rather, the displacement of the individual components is effected by way of the appropriate gas pressure and/or hydraulic pressure. Due to the arrangement according to the invention, the propellant can also simultaneously be utilized to hydraulically brake the pump piston as well as the control slide.
In an advantageous embodiment of the invention it is provided, in this connection, that the circumferential face of the control slide includes, at its free end projecting into the pump chamber, one or a plurality of projections and the receptacle into which the slide is pushed if it is advanced, has a correspondingly widened portion at its input. On the basis of the tapering annular gap formed during the displacement between receptacle and slide, the speed of the slide is thus attenuated.
The same principle is also utilized to brake the pump piston. The advanced pump piston causes the influx of propellant to the injection nozzles to be constricted and thus the velocity of the pump piston is damped, since the propellant exerts a correspondingly larger counterpressure.
The device according to the invention permits the use of monoergolic as well as diergolic, hypergolic propellants. For monoergolic propellants which must be injected uniformly, a cylindrical combustion chamber with rotationally symmetrically arranged slide and pump piston, respectively, is preferably provided. An embodiment having a plurality of separate pump chambers arranged around the charge or combustion chamber is proposed for the use of diergolic, hypergolic propellants. Different propellants are then injected into the combustion chamber from the separate pump chambers through the corresponding injection regions and mix to react with one another in the combustion chamber.
As a whole, the device according to the invention, with its regenerative fluid drive, provides improved and particularly controlled internal ballistics, due to its particular structural design, to permit its use in different caliber tank and artillery guns. The possibility of dosaging the propellant, which is considered to be a special feature of the invention makes it possible to realize controlled combustion. The structural association of the individual components makes additional recoil brake elements substantially superfluous. Rather, the propellant itself takes over this task and it is possible to inject the propellant into the combustion chamber at a high injection pressure.
A fluid propellant gun requires a gastight breechblock which is tight not only during firing. If there are leaks in the pump chamber, the escaping propellant is gasified in the hot gun barrel and must then not act on the crew.
In this connection, an advantageous feature of the invention provides in a particularly simple manner to additionally seal the components against one another by means of appropriate sealing rings. This is particularly easy in connection with rotationally symmetrical components, which is a further advantage of the present invention.
Indirectly, the arrangement according to the invention provides the advantage that it is particularly easy to supply the gun with new projectiles. Due to the provision of radial injection and the appropriate arrangement of the components of the injection device, the area in the extension of the gun barrel can be extended rearwardly, behind the combustion chamber, so as to accommodate the projectile, with new projectiles being supplied through the gun barrel section then formed. This can be done in a particularly simple manner by means of automatic control. A relatively simple breechblock, which can be moved out of the blocking position, reliably seals the combustion chamber during firing. Preferably, a mushroom-type breechblock is provided, as known, for example, for artillery guns.
BRIEF DESCRIPTION OF THE DRAWINGS
Two embodiments of the invention will now be described in greater detail and are additionally schematically illustrated in the drawing figures, wherein:
FIG. 1a is a longitudinal sectional view of a fluid propellant gun which is equipped with an injection device according to one embodiment of the invention.
FIG. 1b is an enlarged view of the region around the pump chamber in the injection device according to FIG. 1a.
FIG. 2 is an enlarged view of a section between combustion chamber and pump chamber in a second embodiment of the injection device according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The fluid propellant gun according to FIG. 1a includes a breech ring 10 having an approximately rectangular cross section. Breech ring 10 has a circular bore 12 in its center. Approximately in the middle of the longitudinal extent of bore 12, a combustion chamber 14 is provided which has a larger cross section than bore 12. In the front portion 12a, of bore 12 (to the left of combustion chamber 14 in FIG. 1a), bore 12 is surrounded by a tube 16 which serves to accommodate a projectile (not shown).
The rear portion 12b of bore 12 (to the right of combustion chamber 14 in FIG. 1a) has essentially the same cross section as front portion 12a. Immediately following combustion chamber 14, however, a transverse channel 20 extending perpendicularly to bore 12b (and perpendicularly to the plane of the drawing) opens into bore 12b. While the side of transverse channel 20 shown on the left in FIG. 1a has a height corresponding to the diameter of bore 12b, transverse channel 20 continues from there as a conically widening section 20a which is followed by a section 20b having a rectangular cross section, with a step 21 extending outwardly from there, again followed by a further section 20c having an unchanging cross section. In the region penetrated by transverse channel 20, bore 12b is made correspondingly wider.
A wedge-type breech 23 having a mushroom-type breechblock 22, as known, for example, in artillery guns, is seated in transverse channel 20. Mushroom-type breechblock 22 can be moved out of the region of bore 12b by pivoting it within transverse channel 20 after wedge-type breech 23 has been opened, thus freeing bore 12b so that a projectile can be brought into tube 16.
The circumferential wall of cylindrical combustion chamber 14 is formed by an injector surface 24. While the rear portion 24a of injector surface 24 facing mushroom-type breechblock 22 has a closed configuration, the remaining portion is provided with radially extending apertures (injection nozzles) 26. The injector surface 24 is held stationary in breech ring 10. Large radially extending openings 28 are provided in the closed portion 24a of injector surface 24 and these openings constitute a connecting conduit to an annular chamber 30 following toward the outside. As shown particularly in the sectional views of FIGS. 1a and 1b, chamber 30 has an approximately triangular cross section. As is evident from FIG. 1a, openings 28 are distributed over the cylindrical injector surface portion 24a at uniform distances from one another.
A pump piston 32 is seated on the exterior of injector surface 24. Pump piston 32 is an annular piston which has a jacket face 34 and a projection 36 projecting inwardly at a right angle from its end. This projection has an approximately trapezoidal cross section.
The outer jacket face 34 of pump piston 32 rests against the corresponding wall of a cylindrical recess 38 in breech ring 10 and its inner frontal face 36a (FIG. 1b), which has the shape of a cylinder section, rests against the outer surface of injector surface 24 and is guided so as to be longitudinally displaceable in recess 38 which constitutes the pump chamber. Breech ring 10 has an annular gap 40 to receive jacket section 34 if pump piston 32 is displaced accordingly which will be described in greater detail below.
Shortly before annular gap 40 opens into recess or pump chamber 38, there is provided an annular seal 42 to seal the pump chamber 38 against chamber 40.
As is evident particularly from FIG. 1b, the section of annular gap 40 opposite seal 42 is made wider toward the outside. An abutment 44 is accommodated in the corresponding chamber section. This abutment projects perpendicularly outwardly from the free frontal end of jacket section 34 of pump piston 32.
Annular gap 40 widens and forms a chamber 46 parallel to jacket section 34 to accommodate a toothed rod 48 which is displaceable parallel to jacket section 34 by means of a drive wheel 50. At its end corresponding to abutment 44, toothed rod 48 is equipped with a cam 52.
The arrangement of toothed rod 48, drive wheel 50 and cam 52 serves to limit the displacement path of pump piston 32 in that, with toothed rod 48 in the appropriate position, abutment 44 is brought against cam 52.
A conduit 54 extending parallel to bore 12 in breech ring 10 opens, at a distance from annular gap 40, into a valve 56 disposed in the frontal face (on the left in FIG. 1a) of pump chamber 38 and permits the intake of propellant into pump chamber 38. However, the valve can also be set to cause pump chamber 38 to be emptied, as will be described in greater detail below.
A sleeve-shaped slide 58 is seated on injector surface 24 and is provided, at its end facing projection 36, with an external circumferential projection 60.
As is evident particularly from FIG. 1b, an annular seal 62 is seated on frontal face 59 of slide 58 and somewhat projects beyond frontal face 59 in the direction toward projection 36 of pump piston 32. The respective dimension lines for annular seal 62 can be seen in FIG. 1b. Annular seal 62 takes care that frontal face 59 is held at a distance from the corresponding wall 36b of projection 36. An annular gap 64 is provided in breech ring 10 to accommodate the rear jacket section of slide 58. A first section 65 of gap 64, when seen from pump chamber 38, has a height which corresponds to slide 58 in the region of projection 60 and this is followed by a section 66 which has a height corresponding to the thickness of the jacket face of the slide. Section 66 changes to a wider annular chamber 68 in which a compression spring 70 is seated. An annular seal 72 is arranged around section 66.
The section of breech ring 10 accommodating annular gaps 40 and 64 as well as chamber 68 is formed by a correspondingly configured insert member 74.
The illustrated fluid propellant gun operates as follows:
First, propellant is introduced through conduit 54 and valve 56 into pump chamber 38, with pump piston 32 being moved to the right (opposite to arrow A in FIG. 1a) and the volume of pump chamber 38 constantly increases correspondingly. Due to the action of spring 70, slide 58 follows. By way of the corresponding setting of toothed rod 48, the maximum displacement of pump piston 32 can be set in that the corresponding abutment 44 abuts against cam 52 of toothed rod 48. Then valve 56 is closed e.g by shutting off the supply of pressured propellant. The device is then in an arrangement as shown in the lower portion of FIG. 1a; in particular, frontal face 59 (seal 62) of slide 58 lies against abutment 36 of pump piston 32 and pump chamber 38 is filled with propellant.
By means of one of the above-described alternative possibilities, a priming charge is then applied, preferably by way of an additional charge attached to the projectile (not shown) in the region of combustion chamber 14. Gas is pressed into annular chamber 30 through openings 28 and associated connecting conduits and gas pressure is exerted onto the rear frontal face of projection 36 of pump piston 32. Once a certain pressure has been reached, due to the very rapid pressure build-up which takes only milliseconds or less, pump piston 32 is pressed forward (in the direction of arrow A) and produces excess pressure in pump chamber 38. This hydraulic pressure acts on the differential face of slide 58 in the region of its frontal face 59 in front of seal 62 and pushes the slide 58 forward against the force of compression spring 70 in the direction of arrow A. The movement of slide 58 is here faster than that of pump piston 32 so that the injector surface 24 and its openings 26 are temporarily exposed and propellant is able to escape through openings 26 into combustion chamber 14. In combustion chamber 14, the propellant is then combusted and more pressure is generated to eject the projectile. At the same time, pump piston 32 follows slide 58 because of the gas pressure generated in the rear so that the pump chamber volume 38 is reduced correspondingly.
When the slide 58 advances further, the widened region 65 of annular gap 64 acts as a brake chamber because of the constricted propellant influx region.
With the movement of pump piston 32, the previously opened apertures region in injector surface 24 is continuously closed again and simultaneously, because of the reduction in the number of outlet openings for the propellant and the thus increased hydraulic pressure, the pump piston is decelerated.
For the subsequent new filling of pump chamber 38, propellant is introduced through conduit 54 and valve arrangement 56, and with increasing fill level pump piston 32 and slide 58, which follows due to the spring action, are returned to their starting positions.
The above-described process is then repeated in the same manner, with a new projectile first having been introduced into tube 16 after breechblock 22, 23 is folded away.
FIG. 2 shows a different embodiment which is distinguished, in particular, by a different configuration of the region around openings 28 of FIG. 1a. As can easily be seen in FIG. 2, a frontal face 36a of projection 36' of annular pump piston 32' does not rest on injector surface 24', but ends at a distance therefrom. Moreover, projection 36' has a step 37 which steps back toward pump chamber 38'. In the starting position for control slide 58' as shown in FIG. 2, the front end of control slide 58' which is designed to correspond to step 37, extends over this step 37. A seal 62' disposed between the corresponding faces of control slide 58' and pump piston 32' takes care that no propellant can escape from pump chamber 38' when slide 58' is closed.
Injector surface 24' is designed such that, with the arrangement of control slide 58' and pump piston 32' in the staring position, an open connection exists from combustion chamber 14 to chamber 30', via the area between the front end 36a of projection 36' and the outer surface of injector section 24', respectively.
When a priming charge is fired, gas is able to flow through corresponding passage openings 29 into a chamber 31 disposed downstream thereof and into chamber 30', respectively, with gas pressure being exerted not only on the rear frontal face of projection 36' of control slide 32', as in the embodiment according to FIGS. 1a and 1b, but particularly also on the end face of control slide 58' which is then opened spontaneously immediately after the pressure build-up and snaps away in the direction opposite to arrow B (arrow B symbolizes the permanent force of spring 70) to thus open apertures 26' of injector section 24' so that propellant can be injected from pump chamber 38' into combustion chamber 14.
Control slide 58' is here opened before pump piston 32' is displaced, with the latter then following, as described in connection with FIGS. 1a and 1b, and again gradually covers the exposed apertures 26'. The braking effect on control slide 58' and pump piston 32' on the part of the propellant is the same as described in connection with the first embodiment.
FIG. 2 shows injector section 24' supported by tube 16' which is extended rearwardly into combustion chamber 14 and is likewise provided with openings 76 extending radially toward combustion chamber 14 in the region of apertures 26' but, as can be seen clearly in FIG. 2, these openings have a much larger cross section than apertures 26'. The gas then flows from combustion chamber 14 through respective openings 76, 26' into chamber 30'.
Instead of an annular pump chamber, it is also possible to realize the present invention in the context of a plurality of pump chambers disposed around the combustion chamber, with each pump chamber having its own arrangement of pump piston and slide for a respective injector surface as disclosed in FIGS. 1 and 2 of U.S. patent application Ser. No. 06/948,092, first mentioned above and incorporated herein by reference. When there are two such pump chambers, they are preferably disposed so that their center points lie on an imaginary diagonal line the rectangular cross section of breech ring 10 drawn through the center of the combustion chamber as shown in FIG. 2 of the above mentioned patent application.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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An injection device for fluid propellants for a fluid propellant gun. The device includes at least one pump chamber for receiving a propellant, with one pump piston movable in each pump chamber. A slide is provided for opening and closing apertures in an injector surface which at least partially surrounds the gun's combustion chamber and which is arranged approximately radially to the projectile ejection direction. The slide and pump piston are configured as mutually freely movable components and a mechanism for developing a pressure is provided for displacing the slide by such pressure.
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BACKGROUND OF THE INVENTION
This invention relates to corporate feed networks for antenna systems.
Corporate feed networks are conventionally used to distribute power from transmit/receive (T/R) modules to array radiating elements.
Vertical distribution of RF signals in active arrays is presently accomplished by means of suspended stripline feeds with in-line coaxial interconnects. Two feeds are required for every column of T/R modules, one for the upper half of the column and one for the lower half. A typical array might require a total of 120 feeds, which make up a significant portion of the total array cost.
The feed housings are made entirely from machined aluminum. They are fabricated and assembled separate from the heat exchangers and installed at a higher assembly level. This method is heavy and consumes a considerable amount of space.
An object of this invention is to provide a feed network which can be smaller, lighter and less expensive to fabricate than conventional feed networks.
SUMMARY OF THE INVENTION
In accordance with the invention, a suspended stripline corporate feed is described with an orthogonal transition to a matched coaxial transmission line at each of its input/output ports. The suspended stripline can have circuit traces plated on one side or the other or both. Alternate input/output (I/O) ports are pointed in opposite directions, so that T/R modules on both sides of the feed can be serviced by the same circuit. This reduces by half the number of feeds required for a given array.
According to one aspect of the invention, half of the feed housing is machined as an integral part of the heat exchanger which cools the T/R modules. The other half is made from injection molded plastic, copper plated to make the surface electrically conductive. The plastic is loaded with glass fibers so that its thermal coefficient of expansion is matched to that of aluminum.
BRIEF DESCRIPTION OF THE DRAWING
These and other features and advantages of the present invention will become more apparent from the following detailed description of an exemplary embodiment thereof, as illustrated in the accompanying drawings, in which:
FIG. 1 is an exploded perspective view illustrative of a feed network embodying the invention.
FIG. 2 shows the feed network of FIG. 1 in assembled form.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3.
FIG. 5 is a cross-sectional view illustrative of an alternate interconnection technique.
FIG. 6 is a simplified schematic of elements of an active array system embodying this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an active array system assembly 50 embodying the present invention. The array includes a plurality of transmit/receive (T/R) modules 52 and 54 disposed respectively on opposite sides of the assembly. The assembly further includes a heat exchanger 60, and the modules 52 and 54 sandwich the heat exchanger for cooling of the modules.
The heat exchanger 60 includes cooling fin stock 62 sandwiched by upper and lower metal plate surfaces 64 and 66, typically formed of aluminum. The lower surface 66 is extended to form aluminum surface 66A, which in turn provides a ground plane channel 72 for a suspended stripline transmission line corporate feed circuit 70 which matches the layout of the feed circuit layout. The other ground plane channel completing the transmission line circuit 70 is defined by a feed cover 80.
The cover 80 is fabricated, in accordance with the invention, of injection molded plastic, and copper plated to make the surface electrically conductive. It is desired that the plastic material have a thermal coefficient of expansion matched to that of aluminum. A plastic such as polyetherimide or that marketed under the trade name ULTEM, both of which are marketed by General Electric Company, loaded with 30% by weight of glass fibers, has been found suitable for the purpose. The cover 80 has a relieved channel pattern formed therein which is the mirror image of the channel pattern formed in the surface 66A.
A pair of power and control signal distribution printed wiring boards (PWBs) 84 and 86 sandwich the aluminum surface member 62A, and the cover 80. The PWBs 84 and 86 carry dc power and control signals for the active elements comprising the assembly 50.
Alternate input/output ports for the transmission line 70 are pointed in opposite directions so that the modules on either side of the heat exchanger can be serviced by the feed comprising the transmission line 70. This is depicted generally in FIG. 1 by coaxial pin launchers 92 and 96, pointing in opposite directions, and the dielectric concentric spacer elements 94 and 98.
FIG. 2 shows the active array system assembly 50 in a assembled configuration.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2. FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3. FIGS. 3 and 4 illustrate in further detail the relationship of the transmission line circuit and the coaxial pin launchers. An end of the dielectric stripline substrate board 70A is supported by a shoulder 67 of the heat exchanger plate 66A, so that the board 70A is suspended between the plate 66A and cover plate 80. As shown in FIG. 3, cover 80 is plated with a copper coating 80A. A conductive line 70B is defined on the upper surface of the substrate board 70A, thereby defining a suspended substrate stripline transmission line. The line 70B makes electrical contact with the conductive coaxial pin launcher 92 extending upwardly through a circular opening formed 104 in the cover 80. The dielectric spacer 94 supports the pin 92 within the opening 104.
An RF/DC flexible interconnect circuit 110 includes a flexible dielectric substrate 112, on which is defined an RF conductive trace 114. The conductive trace 114 contacts the pin launcher 92 to electrically connect to the coaxial line, thereby coupling the suspended stripline circuit 70 to the interconnect circuit 110. The trace 114 in turn leads to a connection (not shown) with circuitry comprising the T/R module 52.
The suspended stripline circuit 70 is also electrically coupled to the T/R module 54 located on the opposite side of the heat exchanger 60 from the module 52. This is done via the coaxial feedthrough comprising coaxial pin launcher 96 and dielectric spacer 98 fitted within circular opening 106 (shown in phantom) in the plate 66A. This coaxial feedthrough extends orthogonally to the suspended stripline circuit, but in the opposite direction from the coaxial feedthrough comprising pin launcher 92, thus allowing the suspended stripline feed network 70 to service T/R modules located on both sides of the heat exchanger. The pin launcher 96 makes electrical contact with the conductive trace 120 comprising flexible interconnect circuit 116, which also includes a flexible dielectric substrate 118. The conductive trace 120 in turn leads to a connection (not shown) with circuitry comprising the T/R module 54.
FIG. 5 shows an alternative embodiment of the manner for connecting the T/R modules 52 and 54 to the suspended stripline feed circuit 70. In this embodiment, the orthogonal pin launchers are connected to orthogonally disposed coaxial feedthroughs, in turn connected through short coaxial cables to coaxial feedthroughs on the T/R modules. The pin launchers 92' and 96' have material removed at the ends thereof to form shoulders 122 and 134, respectively. Coaxial center conductor pins 140 and 150 of respective sub-subminiature assembly (SSMA) connectors extend through bores formed in the cover 80 and in the plate 66A, and are supported by dielectric plugs 142 and 152. The ends of the pins 140 and 150 intersect the respective ends of the pin launchers 92' and 96' and make electrical contact therewith. Connector fittings 144 and 154 complete the respective SSMA connectors. Coaxial cables 160 and 170 electrically interconnect between these SSMA connectors and corresponding connectors 174 and 176 of the T/R modules 52 and 54, thereby completing the connection between the suspended stripline feed circuit 70; and the T/R modules 52 and 54. Covers 130 and 132 seal the exposed ends of the coaxial transitions.
FIG. 6 shows a simplified schematic diagram of components of an active array system 200 embodying the present invention. The system 200 includes a suspended stripline RF feed network 202 including a plated plastic housing as described above. Orthogonal coaxial transitions 204 connect the suspended stripline feed network 202 and the T/R modules 206, the T/R modules 206 are in turn connected to the array radiating elements 208. The feed network 202 further includes an I/O port 210.
It is understood that the above-described embodiments are merely illustrative of the possible specific embodiments which may represent principles of the present invention. Other arrangements may readily be devised in accordance with these principles by those skilled in the art without departing from the scope and spirit of the invention.
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A suspended stripline corporate feed with an orthogonal transition to a coaxial transmission line at each of its input/output ports. Alternate I/O ports are pointed in opposite directions so that devices on both sides of the feed can be serviced by the same circuit. The cover for the feed is made out of injection molded, copper plated plastic. When utilized to distribute RF energy to T/R modules in an Active Array, the feed is machined as an integral part of the heat exchanger which cools the modules.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority under 35 U.S.C. §119(e) to Provisional Application Ser. No. 60/217,023 entitled “Digital Camera With Integrated Accelerometers” filed Jul. 11, 2000, the entire contents of which are hereby incorporated by reference for all purposes.
FIELD OF INVENTION
[0002] The present invention relates to a digital camera system having integrated accelerometers for determining static and dynamic accelerations of said digital camera system. Data relating to the determined static and dynamic accelerations are stored with recorded image data for further processing, such as for correcting image data for roll, pitch and vibrations. Data may also be used on-the-fly for smear suppression caused by vibrations.
BACKGROUND OF THE INVENTION
[0003] When using rectangular film formats like the 35 mm format, images are recorded on film with a “landscape” (horizontal) orientation in respect to the common way of holding a camera. When the photographer wishes to capture a portrait he will tilt the camera 90 degrees and thus acquire an image with a “portrait” (vertical) orientation. Later when the developed images are viewed, the viewing person will manually orient them correctly. Since the images are on paper, it is relatively easy to reorient some of them.
[0004] In digital photography the landscape orientation is the default setting for most cameras. When the captured images are viewed on a display, they will appear with a landscape orientation with no respect to whether the images were actually captured with the camera held in a portrait or landscape orientation. The images then have to be manually inspected and later possibly rotated to reflect their original orientation. Some digital camera manufacturers are now beginning to include a sensor unit, which detects whether the camera is placed in landscape or portrait position when an image is captured.
[0005] In U.S. Pat. No. 5,900,909 an orientation detector which consists of two mercury tilt switches is described. The two mercury switches make it possible to determine whether the user is holding the camera in the normal landscape orientation or in a portrait orientation. There are two portrait orientations: One is the result of a clockwise rotation whereas the other is the result of a counter clockwise rotation. The use of mercury switches has some distinct disadvantages in that mercury can cause great damage when it interacts with the human body, and for that reason it is quite unpopular in many products. Mercury switches usually consume a lot of space in comparison with monolithic IC's. This is due to their very mechanic structure, which makes miniaturisation difficult. In a digital camera it is crucial to minimise the size and weight, so in respect to this, the use of mercury and other primarily mechanically based switches, is not the optimum choice. A mercury switch based solution in a digital camera is limited to detecting a few rough orientations, i.e. landscape and portrait. The robustness and ease of use of the mercury switch are its primary advantages today.
[0006] The main limitation regarding micro-mechanical accelerometers fabricated in e.g. silicon is related to their ability to absorb shock without being damaged.
[0007] Taking pictures with long shutter times and maybe even a high degree of zoom makes the image capture process very sensitive to vibrations, which will result in blurred images. At short shutter times the image is less likely to be affected by vibrations since most vibrations, which will affect a camera, have an upper frequency limit, due to mechanical damping from the surroundings. Especially handheld photography easily results in blurred images when longer shutter speeds are used. One solution to the described limitations is to be able to compensate for most vibrations. Vibrations can be compensated optically by means of a lens module, which is capable of moving the projected image around in the image focus plane. This requires a special and expensive lens.
[0008] When vibrations cannot be compensated, another way of helping the photographer to acquire the optimum images is to inform him about any possibility of blurring, which may have occurred in a captured image. With feedback from the camera regarding the degree of shaking during the exposure time, it is possible for the photographer to decide whether he wants to capture another image of the same scene.
[0009] In U.S. Pat. No. 4,448,510, a camera shake detection apparatus is described. It includes an accelerometer, which is connected to a control circuit, which activates an alarm, when the acceleration exceeds a certain predefined threshold level. The threshold level can be influenced by the exposure time—a long exposure time results in a low threshold level and vice versa for a short exposure time. The output from the accelerometer may also be forced through an integrator before comparing the output to a threshold level to account for the fact that blurring is more probable to occur if a large number of high accelerations are detected. None of the described implementations are able to determine if the camera after a short period of vibrations returns to its initial position or the position where the majority of the exposure time has been spent. In such a case the suggested implementations would generate a “blur” alarm, even though the image could be sharp.
[0010] In some applications, especially the more technically oriented, it can be an advantage to have knowledge about how the camera is physically oriented in space. In a set-up with a digital camera connected to a GPS receiver, knowledge about the roll and pitch of a camera can be used to automatically pin point the scene being photographed. This can be used in aerial photography and other related technical applications. In other set-ups, feedback to the photographer about the exact roll and pitch can be useful for him to correct his orientation of the camera. Another use of the roll information is to automatically correct for small degrees of slant in the sideways direction. In most common photographic situations it is not desirable to have an automatic correction of a slight slant, as the photographer often wants full control of the image orientation. A feature like automatic slant correction should be user configurable in the sense that it can be turned off and on.
[0011] JP 58-222382 discloses an apparatus that automatically corrects inclination of scanned originals by changing the address where the image data is written to reflect the original with no inclination. Inclination is measured by using feedback from a couple of timing marks, which are connected to the slant of the original. Measuring the inclination through the use of timing marks is not useful in digital still photography. General image rotation in software is carried out by moving the original image data to a new position in another image file/buffer.
[0012] The present invention may be implemented in a digital still camera or a digital still camera back and supply a total solution which is very compact, consumes little power, and is applicable in a variety of digital still camera applications. The use of a single detector unit for a variety/plurality of functions decreases the physical size, lowers the power consumption, and keeps the prize down. The use of a micro-mechanical accelerometer as opposed to a mercury switch has the distinct advantage that it does not contain mercury.
[0013] The micro-mechanical accelerometer has several advantages over the mercury switch and the pendulum based orientation detector. Some of these advantages are:
[0014] it can easily be miniaturised,
[0015] it is a measurement device with a high degree of accuracy which can be configured dynamically for a variety of applications through the use of different processing which can be integrated in a digital processing unit or analogue electronics,
[0016] it may be applied to measure both static and dynamic acceleration at the same time. In comparison, the mercury switch and the pendulum are both optimised for measuring static orientation.
[0017] With the integration of more than one measurement axis in a silicon-based chip it becomes possible to measure both dynamic and static acceleration in several directions at the same time. The static acceleration is basically obtained by low-pass filtering the raw outputs from the accelerometer(s). More sophisticated filtering can be applied to handle specific requirements. With static acceleration from at least two axes—which are perpendicular to each other—it is possible to obtain the precise degree of both roll and pitch for a digital still camera. This may be used in technical applications for automatic or manual correction of slant in both sideways and forwards directions. Mercury switches or pendulums are limited to a more rough evaluation of the orientation of the camera (basically limited to two positions).
[0018] A subset of the before-mentioned static acceleration measurement feature is the possibility to automatically determine when an image should be displayed with portrait or landscape orientation. The high precision of the roll and pitch information makes it possible to determine the correct orientation under the most difficult conditions where a slight mechanical tolerance for a mercury switch or pendulum based solution easily would result in an unexpected determination of orientation.
[0019] The mercury switch and pendulum switch based solutions lack the possibility to be dynamically configured to each users need, as their functionality is fixed mechanically when they leave the factory. An example of this could be a user who wishes that his camera should display images with a landscape orientation until he tilts the camera 75 degrees, whereas the normal configuration would be to display an image with a portrait orientation when the camera is tilted more than 45 degrees.
[0020] The measurements of dynamic acceleration (vibration) during the time of exposure may be used in a variety of ways to reduce the possibility of the photographer taking a blurred image. The use of active compensation for camera movements can be used to extend the previous working range for photography in terms of longer exposure time, more zoom, and the ability to capture images in vibration dominated surroundings, i.e. helicopters.
[0021] With a traditional film camera it is necessary to have an expensive lens which corrects the induced vibrations by changing the optical path of incident light. When the vibrations are compensated either by plain image processing with input from the recorded movements, or by active compensation through movement of charges in the image sensor, or by physically moving the image sensor itself, all the outlined compensation solutions described in detail below, enable the use of any type of lens, and are still able to reduce blur. The addition of a little extra image processing to compensate for vibrations through post-processing, or the use of charge movement in the sensor, does not increase the manufacturing cost, as opposed to a solution which changes the optical path.
[0022] When using accelerometers, generation of a “blur” warning is much more fail safe than earlier solutions which were not able to determine if the camera after a short period of vibrations would return to its initial position or the position where the majority of the exposure time had been spent. In such a case the earlier implementations would generate a “blur” alarm, even though the image could be sharp.
SUMMARY OF THE INVENTION
[0023] The present invention is therefore directed to a digital still camera which substantially overcomes one or more of the limitations and disadvantages of the related art. More particularly, the present invention is directed to a digital still camera with a sensor unit for determining static and dynamic accelerations, and methods thereof which substantially overcomes one or more of the limitations and disadvantages of the related art,
[0024] It is an object of the present invention to provide a sensor unit to digital cameras which is very compact, consumes little power, and is applicable in a variety of digital camera applications.
[0025] It is a further object of the present invention to provide a sensor unit to digital cameras capable of providing the following features:
[0026] Low-pass filtering the accelerometer outputs enables exact measurement of roll and pitch which can be used in technical applications for automatic or manual correction of slant in both sideways and forwards directions. The roll and pitch information is also useful in applications where knowledge of the camera shooting direction is needed, i.e. aerial photography.
[0027] A subset of the before mentioned feature is the possibility to automatically determine when an image should be displayed with portrait or landscape orientation.
[0028] A processing unit evaluates the raw accelerometer outputs during the time of exposure. The processing unit evaluates whether or not the measured vibrations may result in an image, which appears to be blurred. The photographer may receive a warning in case the processing unit finds that blur is highly likely to occur in the captured image.
[0029] The raw accelerometer outputs can also be used to keep track of the movements of the camera with respect to the field of gravity. When the image is processed afterwards it is possible to correct the image for blur by using the record of camera movements during the exposure time. During the exposure time, the camera movements can be actively compensated by moving charges (pixel information) in the image sensor in a direction to follow the movements of the projected image in the image plane. The movement of charges in the image sensor can be combined or replaced with mechanical actuators to physically move the image sensor.
[0030] In some cases a little blur may be advantageous to reduce the amount of Moiré image defects which may be introduced when an image is extremely sharp. Using the knowledge about the camera movements during the time of exposure it is possible for the image processor to generate an image with less tendency to show Moiré without the full reduction of sharpness.
[0031] In a first aspect, the present invention relates to a sensor unit to a digital camera, said sensor unit includes a detector which determines static and dynamic accelerations. The detector includes, a first sensor which senses acceleration in a first direction, and provides a first output signal in response to acceleration in the first direction; and a second sensor which senses acceleration in a second direction and provides a second output signal in response to acceleration in the second direction, the second direction being different from the first direction. The sensor unit also includes a processor which processes the first and second output signals. The processor includes a first filter which low-pass filters the first and second output signals so as to obtain information relating to static accelerations, and a second filter which band-pass filters the first and second output signals so as to obtain information relating to dynamic accelerations.
[0032] The first and second directions may be perpendicular to each other. The sensor unit may further include a third sensor which senses acceleration in a third direction and provides a third output signal in response to acceleration in the third direction, the third output signal being provided to the processor so as to obtain information relating to static and dynamic accelerations. The third direction may be perpendicular to the first and second directions.
[0033] The sensor unit may further include an alarm, which may generate an alarm signal in response to at least one of the output signals from the sensor. The alarm signal may be generated when at least one of the output signals exceeds a predetermined level which may relate to the fact that an image starts to get blurred or relate to a certain amount of exposure time. The alarm signal may be constituted by a sound signal, a flashing signal, an image file tag or any combination thereof.
[0034] At least one of the sensors may include a micro-mechanical deflection system. The first, second and third sensor may be integrated in a single micro-mechanical deflection system mounted in the camera house of the digital camera—for example in a digital camera back.
[0035] At least one of the above and other objects may be realized by providing a method of determining static and dynamic accelerations in a digital camera, the method including:
[0036] providing a first sensor sensitive to acceleration in a first direction, said first sensor means being adapted to provide a first output signal in response to acceleration in the first direction,
[0037] providing a second sensor sensitive to acceleration in a second direction, said second sensor being adapted to provide a second output signal in response to acceleration in the second direction, the second direction being different from the first direction,
[0038] low-pass filtering the first and second output signals so as to obtain information relating to static accelerations, and
[0039] band-pass filtering the first and second output signals so as to obtain information relating to dynamic accelerations.
[0040] The method may further include providing a third sensor sensitive to acceleration in a third direction. The third sensor provides a third output signal in response to acceleration in the third direction, the third output signal being provided to the processor so as to obtain information relating to static and dynamic accelerations.
[0041] The first, second and third directions may be essentially perpendicular. The method according to the second aspect may further include generating an alarm signal as mentioned in relation to the first aspect of the present invention.
[0042] At least one of the above and other objects may be realized by providing a digital camera including
[0043] an image recording device, the image recording device comprising a plurality of light sensitive elements,
[0044] a first translator which translates the image recording device in a first direction in response to a first input signal,
[0045] a sensor unit according as set forth above, wherein the band-pass filtered first output signal from the first sensor is provided as the first input signal to the first translating so as to compensate for determined dynamic accelerations in the first direction.
[0046] The digital camera may further include
[0047] a second translator which translates the image recording device in a second direction in response to a second input signal, the second direction being different from the first direction,
[0048] a sensor unit as set forth above, where the band-pass filtered second output signal from the second sensor is provided as the second input signal to the second translator so as to compensate for determined dynamic accelerations in the second direction.
[0049] The first and second directions may be essentially perpendicular. The first and second translators may translate the image recording device in a plane substantially parallel to a plane defined by the plurality of light sensitive elements. The first and second translators may comprise micro-mechanical actuators.
[0050] At least one of the above and other objects may be realized by providing a method of processing image data, the method including:
[0051] providing image data, the image data being stored in a memory,
[0052] providing data or information relating to static accelerations as described above, providing data or information being recorded and stored with the image data, and
[0053] correcting the image data in accordance with the data or information relating to static accelerations so as to correct the image data and reduce the influence of roll and pitch.
[0054] Alternatively, the roll and pitch information may be used to determine whether the optimum way of displaying the image is with a portrait or landscape orientation.
[0055] At least one of the above and other objects may be realized by providing a method of correcting image data during recording of an image of an object, the method including:
[0056] recording image data of the object by projecting the object onto an array of light sensitive elements, recorded image data being generated as electrical charges in the array of light sensitive elements,
[0057] providing information relating to time dependent movements of the array of light sensitive elements relative to the object, and
[0058] correcting the recorded image data in accordance with the provided information relating to movements of the array of light sensitive elements relative to the object by moving charges (pixels) in the array of light sensitive elements so as to correct for relative movements between the array of light sensitive elements and the image of the object.
[0059] At least one of the above and other objects may be realized by providing a method of displaying a recorded image with a predetermined orientation, the method including:
[0060] providing information relating to the degree of roll of the recorded image, the information being provided by first and second sensor means sensitive to accelerations in a first and a second direction, respectively, the second direction being different from the first direction, and
[0061] using the provided information to determine the orientation by which the recorded image is to be displayed and/or stored.
[0062] The orientation by which the recorded image is to be displayed and/or stored may comprise portrait and landscape orientations. The user may determine at which predetermined acceleration levels the recorded image toggles between portrait and landscape orientation. The predetermined acceleration levels may correspond to a predetermined degree of roll of the recorded image.
[0063] At least one of the above and other objects may be realized by providing a method of correcting image data during recording of an image of an object, the method including:
[0064] recording image data of the object by projecting an image of the object onto an array of light sensitive elements,
[0065] providing information relating to time dependent movements of the array of light sensitive elements relative to the image of the object, and
[0066] correcting the recorded image, data in accordance with the provided information relating to movements of the array of light sensitive elements relative to the image of the object by counter moving the array of light sensitive elements so as to compensate for the time dependent movements.
[0067] At least one of the above and other objects may be realized by providing a method of reducing Moiré image defects without full reduction in sharpness, the method including:
[0068] providing an array of light sensitive elements,
[0069] recording an image of an object using the array of light sensitive elements, the image being affected by movements of the array of light sensitive elements relative to the object so that the recorded image appears to be blurred and without Moiré defects,
[0070] information relating to time dependent movements of the array of light sensitive elements relative to the object during the time of exposure, and
[0071] using the provided information as an input to an image processing algorithm so as to reduce Moiré image defects in the recorded image and thereby obtain a modified image with increased sharpness.
[0072] At least one of the above and other objects may be realized by providing a computer program including code adapted to perform the method according to the any of the above methods when the program is run in a computer. The computer program may be embodied on a computer-readable medium.
BRIEF DESCRIPTION OF THE DRAWINGS
[0073] The present invention will now be described with reference to the accompanying figures, where
[0074] [0074]FIG. 1 shows a digital still camera system, where the digital back is optional;
[0075] [0075]FIG. 2 shows roll and pitch of a digital camera with respect to the field of gravity;
[0076] [0076]FIG. 3 shows a block diagram of a digital camera;
[0077] [0077]FIG. 4 illustrates two monitoring axes, where the x-axis is used to monitor the pitch, and the y-axis is to monitor the roll;
[0078] [0078]FIG. 5 shows the pitch working range;
[0079] [0079]FIG. 6 shows the roll working range;
[0080] [0080]FIG. 7 shows an original image (left) and the image after correction (right);
[0081] [0081]FIG. 8 shows how images, which are captured under different pitch and roll conditions, will be displayed;
[0082] [0082]FIG. 9 illustrates how the imaging sensor can be moved in one or more directions in the imaging plane using piezo elements or other exact micro-positioning devices;
[0083] [0083]FIG. 10 illustrates how charges may be moved up or down two rows at a time to match a color filter pattern; and
[0084] [0084]FIG. 11 shows moving of the imaging sensor horizontally using a single piezo element or other micro-positioning device, and moving the pixels in the imaging sensor vertically.
DETAILED DESCRIPTION OF THE INVENTION
[0085] In the following description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known devices and methods are omitted so as not to obscure the description of the present invention with unnecessary details.
[0086] The digital still camera system as shown in FIG. 1, where the digital back is optional, incorporates a section which is able to determine the roll and pitch of the camera with respect to the field of gravity, see FIG. 2. The same section also monitors the vibrations, which occur during the time of exposure. A block diagram can be seen in FIG. 3. The sensor section is comprised of one or more accelerometers, which monitors acceleration in two or three axes placed perpendicular to one another. Together with a digital and/or analogue signal processing section it is possible for the camera to recognise both static acceleration (e.g. gravity) and dynamic acceleration (e.g. vibration) through the use of the same accelerometer unit(s). Preferably the accelerometers are in the same IC. The digital still camera system consists of a lens, a camera house, and in some cases of a digital camera back which is attached to the back of the camera house. The sensor section may be placed anywhere in the digital still camera system.
[0087] Preferably the accelerometer(s) are of the micro-machined type which is integrated in or on a monolithic structure. There are several ways to implement a micro-mechanical accelerometer. One is to form a cantilever in silicon with a very small thickness (μm range). When the entire structure of the device shakes or moves quickly up and down, for example, the cantilever remains still due to its inertia so that the distance between lever and a reference layer changes correspondingly. Such changes in distance between lever and reference layer may be sensed in terms of corresponding changes in electrostatic capacitance between two electrodes, where one is connected to the lever and the other to the reference layer.
[0088] Another principle uses piezo-resistors on the surface of the cantilever beams and their resistance is stress dependent. Acceleration causes a bending of the cantilever beams, which causes stress. Using two longitudinal and two transverse piezo-resistors, which have opposite signs of resistance changes, and connecting them to a Wheatstone Bridge makes it possible to get a signal voltage which is proportional to the acceleration.
[0089] For yet another type of micro-electromechanical accelerometer the sensor is a surface micro-machined structure built on top of the silicon wafer. Polysilicon springs suspend the structure over the surface of the wafer and provide a resistance against acceleration forces. Deflection of the structure can be measured by using a differential capacitor, which consists of independent fixed plates, and central plates attached to the moving mass. The fixed plates are driven by 180° out of phase square waves. Acceleration will deflect the beam and unbalance the differential capacitor, resulting in an output wave whose amplitude is proportional to acceleration. Phase sensitive demodulation techniques are then used to rectify the signal and determine the direction of the acceleration. The output of the demodulator is low pass filtered with a cut-off frequency, which sets the measurement bandwidth limit. A simple digital output signal can be obtained by letting the filtered output drive a duty cycle modulator stage.
[0090] One or more accelerometers which monitors two or three axes, which are perpendicular to one another, may advantageously be mounted in a digital still camera system. With the accelerometer(s) it is possible to determine both the roll and pitch of the camera with respect to gravity with a very high degree of accuracy. When the accelerometer(s) is mounted with monitoring axes as shown in FIG. 4, the x-axis is used to monitor the pitch, and the y-axis is to monitor the roll. Using two axes, the camera movements can be monitored correctly as long as the camera is not upside down—the working range for both roll and pitch is a 180° rotation, which is most commonly used in photography. FIG. 5 shows the pitch working range and FIG. 6 shows the roll working range of a 2-axis system. With a 3-axis system, which also uses information from the z-axis, it is possible to achieve 360° roll and pitch rotation. The degrees of roll and pitch are preferably obtained during the time of exposure and after the accelerometer output typically has been heavily low pass filtered to prevent aliasing due to handshake, i.e. If the accelerometer which is being used contains pre-processing circuits that transforms the analogue output(s) from the basic sensor unit to digital output(s), it is in general most advantageous to use digital signal processing techniques to define the required measurement bandwidth, since it is easier to adapt and optimize for various shooting conditions in terms of varying exposure time and vibrations in the environment surrounding the shooting scene.
[0091] The roll and pitch information is very accurate and can be used as feedback to the photographer to help him physically orient his camera correctly to obtain images without sideways or forwards slant, i.e., pendulum and mercury tilt sensors are not usually able to accomplish this without being physically very large, which makes them unsuited for digital still cameras. The photographer may choose to use a piece of post-processing software which automatically corrects a slight sideways slant in the image by rotating the image counter wise a certain amount of degrees, which is equivalent to the roll information that was recorded during the time when the image was captured. Finally the image may be automatically cropped to fit the frame. FIG. 7 shows an example.
[0092] Since both roll and pitch are measured, the photographer also has access to information about the pitch of the camera, and is thereby able to compensate for this manually or through the use of post-processing software. Knowledge about both sideways and forwards slant can be advantageous in many technical applications.
[0093] The roll and pitch information, which is acquired during the time of exposure, is either embedded in the image file format or attached to a standard image file format. When the image file is displayed, the display software or a pre-processing algorithm can utilize the accurate roll and pitch information to determine the proper orientation of the image and display it either as a portrait or landscape picture. Hysteresis on the roll measurement is used to prevent unexpected switching between portrait and landscape display modes. See FIG. 8, which shows how images which are captured under different pitch and roll conditions will be displayed. The rough sideways rotation can be correctly determined in just about any situation—even when the camera is a couple of degrees from pointing straight to the ground or straight up in the air. If the pitch of the camera shows that the photographer is shooting straight up in the air or straight to the ground, it doesn't make sense to use the roll information to determine how the image should be displayed, instead the image is displayed in landscape, which is most often the natural orientation of a camera image plane. This eliminates the possibility of unexpected rotation of the image when displayed. Without the described check on the pitch reading, images which are captured with the camera pointing straight up or down with almost the same physical orientation may be displayed with different orientations. This is sometimes the case when using pendulum or mercury based tilt sensors.
[0094] Using an image sensor, which enables readout of pixels from each corner in two directions, it is possible to rotate an image without the use of a large temporary storage media (RAM), that way relieving system resources and reducing the overall system overhead. Image information is read straight from the image sensor, which will result in an image with the proper rough orientation (landscape, portrait clockwise, and portrait counter clockwise) as determined by the roll and pitch information which was stored during the time of exposure.
[0095] The accelerometer(s) serve double duty, as their output(s) are also being used to determine the vibrations (dynamic acceleration) which occur during exposure. Vibration information is basically obtained using the raw accelerometer output or maybe by applying some high or band-pass filtering of the output(s) from the accelerometer(s). The filter can be both analogue and digital, typically with the digital filter as the smallest and with the ease of adaptability.
[0096] Vibrations during the exposure time will blur the captured image, and are therefore usually unwanted. The image is most sensitive to vibrations when the exposure time is relatively long or when the photographer zooms in heavily. Whether or not the vibrations, which occur during exposure, will affect the final image depends upon the nature of the vibrations. If the camera is placed in the same steady position for 99.9% of the exposure time, and shakes severely for the remaining 0.1% of the exposure time, the final image will not look blurred. Whereas an image will look blurred when it has been captured with the camera in the same steady position for 50% of the exposure time, and the remaining 50% of the exposure time the camera is physically slightly offset from its initial position. The point is that high acceleration can be accepted for a short amount of time (in respect to the exposure time) as long as the camera returns to its original position, or the position where the majority of the exposure time has been spent.
[0097] Naturally the photographer would prefer that vibrations are removed by mechanical means, but in some cases, i.e. handheld photography, it is not possible. Another way to reduce/remove blur is to monitor the movements of the camera during the exposure time and compensate for the movements by either moving the image which is projected on the image plane or by moving the imaging sensor.
[0098] The vibration information from the accelerometer axes during the exposure time can be used as feedback to reduce the blur in the captured image. Information about acceleration over time along with information about the optics, which generates the image in the imaging plane, will enable blur to be removed/reduced in many ways. The following described methods can be used individually or in combination with one another.
[0099] Using the knowledge about how the projected image moves around in the imaging plane over time, it is possible to mathematically reconstruct the original image by calculating “backwards” from the final image. This solution requires a total log of measured accelerations from the accelerometer(s) axes.
[0100] The imaging sensor can be moved in one or more directions in the imaging plane using piezo elements or other exact micro-positioning devices, see FIG. 9. Thus, it will try to follow the way the projected image moves around in the imaging plane. A solution with two piezo elements takes up quite a bit of space, is expensive, and uses quite a bit of power.
[0101] The charges (pixels) in the image sensor can be moved up and down to follow the movements of the projected image in the vertical direction. This method has some distinct advantages, in that it does not consume any considerable amount of power and does not take up any space. Unfortunately it is limited to the vertical direction. If an image sensor with a Bayer colour filter pattern is used, charges will have to be moved up or down two rows at a time to match the color filter pattern, see FIG. 10. With a monochrome sensor charges can be moved one row at a time.
[0102] A combination of moving the imaging sensor horizontally using a single piezo element or other micro-positioning device, and moving the pixels in the imaging sensor vertically, see FIG. 11. This combination makes it possible to follow the projected image in both the horizontal and vertical direction at a lower cost, lower power consumption and using less space than a solution, which incorporates two piezo elements.
[0103] The vibration pattern is analysed during the exposure cycle. If the acceleration exceeds a certain level for a certain amount of time, which is determined in respect to the exposure time as described in the earlier example, the photographer will receive a warning, which is visual and/or audible and/or attached to the image data. The vibration warning may be automatically turned off by the camera when a flash light is used, since the duration of a flash light burst is very short (<1 ms), thereby reducing the possibility of vibrations during the time when the majority of the light from the exposure hits the imaging sensor.
[0104] In most cases where an image is slightly blurred, the image can be improved by applying a sharpening algorithm to the blurred image. With the vibration information at hand, it is possible for the camera to automatically apply an optimum amount of sharpening to a blurred image. Sharpening can be used as an automatic stand-alone module, which can be added to the resulting image from the before mentioned methods, which all contribute to reduce blur in the image.
[0105] In certain cases a little vibration of the camera may be advantageous as it reduces the possibility of Moiré artifacts in the captured image due to the induced blur. Again using the information about the movements of the projected image in the imaging plane, will enable the image processing software to produce a developed (processed) image with less tendency to show Moiré artifacts without the full loss of sharpness.
[0106] It will be obvious that the invention may be varied in a plurality of ways. Such variations are not to be regarded as a departure from the scope of the invention. All such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the appended claims
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A digital camera system has integrated accelerometers for determining static and dynamic accelerations of the digital camera system. Data relating to static and dynamic accelerations are stored with recorded image data for further processing, such as for correcting image data for roll, pitch and vibrations and for displaying recorded images with a predetermined orientation using information about, e.g., roll. Data may also be used on-the-fly for smear suppression caused by vibrations.
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FIELD OF THE INVENTION
The present invention relates to a jointing and surfacing compound for structural elements, particularly paper-faced plasterboards, and to a method of producing a work such as a partition, a wall covering or a ceiling.
TECHNOLOGICAL BACKGROUND
It is well known to use plasterboards for producing partitions, coverings for vertical or inclined elements, or for producing ceilings, whether suspended or not.
These plasterboards generally consist of a core, essentially made of plaster, covered on each of its sides with a sheet which serves both as reinforcement and as facing and which may consist of paperboard or mineral fibers.
In general, plasterboards are assembled with a first compound and the joints between the plasterboards are finished with a complementary compound. A filling compound is used together with a tape, and in general this has a relatively small shrinkage and good bonding and adhesion to the jointing tape. A finishing compound is used during the last pass in order to finish the work so that it has a monolithic surface. According to application WO-A-97/02395, the compound has the same color as the facing paper of the plasterboard.
Various operators involved in producing a work on a site are in general the plasterer, who positions the plasterboards, the jointer, who prepares the joints between plasterboards (often the jointer and the plasterer are one and the same, while sometimes the jointer and the painter are one and the same) and the painter, who decorates (in general after a printing or primer layer has been applied, except in the case of the aforementioned application WO-A-97/02395). At the present time, painters generally use paints that are applied by means of a spray nozzle, using what is called an “airless” system, namely a container located several tens of meters from the point of application and a single hose with a spray gun fitted with a nozzle on the end, the whole being airless. This has many advantages for storage between work sites, etc. In general, the pressure used is between 120 and 200 bar.
In many cases, the painter, responsible for the final appearance, has to come back to the joints between the plasterboards and treat them again.
There is therefore a need for a compound that can be applied by the same person and/or the same airless equipment and that is suitable for jointing, both for filling and finishing, and for surfacing.
SUMMARY OF THE INVENTION
One subject of the invention is therefore a compound comprising, in percentages by weight relative to the total weight of compound:
40 to 60% of a mineral filler having a diameter d 50 of between 5 and 20 microns; 5 to 10% of hydrophobic expanded perlite having a diameter d 50 of between 20 and 100 microns; and 4 to 20% of a binder.
EMBODIMENTS OF THE COMPOUND
The subject of the invention is also a method of preparing the compound according to the invention.
The subject of the invention is also a method of producing a work, comprising the jointing with a compound and/or the surfacing by applying a compound, and/or the jointing and surfacing by applying a compound, characterized in that the compound is applied by the airless technique. According to one embodiment, the compound is as described in the present application.
Another subject of the present invention is therefore a method of producing a work, comprising the juxtaposition of structural elements, possibly the filling of the gap between the structural elements by means of a filling compound, the application of a tape, the covering of the tape by means of a finishing compound (possibly with filling by means of a filling compound) and being characterized in that the compound according to the invention is used as finishing compound.
Yet another subject of the invention is a method of producing a work, comprising the surfacing of structural elements by using the compound according to the invention.
Yet another subject of the invention is a method of producing a work combining the above two subjects according to the invention.
Another subject of the invention is a method of producing a work, comprising the juxtaposition of paper-faced plasterboards, optionally the application of a tape, the covering of the joint between the plasterboards by means of a delayed-setting compound, characterized in that the compound is applied by the airless technique.
Other features and advantages of the invention will now be described in detail in what follows.
DETAILED DESCRIPTION OF THE INVENTION
Compound According to the Invention
The compound according to the invention comprises, as was indicated, the following components (in % by weight relative to the total weight of the compound):
40 to 60%, preferably 40 to 50%, of a mineral filler having a diameter d 50 of between 5 and 20 microns, preferably between 10 and 15 microns; 5 to 10%, preferably 6 to 7.5%, of hydrophobic expanded perlite having a diameter d 50 of between 20 and 100 microns, preferably between 30 and 70 microns; and 4 to 20%, preferably 5 to 10%, of a binder.
The balance comprises water and possibly other components.
As mineral filler, it is possible to use any mineral filler normally employed for the manufacture of a jointing compound. This is in general a mineral filler of light color, preferably white, the mean diameter d 50 (by weight) of which is generally between 5 and 20 microns, so that the compound after being dried gives a smooth surface and can be easily pumped by an airless machine. Examples of appropriate d 50 are 10 and 15 microns.
As examples of mineral fillers, mention may be made of calcium carbonate, anhydrous calcium sulfate or calcium sulfate dehydrate, magnesium carbonate, dolomite, silicas, silicates, aluminates or other substances.
Preferably, calcium carbonate CaCO 3 is used.
The hydrophobic expanded perlite has a d 50 (by weight) of between 20 and 100 microns. The bulk density of this perlite is preferably greater than 100 kg/m 3 . The d 50 of the particles is generally between 20 and 100 microns, preferably 35 to 70 microns. This perlite is known and may for example be Noblite®, G50, G100, G200, G400 or Sil-Cell®. Without being tied to one theory, the Applicant believes that the small size of the particles and/or a relatively small specific surface area (compared with a size of 150 microns and higher and/or a large specific surface area in the case of “conventional” perlite) makes it possible to avoid crushing the particles. This affords the possibility of using an airless method.
The binder used is one that is conventionally used in the field of compounds and is dispersible in an aqueous phase. It may be in the form of a dry extract or for example in the form of a 50% latex in water. As examples of such binders, mention may be made of polyvinyl alcohol homopolymers, polyvinyl acetate homopolymers (plasticized or unplasticized), ethylene/vinyl acetate copolymers (plasticized or unplasticized EVAs), ethylene/vinyl versatate copolymers, vinyl acetate/vinyl versatate copolymers, polyacrylics, vinyl acetate/acrylic copolymers, styrene/acrylic copolymers, styrene/butadiene copolymers, vinyl acetate/vinyl versatate/vinyl maleate terpolymers, vinyl acetate/vinyl versatate/acrylic terpolymers, terpolymers of vinyl acetate with a vinyl ester of a long-chain acid and with an acrylic acid ester, acrylic terpolymers and blends thereof. It will be preferable to use two or more binders, one dedicated more specifically to water repellency and the other dedicated more particularly to plasticity. It will thus be possible to use combinations of binders: vinyl acetate co- or terpolymer/vinyl copolymer and vinyl copolymer/styrene copolymer/acrylic. When these polymers are supplied, they are either in the form of powder or in the form of a dispersion in water (generally with a content of about 50%).
The proportion of organic binder is preferably between 5 and 10% of the total weight of the compound.
Apart from the components indicated above, the compound generally includes one or more of the following other components:
a slip agent in an amount for example of 0.5 to 10%, preferably 1 to 5%. This slip agent may be a silicate-based agent (different from the mineral filler), especially a clay of the attapulgite type, or it may be any known slip agent, for example talc, mica or a stearate, especially zinc stearate; a workability agent, which is a water-retaining and thickening agent, in an amount for example of 1 to 15%. This water-retaining agent may be methyl hydroxyethyl cellulose; an antifoam agent, in an amount for example of 1 to 15%. This antifoam agent is for example a nonionic surfactant; a silicone derivative, in an amount for example of 1 to 15%. This silicone derivative serves for example as pH buffer in order to obtain a basic medium and/or as viscosity regulator and/or for allowing better stripping, and it may be chosen from siliconates, silanes, hydrogenated silicone oils, silicone emulsions, amino silicone emulsions, alkylsiloxane resins, such as hydrogenomethylpolysiloxane and aminated polydimethylsiloxane, and blends thereof, preferably siliconates; biocides; pigments and optical brighteners; dispersing agents; antigel agents; etc.
A preferred compound according to the invention may comprise, in percentages by weight relative to the total weight of compound:
40 to 50% of calcium carbonate having a diameter d 50 of between 5 and 20 microns, preferably between 10 and 15 microns; 5 to 10%, preferably 6 to 7.5%, of hydrophobic expanded perlite; 5 to 10% of a binder; 1 to 5% of a slip agent comprising a clay and/or a stearate; 1 to 15% of a water-retaining agent; 1 to 15% of an antifoam agent; and optionally 1 to 15% of a silicone derivative, preferably a siliconate.
The compound according to the invention has a density generally between 0.9 and 1.3, preferably between 1 and 1.25 and more preferably 1.15 to 1.21.
The compound generally has a yield point, that is to say its viscosity decreases when a shear is applied and rises again when the shear is removed. This allows it to be applied using the airless technique. The Brookfield viscosity of the compound on leaving the spray nozzle is for example between 0.2 and 0.6 times, preferably between 0.25 and 0.35 times the original value. The viscosity is measured by a Helipath device (from Labomat) (S96 spindle at 10 rpm; 1 min). The values after the compound has rested for 24 hours may be between 150 000 cps and 1 500 000 cps, preferably between 250 000 cps and 1 200 000 cps and more preferably between 300 000 cps and 950 000 cps. The time for the yield point to be reestablished, namely the time between application and the moment when the compound recovers a viscosity close to its original viscosity, is generally between 1 and 120 min, preferably between 5 and 60 min.
The compound according to the invention has a pH that may be controlled by means of the buffer, which may bring the pH to basic values, for example 8 to 9.5.
The compound according to the invention has a solids content that may vary, for example from 50 to 70%, preferably 53 to 67%. Depending on the use, it may be preferable to have relatively high values of this solids content. For an application as jointing, the upper half of the range will be preferred, whereas for a surfacing application, the lower half of the range will be preferred.
The compound according to the invention has one or more of the following properties:
it has good adhesion to the paper constituting the facing of the plasterboard—in fact it is the plasterboard that undergoes cohesive failure; it has good adhesion to a facing of the glass fiber type in order to allow direct application without depositing the facing on renovation work sites; it allows good bonding and adhesion of the jointing tape; it has a color identical to that of the facing paper; it has a negligible shrinkage after drying (for example less than 20%, as determined by the ring test); it has a water absorption “close” to that of the facing paper, so as to avoid having to use a layer of primer before applying a wallpaper or paint, according to the teaching of the aforementioned application WO-A-97/02395; it allows moderate adhesion of the paper constituting the wallpaper, so that one or more subsequent stripping operations are possible; it allows easy paint application (even when the compound is used as sole jointing compound); it offers a surface rendition substantially identical to that of the printing primer layer normally used in the field of interior constructions; and it allows texturing after application.
Method of Preparing the Compound According to the Invention
The compound according to the invention may be prepared by mixing its constituents in any order, or in a chosen order, or according to a particular method that gives good results.
In the first case, the various components are added to the water with stirring.
In the second case, it will be preferable to add the hydrophobic expanded perlite first, preferably in the presence of a foaming agent, and then secondly to add the other components. Water may be added at the end in order to adjust the viscosity, where appropriate.
In the third case, one part of the filler (typically 5 to 10% by weight) is premixed with other components that may be difficult to disperse in water, for example the slip agent and/or the pigments. As an example, it will be possible to use a premix consisting of the filler, the slip agent, the workability agent and optionally a binder in powder form. Preferably, the mineral filler is added before the premixing and the binder afterwards. Water may be added at the end to adjust the viscosity, where appropriate.
Any type of mixer, preferably a horizontal mixer with a staged feed, is used.
Methods of Construction According to the Invention
The compound according to the invention may be used for producing many types of work, such as partitions, wall coverings or ceilings, whether suspended or not, from plasterboards. The compound may also be used on other surfaces, for example concrete surfaces, especially when the buffer for basic pH is present.
The compound according to the invention is particularly suitable for the production of a work using paper-faced plasterboards.
The compound according to the invention is preferably used airlessly, but it is also possible to use it as a conventional compound.
The compound according to the invention may be used as only a jointing compound or as a surfacing compound or both.
The production of a work by means of plasterboards generally comprises the juxtaposition of plasterboards, the filling of the gap between the plasterboards by means of a filling compound, the application of a tape, the covering of the tape by means of the filling compound and then the covering of the filling compound with a finishing compound. The compound according to the invention may be the filling compound and/or the finishing compound. When the compound according to the invention is used for treating the joint, the operator proceeds as follows. The compound according to the invention is applied, to a tape applied in the feathered edges, by airless spraying in line with the joint (using an appropriate nozzle), and then, a few minutes after its application (when the viscosity has risen), the operator closes up the joint. If the operator has only one joint to do, he will then proceed to a second application of the compound (or another compound according to the invention more particularly dedicated to finishing) and to a final smoothing operation. If the operator has to coat the entire surface, he may then apply over the entire surface one and the same surfacing compound without beforehand having to finish off the joint. In this case, the jointing and surfacing compounds may be identical or different.
To produce joints for the feathered edges, it will be preferable to use a self-adhesive glass mesh tape, without a prior filling layer. To produce joints on round-edged plasterboards, and therefore without a tape, the compound is used in the same manner.
Depending on the desired level of finishing, it is possible to deposit, for the surfacing or printing, a film of compound using a wide-jet nozzle.
The compound according to the invention makes it possible to carry out an operation, the surfacing and/or the printing. After application, the compound may be structured using a spatula, a smoothing tool, a plastic embossed roller or any other instrument, depending on the desired relief (spatulated relief, rolled relief, rolled-compressed relief, etc.).
In the case of surface renovation of the type with a glass-fiber-based facing, the compound according to the invention offers adhesion to glass fibers that is sufficient to avoid having to carry out any surfacing or prior deposition of the facing.
One of the main features of the compound according to the invention is its ability to be sprayed by an airless system, the equipment used by painters in particular. These systems offer advantages of robustness, simplicity of use (compressor outside a room with a single hose into the room, no drying of the product since it is airless, etc.). The invention therefore provides a jointing and/or surfacing method using a drying compound based on a mineral filler and binder by spraying using the airless technique. This airless technique uses high pressures, up to 200 bar. All airless machines are suitable, especially M-Tec® forte, Graco® Spackmax®, Elmyggan®, etc.
The compound according to the invention therefore makes it possible to save a considerable amount of time and labor.
The invention is also applicable in the field of delayed-setting compounds, the airless technique being applicable to these compounds. Such delayed-setting compounds are compounds based on plaster (hemihydrate), but which include a setting retarder. Among such setting retarders, mention may be made of maleic anhydride, sodium polyacrylate and polyacrylic acids, and also proteinaceous mixtures available under the name Goldbond High Strength Retarder. The amount is for example from 0.1 to 1% by weight relative to the weight of the hemihydrate. It is also possible to use an accelerator, which is then injected into the mix at the spray nozzle. As accelerator, it is possible to use aluminum sulfate, aluminum nitrate, ferric nitrate, ferric sulfate, ferric chloride, ferrous sulfate, potassium sulfate, sodium carbonate or sodium bicarbonate, aluminum sulfate generally being preferred. The amount may for example vary between 1 and 5% by weight relative to the weight of the hemihydrate.
The additives mentioned above may also be used in the case of the setting compound. In particular, polyvinyl alcohol may be used.
Examples of such compositions are given for example in WO-A-03/027038 and WO-A-03/059838.
EXAMPLES
The following examples are given merely by way of illustration and in no way imply a limiting character. The viscosity is measured at the mixer exit and optionally after resting. In the examples, the following components were used:
Component
Characteristics
Perlite 1
Water-repellent expanded perlite (d 50 = 50 microns)
Perlite 2
Water-repellent expanded perlite (d 50 = 70 microns)
Perlite 3
Water-repellent expanded perlite (d 50 = 50-60 microns)
CaCO 3 1
d 50 = 10 microns
CaCO 3 2
d 50 = 15 microns
Premix 1
CaCO 3 2
44.8%
Cellulose ether
8.8%
Attapulgite
32%
TiO 2
14.4%
Premix 2
CaCO 3 2
31.08%
Cellulose ether
2.70%
Attapulgite
20.72%
Zinc stearate 4.73
Binder 3
31.08%
TiO 2
9.69%
Binder 1
Vinyl acetate/ethylene copolymer dispersed in water
Binder 2
Styrene/acrylic copolymer dispersed in water
Binder 3
Vinyl acetate/vinyl ester of a long-chain acid/acrylic acid
ester terpolymer dispersed in water
To prepare the compounds, the procedure was as follows, using a horizontal mixer. The perlite was added to the starting water, with stirring for 2 minutes. Next, the biocide and the antifoam were added, followed by the mineral filler. Next, the premix was added, then the binder or binders and finally the process was completed with the viscosity-adjusting water, possibly with the siliconate.
Example 1
The following composition 1 was prepared:
Component
Quantity
Starting water
1600
Perlite 1
250
Biocide
15
Antifoam
10
CaCO 3 1
1630
Premix 1
250
Binder 1
140
Binder 2
140
Adjustment water
100
The following characteristics were obtained:
pH
7.8
Density
1.2
Viscosity
360 000 cps
% solids content
55.80%
Example 2
The following composition 2 was prepared:
Component
Quantity
Starting water
1978
Perlite 1
321.5
Biocide
18.5
Antifoam
12
CaCO 3 1
2015
Premix 1
309
Binder 1
173
Binder 2
173
The following characteristics were obtained:
pH
8.36
Density
1.007
Viscosity
324 000 cps*
% solids content
59.49%
*Value after resting: 911 000 cps.
Example 3
The following composition 3 was prepared:
Component
Quantity
Starting water
51.4
Perlite 1
8.36
Biocide
0.48
Antifoam
0.3
CaCO 3 1
52.4
Premix 1
8
Binder 1
4.5
Binder 2
4.5
Adjustment water
6
The following characteristics were obtained:
pH
8.26
Density
1.11
Viscosity
214 000 cps*
% solids content
54.67%
*Value after resting: 826 000 cps.
Example 4
The following composition 4 was prepared:
Component
Quantity
Starting water
58.5
Perlite 3
9.765
Biocide
0.555
Antifoam
0.375
CaCO 3 2
61.2
Premix 1
9.39
Binder 1
5.257
Binder 2
5.257
The following characteristics were obtained:
pH
8.86
Density
1.25
Viscosity
202 000 cps
% solids content
53.95%
Example 5
The following composition 5 was prepared:
Component
Quantity
Starting water
50
Perlite 1
8.36
Biocide
0.48
Antifoam
0.3
CaCO 3 1
52.4
Premix 1
8
Binder 1
4.5
Binder 2
4.5
Adjustment water
7.4
The following characteristics were obtained:
pH
8.54
Density
1.108
Viscosity
220 000 cps
% solids content
54.3%
Example 6
The following composition 6 was prepared:
Component
Quantity
Starting water
38
Perlite 3
7.8
Biocide
0.4
Antifoam
0.3
CaCO 3 2
49.4
Premix 2
11.1
Binder 1
4.2
Adjustment water
2
The following characteristics were obtained:
pH
8.22
Density
1.21
Viscosity
225 000 cps
% solids content
63.1%
Example 7
The following composition 7 was prepared:
Component
Quantity
Starting water
38
Perlite 2
7.4
Biocide
0.65
Antifoam
0.3
CaCO 3 2
49.4
Premix 2
11.7
Binder 1
4.2
The following characteristics were obtained:
pH
7.8
Density
1.208
Viscosity
248 000 cps
% solids content
62.88%
Example 8
The following composition 8 was prepared:
Component
Quantity
Starting water
3800
Perlite 2
740
Biocide
59
Antifoam
30
CaCO 3 2
4940
Premix 2
1163
Binder 1
420
Siliconate
53
The following characteristics were obtained:
pH
11.87
Density
0.910
Viscosity
73 000 cps*
% solids content
63.96%
*Value after resting: 250 000 cps.
Example 9
The following composition 9 was prepared:
Component
Quantity
Starting water
84
Perlite 3
15.6
Biocide
1.282
Antifoam
0.6
CaCO 3 2
98.8
Premix 2
23.3
Binder 1
8.4
The following characteristics were obtained:
pH
7.85
Density
1.090
Viscosity
175 000 cps*
% solids content
63.7%
*Value after resting: 317 000 cps.
Example 10
The following composition 10 was prepared:
Component
Quantity
Starting water
48.5
Perlite 3
10.44
Blue brightener
0.015
Biocide
0.675
Antifoam
0.4
CaCO 3 2
66.150
Premix 2
15.5
Binder 1
5.58
Siliconate
0.74
The following characteristics were obtained:
pH
9.03
Density
1.125
Viscosity
95 000 cps*
% solids content
65.71%
*Value after resting: 195 000 cps.
Example 11
The following composition 11 was prepared:
Component
Quantity
Starting water
58.3
Perlite 1
9.65
Biocide
0.675
Antifoam
0.38
CaCO 3 1
60.5
Premix 1
9.27
Binder 1
5.2
Binder 2
5.2
The following characteristics were obtained:
pH
8.5
Density
1.100
Viscosity
235 000 cps
% solids content
54.25%
Example 12
Joints were produced by spraying using an M-Tec airless machine with 25 m of 19 mm hose and 15 m of 15 mm hose, i.e. a total of 40 m in length. The nozzle had a 60° angle and a 0.051 inch opening.
After bonding the glass mesh at the joint, the spraying of compound 10 from a distance of 30 cm and then straightening the treated joints a few minutes after application resulted in high-quality joints.
The method then involved spraying on plasterboards with joints already treated. The same tools were used, but this time compound 11 was sprayed so as to form a sprayed band 70 cm in width. Without smoothing, a granite-like decorative compound was obtained direct from spraying. Smoothing the spraying compound posed no problem.
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The invention relates to a sealant compound comprising, in weight percent relative to the compound total volume: 40-60% of mineral filler whose diameter d50 ranges from 5 to 20 microns, 5-10% of hydrophobic expanded perlite whose diameter d50 ranges from 20 to 100 microns and 4-20% of binder. A method for preparing the inventive compound is also disclosed. Said invention also relates to producing a work provided with joints made of pointing and/or surfacing compound by applying said compound and/or pointing and surfacing by applying the compound which is characterised in that the compound is applied by airless process. According to the inventive method, said sealant compound is embodied such as described in the invention.
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CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] The present patent application claims the right of priority under 35 U.S.C. §119 (a)-(d) of German Patent Application No. 103 47 702.0, filed Oct. 14, 2003.
FIELD OF THE INVENTION
[0002] The present invention relates to a sintered body based on niobium suboxide. In particular, the present invention relates to sintered shaped bodies which, on account of their resistance to chemicals, are used in chemical apparatus and preferably for the production of anodes for solid electrolyte capacitors, in particular sintered anodes made from niobium suboxide.
BACKGROUND OF THE INVENTION
[0003] Anodes of this type are produced by sintering fine niobium suboxide particles to form a sponge-like structure with an extremely large surface area. A dielectric niobium pentoxide layer is produced on this surface by electrolytic oxidation, and the capacitor cathode, which may consist of manganese dioxide or a polymer electrolyte, is produced on the pentoxide layer. The process used to produce anodes or capacitors of this type, as well as the production of the capacitor precursor powders, includes a range of mechanical and thermal treatment steps in vacuo or reactive and/or protective gas, which entail the risk of contamination with elements which have an adverse effect on the capacitor properties. Therefore, according to WO 021086923 A2, it is proposed that all equipment used for the mechanical or thermal treatment involved in the production of anodes consist of niobium metal or at least be coated with niobium metal.
[0004] One drawback in this context is that niobium metal is a so-called oxygen getter material, which tends to take up oxygen at high temperatures. Accordingly, during high-temperature treatment steps involved in the production of niobium suboxide anodes, which may involve temperatures of up to 1600° C., there is a high risk of oxygen being withdrawn from the niobium suboxide in an uncontrolled way, in particular if there is direct contact between the niobium suboxide and the niobium metal at this high temperature. Furthermore, the niobium metal becomes increasingly brittle as a result of the uptake of oxygen when used repeatedly, and therefore typically has a short service life.
SUMMARY OF THE INVENTION
[0005] According to the invention, it is now proposed that devices which are used in the production of anodes of this type be formed as sintered bodies based on niobium suboxide and if appropriate magnesium oxide.
[0006] Examples of devices of this type include vessels, reactor vessels, reactor linings, mill linings, milling beads, milling rollers, press moulds, press rams, etc.
[0007] In accordance with the present invention, there is provided a sintered body comprising:
(a) 30 to 100 mol % of NbO x ,
wherein x is greater than 0.5 and less than 1.5 (i.e., 0.5<x<1.5); and
(b) 0 to 70 mol % of MgO,
the mole percents being based in each case on the total moles of NbO x and MgO.
[0011] The invention also provides a method for producing solid electrolyte capacitors comprising a niobium suboxide anode, said method comprising:
[0000] pre-treating a pre-cursor of said niobium suboxide anode by a treatment means selected from the group consisting of mechanical treatment, thermal treatment and combinations thereof,
wherein said pre-treatment is performed in an apparatus comprising at least one sintered body according to the present invention upon which said pre-cursor of said niobium suboxide anode is placed.
[0012] In a further embodiment of the above method, said method further comprises the steps of
[0000] providing a sinter plate comprising said sintered body according to the present invention,
placing said pre-cursor of said niobium suboxide anode on said sinter plate,
pre-treating said precursor of said niobium suboxide.
[0013] In general, said pre-cursor of a niobium suboxide anode is produced by pressing.
[0014] The sintered bodies according to the present invention are particularly suitable for use in chemical apparatuses, thus the present invention also provides a chemical apparatus comprising chemically resistant components fabricated from the sintered body according to the present invention.
[0015] Such a chemical apparatus is particularly suitable for the production of capacitor grade niobium suboxide powder.
[0016] Unless otherwise indicated, alt numbers or expressions, such as those expressing quantities of ingredients, mole and volume percents, process conditions, etc., used in the specification and claims are understood as modified in all instances by the term “about.”
DETAILED DESCRIPTION OF THE INVENTION
[0017] The sintered bodies preferably contain niobium suboxide of the formula NbO x , where 0.7<x<1.3.
[0018] It is particularly preferable for the sum of the molar percentages of niobium suboxide and magnesium oxide to be 100% with the exception of inevitable foreign element impurities. In particular, the sintered bodies should be substantially free of iron, chromium, nickel, alkali metals and halogens. The iron, nickel, chromium, sodium, potassium, chlorine and fluorine impurities should particularly preferably each amount to less than 10 ppm, particularly preferably less than 5 ppm, and also preferably in total less than 30 ppm. On the other hand, impurities or alloying elements of vanadium, tantalum, molybdenum and tungsten amounting to up to a few mol %, for example up to 5 mol %, are harmless.
[0019] The sintered bodies according to the invention may advantageously consist of 35 to 100 Mol % of NbO x and 65 to 0 Mol % of MgO. The sintered bodies according to the invention preferably consist of 30 to 60 Mol % of NbO x , and 70 to 40 Mol % of MgO, particularly preferably of 45 to 60 Mol % of NbO x and 55 to 40 Mol % of MgO.
[0020] Preferred sintered bodies according to the invention have porosities of less than 30% by volume, more specifically the sintered bodies according to the invention have porosities of from greater than 0% by volume to less than 30%, particularly preferably less than 20% by volume, more specifically the sintered bodies according to the invention have porosities of from about 1% by volume to less than 15% by volume. The percent volumes being based on the total volume of the sintered body.
[0021] The sintered bodies containing magnesium oxide in accordance with the invention preferably comprise microstructures which include substantially homogeneous niobium suboxide-rich regions and magnesium oxide-rich regions which each extend at most 1.5 μm, preferably at most 1.0 μm in at least one direction. It is preferable for the niobium suboxide-rich regions to comprise at least 95%, particularly preferably at least 99%, of niobium suboxide. The magnesium oxide-rich regions preferably comprise up to 99% of magnesium oxide.
[0022] The sintered bodies according to the invention can be produced using standard ceramic processes. For example, the shaping can be performed by axial and/or isostatic pressing, extrusion, conventional pressure-free or pressurized slip casting or also by injection moulding. Depending on the process used, suitable organic auxiliaries, such as for example PVA, PEG, etc. (for pressing), wax or plasticizers which are commercially available for this purpose (for the injection moulding, etc.), which after moulding can be expelled (binder removal) without leaving any residues by means of a heat treatment in air, under protective gas or in vacuo without altering the basic properties of the inorganic base powder, are added to the powder in a manner which is known per se from sintering technology. In air, a temperature of 250° C., preferably 150° C., should not be exceeded, in order to prevent oxidation of the niobium suboxide.
[0023] In the case of shaping by pressing, the addition of the organic auxiliaries may advantageously be combined with a granulation step in order to improve the flow properties of the powder.
[0024] In the case of slip casting, preliminary drying, preferably in air, has to be carried out after demoulding and prior to the binder removal. Furthermore, a (careful) mechanical treatment using chip-forming processes, such as turning, milling, drilling, etc., can be carried out after the shaping step and prior to the binder removal, in order to make the bodies as close as possible to the desired net shape of the sintered body. A treatment of this type may also be carried out after the binder removal and any pre-sintering step for consolidating the shaped body, in which case machining processes such as dry or wet grinding may also be used.
[0025] The sintering itself is carried out in gastight furnaces under a protective gas atmosphere, such as argon or gas mixtures based on argon together with typically 3 to 10% by volume of hydrogen or the like in order to counteract a change in the oxidation state of the niobium suboxide. Before the sintering begins, the furnace is purged with the protective gas or evacuated and flooded with the protective gas. To avoid direct contact between the shaped body to be sintered and the furnace lining, the shaped body is mounted on supports/spacers (“firing aids”) made from materials which are thermally and chemically stable at the sintering temperature and do not enter into any reaction with the suboxide. Sintering aids made from dense or porous silicon carbide have proven particularly suitable. The sintering preferably takes place at temperatures of less than 1700° C., particularly preferably between 1550 and 1650° C., with a slow heating rate of less than 10 K/min to the sintering temperature, preferably 1 to 3 K/min in the upper temperature range from 1100° C. up to the sintering temperature, with a holding time at the sintering temperature of preferably less than 10 hours, depending on the desired densification of the shaped body and the particle size of the niobium suboxide and optionally magnesium oxide powders used.
[0026] The starting material used for the production of the sintered bodies according to the invention is preferably commercially available high-purity niobium pentoxide with a specific surface area of from 5 to 20 m 2 /g. The niobium pentoxide, either as such or after reduction in flowing hydrogen to form the niobium dioxide, can be reduced to the suboxide by means of magnesium vapour at a temperature of from 950 to 1150° C. This forms an agglomerate powder which contains magnesium oxide inclusions.
[0027] This powder can be used as such after milling to produce the sintered bodies according to the invention. If the starting point is niobium dioxide, sintered bodies which contain approximately 50 Mol % of MgO are obtained. On the other hand, if the starting point is niobium pentoxide, sintered bodies which contain approximately 67 Mol % of magnesium oxide are obtained.
[0028] The starting point for the production of sintered bodies which do not contain any magnesium oxide is preferably likewise fine-particle niobium pentoxide with a high specific surface area. This niobium pentoxide is reduced in flowing hydrogen at a temperature of from 1100 to 1400° C. to form the niobium dioxide. Some of the niobium dioxide is reduced further in magnesium vapour to form the niobium metal. Then, the magnesium oxide which is formed is washed out of the niobium metal by means of acids, for example sulphuric acid. The niobium metal is then heated with a stoichiometric quantity of niobium dioxide in a hydrogen-containing atmosphere to 1100 to 1600° C., leading to conversion to the niobium suboxide, NbO. Other compositions of the sintering powder in accordance with the invention are obtained by correspondingly varying the quantitative ratios of the respective reaction components or mixtures.
[0029] To attain the relatively high densities of the sintered bodies, it is preferable to use fine-particle agglomerate powders, particularly preferably a screened fraction below 38 μm, more preferably below 20 μm.
[0030] Furthermore, the powders which can be used in accordance with the invention to produce the sintered bodies, are eminently suitable for producing coatings by means of high-temperature or plasma spraying, in which case it is possible to produce surface layers which are similar to sintered structures on metals such as niobium, tantalum, molybdenum and/or tungsten. In this case, it is if appropriate possible to additionally use niobium metal powder in subordinate quantities of up to 20% by weight, preferably between 10 and 18% by weight, as binder. Coated devices of this type made from niobium, tantalum, molybdenum or tungsten, according to the invention, are also suitable for the production of solid electrolyte capacitors based on niobium suboxide. Metal devices of this type provided with a coating which is similar to a sintered structure are also intended to be encompassed by the term “sintered body” in accordance with the invention.
PRODUCTION EXAMPLE
[0031] The production of a sintering plate for solid electrolyte capacitor anodes is explained below by way of example for the sintered bodies according to the invention.
[0032] A niobium suboxide powder of composition NbO with a particle size of less than 38 μm and a particle size distribution in accordance with ASTM B822 (Malvern Mastersizer) corresponding to a D10 value of 2.8 μm, a D50 value of 11.4 μm and a D90 value of 25.2 μm is used. The flow properties of the powder are improved by screening granulation and a tumbling treatment without further additives sufficiently for uniform filling of a press mould to be possible. A hard metal press mould with a square aperture with a side length of 125 mm is used. The granulated powder is introduced into the mould and compacted at 2 kN/cm 2 . The pressed body, with dimensions of approximately 125×125×15 mm 3 , after demoulding, is welded into a plastic film and compressed further isostatically at 200 Mpa. The result is a pressed body of approx. 122×122×13 mm 3 . This pressed body is machined on a conventional milling machine in such a way that a dish-like part with an encircling rim with a height of 13 mm and a wall thickness of 5 mm for both the base and the rim remains.
[0033] The green machined part is placed without further pretreatment, inside a SiC vessel, into a gastight furnace heated by means of graphite resistance heating and is sintered. At the start of the sintering, the furnace is evacuated and flooded with a gas mixture comprising 97% by volume of argon and 3% by volume of hydrogen. The heating programme follows a heat-up rate of 10 K/min up to 500° C., a heat-up rate of 5 K/min up to 1100° C., then a heat-up rate of 2.5 K/min up to 1600° C., a holding time of 3 hours at 1600° C., a controlled cooling rate of 5 K/min down to 800° C., followed by uncontrolled cooling to below 150° C. The shaped part which is then removed from the furnace has a density of 6.9 g/cm 3 and a Vickers-Hardness HV 10 of 14 Gpa. It may optionally be remachined on the inside and/or outside in order to establish predetermined geometry and surface structures.
[0034] Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. The priority document and all further documents cited herein are incorporated by reference for all useful purposes.
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Disclosed are sintered bodies that include: (a) 30 to 100 mol % of NbO x , wherein 0.5<x<1.5; and (b) 0 to 70 mol % of MgO. The sintered bodies may be used as inert apparatuses in the production of niobium suboxide powder or niobium suboxide anodes, or as chemically resistant components in chemical apparatuses.
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TECHNICAL FIELD
[0001] The general inventive concept of the present invention relates to networks and more particularly, to systems and methods for evaluating and profiling network traffic.
BACKGROUND
[0002] In a relatively short period of time, Internet usage has expanded astronomically. As illustrated in FIG. 1 , a user typically accesses the Internet 100 via an Internet Service Provider (ISP) 110 . A user may communicate with the ISP 110 via any number of processor-based devices including, but not limited to, personal computers (PCs) 120 , Personal Digital Assistance (PDAs), laptop computers 140 , smart phones and cell phones 150 , etc. with the ever-expanding access and usage of the Internet, ISPs 110 have found that critical to be able to monitor and control access to the Internet 100 in order to assure consistent quality of service (QoS) for users under constantly varying traffic loads. However, the aforementioned need to monitor and control communications traffic is not limited to simply accessing the Internet. All communication networks require such a monitoring and control in order to assure uniform QoS.
[0003] Therefore, various methods of communication traffic profiling have been developed. However, in-depth understanding of Internet traffic profile is a challenging task for researchers and mandatory for most ISPs. Deep Packet Inspection (DPI) assists ISPs in profiling networked applications. Based on this profiling information, ISPs may apply different charging policies, traffic shaping and offer different quality of service (QoS) guarantees to selected users and/or applications. Many critical network services may rely on the inspection of packet payload content instead of solely examining the structured information found in packet headers. New techniques are desired in network devices for packet analysis based on content.
[0004] Existing deep packet inspection (DPI) tools and techniques rely on comparing the content of the packet payload with a set of strings or regular expressions which is assumed to represent a given “signature” of an application. The collection and definition of the proper signatures is a time consuming and challenging task requiring manual effort from protocol experts. In order to ease this manual effort, automatic protocol signature generation tools assist in processing the network traces of a specific application and in defining signature candidates.
[0005] Automatic signature generation is cumbersome due to the several requirements that must be fulfilled. Among these requirements are: the generation should be automatic; it should process a high number of samples within a reasonable time period; it should provide the longest possible signature candidates; and it should find important signatures to accurately represent the underlying traffic.
[0006] As described in an article entitled “The Earlybird System for the Real-time Detection of Unknown Worms”, UCSD, Department of Computer Science, Technical Report CS2003-0761, by S. Singh, C. Estan, G. Varghese, and S. Savage, (hereinafter referred to as Earlybird and incorporated herein by reference) fingerprints of fixed length payload substrings are calculated. A sliding window for the selection of substrings is applied. The signatures are stored via their Rabin-Fingerprint. The source and destination host identifiers (srcIP, dstIP) are taken into account to help in the detection of worm infection.
[0007] As described in an article entitled “Autograph: Toward Automated, Distributed Worm Signature Detection,” in In Proceedings of the 13th Usenix Security Symposium, 2004, pp. 271-286, by H. ah Kim, (hereinafter referred to as Autograph and incorporated herein by reference) signatures are generated by analyzing the prevalence of portions of flow payloads. This does not use knowledge of protocol semantics above the TCP level. It is designed to produce signatures that exhibit high sensitivity (high true positives) and high specificity (low false positives). The aforementioned article is similar to one by Eric Conrad entitled “Detecting Spam with Genetic Regular Expressions,” (herein referred to as GenRegexp and incorporated herein by reference) in the ways of scoring true positive and false positive hits. Autograph uses variable-length content blocks using content-based payload partitioning. The fingerprint is done in the same way as in Earlybird. Autograph filters the candidate fingerprints by the flow destination host cardinality which is typically high for malware.
[0008] As described, in an article entitled “Polygraph: Automatically generating signatures for polymorphic worms,” in SP '05: Proceedings of the 2005 IEEE Symposium on Security and Privacy. Washington, D.C., USA: IEEE Computer Society, 2005, pp. 226-241 by J. Newsome, B. Karp, and D. Song (herein referred to as Polygraph and incorporated herein by reference). Polygraph uses a similar to a ML-based (maximum-likelihood) approach by P. Haffner, S. Sen, O. Spatscheck, and D. Wang, “Acas: automated construction of application signatures,” in MineNet '05, New York, N.Y., USA, 2005 (herein referred to as ACAS and incorporated herein by reference). In Polygraph the substrings are called tokens. The tokens can be of variable length. The tokens are extracted with simple thresholds and later concatenated with variable algorithms such as: (i) generate conjunction signatures with greedy algorithm; (ii) generate token-subsequence signature with the Smith-Waterman algorithm; and (iii) generate bayes signatures where approximate matching is applied. The analyzed traffic is not filtered based on worm types, thus the generated signatures are typical signatures for a set of worms. Clustering techniques are used to identify signatures for the same worm type.
[0009] In general, worm signature generation studies rely on a few formats as variations of sliding-window algorithms. W. Scheirer and M. Chuah in their article entitled “The Strength of Syntax Based Approaches to Dynamic Network Intrusion Detection,” in Information Sciences and Systems, 40th Annual Conference on Volume, March 2006, (incorporated herein by reference) explained the types of available sliding-window algorithms and the selection of break points, which is the hex value of the instruction code corresponding to a specific action among worm's common behavior. The algorithms are called Fixed Partition Sliding Window Scheme (FPSW), Variable-length Partition Sliding Window Scheme (VPSW) and Variable-length Partition with Multiple Breakmarks (VPMB). The window is sliding across the multiple byte streams (or packet payloads) until they find the matching sequences. The problem occurs when applying these algorithms to normal traffic as there are no such break points in the payload due to difference of traffic nature. It is hard to determine where to stop and decide the appropriate comparison window size to start with. Therefore, it is difficult to apply the sliding window algorithm using break points to general Internet applications such as P2P.
[0010] Regular expression creation from spam is a similar recently discussed topic. GenRegexp proposes genetic regular expressions to effectively match spam, and show improvement from generation to generation. Genetic regular expressions leverage the genetic algorithm concepts of fitness, crossover, and mutation to evolve chromosomes across generations to find a superior solution. GenRegexp showed that the winning chromosome from the tenth (10 th ) generation was over nine (9) times as effective as the winning chromosome from the first (1 st ) generation.
[0011] ACAS uses ML-algorithms to construct application signatures based on the argument that ML-based methods are well fitted to this task. In ACAS, the first few bytes of the payloads are encoded to create a feature vector for the ML-algorithms which later extract the common ones. ACAS indicates a successful extraction of signatures from SMTP, FTP and HTTP traffic. However, these protocols can not be regarded as complex as the extracted signatures have not been published.
[0012] In a learned treatise by H. Inoue, D. Jansens, A. Hijazi, and A. Somayaji, entitled “Netadhict: a tool for understanding network traffic,” in LISA'07: Proceedings of the 21st conference on Large Installation System Administration Conference. Berkeley, Calif., USA: USENIX Association, 2007, pp. 1-9 (herein referred to as NetADHICT and incorporated herein by reference), the key idea is that it can identify and present a hierarchical decomposition of traffic that is based upon the learned structure of both packet headers and payloads. Its main benefit is its visualization module but it does not differ much from other ML-based application signature clustering methods. The signatures contain the content, the length and the offset of the signature. The signatures are not merged later.
[0013] J. Ma, K. Levchenko, C. Kreibich, S. Savage, and G. M. Voelker, in a learned treatise entitled “Unexpected Means of Protocol Inference,” in IMC '06: Proceedings of the 6th ACM SIGCOMM conference on Internet measurement. New York, N.Y., USA: ACM, 2006, pp. 313-326, the authors present three classification techniques for capturing statistical and structural aspects of messages exchanged in a protocol: product distributions of byte offsets, Markov models of byte transitions and common substring graphs of message strings. The substrings are not extracted from the payloads but the state transitions are calculated in every possible byte-to-byte step in the payload. The authors compare the performance of these classifiers using real-world traffic traces from three networks in two use settings and demonstrate that the classifiers can successfully group protocols without a priori knowledge. The authors analyzed common plain-text protocols such as, for example, SMTP, DNS and SSL.
[0014] B. Park, Y. J. Won, M. Kim, and J. W. Hong, in a learned treatise entitled, “Towards automated application signature generation for traffic identification,” in NOMS, 2008, pp. 160-167 (herein after referred to as Laser and incorporated herein by reference), use Longest Common Subsequence (LCS) for the signature extraction step. The LCS is extracted from sample flows to be the signature of the given application. The algorithm compares two samples to get the longest common subsequence between them, and then compares it with other samples iteratively to refine it. In Laser, the common substrings are clustered based on packet sizes, similarity distance is calculated among the candidates and in case of high similarity, a character-by-character matching is initialized. Since the Laser algorithm iterates through the substrings multiple times, it is assumed not to be a good candidate for wire-speed processing. This algorithm produced signatures for several P2P protocols as well such as, for example, LimeWire, BitTorrent and Fileguri.
[0015] M. Ye, K. Xu, J. Wu, and H. Po, in a learned treatise entitled “Autosig-automatically generating signatures for applications” in CIT (2) IEEE Computer Society, pp. 104-109 (incorporated herein by reference), the authors presented AutoSig which extracts multiple common substring sequences from sample flows as application signature. All possible common substrings in an application protocol are extracted and then a substring tree is constructed to generate the final.
[0016] In US patent publication no. 2008/0127336 A1, an automated malware signature generation method is described in which malware signature is generated for incoming unknown files based on particular malware classification and access to malware signature is provided. The method includes monitoring incoming unknown files for the presence of malware, analyzing the incoming unknown files based on a set of classifiers of file behavior and a set of classifiers of file content and classifying the incoming unknown files with a particular malware classification based on the analysis of the incoming unknown files. A malware signature is generated for the incoming unknown files based on the particular malware classification and an access is provided to the malware signature.
[0017] In European patent 1959367A2, a method is disclosed for automatic generation of malware signatures from a computer file. The method determines an optimal cluster for generating malware signature and selects functions in optimal cluster as a malware signature.
[0018] The method includes creating a common function library (CFL). The functions of a computer file which does not contain a malware are extracted. The CFL is updated with new common functions while taking into consideration the remaining functions as candidates for generating malware signatures. The remaining functions are divided into clusters according to their location in the file. The optimal cluster for generating the malware signature is determined. The functions in the optimal cluster are selected as the malware signature.
[0019] These documents include basic heuristics which take into consideration text/string pattern signatures. The heuristics collect printable characters, email addresses, urls and names into a database. This is a much simpler task than determining frequently occurring byte signatures with variable length.
[0020] A problem with existing methods is the processing speed. These methods can make only offline traffic processing possible with very limited set of samples which implies less expressive results.
[0021] Another problem is the formal verification of the algorithm's effectiveness. Existing solutions are built from small heuristic blocks. Motif finding is an elaborate mechanism constructed from formally analyzed build blocks.
[0022] However, the usage of these algorithms in network related context is not straightforward due to several reasons. For example, the number of symbols in bioinformatics is four (4) in DNA, five (5) in RNA and nineteen (19) in amino-acid sequences for example. In a network case, a one byte (1-byte) representation of network traffic streams induces 256 different symbols. Moreover, the probability densities of these symbols in a network also differ from those of DNA, RNA, amino acids, etc.
[0023] The information disclosed above is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art.
SUMMARY
[0024] In an exemplary embodiment, a method of automatic signature generation for application recognition and user tracking over a network is disclosed. The method includes receiving a set of flows of Internet traffic, finding motifs in the Internet traffic, rating the motifs by looking them up in the set of flows of Internet traffic using sequence alignment to generate a sequence, creating clusters of motifs from the sequence and generating regular expressions (regexps) from the clusters of motifs to serve as traffic signatures. Aspects of the foregoing exemplary method may also include, prior to the step of finding motifs in the Internet traffic, estimating a Dirichlet mixture based on the flow of Internet traffic received and using said Dirichlet mixture to enhance said step of finding motifs in the Internet traffic. A second flow may be separated from the cluster of motifs having a 80% threshold of hits and the second flows having a 80% threshold of hits may be removed to create a third flow. The third flow may be combined with the motifs to form the sequence.
[0025] Aspects of the foregoing exemplary method may include repeating the steps of finding motifs, aligning the motifs, creating clusters of motifs and generating regexps occurrences until less than 10% of said flow of Internet traffic remains.
[0026] Aspects of the foregoing exemplary method may include pre-processing the flow of Internet traffic to reduce the volume of the flow of Internet traffic and create a filtered flow.
[0027] Aspects of the foregoing exemplary method may include the step of pre-processing by hashing the flow of Internet flows using a Rabin-Karp fingerprinting method to generate hashing results, extracting common substrings from the hashing results, generating signature candidates and removing padding from the signature candidates.
[0028] Aspects of the foregoing exemplary method may include post-processing the regexps occurrences to create a set of regexps.
[0029] Aspects of the foregoing exemplary method may include the post-processing by crosschecking generated signatures with other applications from the regexps occurrences to remove false positive results from the signatures, performing an offset distribution analysis of the signatures and checking for maximum coverage to achieve a global optimum in Internet traffic flow.
[0030] Aspects of the foregoing exemplary embodiment may include automatic signature generation being performed either offline, online, in real time, in a RBS, SGSN, or GGSN in a 3G network or a BRAS, or a DSLAM in a DSL network.
[0031] In another exemplary embodiment, an apparatus for automatic signature generation for application recognition and user tracking over a network receiving a set of flows of Internet traffic is disclosed. The apparatus includes a motif finding module, a sequence alignment module and a create motif clusters module. The motif finding module finds motifs in the set of flows of Internet traffic. The sequence alignment module rates the motifs by looking them up in the set of flows of Internet traffic using sequence alignment and generates a sequence. The create motif clusters module creates clusters of motifs from the sequence and generates regular expressions (regexps) from the clusters of motifs to serve as traffic signatures.
[0032] In a further exemplary embodiment, a computer program executable by a computer system and stored on a computer readable medium for automatic signature generation for application recognition and user tracking over a network is disclosed. The computer program receives a set of flows of Internet traffic, finds motifs in the Internet traffic, rates the motifs by looking them up in the set of flows of Internet traffic using sequence alignment to generate a sequence, creates clusters of motifs from the sequence and generates regular expressions (regexps) from the clusters of motifs to serve as traffic signatures.
[0033] The word “plurality” shall throughout the descriptions and claims be interpreted as “more than one”.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The several features, objects, and advantages of the invention will be understood by reading this description in conjunction with the drawings, in which:
[0035] FIG. 1 is a general systems diagram of users interfacing to and communicating with the Internet via ISPs;
[0036] FIG. 2 is a systems diagram illustrating Internet traffic flow being processed according to an exemplary embodiment of the invention;
[0037] FIG. 3 is a systems diagram illustrating the processing modules according to an exemplary one of a number of embodiments consistent with the invention;
[0038] FIG. 4 is a systems diagram of the processing modules used in regular expression construction motif finding according to an exemplary one of a number of embodiments consistent with the invention;
[0039] FIG. 5 is a performance chart comparing the methodology of the present invention used to determine through positive coverage versus other approaches;
[0040] FIG. 6 is a performance chart comparing the methodology of the present invention used to determine false positive coverage versus other approaches;
[0041] FIG. 7 is a systems diagram of the pre-processing modules according to an exemplary one of a number of embodiments consistent with the invention; and
[0042] FIG. 8 is a systems diagram of the post-processing modules according to an exemplary one of a number of embodiments consistent with the invention.
DETAILED DESCRIPTION
[0043] The following description of the implementations consistent with the invention refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
[0044] According to exemplary embodiments, an automatic application protocol signature generation system is provided. As illustrated in FIG. 2 , this automatic application protocol signature generation system would execute on a processor-based system such as server 200 . Server 200 is not limited to a single server or computer system, but may include any number of processor-based systems. As shown in FIG. 2 , Internet traffic flow is entirely transmitted to the ISPs 110 Internet service provider traffic management system 300 in which normal Internet traffic is received and processed. However, server 200 on which the automatic application protocol signature generation system executes receives a small sample of the Internet traffic flow for analysis which is discussed below. This automatic application protocol signature generation system is able to analyze the Internet traffic flow to provide for a trade-off between speed and signature expressiveness.
[0045] As described in further detail later, Motif finding and sequence alignment algorithms may be used for this task (i.e. for setting up the automatic application protocol signature generation system) as these algorithms are used in bioinformatics for extraction of frequently occurring signatures.
[0046] As illustrated in FIG. 3 , the automatic application protocol signature generation system consists of three major modules. A preprocessing module 600 which receives a byte stream from the Internet traffic flow as illustrated in FIG. 2 . This preprocessing module 600 generates a filtered traffic flow which is input to the regular expression construction motif finding module 380 . Thereafter, the regular expression construction motif finding module 380 generates a series of regular expression (hereinafter referred to as regexp(s)) occurrences which are input into the postproces sing module 780 which outputs the final regexps. It should be noted that the regular expression construction motif finding module 380 may operate without the preprocessing module 600 and the postprocessing module 780 . However, as will be discussed in further detail later, significant processing speed improvements can be realized through the incorporation of preprocessing module 680 and postprocessing module 780 .
[0047] As illustrated in FIG. 4 , an Internet traffic flow which may come directly from the Internet 100 , as illustrated in FIG. 1 and FIG. 2 , maybe input into the estimate Dirichlet mixture module 310 or a filtered Internet traffic flow may be provided by preprocessing module 600 , as illustrated in FIG. 3 . A Dirichlet mixture distribution may be used which is a weighted sum of Dirichlet distributions as discussed by K. Sjolander, K. Karplus, M. Brown, R. Hughey, A. Krogh, I. Mian, and D. Haussler, M.D. in a learned treatise entitled “Dirichlet mixtures: a method for improved detection of weak but significant protein sequence homology,” Computer Applications in the Biosciences, vol. 12, no. 4, pp. 327-345, 1996 (incorporated herein by reference).
[0048] The motif finding module 320 and sequence alignment module 330 may be applied to construct regular expressions from the network traffic. Specifically, the motif finding module 320 may be accomplished as shown in FIG. 1 , of the learned treatise by Wenxuan Zhong, Peng Zeng, Ping Ma, Jun S. Liu and Yu Zhu entitled “RSIR: Regularized Sliced Inverse Regression for Motif Discovery” in Bioinformatics Advance Access Published by Oxford University Press (2005) (incorporated herein by reference). Further, the sequence alignment module 330 may be accomplished as described in the learned treatise entitled “Sequence Alignment: Methods, Models, Concepts, and Strategies” by Michael S. Rosenberg et al., (incorporated herein by reference). As previously discussed, the input of the system may be network traffic that has been collected. It may either be an application-aware active measurement or the capture of the traffic at an aggregating measurement point. If the input traffic is classified according to protocols (such as IMAP, HTTP, Bittorrent, etc.), the generated application signatures can be associated with applications.
[0049] The signatures are typically expected to be at the beginning of the flows if the traffic belongs to signalling or control traffic of an application. In other cases, the signatures can be anywhere in the byte stream. Since protocol messages, such as a large HTTP request for example, may overlap several packets, more than one packet has to be considered. Too many packets may result in too much data that has to be analyzed. In order to reduce the number of packets to be analyzed, only the first ten to one hundred (10-100) packets of each flow may be stored. The storing of the first 10-100 packets of each flow is applicable both in cases where the signatures are in a fixed position or in cases where they can be anywhere in the byte stream.
[0050] The packet traces may be utilized to reconstruct byte streams. That is, the order of the packets has to be rearranged taking into consideration retransmissions for example.
[0051] A motif is a possible gapped sequence of key positions which is a re-occurring semi-deterministic sequence pattern found in multiple sequences generated by the same source. Key positions hold symbols (sequence elements) that are important for the motifs function.
[0052] The prior distribution of the symbol appearances may incorporate prior knowledge of the functional similarities between symbols. As previously discussed, in order to accomplish this, a Dirichlet mixture distribution may be used which is a weighted sum of Dirichlet distributions.
[0053] The reconstructed flows (corresponding to the first 10 to 100 packets of the flow that are stored) may be provided as input to the Dirichlet mixture estimation module 310 . The output of the Dirichlet mixture estimation module is a Dirichlet mixture.
[0054] The Dirichlet mixture and the reconstructed flows may be provided as multiple sequences (as inputs) to the motif finding algorithm.
[0055] A number of motif candidates may be established and each of these motif candidates may be compared to each of the input flows/sequences. The comparison of a motif candidate with an input sequence results in an alignment score. As a motif candidate is compared to each of the input flows/sequences, the alignment score for the motif candidate is accumulated. This process is repeated for each of the motif candidates. The output of the motif finding module 320 is a motif having the best alignment score on the given input sequences. That is, the motif candidate with the highest accumulated alignment score is selected.
[0056] In order to find the flows in which a hit occurred with the selected motif, sequence alignment module 330 may be applied on the flows with the motif candidate (i.e. motif candidate having the highest accumulated alignment score). That is, each of the flows may be compared with the selected motif candidate. The output of sequence alignment module 330 is a list of flow ids, starting and ending positions of the match in the decreasing order of the matching scores.
[0057] Since it is desirable to obtain signatures for regular expression matching, all the appearances of the motifs in the original flows may be collected by saving the substrings in the positions indicated by the sequence alignment process. The byte values on the same positions with multiple occurrences may be collected and a regular expression may be created by putting an OR operator between them. A similar method is used in “MEME-suite [2010],” discussed on website (http://meme.nbcr.net/meme4 — 3 — 0/doc/examples/meme example output files/meme.html) (incorporated herein by reference) for motif to regular expression conversion.
[0058] Applications typically have several protocol messages. In an extreme case, one particular motif could describe all protocol messages but the total alignment score would be lower than when the protocol messages are clustered and several motifs are defined for the message clusters. Motif clusters are created by the create motif clusters module 340 by defining the clusters based on the alignment scores.
[0059] Flows scoring at least 80% of the maximum value may be considered. These flows (the ones meeting the 80% threshold) are separated from the original set of flows and the whole regular expression construction process may be started over once the motif clusters have been created with the removal of flows with a hit accomplished by the remove flows module 350 which are then redirected back into the motif finding module 320 until no flows remain or some other threshold is achieved as illustrated in FIG. 4 .
[0060] The process (i.e. the regular expression creation process) as described above may be shortened (or made faster) with the implementation of a pre-processing module 600 as detailed in FIG. 7 , in the current exemplary embodiment of the present invention.
[0061] Referring to FIG. 7 , in the pre-selection and Rabin Karp fingerprinting module 610 of the pre-processing phase, a fast, memory efficient technique may be applied to reduce the input size of the raw traffic significantly by filtering out substrings that occurred only once in the raw traffic.
[0062] One way to accomplish this is to create hashes from the content of a sliding window. The size of the hash table can be estimated and limited in order to control memory consumption. Then, by flagging each hash value seen, a determination can made as to whether a certain substring has been encountered. In order to correctly detect substrings shorter than the window size (W len ), a separate hash table for all string lengths below W len is needed.
[0063] As previously discussed, the hash algorithm used may be the Rabin-Karp fingerprinting module 610 is described in Earlybird.
[0064] The pre-selection and Rabin Karp fingerprinting module 610 passes a substring to a second step of the pre-processing phase only if it has already been seen more than once. The output of the pre-selection and Rabin Karp fingerprinting module 610 may contain longer substrings divided into shifted smaller substrings occurring multiple times in the output. Therefore, common substring extraction and variable depth pre- and postfix word trees module 620 is included to collect the same pre-fixes and post-fixes into the longest common substring. In this manner, the input to the motif finding module 320 may be further compressed.
[0065] In the common substring extraction and variable depth pre- and postfix word trees 620 illustrated in FIG. 7 , common substrings from the input streams may be extracted. This may be accomplished by running a fixed length sliding window (of length W len ) over the input and inserting all window content into a tree and counting the times each string has been inserted. Each node in the tree may represent a substring which is not longer than W len . By summing the counters on the leafs of each sub-tree below a node, the frequency of occurrence in the input stream of the prefix represented by the node can be determined.
[0066] A list of substrings that occurred more than O min times may be generated. When one of two substrings is a prefix of the other, only the longer one is considered except if the shorter one occurred at least O min times more than the longer one.
[0067] For example, if “abcde” occurred 10 times and “abc” occurred 30 times, it can be deducted that 10 out of the 30 occurrences of “abc” were as part of “abcde”. If O min is 15 for example, “abc” will be printed (or output) with 20 occurrences (since “abc” occurred 20 times more than “abcde” which is more than the O min of 15). The resulting substrings may then be checked in the reverse direction once more to eliminate those which are postfixes of another string that is present.
[0068] The pre-processing module 600 may be run in a second pass on the input stream to detect common substrings longer than W len . In this case, only those window contents which are preceded in the input by one of the substrings of maximum length (W len ) resulting from the first pass may be considered. If many occurrences of such a substring (always following the same W len length substring from the first pass) are detected, this (i.e. common substrings longer than W len ) can be concatenated to the substring from the first pass. This process can be repeated in multiple passes to detect even longer common substrings. The result of the whole tree operation is a list of common substrings with an occurrence count.
[0069] A possible bottleneck in the prefix tree construction operation may be seen in memory consumption during the first pass. Thus, W len has to be chosen as a function of the available memory. Many of the window contents may occur only once; yet, they may all be inserted into the tree. This limits the length of the window (W len ) and lengthens the process.
[0070] The output of the common substring extraction and variable depth pre and postfix word trees 620 is substring candidates with occurrence values. Motif finding may still be needed as there are several practical examples in which (e.g., the middle of a signature) there is a sequence number that takes all the possible 256 values of a byte many times (over the minimum occurrence threshold). These cases can not be handled with the common substring extraction and variable depth pre and postfix word trees 620 alone.
[0071] Feeding the substring candidates to the motif finding module 320 may cause the loss of the occurrence information. A specific substring with high number of occurrences but with few substring variants may not be found by the motif finding module 320 . These signatures (i.e. specific substrings with high number of occurrences but with few substring variants) should be added to motif clusters later. For example, if “abc” occurred 100 times and each of “efxg”, “efyg” and “efzg” occurred 10 times, then the motif finding algorithm in this step would find with the last three, as a motif (“ef.g”) can be found for them and does not consider the first one.
[0072] The output of the common substring extraction and variable depth pre- and postfix word trees 620 often contains signature candidates with long padding (for example, “00” and “ff” runs) in the network messages. Frequently, some optional fields are unused or unset in a protocol or reserved for later usage which results in long zero runs. The motif finding module 320 cannot judge which zero runs are part of a signature or which zero runs are only padding. These long zero runs are not considered to be part of the signatures. Therefore, the remove paddings module 630 is used to removing padding (i.e. the zeroes forming the padding).
[0073] The remove paddings module 630 may be added to the pre-processing phase to remove these zero runs. The remove paddings module 630 of pre-processing module 600 on the signatures skips all the forthcoming zeros in case of two zero bytes (i.e. two consecutive zero bytes). At the following non-zero byte, the collection of a new signature may start. The original signatures may thus be split by the double zero bytes. The same may be performed for the “ff ff” bytes.
[0074] The signature candidates yielded by motif finding module 320 are frequently occurring signatures in the given traffic. In order to further refine and restrict the signatures to the most valuable candidates, several post-processing phases may be applied in the exemplary embodiments of the present invention.
[0075] Referring to FIG. 8 , the crosscheck generated signatures with other applications 710 in the post processing module 780 is the cross-check of the resulting signature candidates with other applications. Those signatures which can lead to false positive results should be removed.
[0076] The offset distribution analysis 720 of the post processing module 780 gathers additional information about the positions of signatures in specific byte streams of flows or packets.
[0077] The offset distribution analysis 720 receives the signatures and the flow list as input and provides the following information per signature: the number of occurrences the given signature occurred at a specific offset considering all the flows; the total number of matches of the specific signature (considering multiple times a multiple match per flow); the number of matches of the specific signature in different flows and the number of different users with hits.
[0078] The resulting signature set has often overlapping coverage on the flow set meaning that for one given flow, there are several signatures which occurred. This overlap is non-optimal for the DPI process as it has to check several signatures for the same hit ratio. In the check maximum coverage module 730 of the post-processing module 780 illustrated in FIG. 8 , the minimal signature set which gives maximal flow, volume or user coverage is selected.
[0079] This check maximum coverage module 730 is called the weighted maximum coverage problem and considered to be NP-hard as discussed in the learned treatise by V. V. Vazirani, “Approximation Algorithms”, New York, N.Y., USA: Springer-Verlag New York, Inc., 2001 (incorporated herein by reference). A global optimum can be reached only by brute-force method comparing the coverage of every possible signature set.
[0080] Several p2p files-sharing and streaming applications (such as for example, winny, share, keyholetv, etc.) transmit encrypted protocol messages. In a particular type of communication, obfuscated user communication, id information during the connection of other peers is sent several times from the dedicated port of the application. The method according to exemplary embodiments may be provided with the filtered traffic of dedicated ports and the existence of such frequently occurring user specific identifier is a strong clue for the identification of the above traffic types (i.e. winny, share, keyholetv).
[0081] The post-processing module 780 has to be exchanged with the cross-checking of high user coverage with the opposite: the only signatures that are acceptable in this case which has coverage only for one specific user.
[0082] If measurements are set up at several measurement points in the network of several ISP even with different access types (for example, both in a mobile and in a fixed network), the user traffic over the network may be tracked. Based on the raw network traffic, the users can be identified with MAC address in the fixed network and with an IMSI in the mobile network. Other, higher level subscriber information (e.g., name, address, telephone number) is usually unavailable due to privacy and other legal issues. Exemplary embodiments as described above can obtain user specific identifiers such as, for example, chat, email, peer login names and makes the association possible.
[0083] The advantage realized by exemplary embodiments as described above, such as the motif finding system being extended with the pre-processing phase, can achieve high flow coverage ratio with low CPU occupancy period. A systematic comparison of the quality of generated signatures in each phase and also to a state-of-the-art tool indicates that more expressive signatures are obtained in a shorter period of time than the state-of-the-art tool to the order of two magnitudes.
[0084] As illustrated in FIG. 5 and FIG. 6 as well as Table 1 listed below, faster processing and the increase in signature expressiveness are so significant exemplary embodiments provide new use cases in traffic classification such as, for example, online per-user signature generation.
[0000]
TABLE 1
A
P
MR
PMR
M
Speed [flow/sec]
0.02
12.76
0.16
3.38
0.16
Avg. sig#
51.43
171.23
13.6
29.3
9.17
[0085] Table 1 illustrates the speed and average number of generated signatures of the various methods, such as, AutoSig (A), Pre-processing (P), Motif to Regexp (MR), Pre-processing and Motif to Regexp (PMR) and Motif (M).
[0086] It will be appreciated that the procedures (arrangement) described above may be carried out repetitively as necessary. To facilitate understanding, many aspects of the invention are described in terms of sequences of actions. It will be recognized that the various actions could be performed by a combination of specialized circuits and software programming.
[0087] Thus, the invention may be embodied in many different forms, not all of which are described above, and all such forms are contemplated to be within the scope of the invention. It is emphasized that the terms “comprises” and “comprising”, when used in this application, specify the presence of stated features, steps, or components and do not preclude the presence or addition of one or more other features, steps, components, or groups thereof.
[0088] The particular embodiments described above are merely illustrative and should not be considered restrictive in any way. The scope of the invention is determined by the following claims, and all variations and equivalents that fall within the range of the claims are intended to be embraced therein.
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An apparatus, method and computer program of automatic signature generation for application recognition and user tracking over a network is described. This apparatus, method and computer program receive a set of flows of Internet traffic, find motifs in the Internet traffic, rate the motifs by looking them up in the set of flows of Internet traffic using sequence alignment to generate a sequence, create clusters of motifs from the sequence and generate regular expressions (regexps) from the clusters of motifs to serve as traffic signatures.
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This is a continuation of application Ser. No. 09/045,750, filed Mar. 20, 1998 now U.S. Pat. No. 6,198,206.
The present invention relates generally to sound generating signal units such as loud speakers and tone generators, and also relates to buzzers, vibrators and devices used for generating a vibration or inertial signal which may be felt or sensed while not producing a highly audible sound. Assemblies of this latter type in the prior art are used, for example, to signal a query by or an active state of a beeper, pager or alarm system, or to otherwise indicate an attention-getting state of a consumer device.
A number of reasonably inexpensive and effective constructions have evolved in the prior art for providing signal units to generate the necessary tones or vibrations for these devices. These include miniature motors with imbalanced rotors to create a sensible vibration; small piezo electric assemblies to vibrate at an audio frequency and create a tone or beep noise; and other, older technologies such as speakers with an electromagnetic voice coil, or a magnetic solenoid driving a diaphragm to create a sound such as an audio tone or a vibratory buzz.
In general, each of these technologies or its method of incorporation in a device has certain limitations such as requiring a high voltage driver or a relatively high current driver; imposing penalties of weight and/or size; increasing the difficulty or cost of assembly into the electronic apparatus in which it is to operate; or requiring special engineering to increase the hardiness or lifetime of the device when installed for its intended conditions of use.
Thus, for example, as applied to an item such as a hand-held pager, which is required to be of extremely small size and low electrical power consumption, yet which is frequently dropped and subject to extreme impact, the defined constraints do not favor either electromagnetic motors, which require a comparatively large amount of electrical power, nor piezoelectric elements, which are sensitive to shock and generally require a case or other structural support to sustain vibration without suffering electrode detachment or crystal breakage. Nonetheless, such sub-assemblies are commonly used in devices of this kind.
Moreover, piezoelectric assemblies have been used for a variety of tone-generating tasks, both in earphones, and in larger, more complex, speaker constructions. In U.S. Pat. No. 5,638,456 one method has been proposed for placing piezo elements on the cover or housing of a laptop computer to form an audio system for the computer. Proposals of this type, however, must addresss not only the problems noted above, but may be required to achieve a degree of fidelity or uniformity of response over their tonal range which is competitive with conventional speaker technologies. Such a goal, if achieved, may be expected to necessitate an unusual mounting geometry, a special cavity or horn, a compensated audio driver, or other elements to adapt the piezo elements to their task or enhance their performance. Thus, not only the sound generator, but its supporting or conditioning elements may require mounting in the device, and these may all require special shaping or other adaptation to be effectively connected to, or to generate signals in, the device.
There is therefore a need for an efficient and durable signal generator which is better suited to the electrical devices of modern consumer taste.
Accordingly, it would be desirable to provide an improved signal generator effective for producing audio or inertial signals.
It would also be desirable to provide a sound/inertial unit of simple construction but readily adapted to device housings of diverse size and shape.
It would also be desirable to provide a sound/inertial unit of simple construction but adapted to processes of manufacture with the device housing.
It would further be desirable to provide such a sound or inertial generator assembly adapted to simplified and more effective installation in a consumer device.
SUMMARY OF THE INVENTION
These and other features are obtained in an audio/inertial signal generator in accordance with the present invention, wherein an actuator includes an electrically actuable member formed of a material such as a ferroelectric or piezo material, which generates acoustic or mechanical signals and is mechanically in contact with a body of polymer material. In one embodiment the member is assembled to a region of a wall or surface, for example, of a housing, and imparts energy thereto. The electrically actuable or piezoelectric member, which may for example cover a region having a dimension approximately one half to three or more centimeters on each side, is preferably compression-bonded to one or more electroded sheets, such as flex circuits, or to a patterned metal shim or the like, which enclose and reinforce the material while providing electrical connection extending over the signal generation unit. The lamination or compression bonding provides structural integrity, for example by stiffening or binding the member, and prevents structural cracks and electrode delamination from developing due to bending, vibration or impact. This construction strengthens and enables the piezo member, which is preferably a sheet or layer with relatively large length and width dimensions compared to its thickness, to be actuated as a single body and engage in vibration or relatively fast changes of state, or more generally, to produce electrically driven displacement, deformation or vibration of the device. That is, it effectively transmits acoustic or mechanical energy through the housing to which it is attached. The structure is adapted for assembly or forming with the housing, and may be installed by cementing together or by a spot fastening process. Preferably, however, the actuable member is formed with or manufactured into the wall or housing by a process such as injection molding wherein the molded body of the device is formed into all or part of a bounding surface of the signal generator, or wherein a solid block of polymer holds the actuable assembly and is itself joined to the housing by fasteners or compatible bonding agents.
The piezo member has the form of a thin layer or sheet, which may extend in a branched or multi-area shape, and may be fabricated with both mechanically active regions and non-mechanically active, or “inactive”, regions. The active regions contain electroded electroactive material, whereas the inactive regions may be regions disjoint from the mechanically active regions and may be shaped or located to position and provide structural support and/or electrical pathways, e.g., mounting hole and electrical lead-in connections, to the active regions. The inactive regions may include non-electroded electroactive material, or may lack the material altogether and contain only electrical lead-ins, cover film, or the like. Portions of the signal unit may be pinned in an injection mold and a device housing then molded about or adjacent to the unit, or else may be positioned and then cemented or thermally bonded to the housing after the housing has been molded, thereby simplifying fabrication of the final device. In one embodiment, the signal unit is a vibrating beam or sheet which may be pinned, clamped or otherwise attached at one or more positions along its length, leaving a portion free to displace and create inertial impulses which are coupled to the housing at the fixed or clamped portion. In that case, the fixed portion may be defined by a block of polymer material molded about the electroactive assembly, thus providing an inert and machinable or clampable region for affixing to the device. In another embodiment, the unit is fastened to or contained within a wall of the device's housing, and couples energy thereto such that the wall acts as a tone-radiating surface. The unit is preferably mechanically connected over a major portion of its surface and activated to produce waves in the attached housing, so that the housing itself forms a novel radiating surface. The signal assembly may have plural separate active regions which are connected, in common or separately, to different portions of the housing wall, and which may be operated variously as sensing switches, audio speakers covering one or more frequency bands, or tactile sub-audio signal indicators. The separate active regions may also be attached to the housing at separated positions and be driven in phased relation to more effectively create particular excitations of regions of the wall , or may be driven as independent pairs to produce stereo sound.
In one exemplary embodiment, the housing is the housing of a laptop or other computer, and the signal assembly includes two flat piezo transducers, each having one or more active regions for producing audio vibration, and which are co-fabricated with the housing by a molding or thermal bonding assembly process to form stereo audio emitters. In another embodiment, the housing is the body of a computer mouse and the generator is coupled to provide sensible disturbances in a button or face of the mouse, or to sense applied force and produce an electrical signal therefrom. In yet another embodiment, a generator is coupled to the housing of a pager or cellular phone in a manner to flex the thin housing wall, such that the housing provides both an inaudible inertial stimulus, and an audibly projected tone for signaling the user, optionally with a strain sensing functionality.
A method of manufacture includes designing a flexible piezoelectric package having an active region with a two-dimensional shape matching one or more faces of a housing, and attaching the package to the housing such that the face or faces radiate audio and/or inertial vibration when the package is energized. A region of the package may also act as a control transducer when the housing is stressed.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will be understood from the description below taken together with the drawings illustrating exemplary embodiments and illustrative applications of the present invention, wherein
FIG. 1 shows one embodiment of a signal unit of the present invention and a method of its fabrication in a device;
FIG. 1A shows another embodiment having separate transducer regions of different type;
FIG. 2 illustrates details thereof;
FIG. 2A illustrates details of a manufacturing mold and fabrication steps;
FIG. 3 illustrates an inertial or audio embodiment of the signal unit of the invention;
FIG. 3A illustrates another inertial or audio embodiment formed as a hybrid sub-assembly;
FIGS. 3B-3D illustrate further embodiments useful for inertial and other signal generation systems;
FIGS. 4 and 4A another embodiment useful for stereo audio systems; and
FIGS. 5A and 5B show further embodiments; and
FIGS. 6A-6L show representiative embodiments in consumer electronic devices.
DETAILED DESCRIPTION
As shown in FIG. 1, one embodiment of the signal unit of the present invention includes a signal actuator 10 , which, together with its electrical connections, is mounted in a consumer electronic device, such as a cellular telephone, a beeper, a computer, or an accessory thereof. The signal actuator 10 in the illustrated embodiment has a generally sheet-like form, having approximately the dimensions of a credit card, and is itself assembled or formed with an upper ply or skin 10 a , a middle layer 10 b , and a lower ply or skin 10 c . The middle layer 10 b includes an electroactive material, such as a piezoceramic material which may, for example, be a piezo-fiber-filled composite material, a sintered piezoceramic sheet material, or other body of piezoelectric material with suitable actuation characteristics as discussed further below. In the illustrated embodiment, the signal actuator extends over an area, which as illustrated, is about the size of several postage stamps. As will be clear from the discussion of specific applications below, its size may range from several millimeters on a side, to several centimeters or more on each side, but the piezo material is in each case a relatively thin layer, under several millimeters and typically about a one eighth to one half millimeter thick. In some embodiments, the actuator is formed with several such sublayers of material laminated together to constitute the overall sheet actuator 10 . For simplicity of discussion below, the electroactive material shall be simply referred to as piezoceramic material, since piezoceramic is readily available and possesses suitable actuation and mechanical properties.
Each of the outer layers 10 a , 10 c includes conductive traces or conductive material for establishing electrical contact with the piezoceramic material, and preferably also a continuous sealing layer such as an insulating support film or a thin metal shim, which in the latter case may be the conductive layer itself. One suitable construction for forming such a piezo area actuator is shown in commonly-owned U.S. Pat. No. 5,656,882, which is hereby incorporated herein by reference in its entirety. That patent describes a general technique for laminating conductive and sealing layers about one or more central layers of piezoelectric material to form a ruggedized and free-standing assembly capable of repeated in-plane strain actuation and bimorph bending actuation. The actuator need not be a simple rectangle or convex shape, but may include a number of separate actuation regions, interconnected by inert portions of the flex circuit layers that position the regions in relation to each other and provide necessary electrical junctions. Such a shape is shown, for example in FIG. 6 of commonly-owned U.S. patent application Ser. No. 08/760,607 filed on Dec. 4, 1996, wherein an F-shaped planar actuator assembly has two active cantilevered arms each containing electroactive material, and connected by intervening regions of flex circuit lamination that contain no fragile material and may be clamped to position the assembly or bent to align the unit before clamping. The 08/760,607 application is also hereby incorporated herein by reference in its entirety. The device illustrated therein also has other regions of its flexible sheet structure which further lack conductive traces and may be punched, drilled, cut or clamped as necessary to fit, align and hold the assembly without impairing its basic mechanical or electrical properties. The above-described actuator fabrication techniques are of broad generality, and may be applied to units wherein the active material comprises sintered piezoceramic sheets, piezopolymer layers, or constructions involving composite piezo material, such as piezo fibers, flakes or powders; these latter may, for example be arrayed to enhance the magnitude or directionality of actuation, or their overall control authority or strength.
In the present construction, the signal assembly is either preformed, for example by the aforesaid techniques, or else a partial piezo assembly is formed including at least one surface /electrode cover layer, and the partial actuator assembly is added to or completed by an injection molding, laminating or assembly process so that a polymer body or shell, e.g., the housing wall 20 , constitutes a further covering, co-acting or enclosing layer. Furthermore, as discussed below in relation to some embodiments of the methods of this invention, one of the outermost layers may have a modulus or mechanical property effective to act against the strain of the piezo assembly and to form a monomorph or bender when integrated with the active signal assembly, so that when the electrodes are energized, bending occurs in the wall 20 and flexural or plate waves are formed. The invention also contemplates constructions wherein several piezoceramic layers are formed into a bimorph assembly, which by itself can be actuated to achieve plate deformations such as bending, and these are coupled into the wall.
Returning now to FIG. 1, as further shown in that Figure, outside of the region occupied by the piezoceramic member 10 b , the module 10 possesses registration points, illustratively alignment holes 11 and notches 12 , which by virtue of its sheet structure are simply formed by a stamping, punching or bulk milling process, or any of the patterning techniques common in circuit board fabrication or microlithography. The module 10 also includes electrical leads 13 , visible through the outer film, which extend to connectors 13 a such as pin socket ribbon cable connectors. Suitable methods of fabricating the module 10 are shown in the aforesaid commonly-owned U.S. Pat. No. 5,656,882 issued Aug. 12, 1997 of Kenneth B. Lazarus et al. That patent describes laminating techniques for forming a free-standing or self-supporting piezo element which is packaged into a card that provides strain actuation over its entire surface. Unlike, for example, arrays of ultrasound-emmitting points, the overall construction is directed to a transducer wherein a broad surface region is to be strain-actuated all at once, and the techniques described therein were found to overcome problems of breakage and delamination in area-type thin sheets. The present invention further incorporates electroactive units in devices and assemblies to which the material is mechanically coupled with an effective inertial or acoustic coupling.
As mentioned above, the constructions of the present invention also include constructions involving bonding one or more electroactive layers to flex or sealing layers which may amount to a less complete package, in which one or more piezo layers are unitized or strengthened, and electroded, sufficiently to be handled, aligned and positioned, and the actuation sub-assembly is then assembled into a housing or sound board by being molded together with or laminated with the device, or into an assembly that is asymmetric about the neutral axis of the piezo layer(s), to provide bending beam, wall flexure or cantilever actuation as coupled to the housing. In this regard the invention also includes constructions in which a piezo bimorph is assembled, for example according to the teachings of the aforesaid patent, and is attached at one or more discrete points, bands or regions so that the bimorph moves and transfers impulses to its points of attachment or contact.
Relevant teachings for this aspect may also be found in the aforesaid commonly-owned and co-pending U.S. patent application Ser. No. 08/760,607 entitled Valve Assembly. That patent application shows representative geometries for providing a piezoelectric/flex circuit sheet assembly mounted as a cantilevered beam that moves a blocking member or mass suspended over a valve or flow opening in a device housing. In accordance with a further aspect of the present invention, discussed more fully below in connection with FIG. 3, by substituting a proof mass for the blocking member and driving the beam to oscillate, such an assembly forms an inertial signal generator.
Continuing with a description of FIG. 1, the housing 20 is illustrated as a thin-walled shell, such as may commonly be formed by injection molding of a thermoplastic material, a contoured box, can, shell or tray-like cover or curved enclosing surface. Examples of such housings or shells are, for example, cases of paging units or cellular telephones, cases of laptop computers, housings of computer mice or hand-held information indicating, switching, tuning or drawing devices, and those of hand-held or carried music playing, radio, or facsimile modem or communication devices. The illustrated shell 20 is substantially rectangular, and includes a first recess 22 and a second recess 23 into which are fitted respective modules 10 . As shown in phantom for the left unit, a flex-circuit portion 15 of the module 10 extends as an alignment or positioning flap from the active central portion of the module 10 . Flap 15 may be formed without the internal layer of piezo material, and it is used for mounting or temporarily positioning the assembly, with registration features 11 , 12 . Each module 10 also contains a connector 13 a , which may for example be a socket, edge connector, or stiff conductive land region, although as noted above several regions may be interconnected by flex conductors, in which case only a single socket is required to energize the distinct regions of piezo material.
As indicated by the schematic exploded view of FIG. 1, the module 10 and housing 20 are preferably mechanically interconnected by being formed together during manufacture, for example by a molding process such as injection molding together between portions 30 , 32 of an injection molding die. In this method of fabrication, the module 10 , including piezo material and at least one lamination of the electrode/strengthening material is positioned and aligned in the cavity of the mold die, for example, by being placed in a recess in one side of the multi-part die assembly, or held by pegs projecting from the wall of the mold cavity. The housing shell 20 is then formed about or against the module 10 by injecting a fluid or plastic polymer material through one or more die inlets 30 a , 30 b , 32 a , 32 b which open into the cavity. Preferably, one wall of the cavity provides support for the module 10 during fabrication, especially when the fabrication is performed by a high pressure injection process. In the illustrated embodiment, the modules 10 may be supported in half-height recesses in the upper die body, so that the plastic mold material covers at least one face and in the finished assembly the modules are partially or entirely embedded, e.g., for half their height, in the surface of the housing 20 . The recess thus positions and aligns the module 10 . Furthermore, the extent to which the module projects from the die and is thus recessed into the molded wall of the housing results in a corresponding thinning of the adjacent region of the housing wall, rendering it more suitable for vibrational actuation. In this case, the presence of the module contributes to strength of the housing wall while allowing it to enjoy better acoustical transmission.
In a representative embodiment for actuation as an audio speaker, modules 10 having a size of approximately one by three inches formed about a single seven mil thick layer of PZT (lead zirconium titanate) piezo material were employed, encasing the piezo within flex circuit material as described in the above-referenced '882 patent, and attached to housing 20 having an overall wall thickness of approximately one half to two millimeters. The polymer constituting the housing wall is substantially less stiff than the unit 10 , which, because of its small thickness dimension, produces a significant strain only along its in-plane axes. Since the surface of module 10 was continuously joined to the adjacent polymer material of the wall, actuation of the piezo produced substantial flexural excitation of the housing itself, causing the housing to act as a speaker and permitting its use for audio sound production.
FIG. 1A shows another embodiment wherein an active signal generation module 10 is mechanically in contact with a housing 20 . In this embodiment, the module 10 has a first portion 1 and a second portion 2 each disposed in a different region of the sheet. Portion 1 is mounted so that its sheet structure is attached at discrete points, illustratively on posts or stand-offs 3 extending from the housing 20 , while portion 2 has its full face affixed to the wall of the housing, in a construction similar to that of FIG. 1 .
FIG. 2 shows a partial section through the signal generator of FIG. 1 or the region 2 of the device of FIG. 1A, illustrating one aspect of this construction. As shown, the piezo material covers a region of the wall, and is located asymmetrically toward one side of the wall, i.e., is attached at the inside surface of the wall. Furthermore the wall thickness is preferably somewhat greater than the thickness of the piezo material as shown, but is nonetheless sufficiently thin so that it is effectively flexed or vibrated by the actuator. In general, when a piezoceramic is used and a polymeric housing is employed, the wall will be appreciably less stiff than the actuation material of the signal generator.
In the above-mentioned commonly owned patents and patent applications, the use of relatively stiff and strong flex circuit materials, such as polyimide, polyester or polyamide-imide materials is preferred for making free standing piezo actuators. In the present construction, however, materials constraints may be relaxed since the assembly is to be supported by the device housing. In the construction of FIGS. 1-2, for example, once the assembly is attached to the wall 20 , the wall itself will normally be effective to limit deflection of the material to below its breaking limit. Preferably for audio actuation a thin piezo layer is used, about one to three tenths of a millimeter thick, and the housing or device wall that it actuates is a wall about one to three times this thickness. Overall, the wall thickness is kept small, but its area is relatively large, so as to effectively couple vibration and transmit sound into air, or, in the case of a sub-audible signal, is sufficiently big to provide a touch-sensible flexing region.
Another consideration in the overall construction is to obtain a sufficiently strong level of adhesion between the actuator and the wall. When the actuator is to be separately cemented onto a pre-formed housing, this is achieved by using an adhesive that is compatible with the surface materials of the housing and actuator, and clamping the broad faces against each other. When assembly is performed by molding the housing about the actuator sheet or with one surface entirely in contact with the actuator sheet as discussed above, then effective mechanical continuity can be achieved, even when using a stiff smooth surface layer such as a polyimide flex circuit material for the actuator, by first coating the outer surface of the actuator with an adhesive that is compatible with both the circuit layer and the injected plastic material, and then molding the housing in contact with the coated piezo assembly so that both are secured together. In one prototype of a unit as shown in FIG. 1, the piezo material was formed into an electroded actuable unit using a polyester film cover layer, and a one mil thick sheet of adhesive was placed over the polyester which was then positioned in the injection mold. Integration with the housing was effected by injection molding of a heated polycarbonate plastic matrix at several thousand psi pressure while the piezo assembly was fitted in the face of the injection molding cavity. Other thermoplastics, as well as materials such as rubber, curable polyimide, epoxy or curable liquids may be used to good effect, and the use of fluid or less viscous materials may be effective for low pressue forming, such as casting techniques. Also, when a relatively penetrating curable liquid is used, the construction may eliminate certain electrode, enclosing layers, or adhesive layers from the sheet actuator assembly, and achieve sufficient strength and conductivity with metallized piezo elements embedded in the cured molding or casting. When the matrix material cures by cross linking or drying, this effect may also serve to place the piezo material under compressive stress and enhance its longevity and elastic actuation characteristics. The invention also contemplates constructions wherein the housing is formed by a process of laying-up a composite fiber/binder shell, such as a glass-epoxy or graphite-binder lamination procedure, to form a wall structure in which one or mores modules are sealed within, partly embedded, or surface-attached to, the composite body.
A further desirable structural arrangement achieved with the construction of FIG. 2 is that by placing the module 10 in a construction wherein its full face, or a full region of a portion of a face, is affixed over a continuous area of the housing, the actuation of the module can produce in-plane strain wherein relatively large displacements are developed over its extent and a monomorphic bending action, or flexural excitation, of the housing wall is achieved. This allows the construction, when actuated at a low frequency, to form a silent but tactile actuation of the housing, with an effect similar to that of the conventional imbalanced rotor signal units of the prior art.
When forming the device by injection molding at elevated pressure and temperature, the mold is preferably operated to avoid excessive force on the piezo, and to avoid subjecting the piezo to excessive heat. FIG. 2A shows in cross section this fabrication method. Mold forms 30 , 32 are brought together to define a mold cavity 33 between opposed faces 30 b , 32 b , and a mass of forming material 40 is introduced into the cavity to fill the available space. The mold body is configured so that one surface 30 a , 32 a of each half fits tightly against the other, and seals, so that the cavity is closed and the material 40 assumes the thin extended contoured shape of the remaining space in the mold cavity. The actuator assembly is fitted into a recess 32 c in the surface 32 b so that it is out of the turbulent injection flow path and is closely and uniformly supported against surface pressure. In the illustrated mold assembly, a material inlet 50 includes an inner material passage 55 controlled by a valve 51 to selectively open an outlet orifice 55 a of a supply conduit 52 that opens to the interior of the cavity. A heater 53 surrounds the conduit 52 and maintains the plastic material at a temperature to keep it sufficiently fluid at the flow pressure involved, which may, for example be several thousand psi. Preferably, however, the mold itself resides and is maintained at a low temperature which is, for example, below the Curie temperature of the electroactive material. Thus, in a molding process where the temperature of the matrix is raised to form its shape, the recess 32 c forms both a mechanical support and a thermally protective sink for the assembly 10 . Using such an arrangement, a polycarbonate material may be dependably injection molded at a temperature of about 300° F. at pressures of 13.5-15 Kpsi without damaging the piezo material.
In the mold assembly illustrated in FIG. 2A, a single orifice 55 a is shown. It will be understood, however, that multiple material inlets may be provided, as well as one or more closable sprues or vents, to assure complete filling of the cavity. Overall, the mold may be configured to quickly fill and quickly cool down the injected material, so that the electroactive material does not experience the high initial temperature of the injection melt. Preferably, the material inlets and vents or outlets are arranged so that the moving flow of material acts only against a fully supported actuator sheet, thus minimizing the possibility of breakage. For this purpose, the recess 32 c can be quite shallow, or may be absent altogether. In the absence of a mold face recess, the partially assembled module 10 can be temporarily held in position in the cavity by retractible or fixed alignment pins or by a spot of contact adhesive, or by any other suitable means.
In other embodiments, the module 10 may be fastened to the housing by the flap portion 15 , while the active signal portion is attached—e.g., cemented or injection molded—to a separate element such as a circuit board, or to a diaphragm or horn which improves the efficiency of sound signal radiation.
The use of a thin layer of piezo material allows the material to be actuated and change state at relatively high frequency, namely in the audio band, despite its capacitive nature, while using relatively low drive voltages. When driven at lower frequencies, under several hundred Hz and, in a beeper preferably at resonance (about one hundred ninety Hz in one device), the actuator produces an easily felt but substantially inaudible flexural or vibratory movement which is referred to herein as an “inertial” signal. Driving in this manner produces a substantially elastic disturbance of the signal unit and/or housing, and thus may be resonantly driven using relatively little power. The module may produce signals such as a tone or a buzz, which are generated at audio or lower frequency and are electrically synthesized signals.
One form of signal, which is both inertial and non-audio, is obtained by producing a vibration of the wall that because of its low amplitude and/or form of vibration does not radiate sound, or radiates only a low buzz or murmur. This excitation, which corresponds very closely to that conventionally produced in a paging device by means of an imbalanced electromagnetic motor, is achieved in accordance with one aspect of the invention by providing a signal-producing piezo package as described above and attaching the package to the housing such that a portion of the package area undergoes an actual displacement, such as a oscillating bending motion, while another portion of the package is clamped, pinned or otherwise attached at an end or inner portion thereof to the housing so that the inertial imbalance of the moving package is transmitted into the housing as vibrational energy.
FIG. 3 illustrates such an embodiment. As shown in that figure, a housing 200 , such as the housing of a beeper or the like, has a module or signal unit 100 mounted thereon with a part of the unit fixedly clamped between a pedestal 201 and cap 202 so that it is cantilevered over the housing floor. A ribbon-like flex circuit extends to a power connector 110 to energize the active portion of the unit 100 , which is fabricated as a bimorph, or as a piezo/metal shim monomorph, so that it bends like a diving board and oscillates about its clamped end. A mass 3 is preferably mounted at the moving end to accentuate the imbalance, and the entire unit may be driven in resonant oscillation so that the inertial imbalance transfers a relatively large amplitude periodically varying force to the pedestal 201 and creates an inertial vibration in the housing. The dimensions and stiffness of the sheet construction may be selected so that the unit 100 resonates and little power is required to initiate or maintain its oscillation. Similarly, as described in the above-referenced patents and applications, circuit elements forming an R-C or RLC circuit may be incorporated in the planar sheet construction. In addition, the electrode connection portions of the sheet element may also carry other circuit elements, including non-planar elements which are attached following the basic sheet assembly. These elements may include audio amplifier, voice or sound generator, or filter/signal processing chips connected and configured to adapt one or more portions of the unit 100 to emit audio sound, or to sense audio or tactile signals.
Such additional circuit elements are advantageously used in the device of FIG. 1A, a plan view from above of a signal unit incorporating both audio and inertial generation portions. As shown, the unit includes a sheet-like packaged piezo assembly in which the first active piezo area 1 and the second active piezo area 2 both extend in a common sheet, with flexible packaging or circuit portions that may allow a common connector to energize both portions while separately positioning each for cementing, injection molding or other form of attachment in the device. The portions are separated by flexible bands of interconnecting material, and each may be separately actuated essentially without introducing cross-talk in the other. Either portion may be set up as a cantilever beam, bender, free-space vibrational source, or audio vibration or inertial bender plate fully affixed to the wall.
FIG. 3A shows another embodiment 300 of the invention. Unit 300 is a hybrid actuator assembly adapted for simple mechanical attachment to diverse user devices. As shown, the unit 300 has an actuator sheet portion 310 which may be a vibrator, monomorph or bimorph bender or other thin sheet area piezo actuator device as described above, and a body 320 . Body 320 may be a block, as shown, which may for example include or accommodate bolt holes for conventional attachment to a wall or housing, and may be formed by molding, casting or cementing about the sheet portion 310 . Body 320 may alternatively be a more complex shape, such as an L-bracket, multi-post standoff, horn, or other shape specifically adapted to mounting in a specific housing or audio system.
FIGS. 3B and 3C show further mechanically useful embodiments wherein a polymeric housing or wall 200 is attached to an electroactive module 100 of the present invention. Also shown is a weight or mass 3 carried on the module 100 to increase its inertia. These embodiments are advantageously applied to create inertial impulses and couple them into the wall. The embodiment of FIG. 3B may also be constructed without the weight 3 so as to constitute a lighter structure, which may, for example, function as a direct-to-air sound emitter, or which may be configured to reinforce or amplify the level of vibration induced in or coupled to the housing wall through the solid support. While these two Figures show a pinned-pinned or boundary-clamped module mounting (FIG. 3 B), and a pinned or clamped end module (FIG. 3 C), the invention contemplates structures wherein the module is mechanically coupled to the housing by other appropriate mechanical arrangements of clamp, pin, bias contact or partially free configurations to allow the module to both generate the desired mechanical action and couple it to the housing. The invention further contemplates other constructions employing a module 10 as described herein, which extend or improve the art.
Thus, FIG. 3D shows a construction wherein a module 10 as described above is attached to a wall 200 through a support rim or discrete supports 201 , which as shown are place at edges of an active region 10 a of the module 10 . The structure is assembled such that the wall receives energy by direct vibrational coupling through the support 201 (indicated by way arrow “a”) as well as energy coupled through the atmosphere (e.g., sound, indicated by straight arrows “b”). The housing thus produces signals (denoted by arrows “c”) at its surface. The assembly may be tuned for a coupled resonance of the emitting region of the wall, or may employ a perforated region such that, for example the “b” energy is radiated through as an audio while the “a” energy is applied as a tactile signal actuation of the wall. Because the module 10 contains a region of material which is actuated in bulk, the size or dimensions of the housing or attachment region may be varied arbitrarily while still employing the same module for all applications. Thus, for example, the assembly of FIG. 3D may employ the same module 10 when the supports 201 are to be spaced two centimeters apart, or three centimeters apart. This feature allows great leeway in implementing actuator housings wherein, for example, a portion of the wall 200 is required to have a particular thickness, and yet to also flex or to resonate at a particular frequency, since it is no longer to design the wall to fit the mounting and actuation parameters of a fixed driver such as a speaker. Instead, one may simply determine the required wall properties, for example so that it has a response at the desired signal (e.g., a 100 Hz flexural resonance, or an audio response to vibrational stimulation) and the module is attached so that it is dynamically coupled to the shell to amplify or enhance the response of the shell.
FIGS. 4 and 4A show top and sectional views of yet another embodiment 400 of the invention. In this embodiment, several separate electroactive units 410 a , 410 b and 410 c are each affixed in a common wall 420 . One is centrally positioned to actuate the panel as a whole to, for example, radiate longer wavelength acoustic energy, while two other actuators are positioned diametrically apart to provide separate emission regions which may for example be used for stereo speakers at higher or more directional frequencies. These actuator units may be positioned in other locations as desired, for example to connect with specific circuitry in the intended device, or located to avoid nodal or resonant positions of the wall, by suitable design of the mold cavity or assembly fixtures. In addition to actuation as audio or non-audio generators, the actuators may be used for sensing and user feedback. In this case, the described sheet structure may be embedded more deeply in the wall so that only a thin, flexible membrane-like portion of the wall covers the actuator and the user's touch transmits strain into the sheet for forming a signal. When used as a sensor, materials with less stiffness, strength and/or control authority, such as flexible PVDF film or composite, may be employed in forming the module 10 .
The invention is also adapted to provide manufacturing efficiency for the incorporation of multiple different functional drivers within a single device. This is done as indicated by FIG. 5A, by providing a multipurpose actuator unit 510 which is fabricated as a sheet structure in the manner indicated above, and has both a plurality of active regions 512 a , 512 b , 512 c and its connecting or alignment features, such as edges, fastening holes and the like 514 a , 514 b , 514 c positioned to fasten in a single step to a housing and thus to provide a plurality of possibly different inertial, audio or sensing control devices therein. One or more of the active regions 512 may be fabricated with a closely spaced set of circuit elements 513 as shown in active region 511 of FIG. 5 B.
Furthermore, because the actuator itself may be readily manufactured in large sheets containing multiple separate units, and, as described in the foregoing patents, these may be shaped and configured in part by lithographic (e.g., electrode pattern-forming) and lamination techniques, the size and shape of the modules 10 is readily adapted to each required application while keeping unit design and manufacturing costs reasonable.
FIGS. 6A-6L illustrate representative examples of embodiments of the invention configured as audio, signal or sensing units in a variety of consumer electronic devices. In these figures, a sound-emitter is indicated pictorially by a small triangle, while a star is used as a legend to illustrate a suitable region of the housing for a vibratory or inertial transducer. The latter may also be used for sensing pressure or contact feedback from the user, which is preferred in some applications noted below.
As shown in FIGS. 6A-6C, in a laptop computer, not only the broad panels of the device—such as the cover—may be used, but sound generators may be positioned to radiate at the sides or floor of the case, or around the edge of the keyboard or display. Some suitable positions for inertial signal units include the feet, bottom sides and the palm rest area P. Similarly, in a cellular telephone, as shown in FIG. 6D, not only may the ear and voice regions be implemented with modules of the present invention, but even faces of the housing such as the side or back may be fitted with any of the forms of signal transducer described above. For small units such as pagers (FIG. 6E) or beepers (FIG. 6F) all three type of signals may be conveniently positioned on the housing. The construction is particularly advantageous in efficiently producing inertial signals at a body-contact region of a small housing such as the belt clip area of a pager, or the edge or face of a beeper. For items such as a PDA (personal digital assistant) as shown in FIGS. 6G and 6H, the signal units may be positioned as described above for laptop computers. Here again, the scalability and lithographic manufacturing techniques of the present invention make the modules 10 especially advantageous.
For a computer mouse, both the control buttons and the palm region may be fitted to a module to produce sound or tactile signals, and the button or buttons may further function biodirectionally to also receive user input—e.g. to function as touch-switches or force sensors, as shown in FIG. 6 I. Finally, for devices such as cassette players (FIG. 6J) or compact disc players (FIGS. 6K and 6L) not only may the module 10 be configured for audio, inertial or other signals, but the module may be configured with one or more regions to act as sensors S to perform user input functions, replacing such small and easily missed control buttons as the pause, stop and repeat buttons of the prior art with larger or widely separated actuation regions of the housing. This latter feature allows a user, for example, to more easily control the device by a simple touch while the device remains in a pocket or carry bag, without the difficulty of first removing it or ascertaining by feel the position of each of the numerous small control buttons.
This completes a description of basic aspects of the invention and several exemplary embodiments, which are described both to illustrate points of departure from the prior art and show the manner of adapting representative methods and structures of the invention to specific devices. Such description will be understood as illustrative of the invention, but is not intended to limit the scope thereof. The invention being thus disclosed, variations and modifications, as well as adaptations thereof to diverse devices and improvements, will occur to those skilled in the art, and such variations, modifications and improvements are considered to be within the scope of the invention as defined by the claims appended hereto.
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An electrically driven signal unit is adapted for one-step assembly or injection molding with a device housing to vibrate, flex, beep or emit audio signals, or to sense and provide tactile feedback or control. The signal unit is a package with one or more active areas each containing a layer of ferroelectric or piezoelectric material, connected by inactive areas which may position, align and conduct electricity to the active areas. The active areas may be coupled over a region to transmit compressional, shear or flexural wave energy into the housing, or may contact at discrete regions while bending or displacing elsewhere to create inertial disturbances or impulses which are coupled to create a tactile vibration of the housing. The unit may be assembled such that the housing, the sheet or discrete areas thereof form a bender to provide tactile or sub-auditory signals to the user, or may be dimensioned, attached and actuated to produce audio vibration in the combined structure and constitute a speaker. In other embodiments one or more active regions of piezo material are attached to thin or movable wall regions of the unit to sense strain and, in conjunction with a conditioning circuit, produce electrical switching or control signals for the device. The invention also includes electroactive sheet structures having a polymer block, bracket or functional body formed therearound, which serves as a mounting, coupling or functional operating structure for the driven device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is entitled to the benefit of Provisional Patent Application Ser. No. 60/718,934 filed Sep. 19, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The field of this invention is advertising, browsing, managing and booking vacation rental properties worldwide using electronic means of (a) communications, (b) data storage and retrieval, (c) online reservations, (d) transfers of payments, and (e) providing customer service.
[0004] These days in the travel business, the trend is for vacationers to do all their planning online, and as the vacation rental business grows (4 out of 10 homes sold in 2005 were second homes), it needs to keep up with the latest trends in technology. Online availability calendars, up-to-date rates and online bookings are three important things renters want when dealing with vacation rental properties.
[0005] A complete system is disclosed, a method and system that meets the needs of today's Internet-oriented vacationers and vacation rental property owners.
[0006] 2. Discussion of Prior Art
[0007] Traditionally, vacation rental properties generate income for their owners through rent payments and are managed by a local property management company. The owner will not typically have any visibility with respect to the process. The exposure of the owner's rental property to prospective renters is therefore left to the direction of the management company and is limited on a per-property basis because said management company has no vested interest in any single property. In addition owners are subject to various fees and expenses imposed by the management company including up to fifty percent of the gross rental income as payment for their services. Many vacation rental property owners' profits are subsequently eroded away by fees charged by avaricious management companies.
[0008] With respect to a renter, reserving a vacation rental is often a difficult task which may include multiple steps and involve a great deal of time. Even with the expansion of the Internet, the searching process is slow and cumbersome. For example, many traditional property management companies provide an Internet Listing Service (“ILS”) but only those properties which they represent are listed. All the vacation rental properties in a community or region may be spread across several disparate ILS websites and without a centralized database there is a high likelihood of double booking. For example, two different ILS websites may each reserve the same property on the same day. These, and other difficulties, create undesirable delays and frustrations for vacation rental property renters and owners, and may reduce the ability for property managers to attract renters and increase occupancy rates. Many of these features and functionalities have been unavailable due to the difficulty of aggregating data from disparate, often antiquated, property management computer systems.
[0009] Many of what I refer to as “traditional” vacation rental listing websites have become available for vacation rental owners to advertise their rentals, providing basic advertising and listings for vacation rental properties. However vacationers who browse said “traditional” websites searching for vacation rental properties are required to correspond with the owner (either via submitting information into an email form which gets sent to the owner, or by telephone) who may or may not be immediately available to answer inquiries. In addition, most inquiries are typically in regards to the availability and cost of the vacation rental property for specific dates. The owner spends a lot of time answering the same questions over and over again. Moreover, there is no established way of screening prospective renters. If a vacation rental owner decides not to rent to a particular renter or the need of the renter are not matched by the vacation rental property (for example in terms of availability, cost, amenities or location) the renter is forced to return to the original search process to find another suitable vacation rental.
[0010] Furthermore, when a vacationer actually finds a vacation rental property matching their needs, there remains the task of payment resulting from the vacationers lease obligations and the like. Because each vacation rental property is like a separate business entity, each with its own method of accepting and processing payments and refunds (for security deposit refunds for example), there is no universal method of booking and payment for renters of vacation rental properties.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention overcomes the limitations and expenses imposed by traditional vacation rental property management methods and “traditional” vacation rental advertising websites by providing a system for finding, browsing, managing, booking, rating and advertising vacation rental properties worldwide via a network such as the Internet.
[0012] The invention is composed of a renter reservation system, an owner management system and a plurality affiliates or publishers of Internet content established to provide goods and/or services to prospective renters and/or vacation rental property owners and works in a client/server environment by receiving, storing and tracking data associated with a vacation rental property owner, the vacation rental property itself, reservation and guest information and rental property listing click-throughs from a client system and assigns a unique identifier to each in a centralized relational database.
[0013] In addition, all vacation rental property listings are subject to an instantaneous auction, among other factors, to determine their relative positioning in listing search results. Client system click-throughs are defined as when a prospective renter clicks on a vacation rental property listing provided by the affiliate's system and the full listing data is displayed on the client system. Each click-through is associated with a per-property owner-defined Cost-Per-Click (CPC) which is later tallied and invoiced to the property owner and distributed to affiliates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention will hereinafter be described in conjunction with the appended drawing figures, wherein like numerals denote like elements, and:
[0015] FIG. 1 is a diagram illustrating an environment within which the invention may be implemented;
[0016] FIG. 2 is a diagram functionally illustrating a management system consistent with the invention;
[0017] FIG. 3 is a diagram functionally illustrating an owner tools component consistent with the invention;
[0018] FIG. 4 is a diagram functionally illustrating a vendor tools component consistent with the invention;
[0019] FIG. 5 is a diagram functionally illustrating a publisher tools component consistent with the invention;
[0020] FIG. 6 is a flowchart of an exemplary reservation request method in accordance with one aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention provides a method and system for managing, reserving and listing vacation rental properties using a plurality of content providers in a client/server environment to a worldwide audience of vacation rental property owners and potential renters. In this regard, the present invention may be described in terms of functional modules or components, network diagrams, and various processing steps realized by hardware and software components configured to perform the specified functions. It should be noted that the present invention may employ conventional techniques for data transmission and processing, and the like. Such general techniques and components are known to those skilled in the art and are not described in detail herein.
[0022] A. Environment and Architecture
[0023] With reference to the conceptual diagram shown in FIG. 1 , an exemplary embodiment in accordance with the present invention includes the owner management system 150 , at least one owner 100 of vacation rental property 110 , and at least one publisher 140 configured to provide goods and/or services to user 120 and/or owner 100 . Owner management system 150 , user 120 , owner 100 , publisher 140 and vendor 130 are all configured to communicate with each other over a network 160 (e.g., the Internet).
[0024] User 120 may be a potential renter of vacation rental property 110 . Owner 100 may be the party that owns vacation rental property 110 or an agent authorized to act on the owner's behalf.
[0025] Owner management system 150 is configured to communicate with the various systems primarily to coordinate the management and listing of the vacation rental property 110 and secondarily to facilitate an income stream from user 120 to owner 100 and from owner 100 to vendor 130 and publisher 140 . Owner management system 150 may perform a variety of functions, as explained in more detail below in reference to FIG. 2 .
[0026] The income stream from user 120 to owner 100 is a traditional income stream derived from a rental obligation of user 120 . The income stream from owner 100 to vendor 130 is also a traditional income stream derived from maintenance or housekeeping costs associated with vacation rental property 110 . The income stream from owner 100 to publisher 130 is non-traditional in the sense that it is derived in response to a request received from user 120 for listing data for vacation property 110 via publisher 140 . All income streams are preferably collected automatically from user 120 and owner 100 via a corresponding e-commerce module.
[0027] Publisher 140 is the entity that will issue a request for vacation rental listings to management system 150 , obtain the listings from management system 150 , and present the listing to the user 120 . User 120 may then check the availability and/or any additional property data of specific properties of a selected property type with selected property amenities and of a selected property location, by communicating a request via a publisher 140 to management system 150 .
[0028] FIG. 2 is a diagram functionally illustrating a management system consistent with the invention. The system includes an owner tools component 210 , a vendor tools component 220 and a publisher/affiliate tools component 230 . All of these components interface with one or more relational databases 240 . To help understand the invention, other components of the management system will be explained below. Furthermore, although FIG. 2 shows a particular arrangement of components constituting management system 150 , those skilled in the art will recognize that not all components need be arranged as shown, not all components are required, and that other components may be added to, or replace, those shown.
[0029] Owner tools component 210 is the component by which owner 100 enters information required for listing and managing one or more vacation rental properties. Owner tools component 210 contains a variety of tools designed to help owner 100 to manage vacation rental property 110 and also to create and monitor listings. The data required for, or obtained by, owner tools component 210 resides in a database 240 . Owner tools component 210 may perform a variety of functions, as explained in more detail below in reference to FIG. 3 .
[0030] Vendor tools component 220 is the component by which vendor 130 enters information required for initiating and managing its services to owner 100 . Vendor tools component 220 contains a variety of tools designed to help vendor 130 initiate, monitor, and manage its maintenance jobs associated with vacation rental property 110 . The data required for, or obtained by, vendor tools component 220 resides in a database 240 . Vendor tools component 220 may perform a variety of functions, as explained in more detail below in reference to FIG. 4 .
[0031] Publisher tools component 230 is a component that interfaces with publisher 140 to obtain or send vacation rental listing information. For example, publisher 140 may send a request for one or more vacation rental listings to publisher tools component 230 . The data required for, or obtained by, publisher tools component 230 resides in a database 240 . Publisher tools component 230 may perform a variety of functions, as explained in more detail below in reference to FIG. 5 .
[0032] Databases 240 contain a variety of data used by management system 150 . In addition to the information mentioned above, databases 240 may contain statistical information about what listings have been displayed, how often they have been shown, the number of times they have been selected, who has selected those listings, how often display of the listing has led to a reservation, etc. Although databases 240 are shown in FIG. 2 as one unit, one of ordinary skill in the art will recognize that multiple databases may be employed for gathering and storing information used in management system 150 .
[0033] FIG. 3 is a diagram functionally illustrating an owner tools 210 component consistent with the invention. The system includes an owner entry component 310 , an owner modules component 320 , and an owner billing component 330 . The data required for, or obtained by, owner tools component 210 resides in a database 240 .
[0034] Owner entry component 310 is the component by which owner 100 enters information required for listing and managing one or more vacation rental properties. The data required for, or obtained by, owner entry component 310 resides in a database 240 .
[0035] Owner modules component 320 contains a variety of modules or tools designed to help owner 100 to manage its vacation rental properties and also to create and monitor listings. For example, owner modules component 320 may contain a tool for helping owner 100 estimate the number of click-throughs a listing will receive for a particular publisher.
[0036] Other possible modules may be provided as well. Depending on the nature of the module, one or more databases 240 may be used to gather or store information.
[0037] Owner modules component 320 preferably includes the following modules: an account overview module, a properties module, a bookings module to track reservations and guest information, a tasks module to track and notify the owner of tasks associated with specific reservations such as housekeeping and security deposit refinds and the like, a finance module to track payments and expenses, a calendar module to display and amend availability information, a marketing module, and a support module.
[0038] Owner billing component 330 helps perform billing-related functions. For example, owner billing component 330 generates invoices for a particular vacation rental listing or vendor. In addition, owner billing component 330 may be used by owner 100 to monitor the amount being expended for its various vacation rental properties. The data required for, or obtained by, owner billing component 330 resides in a database 240 .
[0039] FIG. 4 is a diagram functionally illustrating a vendor tools component 220 consistent with the invention. The system includes a vendor entry component 410 , a vendor modules component 420 , and a vendor billing component 430 . The data required for, or obtained by, vendor tools component 220 resides in a database 240 .
[0040] Vendor entry component 410 is the component by which vendor 130 enters information required for initiating and managing its services to an owner. The data required for, or obtained by, vendor entry component 410 resides in a database 240 .
[0041] Vendor modules component 420 contains a variety of modules or tools designed to help vendor 130 initiate, monitor, and manage its maintenance or housekeeping jobs associated with a vacation rental property. For example, vendor modules component 420 may contain a tool for helping vendor 130 to schedule housekeeping jobs for a particular vacation rental. Other possible modules may be provided as well. Depending on the nature of the module, one or more databases 240 may be used to gather or store information.
[0042] Vendor billing component 430 helps perform billing-related functions. For example, vendor billing component 430 generates invoices for a particular vacation rental. In addition, vendor billing component 430 may be used by vendor 130 to monitor the amount of income associated with a particular vacation rental. The data required for, or obtained by, vendor billing component 430 resides in a database 240 .
[0043] FIG. 5 is a diagram functionally illustrating a publisher tools component 230 consistent with the invention. The system includes a listing search component 510 , a listing serving component 520 , and a listing display component 530 . The data required for, or obtained by, publisher tools component 230 resides in a database 240 .
[0044] Listing search component 510 interfaces with publisher 140 to obtain or send vacation rental listing information. For example, publisher 140 may send a request for one or more vacation rental listings to search component 510 . The request may include information such as the site requesting the listing, any information available to aid in selecting the listing, the number of listings requested, etc. In response, search component 510 may provide one or more vacation rental listings to publisher 140 . In addition, publisher 140 may send information about the performance of the listing back to the management system via the search component 510 . This may include, for example, the statistical information described above in reference to a database 240 . The data required for, or obtained by, ad consumer interface component 250 resides in a database 240 .
[0045] Listing serving component 520 receives an ordered list of vacation rental listings from listing search component 510 , and formats that list into a manner suitable for presenting to publisher 140 . This may involve, for example, rendering the listing data into hypertext markup language (“HTML”), into a proprietary data format, etc.
[0046] Listing display component 530 receives a unique vacation rental property listing identifier from publisher 140 , and formats the listing data into a manner suitable for presenting to publisher 140 . This may involve, for example, rendering the listing data into hypertext markup language (“HTML”), into a proprietary data format, etc.
[0047] B. Operation
[0048] Referring to the flowchart shown in FIG. 6 in conjunction with the system overview shown in FIG. 1 , an example reservation request from user 120 operates as follows. First, user 120 utilizes publisher 140 to submit a vacation rental listing search request (step 601 ) to management system 150 . Management system 150 parses and processes the request (step 602 ), then searches databases 240 (step 603 ) for listings matching the search criteria in 601 . Search criteria may include details such as location, size, amenities, availability and the like. Management system 150 then formats the search results (step 604 ) in a suitable format for presenting to publisher 140 . This may involve, for example, rendering the listing data into hypertext markup language (“HTML”), into a proprietary data format, etc.
[0049] At this time, user 120 may browse the listings and select a particular listing of interest by submitting a listing request (step 605 ) to management system 150 . Management system 150 receives and processes the listing request (step 606 ) which may include steps such as incrementing the number of times a listing has been requested and storing that data in databases 240 . Management system 150 then formats the listing data (step 607 ) in a suitable format for presenting to publisher 140 . This may involve, for example, rendering the listing data into hypertext markup language (“HTML”), into a proprietary data format, etc.
[0050] At this time, user 120 may decide to make a reservation for this vacation rental by submitting a reservation request (step 608 ) via publisher 140 to management system 150 . Management system 150 receives and processes the reservation request (step 609 ) which may include steps such as querying user 120 for personal contact information and storing the reservation request and user information in databases 240 . Management system 150 then determines if owner 100 accepts online rental payments (step 610 ). Online payments are preferably handled via a corresponding e-commerce module or a third-party provider such as PayPal.com (step 611 ). Management system 150 then sends a reservation request notification to owner 100 (step 612 ) via e-mail, web-page update, PDA, pager, or the like.
[0051] At this time, it is the responsibility of owner 100 to determine if payment has been received and confirmed (step 613 ) for the reservation above. Owner 100 uses management system 150 to confirm payment and management system 100 processes the confirmation (step 614 ) which may include steps such as updating availability data in databases 240 , sending a reservation confirmation notification (via email) to user 120 and automatically scheduling housekeeping tasks associated with the reservation.
[0052] C. Conclusion
[0053] The foregoing description of preferred embodiments of the present invention provides illustration and description, but is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention.
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A method and system for finding, browsing, managing, booking, rating and advertising vacation rental properties worldwide via a network such as the Internet composed of a renter reservation system, an owner management system and a plurality affiliates or publishers of Internet content established to provide goods and/or services to prospective renters and/or vacation rental property owners and works in a client/server environment by receiving, storing and tracking data associated with a vacation rental property owner, the vacation rental property itself, reservation and guest information and rental property listing click-throughs from a client system and assigns a unique identifier to each in a centralized relational database.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from Provisional Patent Application No. 60/415,641 filed Oct. 2, 2002, which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for producing a purified and pressurized liquid carbon dioxide stream.
BACKGROUND
Highly pressurized, purified liquid carbon dioxide is required for a variety of industrial processes. Such highly pressurized liquid is produced by purifying industrial grade liquid carbon dioxide that is available at about 13 to 23 bar (1.3 to 2.3 MPa) and then pumping the liquid to a pressure of anywhere from between about 20 and about 68 bar (2 to 6.8 MPa). The problem with pumping, however, is that impurities such as particulates or hydrocarbons can be introduced into the product stream as a byproduct of mechanical pump operation.
U.S. Pat. No. 6,327,872, incorporated by reference herein, and assigned to The BOC Group, Inc., the assignee of the present application, is directed to a method and apparatus for producing a pressurized high purity liquid carbon dioxide stream in which a feed stream composed of carbon dioxide vapor is purified within a purifying filter and then condensed within a condenser. The resulting liquid is then alternately introduced and dispensed from two first and second pressure accumulation chambers on a continuous basis, in which one of the first and second pressure accumulation chambers acts in a dispensing role while the other is being filled.
High purity CO 2 can be used for the cleaning of optical components using the solvation and momentum transfer effects of CO 2 when sprayed onto the optics. These benefits are achieved only if the purity of the CO 2 is very high and the CO 2 is delivered at a high pressure.
SUMMARY
The present invention relates to a method and apparatus for producing a purified and pressurized liquid carbon dioxide stream in which a feed stream composed of carbon dioxide vapor is condensed into a liquid that is subsequently pressurized, such as by being heated within a chamber.
A batch process is provided for producing a pressurized liquid carbon dioxide stream comprising:
distilling a feed stream comprising carbon dioxide vapor off of a liquid carbon dioxide supply;
introducing the carbon dioxide vapor feed stream into at least one purifying filter;
condensing the purified feed stream within a condenser to form an intermediate liquid carbon dioxide stream;
introducing the intermediate liquid carbon dioxide stream into at least one high-pressure accumulation chamber;
heating said high pressure accumulation chamber to pressurize the liquid carbon dioxide contained therein to a delivery pressure; and,
delivering a pressurized liquid carbon dioxide stream from the high-pressure accumulation chamber; and,
discontinuing delivery of the pressurized liquid carbon dioxide stream for replenishing the high pressure accumulation chamber.
The process may include venting the high-pressure accumulation chamber to the condenser to facilitate introduction of the intermediate liquid stream into the accumulation chamber. In certain embodiments, the intermediate liquid carbon dioxide stream is accumulated in a receiver prior to introduction into the high-pressure accumulation chamber, and in certain embodiments, the condenser is integral with the receiver.
In one embodiment, the process includes passing the pressurized liquid carbon dioxide stream through a particle filter prior to delivery to a cleaning process.
An apparatus is provided for producing a purified, pressurized liquid carbon dioxide stream comprising:
a bulk liquid carbon dioxide supply tank for distilling off a feed stream comprising carbon dioxide vapor;
a purifying filter for purifying the carbon dioxide vapor feed stream;
a condenser for condensing the carbon dioxide vapor feed stream into an intermediate liquid carbon dioxide stream;
a receiver for accumulating the intermediate liquid carbon dioxide stream;
a high-pressure accumulation chamber for accepting the intermediate liquid carbon dioxide stream from the receiver;
a heater for heating the high-pressure accumulation chamber for pressurizing the carbon dioxide liquid contained therein to a delivery pressure;
a sensor for detecting when the high-pressure accumulation chamber requires replenishment of liquid carbon dioxide;
a flow network having conduits connecting the bulk supply tank, the condenser, the receiver and the high-pressure accumulation chamber and for discharging said pressurized liquid carbon dioxide stream therefrom;
the conduits of said flow network including a vent line from the high-pressure accumulation chamber to the condenser to facilitate introduction of the intermediate liquid carbon dioxide stream into the accumulation chamber; and,
the flow network having valves associated with said conduits to allow for isolation of components of the apparatus.
In one embodiment, a particle filter is connected to the flow network to filter the pressurized liquid carbon dioxide stream.
In certain embodiments, the condenser includes an external refrigeration circuit having a heat exchanger to condense the vapor feed stream through indirect heat exchange with a refrigerant stream. In certain embodiments, the condenser is integral with the receiver.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an apparatus for carrying out the process according to one embodiment.
FIG. 2 is a schematic view of an alternative embodiment of an apparatus for carrying out the process.
DETAILED DESCRIPTION
An apparatus and process are provided including introducing a feed stream comprising carbon dioxide vapor into a purifying filter, such as for carrying out gas phase purification; condensing the purified CO 2 stream, such as by use of mechanical refrigeration or cryogenic refrigerants; isolating the high purity liquid CO 2 ; and, vaporizing a portion of the liquid CO 2 , such as by using a heater element, to achieve the target pressure.
In one embodiment, the apparatus and process operating cycle is designed to maintain a continuous supply of high-pressure pure liquid carbon dioxide for a period up to about 16 hours, with about 8 hours to reset the system, that is, to replenish the high purity liquid carbon dioxide available for delivery. An example of the operating cycle and corresponding “Modes”, and the logic controlling the cycle of the system is presented below in Table 1.
By way of example, in one embodiment, gaseous carbon dioxide is withdrawn from a bulk tank of liquid carbon dioxide, where single stage distillation purification occurs, removing a majority of the condensable hydrocarbons. From the bulk tank, the gaseous carbon dioxide passes through a coalescing filter, providing a second level of purification. The gaseous carbon dioxide is re-condensed in a low-pressure accumulator, providing the third level of purification by removing the non-condensable hydrocarbons. The low-pressure liquid is then transferred to a high-pressure accumulator. Once filled, an electric heater pressurizes the accumulator up to the desired pressure set-point. Upon reaching the pressure set point, the accumulator enters Ready mode (Mode 4 , as in Table 1). In one embodiment, the process maintains high purity liquid carbon dioxide to the point of use for a period of up to about 16 hours. After the liquid has been expended, the system may return to Mode 1 and repeat the operating sequence.
With reference to FIG. 1 , a carbon dioxide purification and supply apparatus is shown generally at 1 . From a bulk supply of liquid carbon dioxide 10 , a feed stream 11 comprising carbon dioxide vapor is distilled in a first purification stage, and is introduced into a purifying particle filter 13 and a coalescing filter 14 which can be any of a number of known, commercially available filters, for a second stage purification. Valves 12 and 15 are provided to isolate the purifying filter(s) 13 , 14 . The bulk supply may be a tank of liquid CO 2 maintained at about 300 psig (2.1 MPa) and about 0° F. (−18° C.). As carbon dioxide vapor is drawn out of the bulk supply tank, a portion of the liquid carbon dioxide in the bulk tank is drawn through conduit 16 and introduced to a pressure build device 17 such as an electric or steam vaporizer or the like, to maintain the pressure relatively constant within the bulk supply tank even though carbon dioxide vapor is being removed. The vaporizer takes liquid CO 2 from the supply tank and uses heat to change the CO 2 from the liquid phase to the gas phase. The resulting CO 2 gas is introduced back into the headspace of the supply tank.
The feed stream 11 after having been purified in the second stage is introduced into a condenser 18 that is provided with a heat exchanger 21 to condense the carbon dioxide vapor into a liquid 19 . Such condensation is effected by an external refrigeration unit 22 that circulates a refrigeration stream through the heat exchanger, preferably of shell and tube design. Isolation valves 28 and 29 can be provided to isolate refrigeration unit 22 and its refrigerant feed line 26 and return line 27 . The liquid carbon dioxide 19 is temporarily stored in a receiver vessel 20 , that is, a low pressure accumulator. The level of liquid in the receiver vessel 20 is controlled by a level sensor 44 (such as a level differential pressure transducer) and a pressure sensor 54 (such as a pressure transducer) via a controller (not shown), such as a programmable logic computer.
An intermediate liquid stream comprising high purity CO 2 liquid 24 is introduced from the receiver vessel 20 into a high-pressure accumulation chamber 30 . The high-pressure accumulation chamber 30 is heated, for example, by way of an electrical heater 31 , to pressurize the liquid to a delivery pressure of the pressurized liquid carbon dioxide stream to be produced by apparatus 1 .
An insulation jacket 23 , such as formed of polyurethane or the equivalent, can be disposed about the condenser 18 , the conduit for carrying the liquid CO 2 19 , the high pressure accumulation vessel 30 , and the outlet conduit 32 and associated valves to maintain the desired temperature of the liquid CO 2 .
A valve network controls the flow within the apparatus 1 . In this regard, fill control valve 25 controls the flow of the intermediate liquid stream from the receiver vessel 20 to the high-pressure accumulation chamber 30 . Control of the flow of the high pressure liquid carbon dioxide through outlet conduit 32 is effected by product control valve 34 . Drain valve 33 also is connected to outlet conduit 32 for sampling or venting, as needed. The venting of the high-pressure accumulation chamber 30 via vent line (conduit) 51 to the condenser 18 is controlled by vent control valve 52 . A pressure relief line 55 from the condenser 18 to the receiver vessel 20 passes vapor from the receiver vessel 20 back to the condenser 18 as liquid carbon dioxide 19 enters the receiver vessel 20 .
A pressure sensor 53 (such as a pressure transducer) monitors the pressure and a level sensor 45 (such as a level differential pressure transducer) monitors the level of liquid carbon dioxide within the high-pressure accumulation chamber 30 in order to control the heater 31 for vaporizing a portion of the liquid carbon dioxide, so that a desired pressure of the liquid carbon dioxide can be supplied therefrom. A temperature sensor (not shown) can monitor the liquid carbon dioxide temperature in the heater 31 or accumulation chamber 30 .
The process has six operating sequences, or modes, for the high-pressure carbon dioxide accumulator (AC-1). The cycle logic controls the valves, heaters and refrigeration according to these modes. Table 1 lists the possible operation modes.
TABLE 1
High-Pressure Accumulator Status Modes.
Desig-
Mode
nation
Description
Offline
0
All valves closed, heaters off,
refrigeration off.
Vent
1
Depressurize accumulator 30 prior to
refilling with low-pressure liquid. Vent
valve 52 open. Fill valve 25 and product
valve 34 closed. Refrigeration on.
Fill
2
Filling accumulator 30 with low-
pressure liquid. Vent valve 52 and fill
valve 25 open. Product valve 34 closed.
Refrigeration on.
Pressurize
3
Pressurizing accumulator 30 up to the
set point (i.e. using electric immersion
heater 31). Vent, fill and product valves
closed.
Ready
4
System hold at pressure awaits
dispensing high pressure liquid. Vent,
fill and product valves closed.
Online
5
System supplying high-pressure liquid.
Product valve 34 open. Vent valve 52
and fill valve 25 closed.
High pressure carbon dioxide from the high pressure accumulator travels through outlet conduit 32 and may be again purified in a further purification stage by one of two particle filters 41 and 42 . The particle filters 41 and 42 can be isolated by valves 35 , 36 and 37 , 38 respectively, so that one filter can be operational while the other is isolated from the conduit by closure of its respective valves, for cleaning or replacement. The high pressure, purified liquid carbon dioxide stream 43 emerges from the final filtration stage for use in the desired process, such as cleaning of optic elements.
The optical component to be processed is contacted with high purity CO 2 directly in a cleaning chamber, such that the contamination residue is dissolved and dislodged by the CO 2 . The liquid CO 2 may be supplied to the cleaning chamber at about 700 psig to about 950 psig (4.8 MPa to 6.6 MPa) or higher.
When the high-pressure accumulation chamber 30 is near empty, as sensed by level sensor 45 and/or the pressure sensor 53 , vent control valve 52 opens to vent the high-pressure accumulation chamber. Fill control valve 25 opens to allow intermediate liquid stream 24 to fill the high-pressure accumulation chamber 30 . When the differential pressure sensor indicates the completion of the filling, control valves 25 and 52 close, and the liquid carbon dioxide is heated by electrical heater 31 to again pressurize the liquid within the high-pressure accumulation chamber 30 .
Pressure relief valves 46 , 47 , 48 may be provided for safety purposes, in connection with the high-pressure accumulation chamber 30 , receiver vessel 20 , and condenser 18 , respectively.
Other exemplary embodiment(s) of the apparatus are shown in FIG. 2 . Elements shown in FIG. 2 which correspond to the elements described above with respect to FIG. 1 have been designated by corresponding reference numbers. The elements of FIG. 2 are designed for use in the same manner as those in FIG. 1 unless otherwise stated.
With reference to FIG. 2 , an alternative carbon dioxide purification and supply apparatus is shown generally at 2 . From a bulk supply of liquid carbon dioxide 10 , a feed stream 11 comprising carbon dioxide vapor is distilled in a first purification stage, and is introduced into a purifying particle filter 13 and a coalescing filter 14 which can be any of a number of known, commercially available filters, for a second stage purification. Valves 12 and 15 are provided to isolate the purifying filter(s) 13 , 14 .
The feed stream 11 after having been purified in the second stage is introduced into the receiver vessel 20 that is provided with a heat exchanger 21 to condense the carbon dioxide vapor into a liquid. Such condensation is effected by an external refrigeration unit 22 that circulates a refrigeration stream through the heat exchanger, preferably of shell and tube design. Isolation valves 28 and 29 can be provided to isolate refrigeration unit 22 and its refrigerant feed line 26 and return line 27 . The liquid carbon dioxide is temporarily stored in the receiver vessel 20 , that is, a low pressure accumulator.
As may be appreciated, since vapor is being condensed within receiver 20 , a separation of any impurities present within the vapor might be effected by which the more volatile impurities would remain in uncondensed vapor and less volatile impurities would be condensed into the liquid. Although not illustrated, sample lines might be connected to the receiver vessel 20 for sampling and drawing off liquid and vapor as necessary to lower impurity concentration within the receiver.
An intermediate liquid stream comprising high purity liquid 24 is introduced into first and second pressure accumulation chambers 30 a and 30 b . First and second pressure accumulation chambers 30 a and 30 b are heated, preferably by way of electrical heater 31 , to pressurize the liquid to a delivery pressure of the pressurized liquid carbon dioxide stream to be produced by apparatus 2 .
A valve network controls the flow within the apparatus. In this regard, fill control valve 25 controls the flow of the intermediate liquid stream from the receiver 20 to the high-pressure accumulation chambers 30 a and 30 b . Control of the flow of the high pressure liquid carbon dioxide through outlet conduit 32 is effected by product control valve 34 . Drain valve 33 also is connected to outlet conduit 32 for sampling or venting, as desired. The venting of the high-pressure accumulation chamber 30 via vent line (conduit) 51 to the condenser 18 is controlled by vent control valve 52 .
First and second high pressure accumulation chambers 30 a and 30 b may be interconnected by conduit 39 without an isolation valve interposed there between, so that both act effectively as a single unit, at lower cost.
A pressure sensor 53 (such as a pressure transducer) monitors the pressure and a level sensor 45 (such as a level differential pressure transducer) monitors the level of liquid carbon dioxide within the high-pressure accumulators 30 a and 30 b in order to control the heater 31 for vaporizing a portion of the liquid carbon dioxide, so that a desired pressure of the liquid carbon dioxide can be supplied therefrom.
High pressure carbon dioxide from the high pressure accumulator travels through outlet conduit 32 and is again purified in a further purification stage by one of two particle filters 41 and 42 . The particle filters 41 and 42 can be isolated by valves 35 , 36 and 37 , 38 respectively, so that one filter can be operational while the other is isolated from the conduit by closure of its respective valves, for cleaning or replacement. The high pressure, purified liquid carbon dioxide stream 43 emerges from the final filtration stage for use in the desired process as described above. When the requirement for the purified carbon dioxide stream 43 is no longer needed, or can no longer be met, the apparatus begins a replenishment cycle. That is, after Mode 5 is complete, the system can return sequentially to Mode 1 , Mode 2 , and so on, as set forth in Table 1.
Further features of the apparatus and process include a fully automated microprocessor controller which continuously monitors system operation providing fault detection, pressure control and valve sequencing, ensuring purifier reliability, while minimizing operator involvement. By way of example and not limitation, level sensors 44 , 45 , pressure sensors 53 , 54 , and temperature sensors can provide information for the controller, in order to provide instructions to flow control valves 15 , 34 , 52 , or pressure relief valves 46 , 47 , 48 . The valves in the apparatus may be actuated pneumatically, by pulling a tap off of the CO 2 vapor conduit such as at valve 57 , to supply gas for valve actuation.
The apparatus may include system alarms to detect potential hazards, such as temperature or pressure excursions, to ensure system integrity. Alarm and warning conditions may be indicated at the operator interface and may be accompanied by an alarm beeper. A human machine interface displays valve operation, operating mode, warning and alarm status, sequence timers, system temperature and pressure, heater power levels, and system cycle count.
In summary, industrial grade CO 2 gas may be pulled off of the head space of a supply tank where the supply tank acts as a single stage distillation column (Stage 1 ). The higher purity gas phase is passed through at least a coalescing filter, reducing the condensable hydrocarbon concentration and resulting in a higher level of purity (Stage 2 ). Stage 3 includes a mechanical or cryogenic refrigeration system to effect a phase change from the gas phase back to the liquid phase. All non-condensable hydrocarbons and impurities are thus removed from the operative carbon dioxide liquid stream.
The subject apparatus and process permits cyclic operation of the process, rather than continuous feed operation. The apparatus and process is also of a more economical design (by approximately half) due to the reduction from continuous or multi-batch to single batch operation. The apparatus and process is further of a more economical design than prior art systems, due to the omission of accessory equipment like boilers and condensers. The reduced footprint allows for location of the apparatus closer to the point of use, resulting in less liquid carbon dioxide boil-off.
It will be understood that the embodiment(s) described herein is/are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the invention. All such modifications and variations are intended to be included within the scope of the invention as described herein. It should be understood that the embodiments described above are not only in the alternative, but can be combined.
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A batch process and apparatus for producing a pressurized liquid carbon dioxide stream includes distilling a feed stream of carbon dioxide vapor off of a liquid carbon dioxide supply; introducing the carbon dioxide vapor feed stream into at least one purifying filter; condensing the purified feed stream within a condenser to form an intermediate liquid carbon dioxide stream; introducing the intermediate liquid carbon dioxide stream into at least one high-pressure accumulation chamber; heating the high pressure accumulation chamber to pressurize the liquid carbon dioxide contained therein to a delivery pressure; delivering a pressurized liquid carbon dioxide stream from the high-pressure accumulation chamber; and, discontinuing delivery of the pressurized liquid carbon dioxide stream for replenishing the high pressure accumulation chamber.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for detecting a physiological signal, in which at least one ventilation parameter is measured and analyzed to control a ventilation pressure.
The invention also concerns a device for detecting a physiological signal, which has a sensor for measuring a ventilation parameter and a control unit for producing a ventilation pressure.
The invention further concerns a device for monitoring at least one ventilation parameter while respiratory gas is being supplied to a patient, which has a sensing device for detecting the behavior of the ventilation parameter as a function of time.
2. Description of the Related Art
Large numbers of persons suffer from sleep disorders, which affect the well-being of these persons during the day and in some cases have an adverse effect on their quality of life. One of these sleep disorders is sleep apnea, which is treated primarily by CPAP therapy (CPAP=continuous positive airway pressure), in which a flow of respiratory gas is continuously supplied to the patient through a nasal mask as the patient sleeps. A hose connects the mask with a ventilator, which includes a blower that produces a gas flow with, for example, a positive pressure of 5 to 20 mbars.
The gas flow is supplied to the patient either at constant pressure or, to relieve the respiratory work of the patient, at a lower level during expiration.
The lowering and raising of the ventilation pressure are effected on the basis of various events identified by the device and by measured respiratory parameters.
The following are examples of such events: mouth expiration, mouth breathing, leakage, swallowing, speaking, sneezing, coughing, increase in respiratory flow, decrease in respiratory flow, flattening of the respiratory flow, cessation of respiratory flow, increase in resistance, leakage, apnea, hypopnea, snoring, inspiration, expiration, interruption of breathing, increase in respiratory volume, decrease in respiratory volume, inspiratory constriction of the respiratory flow, inspiratory peak flow, decrease in the inspiratory flow after peak flow, second maximum of the inspiratory peak flow, increase in the pressure of the respiratory gas, decrease in the pressure of the respiratory gas, increase in the flow of the respiratory gas, decrease in the flow of the respiratory gas, increase in the volume of respiratory gas delivered, decrease in the volume of respiratory gas delivered.
SUMMARY OF THE INVENTION
The object of the present invention is to improve a method of the aforementioned type in such a way that pressure control is optimized.
Another object of the present invention is to construct a device of the aforementioned type for optimization of pressure control.
A further object of the present invention is to further optimize a device of the aforementioned type.
The three objects listed above are met by the three combinations of features specified at the beginning.
The method of the invention is aimed at detecting obstructive apneas, explicitly, at the end of an apnea, since these are usually difficult to distinguish from central apneas or difficult to detect at all. If apneas are detected exclusively by an approximately zero line in the flow, the distinction obstructive/central is not possible. Oscilloresistometry is available for this purpose (EP 0 705 615 B1), but it requires considerable design expense, results in higher production costs, and is not suitable for all types of masks.
The method of the invention makes it possible to detect obstructive apnea more simply and reliably than methods that make use of pressure to detect the obstructive apnea. The device used in this method has a pressure sensor that senses the pressure signals in the patient system, which consists, for example, of a respiratory hose, pressure hose, patient interface, expiratory element, etc., and feeds them to an analyzer. The analyzer analyzes the pressure curve and makes use of the fact that, at the end of an episode of obstructive apnea, an abrupt pressure drop, obstructive pressure peak (OPP) can usually be measured when the respiratory passages suddenly open, and the pressure between the mask and the respiratory tract must be equalized.
During the obstructive apnea, the lower respiratory tract of the patient is disconnected from the system respiratory hose/mask/upper respiratory tract, so that typically a pressure difference between the mask and the lower respiratory tract develops as a result of the respiratory excursions of the patient. When the respiratory tract reopens, this results in a pressure equalization, which can be detected as a pressure surge in the mask or in the patient system, as an abrupt increase in the rotational speed of the blower, or as an abrupt flow pulse. Typically, it is rapidly equalized by the control response of the therapeutic apparatus, but overshooting can occur, and this can lead to abrupt pressure increases.
In central apneas, the lower respiratory tract always remains connected with the system respiratory hose/mask/upper respiratory tract, and there are no respiratory excursions of the patient. Therefore, a pressure difference that must be equalized at the end of the apnea cannot arise.
These effects appear especially when the patient is already connected to the therapeutic apparatus and is receiving therapy, i.e., when a certain pressure is already being applied in the respiratory mask.
Changes in the respiratory tract are usually accompanied by fluctuations near the maxima of the flow curve. These changes can be caused by obstruction or can have other causes, so that obstruction cannot be definitely identified.
However, if the values of the pressure curve are also considered, the previously mentioned pressure peaks in the time interval of the maxima can also be recorded and recognized during obstructive respiratory tract changes, since the vibration of the tissue surrounding the upper respiratory passages represents a further cause of obstructive pressure peaks—especially at the instant of opening or closing. In this regard, it is important inspiratory and expiratory pressure peaks can arise due to artifacts, such as coughing, speaking, swallowing, leakage, and mouth expiration, and are an indication that the inspiratory pressure peaks in the corresponding segment are possibly not a reliable indication of obstructions. These pressure peaks make it possible to draw conclusions about the type of instruction.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of the disclosure. For a better understanding of the invention, its operating advantages, specific objects attained by its use, reference should be made to the drawing and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 shows a basic design of a ventilator.
FIG. 2 is a schematic representation of a ventilator with the detection of flow fluctuations.
FIG. 3 shows a flow curve in obstructive apnea and in central apnea.
FIG. 4 shows a pressure curve in central apnea.
FIG. 5 shows a pressure curve in obstructive apnea.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the basic design of a ventilator. A respiratory gas pump is installed inside an apparatus housing 1 , which has an operating panel 2 and a display 3 . A connecting hose 5 is attached by a coupling 4 . The coupling 4 can be quickly and easily connected to the ventilator by an operating element 13 . An additional pressure-measuring hose 6 , which can be connected with the ventilator housing 1 by a pressure input connection 7 , can run along the connecting hose 5 . To allow data transmission, the ventilator housing 1 has an interface 8 . An expiratory element 14 is installed in an expanded area of the connecting hose 5 that faces away from the apparatus housing 1 . Not shown are a pressure gauge and a flowmeter, which are located near the patient in the vicinity of the patient interface, or in the vicinity of the ventilator, or in the vicinity of the connecting hose.
A mask 9 , which is held on the patient's head by a headband 10 , can also be attached by the respiratory hose 5 .
According to the embodiment in FIG. 2 , a ventilator 15 for carrying out CPAP or APAP ventilation is connected with a mask 9 by a connecting hose 5 . The connecting hose 5 has a constant opening as the expiratory element 14 . The patient's lung 16 is also shown. A supply pressure P produced by the ventilator is present in the area of a section of line 17 . In the vicinity of the mask 9 , a pressure P 1 that corresponds to a CPAP pressure can be determined at a measuring point 18 on the patient side. A possible obstruction can occur in an airway 19 , and a pressure P 2 is present on the other side of the obstruction from the measuring point 18 at a measuring point 20 in the airway 19 .
Excursions produced during an episode of apnea lead to pressure fluctuations at the measuring point 20 .
FIG. 3 shows a flow curve that is typical in both obstructive and central apnea. Almost no flow is occurring during the apnea due to the obstruction of the airway, while typical flow fluctuation is observed before the occurrence of the apnea. A typical flow fluctuation is referred to as flattening and describes a flattening of the flow curve in the vicinity of the maximum flow. In accordance with the invention, the beginning of the apnea is identified at least by a flow fluctuation, and the end of the apnea is identified at least by a pressure fluctuation.
FIG. 4 shows a pressure curve that corresponds to the flow curve in FIG. 3 during the occurrence of an episode of central apnea. Typical small pressure fluctuations in the mask pressure occur during breathing due to the use of a pressure controller. At the time of the flow fluctuation, a corresponding pressure fluctuation also occurs in the case of central apnea.
FIG. 5 shows a pressure curve associated with the occurrence of an episode of obstructive apnea. As in the case of the pressure curve in FIG. 4 , we again find a pressure fluctuation corresponding to the flow fluctuation, but in this case there is also a brief additional pressure change shortly before the end of the apnea when the airways open due to a pressure equalization between the mask and the respiratory tract. The time axes of FIGS. 3 , 4 , and 5 are identical.
If an episode of apnea is detected in the flow signal, the detection unit looks for short, significant deflections in the pressure channel. “Short” means much shorter than a typical respiratory period of a patient. Possible artifacts caused by movements of the patient, hose, etc., or by the patient's heartbeat are tuned out. This is accomplished by evaluating only deflections which occur in the last interval of the apnea or during the first breath after the apnea and which are greater than a detection threshold value. In an especially preferred embodiment of the invention, this threshold value can be automatically adaptively adjusted to allow optimum separation of artifacts and pressure deflections caused by obstructions.
For example, in accordance with the invention, a pressure mean value is determined during an episode of apnea. If the pressure mean value changes or the amplitude of the pressure mean value rises, this indicates the end of an episode of apnea. A change in the pressure mean value is preferably used as a control parameter for controlling the ventilator.
To achieve optimum therapy, this detection threshold value is additionally varied as a function of the therapeutic pressure, specifically, in such a way that, at low therapeutic pressures, the sensitivity of the detection of episodes of obstructive apnea is increased, and at higher therapeutic pressures, the specificity of the detection of episodes of obstructive apnea is increased.
Especially in the case of partial obstructions, the pressure signal and the flow signal are considered together, and the ventilator is automatically controlled on the basis of the pressure and/or flow signals. Definable irregularities in the behavior of the pressure signal and the flow signal are detected and used as control parameters for controlling the ventilator.
While specific embodiments of the invention have been described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.
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In a method for detecting a physiological signal at least one ventilation parameter is measured. The device for detecting a physiological signal has at least one sensor for measuring a ventilation parameter and a control unit for the ventilation pressure. A device for monitoring at least one ventilation parameter while respiratory gas is being supplied to a patient is provided with a sensing device for detecting the behavior of the ventilation parameter as a function of time.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a control system of pumping operation using an AC exciting generator-motor, which is applied to a variable speed system of a pumped storage power plant, and, particularly, to an improved manner of stopping the pumping operation thereof.
2. Description of the Related Art
Recent pumped storage power plants have tendencies to enhance their power capacities as well as to expand their heads between upper and lower reservoirs in view of their conditions of location and/or their operational efficiencies. Conventionally, a sync machine is used as the generator-motor of the power plant, and, therefore, the rotation speed thereof is fixed at constant.
In such a power plant, when the pumping operation must stop, the wicket gate of the reversible pump-turbine is controlled to be closed or squeezed, and when the opening of the wicket gate falls under a predetermined degree, the generator-motor is disconnected (parallel CB off) from the power system.
According to a conventional pumping operation stopping control, however, the degree of squeezing the opening of the wicket gate does not proportionally correspond to the input power of the generator-motor. For instance, when the opening of the wicket gate is squeezed to 20% of the full opening, the input power is decreased to only 70-80% of the power used in the operating head or pumping head.
This means that a parallel circuit breaker (CB) must disconnect the generator-motor from the power system under a condition that the generator-motor is supplied with a certain input power. Such input power becomes large as the power capacity of the generator-motor is increased.
Under such circumstances, when the pumping operation is stopped, power fluctuations in the power system, caused by the parallel CB off of the circuit breaker, are liable to occur. Further, the parallel CB off with large input power of the generator-motor shortens the life of the circuit breaker.
An AC exciting generator-motor can be used in place of a conventional sync machine. In this case the rotor side of the generator-motor is connected to a cycloconverter, to thereby constitute a variable speed system.
FIG. 7 shows a main circuit configuration of such a variable speed system for a pumped storage power plant. In the figure, the rotor shaft of AC exciting generator-motor (IM) 2 is mechanically coupled to reversible pump-turbine 1 directly. The stator side of generator-motor 2 is electrically connected to power system 4, via parallel circuit breaker 3. Also connected to the stator side is breaking disconnecting switch 5.
Incidentally, the exciting magnetic field of AC exciting generator-motor 2 is synchronized with the frequency of system 4, but the rotation speed of the rotor thereof is independent of the system frequency.
The input side of cycloconverter 6 is electrically connected to power system 4, via circuit breaker 7 of the cycloconverter. Cycloconverter 6 converts the frequency of the power from system 4 into a prescribed frequency. The frequency-converted power from cycloconverter 6 is applied to the rotor side of AC exciting generator-motor 2.
In the above variable speed system, the degree of opening of the wicket gate of reversible pump-turbine 1 and the rotation speed thereof are controlled to be proper values in accordance with the pumping head (or simply, head) obtained at the time of pumping operation. By such control according to the wicket gate opening degree and the rotation speed, the AC exciting generator-motor can perform the pumping operation with a given amount of power corresponding to excess power in the system.
For a process from the pumping-operation state to the completely-stopped state of generator-motor 2, the key point of the above variable speed system resides in a manner of decreasing the input power of generator-motor 2.
In manner to achieve the above key point, the input power of generator-motor 2 is reduced to decrease the rotation speed of reversible pump-turbine 1 while controlling the wicket gate to be closed.
However, if the rotation speed of reversible pump-turbine 1 is largely decreased, the pump-discharge pressure of pump-turbine 1 is excessively reduced so that the operation of pump-turbine 1 enters the reverse pumping area. In the reverse pumping area, a reverse flow of water from an upper reservoir to a lower reservoir happens even if pump-turbine 1 operates in the pumping mode. When such a reverse flow happens, vibrations and/or temperature-rise due to agitating or dispersing loss in pump-turbine 1 occur. An operation with such vibrations/temperature-rise cannot be continued. Consequently, when this is the case, generator-motor 2 has to be parallel CB off (or switch-off) from power system 4, with certain input power.
Thus, for a pumped storage power plant in which numerous start/stop operations are to be done, the above-mentioned control will shorten not only the life of the pump-turbine but also lessen that of the circuit breaker (parallel CB), with substantial fluctuations in the power system connected to the pump-turbine.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a control system of pumping operation using an AC exciting generator-motor, by which fluctuations in the power system can be lessened and can prevent reduction of the life of a circuit breaker and/or reversible pump-turbine.
To achieve the above object, a system of the present invention controls to decrease the rotation speed of an AC exciting generator-motor (wound-rotor type variable speed AC motor). The opening of the wicket gate of reversible pump-turbine is controlled to be closed or squeezed in response to the controlled rotation speed of the generator-motor. When the rotation speed of the AC exciting generator-motor is decreased to a given minimum speed at the pumping head, an amount of AC excitation for the generator-motor is controlled such that the input power of the generator-motor becomes substantially zero. After the input power becomes substantially zero, the generator-motor is subjected to a parallel CB off.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a configuration of a control system of pumping operation using an AC exciting generator motor according to an embodiment of this invention;
FIG. 2 is a block diagram explaining the control sequence for stopping the pumping operation of the embodiment of FIG. 1;
FIGS. 3A-3J are timing charts illustrating the pumping operation stopping control for the embodiment of FIG. 1;
FIG. 4 is a graph illustrating the relation among the pumping head of the reversible pump-turbine, the pump input power of the AC exciting generator-motor, and the rotation speed of the generator-motor;
FIG. 5 is a block diagram showing an example of the head detector (15) used in the embodiment of FIG. 1;
FIG. 6 is a block diagram showing an example of the controller (10) used in the embodiment of FIG. 1; and
FIG. 7 shows a material part of a variable speed system for a pumped storage power plant, which is used for explaining the background art of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of this invention will be described with reference to the accompanying drawings. In the description the same or functionally equivalent elements are denoted by the same or similar reference numerals, to thereby simplify the description.
FIG. 1 shows a configuration of a control system of pumping operation using an AC exciting generator-motor according to an embodiment of this invention.
The rotor shaft of 3-phase AC exciting generator-motor (wound-rotor type) 2 is mechanically coupled to reversible pump-turbine 1 directly. The stator of generator-motor 2 is electrically connected to 3-phase AC power system 4, via parallel CB (circuit breaker) 3 and main power transformer 8. The stator of generator-motor 2 is also connected to breaking disconnecting switch 5.
Circulating current type cycloconverter 6 changes the frequency (e.g., 50 Hz) of power system 4 by a prescribed frequency (e.g., 0 to +5 Hz) and controls its output voltage VG2 as well as its output current IG2. The input side of cycloconverter 6 is connected to power system 4, via cycloconverter power transformers 9 and cycloconverter circuit breaker 7. The output side of cycloconverter 6 is connected to the rotor side of AC exciting generator-motor 2.
Controller 10 sends commands to reversible pump-turbine 1, parallel CB 3, and cycloconverter 6. According to these commands, the control for opening of the wicket gate of pump-turbine 1, the shutdown (parallel off) of CB 3, the rotation speed control of generator-motor 2, and the active power control are effected.
Process variables for obtaining the above commands are input to controller 10. More specifically, controller 10 receives signals VG1, IG1, IG2, N, and ΔH. Signal VG1 is obtained by detecting the input voltage (VG1) of generator-motor 2, via potential transformer 11. Signal IG1 is obtained by detecting the input current (IG1) of generator-motor 2, via current transformer 12. Signal IG2 is obtained by detecting the output current (IG2) of cycloconverter 6, via current transformer 14. Signal N is obtained by detecting the rotation speed (N) of generator-motor 2, via speed sensor (tachometer) 13. Signal ΔH is obtained by detecting the pumping head at the time of pumping operation, via head detector 15.
Active power controller 16 detects whether the rotation speed of pump-turbine 1 reaches a prescribed speed for the current pumping head. When controller 16 detects that pump-turbine 1 reaches the prescribed speed, it sends a result (E16) of the detection to controller 10.
FIG. 2 is a block diagram explaining the control sequence for stopping the pumping operation of the embodiment of FIG. 1. FIGS. 3A-3J are timing charts illustrating the pumping operation stopping control for the embodiment of FIG. 1. The manner of operating the control system of this invention will now be described with reference to these figures.
Assume that during the pumping operation (B1 in FIG. 2) a stop command (B2 in FIG. 2) is generated at time t1. Then, controller 10 controls output current IG2 (FIG. 3H) and output voltage VG2 of cycloconverter 6 such that rotation speed N (FIG. 3J) of AC exciting generator-motor 2 decreases (B3 in FIG. 2).
The degree of opening (FIG. 3A) of the wicket gate of reversible pump-turbine 1 is controlled by controller 10 to be a specific opening degree. This specific opening degree is determined by an arithmetic calculation based on pumping head ΔH, detected by head detector 15, and rotation speed N of generator-motor 2, detected by speed sensor 13 (B4 in FIG. 2). Then, the pump input power of pump-turbine 1 or input current IG1 (FIG. 3F) of generator-motor 2 decreases in proportion to rotation speed N (FIG. 3J).
At time t2, rotation speed N (FIG. 3J) of generator-motor 2 reaches a minimum rotation speed which depends on the pumping head (B5 in FIG. 2) detected at time t2. This minimum rotation speed represents the minimum value for preventing occurrence of reverse pumping in reversible pump-turbine 1. At time t2, active power controller 16 detects the minimum value of rotation speed N (B6 in FIG. 2), so that the active power control for generator-motor 2 by means of cycloconverter 6 starts (B7 in FIG. 2). By this control, input current IG1 (FIG. 3F) of generator-motor 2 is controlled to be zero.
FIG. 4 shows a relation among pumping head ΔH of reversible pump-turbine 1, the pump input power of AC exciting generator-motor 2, and rotation speed N of generator-motor 2. The detection of the minimum rotation speed by means of active power controller 16 is carried out, using output ΔH detector 15 and output N of sensor 13, according to the minimum rotation speed characteristic as is shown in FIG. 4.
For instance, assume that the pumping head represented by output ΔH of detector 15 is denoted by Hp. In this case, the minimum rotation speed at head Hp, which represents the boundary of occurrence of reverse pumping, is 98.2% of the rated speed, as is illustrated in FIG. 4. Further, in this case, the pump input power is 62% of the rated value as is shown in FIG. 4. Incidentally, the above minimum rotation speed becomes high as the value of pumping head Hp becomes large.
At time t3, input current IG1 (FIG. 3F) of generator-motor 2 is rendered to be zero with the active power control for generator-motor 2 by cycloconverter 6. When current IG1=0, or input power=0, is detected in controller 10 (B8 in FIG. 2), a parallel off command (FIG. 3D) is sent from controller 10 to parallel CB 3.
Parallel CB 3 is cutoff by the parallel off command (B9 in FIG. 2) so that input voltage VG1 (FIG. 3G) of generator-motor 2 is reduced to zero. At the same time, the wicket gate of reversible pump-turbine 1 is fully closed (B10 in FIG. 2), and a gate block command is sent from controller 10 to cycloconverter 6 so that output voltage VG2 (FIG. 3I) and output current IG2 (FIG. 3H) of cycloconverter 6 are reduced to zero. The resultant VG2=0 renders frequency fG (FIG. 3E) of generator-motor 2 to zero.
When input voltage VG1 (FIG. 3G) of generator-motor 2 becomes zero, breaking disconnecting switch 5 is turned on (from t3 to t4 in FIG. 3C) for effecting regenerative braking. Following to this, gate signals of cycloconverter 6 are de-blocked at time t4, and an AC excitation is effected on generator-motor 2. This excitation applies regenerative braking to generator-motor 2, so that the rotation speed thereof rapidly decreases. When generator-motor 2 completely stops at time t5, cycloconverter 6 is again subjected to gate-blocking, to thereby release the regenerative braking (B11 in FIG. 2). Also at time t5, breaker 7 of cycloconverter 6 becomes off (FIG. 3B).
Incidentally, electrical braking obtained by applying a DC excitation to generator-motor 2 can be utilized to stop generator-motor 2.
FIG. 5 is a block diagram showing an example of head detector 15 used in the embodiment of FIG. 1. Lower reservoir 52 is connected to upper reservoir 51 via pipe 50 which is passing through reversible pump-turbine 1 and wicket gate 1a. Water level sensor 151 detects the water level of upper reservoir 51 and provides potential signal L1 proportional to the upper reservoir water level. Water level sensor 152 detects the water level of lower reservoir 52 and provides potential signal L2 proportional to the lower reservoir water level. Signals L1 and L2 are input to head calculator 150. Calculator 150 detects the potential difference between signals L1 and L2, and outputs signal ΔH proportional to the detected potential difference.
FIG. 6 is a block diagram showing an example of controller 10 used in the embodiment of FIG. 1. Input voltage and input current to the stator winding of AC exciting generator-motor 2 are denoted by signals VG1 and IG1, respectively. Signals VG1 and IG1 are input to power detector 100. Detector 100 detects the in-phase components of input signals VG1 and IG1, and generates power signal E100 from the product of these in-phase components. Power signal E100 represents the active power input to the stator of generator-motor 2.
Power signal E100 from detector 100 is input to zero-power detector 101. Detector 101 compares the level of input power signal E100 with a given comparison level corresponding to the zero-power. When the level of signal E100 falls under the comparison level, detector 101 sends parallel off command E101 to parallel CB 3 so that CB 3 is turned off.
Output signal N of speed sensor 13 and output signal ΔH of head detector 15 are both input to active power controller 16. Controller 16 is provided with a data table indicating of a characteristic as is shown in FIG. 4. Such a data table is predetermined for each of actual pumping operation systems. Controller 16 compares input signals N and ΔH with the data table and generates signal E16 for determining the opening of wicket gate 1a and the AC exciting amount (VG2·IG2) applied from cycloconverter 6 to generator-motor 2.
Signals E16 and ΔH are input to wicket gate controller 102. Controller 102 supplies the wicket gate (1a) of reversible pump-turbine 1 with signal E102 for controlling the opening of the wicket gate. The opening of the wicket gate is largely closed or squeezed as the signal level of E16 becomes low or as the signal level of ΔH becomes high.
Signal E16 from controller 16 is supplied as a power reference to adder 103. Adder 103 also receives signal E100 from power detector 100. Error signal E103 of signal E100 with respect to signal E16 is supplied from adder 103 to output controller 104. Controller 104 receives output signal ΔH from head detector 15, and outputs error signal E104 corresponding to E103. Error signal E104 is weighted by the magnitude of signal ΔH in controller 104.
Error signal E104 is supplied as a speed reference to adder 105. Adder 105 also receives output signal N from speed sensor 13. Error signal E105 of signal E104 with respect to signal N is input to speed controller 106. Controller 106 amplifies input signal E105, and sends amplified signal E106 to adder 108.
Adder 108 also receives signal E107 corresponding to both voltage and current signals VG1 and IG1, and current signal IG2 representing a current from cycloconverter 6 to generator-motor 2. Composite signal E108 of signals E106, E107, and IG2 is input to gate controller 109. Controller 109 performs on/off control of switching elements contained in cycloconverter 6.
Although the embodiment of FIG. 1 employs 3-phase equipment (2, 6, 9), the scope of the present invention is not limited to 3-phase. Further, cycloconverter 6 may be a variable frequency AC power source other than a cycloconverter. Any other hydraulic machine can be used in place of or together with reversible pump-turbine 1.
As mentioned above, according to the present invention, when the pumping operation of a pumped storage power plant is to be stopped, rotation speed N of AC exciting generator-motor 2 is reduced by the control of controller 10. At this time, the opening of the wicket gate of reversible pump-turbine 1 is closed in response to the reduction in speed N. Rotation speed N of AC exciting generator-motor 2 is reduced to the minimum speed for the current pumping head. Then, active power control for generator-motor 2 is performed, and when the input power of generator-motor 2 becomes zero, parallel CB 3 is turned off.
Since the parallel CB off is carried out at the input power zero condition, power system 4 can be free of fluctuations at the time of stop of the pumping operation, and, in addition, the life of parallel CB 3 is not reduced by the repetitive parallel CB off operations. Further, since reversible pump-turbine 1 can be stopped without unsuitable reverse pumping operation, the life of pump-turbine 1 can be expanded.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiment but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent arrangements.
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A control system of pumping operation comprises a cycloconverter for converting AC power from a AC power system into AC power having a given frequency, anAC exciting generator-motor, having a stator side electrically connected to the AC power system, having a rotor side electrically connected to the cycloconverter, and having a rotor shaft mechanically coupled to a pump-turbine by which the pumping operation is carried out, a circuit breaker inserted between the AC power system and the AC exciting generator-motor, a rotation speed controller for controlling a rotation speed of the AC exciting generator-motor such that the rotation speed becomes slow when the pumping operation is to be stopped, an AC excitation controller for decreasing a degree of excitation effected by the cycloconverter, wherein decreasing of the excitation degree starts when the rotation speed of the AC exciting generator-motor reaches a given minimum value, and a circuit breaker controller for turning off the circuit breaker when input power, supplied from the AC power system to the AC exciting generator-motor becomes substantially zero.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application Serial No. 60/333,741, filed Nov. 29, 2001.
BACKGROUND OF THE INVENTION
[0002] Oxazolidinones represent the first new class of antibacterials to be developed since the quinolones. The oxazolidinones are synthetic antibacterial compounds that are orally or intravenously active against problematic multidrug resistant Gram positive organisms and are not cross-resistant with other antibiotics. See Riedl et al, Recent Developments with Oxazolidinone Antibiotics, Exp. Opin. Ther. Patents (1999) 9(5), Ford et al., Oxazolidinones: New Antibacterial Agents, Trends in Microbiology 196 Vol. 5, No. 5, May 1997 and WO 96/35691.
[0003] This invention relates to new oxazolidinones having a cyclopropyl moiety, which are effective against aerobic and anerobic pathogens such as multi-resistant staphylococci, streptococci and enterococci, Bacteroides spp., Clostridia spp. species, as well as acid-fast organisms such as Mycobacterium tuberculosis and other mycobacterial species.
SUMMARY OF THE INVENTION
[0004] The present invention relates to compounds of formula I:
[0005] its enantiomer, diastereomer, or pharmaceutically acceptable salt, hydrate or prodrug thereof wherein:
[0006] R 1 represents
[0007] i) hydrogen,
[0008] ii) NR 5 R 6 ,
[0009] iii) CR 7 R 8 R 9 , C(R) 2 OR 14 , CH 2 NHR 14 , C(═O)R 13 , C(═NOH)H, C(═NOR 13 )H, C(═NOR 13 )R 13 , C(═NOH)R 13 , C(═O)N(R 13 ) 2 , C(═NOH)N(R 13 ) 2 , NHC(═X 1 )N(R 13 ) 2 , (C═NH)R 7 , N(R 13 )C(═X 1 )N(R 13 ) 2 , COOR 13 , SO 2 R 14 , N(R 13 )SO 2 R 14 , N(R 13 )COR 14 , or (C 1-6 alkyl)CN, CN, CH═C(R) 2 , OH, C(═O)CHR 13 , C(═NR 13 )R 13 , NHC(═X 1 )R 13 ; or
[0010] iv) C 5-10 heterocycle optionally substituted with 1-3 groups of R 7 , which may be attached through either a carbon or a heteroatom;
[0011] represents aryl or heteroaryl, heterocycle, heterocyclyl or heterocyclic, provided that in the case of a heteroaryl, heterocycle, heterocyclyl or heterocyclic, the cyclopropyl is not attached to a nitrogen atom on the ring;
[0012] R 3 represents
[0013] i) NR 13 (C═X 2 )R 12 ,
[0014] ii) NR 13 (C═X 1 )R 12 ,
[0015] iii) NR 13 SO 2 R14,
[0016] iv) NR 13 (CHR 13 ) 0-4 aryl,
[0017] v) NR 13 (CHR 13 ) 0-4 heteroaryl,
[0018] vi) S(CHR 13 ) 0-4 aryl,
[0019] vii) S(CHR 13 ) 0-4 heteroaryl,
[0020] viii) O(CHR 13 ) 0-4 aryl, or
[0021] ix) O(CHR 13 ) 0-4 heteroaryl;
[0022] x) OCR 13 ═NR 16
[0023] xi)
[0024] R 4 and R 4a independently represent
[0025] i) hydrogen,
[0026] ii) halogen,
[0027] iii) C 1-6 alkoxy,
[0028] iv) C 1-6 alkyl,
[0029] v) CN,
[0030] vi) Aryl, or
[0031] vii) heteroaryl
[0032] r and s independently are 1-3, with the provision that when (R 4a ) s and (R 4 ) r are attached to an Ar or HAr ring the sum of r and s is less than or equal to 4;
[0033] represents an optionally substituted aromatic heterocyclic group containing at least one nitrogen in the ring and which is attached through a bond on any N, and which is unsubstituted or contains 1 to 3 substituents of R 16 ;
[0034] R 5 and R 6 independently represent
[0035] i) hydrogen,
[0036] ii) C 1-6 alkyl optionally substituted with 1-3 groups of halogen, CN, OH, C 1-6 alkoxy, amino, imino, hydroxyamino, alkoxyamino, C 1-6 acyloxy, C 1-6 alkylsulfenyl, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, aminosulfonyl, C 1-6 alkylaminosulfonyl, C 1-6 dialkylaminosulfonyl, 4-morpholinylsulfonyl, phenyl, pyridine, 5-isoxazolyl, ethylenyloxy, or ethynyl, said phenyl and pyridine optionally substituted with 1-3 halogen, CN, OH, CF 3 , C 1-6 alkyl or C 1-6 alkoxy;
[0037] iii) C 1-6 acyl optionally substituted with 1-3 groups of halogen, OH, SH, C 1-6 alkoxy, naphthalenoxy, phenoxy, amino, C 1-6 acylamino, hydroxylamino, alkoxylamino, C 1-6 acyloxy, aralkyloxy, phenyl, pyridine, C 1-6 alkylcarbonyl, C 1-6 alkylamino, C 1-6 dialkylamino, C 1-6 hydroxyacyloxy, C 1-6 alkylsulfenyl, phthalimido, maleimido, succinimido, said phenoxy, phenyl and pyridine optionally substituted with 1-3 groups of halo, OH, CN, C 1-6 alkoxy, amino, C 1-6 acylamino, CF 3 or C 1-6 alkyl;
[0038] iv) C 1-6 alkylsulfonyl optionally substituted with 1-3 groups of halogen, OH, C 1-6 alkoxy, amino, hydroxylamino, alkoxylamino, C 1-6 acyloxy, or phenyl; said phenyl optionally substituted with 1-3 groups of halo, OH, C 1-6 alkoxy, amino, C 1-6 acylamino, CF 3 or C 1-6 alkyl;
[0039] v) arylsulfonyl optionally substituted with 1-3 of halogen, C 1-6 alkoxy, OH or C 1-6 alkyl;
[0040] vi) C 1-6 alkoxycarbonyl optionally substituted with 1-3 of halogen, OH, C 1-6 alkoxy, C 1-6 acyloxy, or phenyl, said phenyl optionally substituted with 1-3 groups of halo, OH, C 1-6 alkoxy, amino, C 1-6 acylamino, CF 3 or C 1-6 alkyl;
[0041] vii) aminocarbonyl, C 1-6 alkylaminocarbonyl or C 1-6 dialkylaminocarbonyl, said alkyl groups optionally substituted with 1-3 groups of halogen, OH, C 1-6 alkoxy or phenyl;
[0042] viii) five to six membered heterocycles optionally substituted with 1-3 groups of halogen, OH, CN, amino, C 1-6 acylamino, C 1-6 alkylsulfonylamino, C 1-6 alkoxycarbonylamino, C 1-6 alkoxy, C 1-6 acyloxy or C 1-6 alkyl, said alkyl optionally substituted with 1-3 groups of halogen, or C 1-6 alkoxy;
[0043] ix) C 3-6 cycloalkylcarbonyl optionally substituted with 1-3 groups of halogen, OH, C 1-6 alkoxy or CN;
[0044] x) benzoyl optionally substituted with 1-3 groups of halogen, OH, C 1-6 alkoxy, C 1-6 alkyl, CF 3 , C 1-6 alkanoyl, amino or C 1-6 acylamino;
[0045] xi) pyrrolylcarbonyl optionally substituted with 1-3 of C 1-6 alkyl;
[0046] xii) C 1-2 acyloxyacetyl where the acyl is optionally substituted with amino, C 1-6 alkylamino, C 1-6 dialkylamino, 4-morpholino, 4-aminophenyl, 4-(dialkylamino)phenyl, 4-(glycylamino)phenyl; or
[0047] R 5 and R 6 taken together with any intervening atoms can form a 3 to 7 membered heterocyclic ring containing carbon atoms and 1-2 heteroatoms independently chosen from O, S, SO, SO 2 , N, or NR 8 ;
[0048] R 7 represents
[0049] i) hydrogen, halogen, OH, C 1-6 alkoxy, C 1-6 alkyl, alkenyl,
[0050] ii) amino, C 1-6 alkylamino, C 1-6 dialkylamino, hydroxylamino or C 1-2 alkoxyamino all of which can be optionally substituted on the nitrogen with C 1-6 acyl, C 1-6 alkylsulfonyl or C 1-6 alkoxycarbonyl, said acyl and alkylsulfonyl optionally substituted with 1-2 of halogen or OH;
[0051] R 8 and R 9 independently represent
[0052] i) H, CN,
[0053] ii) C 1-6 alkyl optionally substituted with 1-3 halogen, CN, OH, C 1-6 alkoxy, C 1-6 acyloxy, or amino,
[0054] iii) phenyl optionally substituted with 1-3 groups of halogen, OH, C 1-6 alkoxy; or
[0055] R 7 and R 8 taken together can form a 3-7 membered carbon ring optionally interrupted with 1-2 heteroatoms chosen from O, S, SO, SO 2 , NH, and NR 8 ;
[0056] X 1 represents O, S or NR 13 , NCN, or NSO 2 R 14 ;
[0057] X 2 represents O, S, NH or NSO 2 R 14 ;
[0058] R 10 represents hydrogen, C 1-6 alkyl or CO 2 R 15 ;
[0059] R 11 represents hydrogen, C 1-6 alkyl, C 1-6 alkanoyl, halogen, amino, C 1-6 acylamino, C 1-6 alkoxy, OH or CF 3 ,; NHC 1-6 alkyl, or N(C 1-6 alkyl) 2 , where said alkyl may be substituted with 1-3 groups of halo, OH or C 1-6 alkoxy;
[0060] R 12 represents hydrogen, C 1-6 alkyl, C 1-6 cycloalkyl, heteroaryl, wherein said heteroaryl may be substituted with 1-2 groups of C 1-6 alkyl, NH 2 , C 1-6 alkylamino, C 1-6 alkoxy or C 1-6 dialkylamino, where said alkyl may be substituted with 1-3 groups of halo, OH or C 1-6 alkoxy; alkylthio, alkylsulfinyl, alkylsulfonyl or cyano;
[0061] Each R 13 represents independently hydrogen, C 1-6 alkyl, NR 5 R 6 , SR 8 , S(O)R 8 , S(O) 2 R 8 , CN, C 1-6 alkylS(O)R, OH, C 1-6 alkoxycarbonyl, C 6-10 arylcarboxy, hydroxycarbonyl, C 1-6 acyl, C 3-7 membered carbon ring optionally interrupted with 1-4 heteroatoms chosen from O, S, SO, SO 2 , NH and NR 8 where said C 1-6 alkyl or C 1-6 acyl groups may be independently substituted with 0-3 halogens, hydroxy, N(R) 2 , CO 2 R, C 6-10 aryl, C 5-10 heteroaryl, or C 1-6 alkoxy groups;
[0062] When two R 13 groups are attached to the same atom or two adjacent atoms they may be taken together to form a 3-7 membered carbon ring optionally interrupted with 1-2 heteroatoms chosen from O, S, SO, SO 2 , NH, and NR 8 ;
[0063] R represents hydrogen or C 1-6 alkyl;
[0064] R 14 represents amino, C 1-6 alkyl, C 1-6 haloalkyl, five to six membered heterocycles or phenyl, said phenyl and heterocycles optionally substituted with 1-3 group of halo, C 1-6 alkoxy, C 1-6 acylamino, or C 1-6 alkyl, hydroxy and/or amino, said amino and hydroxy optionally protected with an amino or hydroxy protecting group;
[0065] R 15 is C 1-6 alkyl or benzyl said benzyl optionally substituted with 1-3 groups of halo, OH, C 1-6 alkoxy, amino, C 1-6 acylamino, or C 1-6 alkyl;
[0066] R 16 represents CN, NH 2 , OH, hydroxy C 1-6 alkyl, C 1-6 alkyl, COOC 1-6 alkyl, COOH, CONH 2 , CON(C 1-6 alkyl) 2 , CONHC 1-6 alkyl, CHO, C═NOH, C═NOC 1-6 alkyl, (CH 2 ) 1-3 NH 2 , (CH 2 ) 1-6 NHOC 1-6 alkyl, (CH 2 ) 1-6 N(C 1-6 alkyl) 2 ,
[0067] m, n, and q represents 0-1.
[0068] Another aspect of the invention is concerned with the use of the novel antibiotic compositions in the treatment of bacterial infections.
DETAILED DESCRIPTION OF THE INVENTION
[0069] The invention is described herein in detail using the terms defined below unless otherwise specified.
[0070] The compounds of the present invention may have asymmetric centers, chiral axes and chiral planes, and occur as racemates, racemic mixtures, and as individual diastereomers, with all possible isomers, including optical isomers, being included in the present invention. (See E. L. Eliel and S. H. Wilen Stereochemistry of Carbon Compounds (John Wiley and Sons, New York 1994, in particular pages 1119-1190).
[0071] When any variable (e.g. aryl, heterocycle, R 5 , R 6 etc.) occurs more than once, its definition on each occurrence is independent at every other occurrence. Also combinations of substituents/or variables are permissible only if such combinations result in stable compounds.
[0072] The term “alkyl” refers to a monovalent alkane (hydrocarbon) derived radical containing from 1 to 15 carbon atoms unless otherwise defined. It may be straight or branched. Preferred alkyl groups include lower alkyls which have from 1 to 6 carbon atoms such as methyl, ethyl, propyl, isopropyl, butyl and t-butyl. When substituted, alkyl groups may be substituted with up to 3 substituent groups, selected from the groups as herein defined, at any available point of attachment. When the alkyl group is said to be substituted with an alkyl group, this is used interchangeably with “branched alkyl group”.
[0073] Cycloalkyl is a species of alkyl containing from 3 to 15 carbon atoms, without alternating or resonating double bonds between carbon atoms. It may contain from 1 to 4 rings which are fused. Preferred cycloalkyl groups are cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl. When substituted, cycloalkyl groups may be substituted with up to 3 substituents which are defined herein by the definition of alkyl.
[0074] Alkanoyl refers to a group derived from an aliphatic carboxylic acid of 2 to 4 carbon atoms. Examples are acetyl, propionyl, butyryl and the like. The term “alkoxy” refers to those groups of the designated length in either a straight or branched configuration and if two or more carbon atoms in length, they may include a double or a triple bond. Exemplary of such alkoxy groups are methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, tertiary butoxy, pentoxy, isopentoxy, hexoxy, isohexoxy allyloxy, propargyloxy, and the like.
[0075] refers to aryl or heteroaryl, heterocycle, Het, heterocyclyl or heterocyclic as described immediately below.
[0076] Aryl refers to any stable monocyclic or bicyclic carbon ring of up to 7 atoms in each ring, wherein at least one ring is aromatic. Examples of such aryl elements include phenyl, naphthyl, tetrahydronaphthyl, indanyl, indanonyl, biphenyl, tetralilnyl, tetralonyl, fluorenonyl, phenanthryl, anthryl, acenaphthyl, and the like substituted phenyl and the like. Aryl groups may likewise be substituted as defined. Preferred substituted aryls include phenyl and naphthyl.
[0077] The expression
[0078] represents an optionally substituted aromatic heterocyclic group containing 1 to 4 nitrogen atoms and at least one double bond, and which is connected through a bond on any nitrogen. Exemplary groups are 1,2,3-triazole, 1,2,4-triazole, 1,2,5-triazole, tetrazole, pyrazole, and imidazole, any of which may contain 1 to 3 substituents selected from CN, NH 2 , OH, C 1-6 alkyl, COOC 1-6 alkyl, COOH, CONH 2 CON(C 1-6 alkyl) 2 , CONH(C 1-6 alkyl), CHO, C═NOC 1-6 alkyl, (CH 2 ) 1-3 NH 2 , NHAc, or N(C 1-6 alkyl) 2 .
[0079] The term heterocycle, heteroaryl, Het, heterocyclyl or heterocyclic, as used herein except where noted, represents a stable 5- to 7-membered mono- or bicyclic or stable 8- to 11-membered bicyclic heterocyclic ring system, any ring of which may be saturated or unsaturated, and which consists of carbon atoms and from one to four heteroatoms selected from the group consisting of N, O and S, and wherein the nitrogen and sulfur heteroatoms may optionally be oxidized, and the nitrogen heteroatom may optionally be quatemized (in which case it is properly balanced by a counterion), and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached at any heteroatom or carbon atom which results in the creation of a stable structure. The term heterocycle or heterocyclic includes heteroaryl moieties. “Heterocycle” or “heterocyclyl” therefore includes the above mentioned heteroaryls, as well as dihydro and tetrahydro analogs thereof. The heterocycle, heteroaryl, Het or heterocyclic may be substituted with 1-3 groups of R 7 . Examples of such heterocyclic elements include, but are not limited to the following: piperidinyl, piperazinyl, 2-oxopiperazinyl, 2-oxopiperidinyl, 2-oxopyrrolodinyl, 2-oxoazepinyl, azepinyl, pyrrolyl, 4-piperidonyl, pyrrolidinyl, pyrazolyl, pyrazolidinyl, imidazolyl, imidazolinyl, imidazolidinyl, pyridyl, pyrazinyl, pyrimidinyl, pyrimidonyl, pyridinonyl, pyridazinyl, oxazolyl, oxazolidinyl, isoxazolyl, isoxazolidinyl, morpholinyl, thiazolyl, thiazolidinyl, isothiazolyl, quinuclidinyl, isothiazolidinyl, indolyl, quinolinyl, isoquinolinyl, benzimidazolyl, thiadiazoyl, benzopyranyl, benzothiazolyl, benzoxazolyl, furyl, tetrahydrofuryl, tetrahydropyranyl, thiophenyl, imidazopyridinyl, tetrazolyl, triazinyl, thienyl, benzothienyl, thiamorpholinyl sulfoxide, thiamorpholinyl sulfone, naphthpyridinyl, dihydropyrimidinyl, dihydropyrrolyl, dihydroquinolinyl, dihydrotetrazolyl, dihydrotriazolyl, dihydrothienyl, dihydrooxazolyl, dihydrobenzothiophenyl, dihydrofuranyl, benzothiazolyl, benzothienyl, benzoimidazolyl, benzopyranyl, benzothiofuranyl, carbolinyl, chromanyl, cinnolinyl, benzopyrazolyl, benzodioxolyl and oxadiazolyl. Additional examples of heteroaryls are illustrated by formulas a, b, c and d:
[0080] wherein R 16 and R 17 are independently selected from hydrogen, halogen, C 1-6 alkyl, C 2-4 alkanoyl, C 1-6 alkoxy; and R 18 represents hydrogen, C 1-6 alkyl, C 2-4 alkanoyl, C 1-6 alkoxycarbonyl and carbamoyl.
[0081] The term “alkenyl” refers to a hydrocarbon radical straight, branched or cyclic containing from 2 to 10 carbon atoms and at least one carbon to carbon double bond. Preferred alkenyl groups include ethenyl, propenyl, butenyl and cyclohexenyl.
[0082] The terms “quaternary nitrogen” and “positive charge” refer to tetravalent, positively charged nitrogen atoms (balanced as needed by a counterion known in the art) including, e.g., the positively charged nitrogen in a tetraalkylammonium group (e.g. tetramethylammonium), heteroarylium, (e.g., N-methyl-pyridinium), basic nitrogens which are protonated at physiological pH, and the like. Cationic groups thus encompass positively charged nitrogen-containing groups, as well as basic nitrogens which are protonated at physiologic pH.
[0083] The term “heteroatom” means O, S or N, selected on an independent basis.
[0084] The term “prodrug” refers to compounds which are drug precursors which, following administration and absorption, release the drug in vivo via some metabolic process. Exemplary prodrugs include acyl amides of the amino compounds of this invention such as amides of alkanoic(C 1-6 )acids, amides of aryl acids (e.g., benzoic acid) and alkane(C 1-6 )dioic acids.
[0085] Halogen and “halo” refer to bromine, chlorine, fluorine and iodine.
[0086] When a group is termed “substituted”, unless otherwise indicated, this means that the group contains from 1 to 3 substituents thereon.
[0087] When a functional group is termed “protected”, this means that the group is in modified form to preclude undesired side reactions at the protected site. Suitable protecting groups for the compounds of the present invention will be recognized from the present application taking into account the level of skill in the art, and with reference to standard textbooks, such as Greene, T. W. et al. Protective Groups in Organic Synthesis Wiley, New York (1991). Examples of suitable protecting groups are contained throughout the specification.
[0088] Examples of suitable hydroxyl and amino protecting groups are: trimethylsilyl, triethylsilyl, o-nitrobenzyloxycarbonyl, p-nitrobenzyloxycarbonyl, t-butyldiphenylsilyl, t-butyldimethylsilyl, benzyloxycarbonyl, t-butyloxycarbonyl, 2,2,2-trichloroethyloxycarbonyl, allyloxycarbonyl and the like. Examples of suitable carboxyl protecting groups are benzhydryl, o-nitrobenzyl, p-nitrobenzyl, 2-naphthylmethyl, allyl, 2-chloroallyl, benzyl, 2,2,2-trichloroethyl, trimethylsilyl, t-butyldimethylsilyl, t-butyldiphenylsilyl, 2-(trimethylsilyl)ethyl, phenacyl, p-methoxybenzyl, acetonyl, p-methoxyphenyl, 4-pyridylmethyl, t-butyl and the like.
[0089] The cyclopropyl containing oxazolidinone compounds of the present invention are useful per se and in their pharmaceutically acceptable salt and ester forms for the treatment of bacterial infections in animal and human subjects. The term “pharmaceutically acceptable ester, salt or hydrate,” refers to those salts, esters and hydrated forms of the compounds of the present invention which would be apparent to the pharmaceutical chemist. i.e., those which are substantially non-toxic and which may favorably affect the pharmacokinetic properties of said compounds, such as palatability, absorption, distribution, metabolism and excretion. Other factors, more practical in nature, which are also important in the selection, are cost of the raw materials, ease of crystallization, yield, stability, solubility, hygroscopicity and flowability of the resulting bulk drug. Conveniently, pharmaceutical compositions may be prepared from the active ingredients in combination with pharmaceutically acceptable carriers. Thus, the present invention is also concerned with pharmaceutical compositions and methods of treating bacterial infections utilizing as an active ingredient the novel cyclopropyl containing oxazolidinone compounds.
[0090] The pharmaceutically acceptable salts referred to above also include acid addition salts. Thus, when the Formula I compounds are basic, salts may be prepared from pharmaceutically acceptable non-toxic acids, including inorganic or organic acids. Included among such acid salts are the following: acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, bisulfate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, fumarate, glucoheptanoate, glycerophosphate, hemisulfate, heptanoate, hexanoate, hydrochloride, hydrobromide, hydroiodide, 2-hydroxyethanesulfonate, isethionic, lactate, maleate, mandelic, malic, maleic, methanesulfonate, mucic, 2-naphthalenesulfonate, nicotinate, nitric oxalate, pamoate, pectinate, persulfate, 3-phenylpropionate, picrate, pivalate, propionate, phosphate, pantothenic, pamoic, sulfate, succinate, tartrate, thiocyanate, tosylate and undecanoate.
[0091] When the compound of the present invention is acidic, suitable “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 aluminum, ammonium, calcium, copper, ferric, ferrous, lithium, magnesium, manganic salts, manganous, potassium, sodium zinc and the like. Particularly preferred are the ammonium, calcium, magnesium, potassium and sodium salts. Salts derived from pharmaceutically acceptable inorganic non-toxic bases include salts of primary, secondary and teritiary amines, substituted amines including naturally occurring substituted amines, cyclic amines and basic ion exchange resins, such as arginine, betaine caffeine, choline, N,N 1 -dibenzylethylenediamine, diethylamine, 2-diethylaminoethanol, 2-dimethylaminoethanol, ethanolamine, ethylenediamine, N-ethylmorpholine, N-ethylpiperidine, glucamine, glucosamine, histidine, hydrabamine, isopropylamine, lysine, methylglucamine, morpholine, piperazine, piperidine, polyamine resins, procaine, purines, theobromine, triethylamine, trimethylamine tripropylamine, tromethamine and the like.
[0092] The pharmaceutically acceptable esters are such as would be readily apparent to a medicinal chemist, and include those which are hydrolyzed under physiological conditions, such as “biolabile esters”, pivaloyloxymethyl, acetoxymethyl, phthalidyl, indanyl and methoxymethyl, and others.
[0093] Biolabile esters are biologically hydrolizable, and may be suitable for oral administration, due to good absorption through the stomach or intenstinal mucosa, resistance to gastric acid degradation and other factors. Examples of biolabile esters include compounds.
[0094] Another embodiment of this invention is realized when R 1 independently represent H, NR 5 R 6 , CN, OH, C(R) 2 OR 14 , NHC(═X1)N(R 13 ) 2 , C(═NOH)N(R 13 ) 2 , or CR 7 R 8 R 9 and all other variables are as described herein.
[0095] Another embodiment of this invention is realized when
[0096] is phenyl, pyridine, pyrimidine, or piperidine and all other variables are as described herein.
[0097] Another embodiment of this invention is realized when R 1 is NR 5 R 6 and all other variables are as described herein.
[0098] Another embodiment of this invention is realized when R 1 is CN and all other variables are as described herein.
[0099] Still another embodiment of this invention is realized when R 5 and R 6 independently are:
[0100] i) H,
[0101] ii) C 1-6 alkyl optionally substituted with 1-3 groups of halogen, CN, OH, C 1-6 alkoxy, amino, hydroxyamino, alkoxyamino, C 1-6 acyloxy, C 1-6 alkylsulfenyl, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, aminosulfonyl, C 1-6 alkylaminosulfonyl, C 1-6 dialkylaminosulfonyl, 4-morpholinylsulfonyl, phenyl, pyridine, 5-isoxazolyl, ethyenyloxy, or ethynyl, said phenyl and pyridine optionally substituted with 1-3 halogen, CN, OH, CF 3 , C 1-6 alkyl or C 1-6 alkoxy;
[0102] iii) C 1-6 acyl optionally substituted with 1-3 groups of halogen, OH, SH, C 1-6 alkoxy, naphthalenoxy, phenoxy, amino, C 1-6 acylamino, hydroxylamino, alkoxylamino, C 1-6 acyloxy, phenyl, pyridine, C 1-6 alkylcarbonyl, C 1-6 alkylamino, C 1-6 dialkylamino, C 1-6 hydroxyacyloxy, C 1-6 alkylsulfenyl, phthalimido, maleimido, succinimido, said phenoxy, phenyl and pyridine optionally substituted with 1-3 groups of halo, OH, CN, C 1-6 alkoxy, amino, C 1-6 acylamino, CF 3 or C 1-6 alkyl; or
[0103] iv) benzoyl optionally substituted with 1-3 groups of halogen, OH, C 1-6 alkoxy, C 1-6 alkyl, CF3, C 1-6 alkanoyl, amino or C 1-6 acylamino and all other variables are as described herein.
[0104] Yet another embodiment of this invention is realized when X 1 represents O and all other variables are as described herein.
[0105] A preferred embodiment of this invention is realized when the structural formula is II:
[0106] wherein R 1 , R 4 , R 4a , and R 3 are as described herein.
[0107] Another preferred embodiment of this invention is realized when R 1 is CN or NR 5 R 6 .
[0108] Preferred compounds of this invention are:
[0109] N-[5(S)-3-[4-[(1-t-Butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0110] N-[5(S)-3-[4-(1-Carboxycyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0111] N-[5(S)-3-[3-Fluoro-4-(1-hydroxymethylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0112] N-[5(S)-3-[4-(1-Aminocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0113] N-[5(S)-3-[4-(1-Aminocyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0114] N-[5(S)-3-[4-(1-Aminocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0115] N-[5(S)-3-[3-Fluoro-4-(1-formylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0116] N-[5(S)-3-[3-Fluoro-4-(1-(hydroxyimino)methylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0117] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0118] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thioacetamide,
[0119] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]thioacetamide,
[0120] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]methanesulfonylamide,
[0121] N-[5(S)-3-[4-[(1-t-Butoxycarbonyl)cyclopropan-1-yl]-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0122] N-[5(S)-3-[3,5-Difluoro-4-(1-hydroxymethylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0123] N-[5(S)-3-[3,5-Difluoro-4-(1-formylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0124] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0125] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]difluoroacetamide,
[0126] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]difluoroacetamide,
[0127] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]difluoroacetamide,
[0128] 5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,2,4-oxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]aminomethyloxazolidin-2-one,
[0129] 5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,2-isoxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]aminomethyloxazolidin-2-one,
[0130] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-5-[N-(1,2,4-oxadiazolyl-3-yl)amino]methyloxazolidin-2-one,
[0131] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-5-[N-(1,2,4-oxadiazolyl-3-yl)amino]methyloxazolidin-2-one,
[0132] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-5-[N-(1,2,3,4-thiatriazolyl-5-yl)amino]methyloxazolidin-2-one,
[0133] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-5-[N-(1,2,3,4-thiatriazolyl-5-yl)amino]methyloxazoidin-2-one,
[0134] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,2,3,4-thiatriazolyl-5-yl)amino]methyloxazolidin-2-one,
[0135] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-5-[N-(1,2-isoxadiazolyl-3-yl)amino]methyloxazolidin-2-one,
[0136] (S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-5-[N-(1,2-isoxadiazolyl-3-yl)amino]methyloxazolidin-2-one,
[0137] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide,
[0138] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]thioacetamide,
[0139] 5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,2,4-oxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one,
[0140] 5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,2-isoxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one,
[0141] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,2,4-oxadiazolyl-3-yl)amino]methyloxazolidin-2-one,
[0142] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,2-isoxadiazolyl-3-yl)amino]methyloxazolidin-2-one,
[0143] 5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,2-isoxadiazolyl-3-yl)oxy]methyloxazolidin-2-one,
[0144] 5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,3-thiazolyl-2-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one,
[0145] 5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,3,4-thiadiazolyl-2-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one,
[0146] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,3-thiazolyl-2-yl)amino]methyloxazolidin-2-one,
[0147] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-5-[N-(1,3-thiazolyl-2-yl)amino]methyloxazolidin-2-one,
[0148] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-5-[N-(1,3-thiazolyl-2-yl)amino]methyloxazolidin-2-one,
[0149] 5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,3,4-thiadiazolyl-2-yl)amino]methyloxazolidin-2-one,
[0150] S-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]dithiocarbamate,
[0151] S-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]dithiocarbamate,
[0152] S-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]dithiocarbamate,
[0153] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiourea,
[0154] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiourea,
[0155] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]thiourea,
[0156] O-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiocarbonate,
[0157] O-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiocarbonate,
[0158] N′-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiourea,
[0159] N′-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiourea,
[0160] N′-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]thiourea, O-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]thiocarbonate,
[0161] N′-Cyano N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamidine, and
[0162] N′-Cyano N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamidine, or
[0163] their enantiomer, diastereomer, or pharmaceutically acceptable salt, hydrate or prodrug thereof wherein.
[0164] The compounds of the present invention can be prepared according to the procedures of the following schemes and general examples, using appropriate materials, and are further exemplified by the following specific examples. The compounds illustrated in the examples are not, however, to be construed as forming the only genus that is considered as the invention. The following examples further illustrate details for the preparation of compounds of the present invention. Those skilled in the art will readily understand that known variations of the conditions and processes of the following preparative procedures can be used to prepare the compounds of the present invention. All temperatures are in degrees Celsius unless otherwise noted.
[0165] General Schemes for the preparation of the compounds of the present invention are detailed in Schemes I-IV. It should be recognized that the chemical transformations depicted in Schemes I-IV are performed in one possible sequence. It will be recognized by those skilled in the art that modifications of the described schemes can be mentioned in which the requisite transformations can be performed in a different sequence to obtain the compounds of the present invention. Thus, the general sequence of synthetic transformations described below should not be construed as limiting with regard to the preparation of the compounds of the present invention. As shown in Schemes I-II one general procedure for the preparation of the Compounds of the present invention begins from readily available nitroaromatic or nitroheteroaromatic compounds, A, which are optimally substituted with a leaving group (X) appropriate for substitution. In many cases a preferred leaving group is picked from one of the halogens, but those skilled in the art will recognize that in some cases other leaving groups may be substituted such as sulfonyl or phosphoryl ethers. Treatment of the selected compounds with a malonyl ester in the presence of an appropriate base readily selected by practitioners of the art followed by in situ hydrolysis of the resulting diester and decarboxylation under acidic conditions affords the resulting nitro substituted aromatic or heteroaromatic acetic acid. Typical malonyl esters would include ethyl or other lower alkyl esters as well as aryl esters such as phenyl or substituted phenyl esters. Many strong bases can be used for performing this transformation, some preferred bases include metal hydrides such as sodium hydride or potassium hydride along with non-nucleophilic amide bases such as lithium diisopropylamide or the like or alkoxide bases such as sodium ethoxide or sodium methoxide. Likewise a variety of aqueous acids sulfuric acid or hydrochloric acid can be envisioned for the hydrolysis and if necessary appropriate cosolvents such as acetic acid or propionic acid may be employed in the in situ decarboxylation of the intermediate diester to the desired aromatic or heteroaromatic acetic acid. Optionally the hydrolysis mixture may be heated to accelerate the rate of the reaction and often it is convenient to reflux the reaction mixture until the reaction has been completed. In a second step the aromatic or heteroaromatic acetic acid obtained above is esterified to form B. It will be recognized that there are a plethora of potential methods for the preparation of esters from acids and potentially many of them could be used for the preparation of the desired aromatic or heteroaromatic phenylacetic acid ester. While a number of alkyl esters could be formed in the above transformation the use of the t-butyl ester or other tertiary alkyl ester is preferred for the subsequent transformations. These esters may be prepared by a variety of methods such as reacting the aromatic or heteroaromatic phenyl acetic acid in a non-polar solvent with a 1,1-disubstituted olefin in the presence of a strong acid such as sulfuric acid. Alternatively the requisite tertiary alkyl ester B can be formed by in situ formation of an acid chloride or a mixed anhydride and allowing the resulting activated acid to react with a tertiary alcohol such as t-butanol or t-amyl alcohol to form the requisite tertiary ester. Preferred reagents for the activation of the aromatic or heteroaromatic acid include, but are not limited to, oxalyl chloride, thionyl chloride, or di-t-butyldicarbonate.
[0166] In the next step the ester B is converted to the acrylate C. A convenient method for the preparation of C is the reaction of B with Bis-N,N-dimethylaminomethane or another appropriate formaldehyde equivalent in an a nonprotic polar solvent such as dimethylsulfoxide or dimethylformamide or the like in the presence of an anhydride such as acetic anhydride. In this way the acrylate C is conveniently prepared and can be converted to the desired 1,1-substituted cyclopropane, D, by reaction with an ylide precursor such as trimethylsulfoxonium iodide in the presence of a non-nucleophilic base such as potassium t-butoxide of sufficient strength to form the requisite ylide.
[0167] The nitro cyclopropane D is then reduced to the amino compound and acylated to the carboxybenzyl-protected intermediate E. Numerous methods for the reduction of aromatic and heteroaromatic nitro compound to the corresponding amines will be well known to those familiar with the art and these are incorporated within the scope of the present invention. Particularly useful however is the reduction of the nitro group with hydrogen gas in the presence of a metal catalyst such as platinum, palladium, or ruthenium deposited on an inert carrier such as carbon in an appropriate solvent such as methanol, ethanol, acetic acid, ethyl acetate and the like. Alternatively other reducing agents such as SnCl 2 or FeCl 3 could be employed in the present reduction. The amine so synthesized is then acylated with an alkylchloroformate such as benzylchloroformate in a non-polar solvent such as tetrahydrofuran, ethyl ether, or methylene chloride to afford the required carboxybenzylprotected amine, E. The oxazolidinones of the present invention are then readily prepared in a stepwise fashion by first deprotonating E in an ethereal solvent such as tetrahydrofuran or diethyl ether with a strong base such as an alkyl lithium, alkyl magnesium halide or a dialkyl lithium amide. Examples of bases appropriate for this transformation would include but are not limited to n-butyl lithium, methyl magnesium bromide, t-butyl lithium, sec-butyl lithium, or lithium diisopropyl amide and the like. Typically the deprotonation is carried out at a reduced temperature in the range of 0° C. to −100° C. but may be performed at any appropriate temperature. Addition of a glycydyl ester such as glycidyl butyrate followed by warming to room temperature affords the desired 5-hydroxyoxazolidinone, F, of the present invention. It should be noted that if an R-glycydyl ester is used an R-5-hydroxyoxazolidinone will be obtained while if an S-glycydyl ester is employed an S-5-hydroxyoxazloidinone will be obtained. By this way oxazolidinones that are substantially single enantiomers can be prepared. However if racemic F would be desired, it would be readily prepared from an appropriate racemic glycydyl ester.
[0168] Optionally, if a 1-cyanosubstituted cyclopropane is desired in the compounds of the present invention the ester D may be converted to the cyano compound G. It will be recognized that there are several methods and reagents for carrying out this transformation. For example the ester may be hydrolyzed to the acid and subsequently reduced to the carbinol. Oxidation to the aldehyde followed by formation of the oxime and dehydration would then afford the cyano compound G. Alternatively the ester may be directly reduced to the carbinol and then converted to G as described above. In another modification of the invention one could directly convert the ester to the aldehyde and thence to G. All of the above methods are incorporated into the present invention. However, a particularly preferred procedure for performing this transformation involves removal of the ester under acidic conditions, such as treatment with trifluoroacetic acid, hydrochloric acid or another appropriate strong acid, conversion of the resulting acid to a mixed anhydride in situ by treatment with a reagent such ethylchloroformate and an amine base such as triethylamine and reduction of the resulting mixed anhydride with a hydride reducing agent such as sodium borohydride, lithium borohydride, lithium aluminum hydride, diisobutylaluminum hydride, or one of many other appropriate hydride reducing agents well known to practitioners of the art. The resulting carbinol is then oxidized to the aldehyde with reagents suitable for this transformation such as the Dess-Martin reagent or 1-hydroxy-1-benziodoxol-3(1H)-one, dimethylsulfoxide/oxalyl chloride, chromium trioxide pyridine complex, or another reagent chosen from oxidizing agents appropriate for this transformation. The resulting aldehyde is then converted to the oxime using hydroxylamine hydrochloride and an appropriate buffer such as sodium acetate and dehydrated with an appropriate dehydrating agent such as acetic anhydride or diisopropylazodicarboxylate in the presence of triphenyl phosphine to afford the requisite cyano compound, G. In a manner similar to that described above for the transformation of D to F, intermediate G can be converted to the 5-hydroxyoxazolidinone of the present invention H.
[0169] The 5-hydroxyoxazolidinones F and H are useful intermediates for the preparation of compounds of the present invention. In Scheme II further modifications of H are illustrated but it will be realized that similar modifications of F can be performed to form analogous compounds of the present invention and that further modification of both F and H are incorporated within the present invention. The hydroxymethyloxazolidinone H can be converted to a leaving group by treatment with an appropriate reagent. Preferred leaving groups include the mesylate, tosylate, benzenesulfonate, trifluoromethanesulfonate, halides and the like and the methods to produce these intermediates will be readily recognized by those skilled in the art. A preferred leaving group is the mesylate I which may be readily prepared by treatment with methanesulfonylchloride in a nonpolar solvent such as methylene chloride, tetrahydrofuran, diethylether, carbon tetrachloride, dichloroethane and the like using a tertiary amine such as triethylamine as a catalyst. The resulting mesylate I can be further converted to compounds of the present invention by treatment with a variety of nucleophiles which substitute the mesylate radical with the nucleophile radical of the present invention. Examples of nucleophiles that can be used include, but are not limited to sodium azide, sodiumthiocyanate, heterocycles such as 1,2,3-triazole, imidazole, pyrazole and the like optionally activated as their metal salts by the addition of sodium hydride or other such appropriate base. Typical solvents for these reactions include such solvents as dimethylformamide or dimethylsulfoxide which are particularly useful for displacements of this type but may also include less polar solvents such as methylene chloride, tetrahydrofuran, diethyl ether, or alcohol solvents such as methanol, ethanol , or isopropyl alcohol when appropriate. A particularly useful intermediate is the 5-azidomethyl oxazolidinone J. The azide J can be used as a substrate in 1,3-dipolar additions in which a substituent is added to the proximal and distal nitrogens of the azide to afford 1,2,3-triazole analogues. For example treatment of J with norbomadiene at reflux in dioxane affords the 1-substituted, 1,2,3-triazole while treatment with malononitrile affords the 4-cyano-5-amino-1,2,3-triazole. Similarly the 5-hydroxymethyl-1,2,3-triazole can be prepared from J and propargyl alcohol which can itself be transformed to a variety of analogues of the present invention by modifications of the hydroxymethyl group to the aldehyde, oxime, oximemethyl ether, and cyano analogues and the like by methods which will be readily apparent to those of ordinary skill in the art. Treatment of J in a similar manner with t-butyl propiolate affords the t-butyl 1-substituted-1,2,3-triazole-4-carboxylate and the ester can be further transformed to the acid and modified to further amide and ester analogues of the present invention. Alternatively reduction of the ester to the hydroxymethyl analogue would allow further modification as described above for the 5-hydroxymethyl regioisomer.
[0170] In addition to being a substrate for 1,3-dipolar additions, the 5-azidomethyl oxazolidinone J can be reduced to the 5-aminomethyl oxazolidinone K. The 5-aminomethyl oxazolidinone can be acylated with a wide variety of acylating agents under appropriate conditions. Examples of acylating agents used to prepare compounds of the present invention include, but are not limited to acetic anhydride, difluoroacetic anhydride, trifluoroacetic anhydride, bis-2(1H)-hydroxypyridine thiocarbonate, methylisothiocyanate, O-methyl-N-cyanoacetamide, propionic anhydride, methylchloroformate, dichloroacetylchloride, N-cyanodithioiminocarbonate, and sulfonyl chlorides such as methane sulfonyl chloride and the like. Alternatively carboxylic acids can be used to acylated the 5-aminomethyloxazolidinone, K. In these modifications the carboxylic acids are typically activated for acylation by conversion to the acid chloride with thionyl chloride or oxalyl chloride or activated in situ with a carbodiimde such as dicyclohexyl carbodiimide. Examples of carboxylic acids that can be used to acylate K include but are not limited to cyclopropanecarboxylic acid, 2-methoxyacetic acid, furn-3-carboxylic acid, pyrazine-2-carboxylic acid, isoxazole-5-carboxylic acid, 1,2,5-thiadiazole-3-carboxylic acid, 4-methylthiazole-5-carboxylic acid, formic acid, methylthioacetic acid, methylsulfonylacetic acid, 2,2,-dichlorocyclopropane-1-carboxylic acid, 2-chloropropionic acid, 1-cyano-cyclopropane-1-carboxylic acid, 1-hydroxycyclopropane-1-carboxylic acid.
[0171] One preferred modification of the 5-aminomethyl-oxazolidinone K is the 5-acetamidomethyl oxazolidinone L which is readily prepared from K by treatment with acetic anhydride. The acetamide L can be further modified to the thioacetamide by treatment with Lawesson's reagent, or alkylated with alkyl halides such as methyl iodide in the presence of a suitable base such as potassium t-butoxide to afford the N-alkylacetamides.
[0172] Further compounds of the present invention can be prepared by displacement of the hydroxyl group of the 5-hydroxymethyloxazolidinone H with an appropriate nucleophile. Typically displacements of this sort are carried out under conditions known to those skilled in the art as Mitsunobu conditions. These generally involve in situ activation of H with an azodicarboxylate analogue such as diethylazodicarboxylate, diisopropylazodicarboxylate, or tetramethylazodicarboxamide, in the presence of a phosphine such as tributyl phosphine, triphenyl phosphine or trifuryl phosphine in a suitable solvent such as benzene, ether, toluene, tetrahydrofuran, or methylene chloride. Among the nucleophiles used in such displacement reactions to prepare compounds of the present invention include but are not limited to N-benzoyloxyacetamide heterocycles such as 1,2,4-triazole, pyrazole, 1H-tetrazole, 3-hydroxyisoxazole, and t-butoxycarbonylprotected aminoheterocycles such as 3-N-(t-butoxycarbonyl)amino-1,2,4-oxadiazole, 3-N-(t-butoxycarbonyl)amino-1,2-isoxazole, 2-N-(t-butoxycarbonyl) amino-1,3-thiazole, and 2-N-(t-butoxycarbonyl)amino-1,3,4-thiadiazole, and 2-N-(t-butoxycarbonyl)aminopyridine. In those cases where an amino group is protected as a t-butoxycarbonyl derivative or where an hydroxy is protected by a benzoyl group, these protecting groups can be removed under conditions well known to those skilled in the art to prepare the corresponding amino or hydroxyl analogues of the present invention.
[0173] As mentioned above and as shown in Scheme III the 5-hydroxymethyl oxazolidinone F can converted to the mesylate M which can in turn be converted to the 5-azidomethyloxazolidinone N. The 5-azidomethyloxazolidinone N can be reduced to the 5-aminomethyloxazolidinone O which can in turn be acylated to the 5-acetamidooxazolidinone P. These conversions can be carried out in a manner exactly analogous to the conversion of H to L as described in Scheme II. Moreover further modifications of F, M, N, O, and P can be carried out. For example analogous modifications to that described for H can be carried out on F to afford further compounds of the present invention. Likewise, M can be modified analogous to I, N modified analogous J, O modified analogous to K, and P modified analogous to L. All of these analogous modifications are incorporated into the compounds of the present invention. In addition the t-butoxycarbonyl group of F, M, N, O, and P can be independently modified to form further compounds of the present invention. These modifications are exemplified in Scheme IV for compound P, but it will be readily recognized by those with ordinary skill in the art that analogous modifications could be made to F, M, N, or O independently and all of the potential modifications are incorporated into the compounds of the present invention.
[0174] As shown in Scheme IV compound P can be treated with a strong acid such as trifluoroacetic acid or hydrochloric acid in a nonpolar solvent such as methylene chloride to afford the carboxylic acid Q. It will be recognized by those with ordinary skill in the art that a variety of methods are known for the conversion of Q to the amine R. In a preferred method Q is treated with triphenylphosphoryl azide in a nonpolar solvent such as methylene chloride in the presence of a tertiary amine base to afford R. Alternatively Q can be reduced to the hydroxymethyl compound S by formation of the mixed anhydride with alkylchloroformate such as ethylchloroformate in the presence of a tertiary amine base and the in situ formed anhydride reduced with aqueous sodium borohydride which after workup in the standard way affords S. As described above a variety of methods are available for the oxidation of primary alcohol to the aldehyde, thus in a preferred, but not limiting transformation S is treated with 1-hydroxy-1,2-benziodoxol-3(1H)-one 1-oxide to afford the aldehyde T. The compound T can be converted to the oxime U by treatment with hydroxylamine hydrochloride in an alcoholic solvent such as methanol in the presence of a mild base such as sodium acetate. It should be recognized that dehydration of T by methods described above for the dehydration of oximes provides an alternative method for the preparation of L.
[0175] Suitable subjects for the administration of the formulation of the present invention include mammals, primates, man, and other animals. In vitro antibacterial activity is predictive of in vivo activity when the compositions are administered to a mammal infected with a susceptible bacterial organism.
[0176] Using standard susceptibility tests, the compositions of the invention are determined to be active against MRSA and enterococcal infections. The compounds of the invention are formulated in pharmaceutical compositions by combining the compounds with a pharmaceutically acceptable carrier. Examples of such carriers are set forth below.
[0177] The compounds may be employed in powder or crystalline form, in liquid solution, or in suspension. They may be administered by a variety of means; those of principal interest include: topically, orally and parenterally by injection (intravenously or intramuscularly).
[0178] Compositions for injection, a preferred route of delivery, may be prepared in unit dosage form in ampules, or in multidose containers. The injectable compositions may take such forms as suspensions, solutions, or emulsions in oily or aqueous vehicles, and may contain various formulating agents. Alternatively, the active ingredient may be in powder (lyophilized or non-lyophilized) form for reconstitution at the time of delivery with a suitable vehicle, such as sterile water. In injectable compositions, the carrier is typically comprised of sterile water, saline or another injectable liquid, e.g., peanut oil for intramuscular injections. Also, various buffering agents, preservatives and the like can be included.
[0179] Topical applications may be formulated in carriers such as hydrophobic or hydrophilic bases to form ointments, creams, lotions, in aqueous, oleaginous or alcoholic liquids to form paints or in dry diluents to form powders.
[0180] Oral compositions may take such forms as tablets, capsules, oral suspensions and oral solutions. The oral compositions may utilize carriers such as conventional formulating agents, and may include sustained release properties as well as rapid delivery forms.
[0181] The dosage to be administered depends to a large extent upon the condition and size of the subject being treated, the route and frequency of administration, the sensitivity of the pathogen to the particular compound selected, the virulence of the infection and other factors. Such matters, however, are left to the routine discretion of the physician according to principles of treatment well known in the antibacterial arts. Another factor influencing the precise dosage regimen, apart from the nature of the infection and peculiar identity of the individual being treated, is the molecular weight of the compound.
[0182] The novel antibiotic compositions of this invention for human delivery per unit dosage, whether liquid or solid, comprise from about 0.01% to as high as about 99% of the cyclopropyl containing oxazolidinone compounds discussed herein, the preferred range being from about 10-60% and from about 1% to about 99.99% of one or more of other antibiotics such as those discussed herein, preferably from about 40% to about 90%. The composition will generally contain from about 125 mg to about 3.0 g of the cyclopropyl containing oxazolidinone compounds discussed herein; however, in general, it is preferable to employ dosage amounts in the range of from about 250 mg to 1000 mg and from about 200mg to about 5 g of the other antibiotics discussed herein; preferably from about 250 mg to about 1000 mg. In parenteral administration, the unit dosage will typically include the pure compound in sterile water solution or in the form of a soluble powder intended for solution, which can be adjusted to neutral pH and isotonic.
[0183] The invention described herein also includes a method of treating a bacterial infection in a mammal in need of such treatment comprising administering to said mammal the claimed composition in an amount effective to treat said infection.
[0184] The preferred methods of administration of the claimed compositions include oral and parenteral, e.g., i.v. infusion, i.v. bolus and i.m. injection formulated so that a unit dosage comprises a therapeutically effective amount of each active component or some submultiple thereof.
[0185] For adults, about 5-50 mg/kg of body weight, preferably about 250 mg to about 1000 mg per person of the cyclopropyl containing oxazolidinone antibacterial compound and about 250 mg, to about 1000 mg per person of the other antibiotic(s) given one to four times daily is preferred. More specifically, for mild infections a dose of about 250 mg two or three times daily of the cyclopropyl containing oxazolidinone antibacterial compound and about 250 mg two or three times daily of the other antibiotic is recommended. For moderate infections against highly susceptible gram positive organisms a dose of about 500 mg each of the cyclopropyl containing oxazolidinone and the other antibiotics, three or four times daily is recommended. For severe, life-threatening infections against organisms at the upper limits of sensitivity to the antibiotic, a dose of about 500-2000 mg each of the cyclopropyl-containing oxazolidinone compound and the other antibiotics, three to four times daily may be recommended.
[0186] For children, a dose of about 5-25 mg/kg of body weight given 2, 3, or 4 times per day is preferred; a dose of 10 mg/kg is typically recommended. The invention is further described in connection with the following non-limiting examples.
[0187] Antibacterial Activity
[0188] The pharmaceutically-acceptable compounds of the present invention are useful antibacterial agents having a good spectrum of activity in vitro against standard bacterial strains, which are used to screen for activity against pathogenic bacteria. Notably, the pharmaceutically-acceptable compounds of the present invention show activity against vancomycin-resistant enterococci, streptococci including penicillin-resistant S. pneumoniae , methicillin-resistant S. aureus, M. catarrhalis , and C. pneumoniae . The antibacterial spectrum and potency of a particular compound may be determined in a standard test system.
[0189] The following in vitro results were obtained based on an agar dilution method except for C. pneumoniae . The activity is presented as the minimum inhibitory concentration (MIC)
[0190] [0190] S. aureus and M. catarrhalis were tested on Mueller-Hinton agar, using an approximate inoculum of 1×10 4 cfu/spot an incubation temperature of 35C for 24 hours. The MIC was defined as the lowest concentration at which no visible bacterial growth was observed.
[0191] Streptococci and enterococci were tested on Mueller-Hinton agar supplemented with 5% defibrinated horse blood , using an approximate inoculum of 1×10 4 cfu/spot an incubation temperature of 35C in an atmosphere of 5% CO 2 for 24 hours. The MIC was defined as the lowest concentration at which no visible bacterial growth was observed.
[0192] [0192] C. pneumoniae was tested using minimum essential medium supplemented with 10% heat-inactivated fetal bovine serum, 2 mM L-glutamine, 1 mg/ml cycloheximide and non essential amino acid. HeLa 229 cells were inoculated with 10 4 inclusion-forming units of C. pneumoniae strain per mL. Infected cells were incubated with test compounds in complete medium at 35C in an atmosphere of 5% CO 2 for 72 hours. Cells monolayers were fixed in methanol, stained for chlamydial inclusions with an fluorescein-conjugated anti-Chlamydia monoclonal antibody, and were observed with fluorescence microscope. The MIC was defined as the lowest concentration at which no inclusion was observed.
MIC (μg/ml) Strains example 7 example 8 example 18 example 32 Linezolid Staphylococcus aureus Smith 0.5 0.125 0.5 0.125 1 CR 4 0.5 16 2 16 MR 0.5 0.125 0.5 0.125 1 Streptococcus pneumoniae IID553 1 0.25 1 0.25 2 PRQR 1 0.25 1 0.125 1 Streptococcus pyogenes IID692 0.5 0.125 1 0.125 1 Enterococcus faecium VRQR 0.5 0.25 1 0.25 2 Moraxella catarrhalis ATCC25238 4 0.5 8 0.5 4 Chlamydia pneumoniae ATCCVR-1360 0.5 0.25 NT 4 8
[0193] The invention described herein is exemplified by the following non-limiting examples. The compound data is designated in accordance to General Guidelines for Manuscript Preparation , J. Org. Chem. Vol. 66, pg. 19A, Issue 1, 2001. The invention described herein is exemplified by the following non-limiting examples. The compound data is designated in accordance to General Guidelines for Manuscript Preparation , J. Org. Chem. Vol. 66, pg. 19A, Issue 1, 2001.
EXAMPLE 1
N-[5(S)-3-[4-[(1-t-Butoxycarbonyl)cyclopropan-1-yl]-3-fluorphenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0194] [0194]
[0195] Step 1
[0196] 5(R)-3-[4-[(1-t-Butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]-5-hydroxymethyloxazolidin-2-one.
[0197] To a solution of t-butyl 1-(4-benzyloxycarbonylamino-2-fluorophenyl)cyclopropane-1-carboxylate (7.30 g) in dry tetrahydrofuran (100 mL) was added a solution of n-butyllithium in hexane (1.6 M, 11.9 mL) at −78° C., and the mixture was stirred at the same temperature for 30 min. (R)-Glycidyl butyrate (2.16 g) was added to the mixture at −78° C. and the mixture was allowed to stand at room temperature for 12 hours. After quenching the reaction with the addition of saturated ammonium chloride solution, the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. A suspension of the residue and potassium carbonate (3 g) in methanol (50 mL) was stirred at room temperature for 10 min. After dilution the mixture with water, the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=1:4) of the residue gave 5(R)-3-[4-[(1-t-butoxycarbonyl)-cyclopropan-1-yl]-3-fluorophenyl]-5-hydroxymethyloxazolidin-2-one.
[0198] MS (EI + ) m/z: 351 (M + ).
[0199] HRMS (EI + ) for C 18 H 22 FNO 5 (M + ): calcd, 351.1482; found, 351.1469.
[0200] Step 2
[0201] 5(R)-Azidomethyl-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]-oxazolidin-2-one.
[0202] To a solution of 5(R)-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]-5-hydroxymethyloxazolidin-2-one (2.00 g) in dichloromethane (15 mL) was successively added triethylamine (1.59 mL) and methanesulfonyl chloride (1.23 g) at 0° C., and the mixture was stirred at the same temperature for 30 min. The mixture was washed with saturated sodium hydrogencarbonate solution and brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo to give 5(R)-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]-5-methanesulfonyloxymethyloxazolidin-2-one. This was used in the next step without further purification. The mixture of crude 5(R)-3-[4-[(1-t-butoxycarbonyl)-cyclopropan-1-yl]-3-fluorophenyl]-5-methanesulfonyloxymethyloxazolidin-2-one thus obtained and sodium azide (1.30 g) in N,N-dimethylformamide (15 mL) was heated at 60° C. for 9 hours, and then concentrated in vacuo. The residue was diluted with ethyl acetate and washed with water and brine. The organic extracts were dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo to give 5(R)-azidomethyl-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]-oxazolidin-2-one. MS (EI + ) m/z: 376 (M + ).
[0203] HRMS (EI + ) for C 18 H 21 FN 4 O 4 (M + ): calcd, 376.1547; found, 376.1524.
[0204] Step 3
[0205] N-[5(S)-3-[4-[(1-t-Butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0206] A suspension of crude 5(R)-azidomethyl-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]oxazolidin-2-one thus obtained in step 2 and palladium catalyst (10% on charcoal, 214 mg) in ethyl acetate (57 mL) was hydrogenated at 1 atmosphere for 3 hours at room temperature. After filtration of the catalyst, the filtrate was concentrated in vacuo to give 5(S)-aminomethyl-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]oxazolidin-2-one. To a solution of crude 5(S)-aminomethyl-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]oxazolidin-2-one thus obtained in ethyl acetate (50 mL) was added triethylamine (4.8 mL) and acetic anhydride (1.6 mL), and the mixture was stirred at room temperature for 2 hours. After quenching the reaction by the addition of saturated sodium hydrogencarbonate solution, the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate:methanol=20:1) of the residue gave N-[5(S)-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide. MS (EI + ) m/z: 392 (M + ).
[0207] HRMS (EI + ) for C 20 H 25 FN 2 O 5 (M + ): calcd, 392.1748; found, 392.1730.
EXAMPLE 2
N-[5(S)-3-[4-(1-Carboxycyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0208] [0208]
[0209] To a solution of N-[5(S)-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (0.73 g) in dichloromethane (10 mL) was added trifluoroacetic acid (5 mL) at 0° C., and the mixture was stirred at room temperature for 1 hour, then concentrated in vacuo to give N-[5(S)-3-[4-(1-carboxycyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide. MS (EI + ) m/z: 336 (M + ).
[0210] HRMS (EI + ) for C 16 H 17 FN 2 O 5 (M + ): calcd, 336.1122; found, 336.1140.
EXAMPLE 3
N-[5(S)-3-[3-Fluoro-4-(1-hydroxymethylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0211] [0211]
[0212] To a solution of N-[5(S)-3-[4-(1-carboxycyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (500 mg) in tetrahydrofuran (10 mL) was successively added triethylamine (249 L) and ethyl chloroformate (156 L) at 0° C., and the mixture was stirred at the same temperature for 30 min. To a suspension of sodium borohydride (562 mg) in water (5 mL) was added the above mixture at 0° C., and the mixture was stirred at room temperature for 30 min. The mixture was adjusted to pH 2 by the addition of 1 N hydrochloric acid, and extracted with dichloromethane. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate:methanol=9:1) of the residue gave N-[5(S)-3-[3-fluoro-4-(1-hydroxymethylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide. MS (EI + ) m/z: 322 (M + ).
[0213] HRMS (EI) for C 16 H 19 FN 2 O 4 (M): calcd, 322.1329; found, 322.1319.
EXAMPLE 4
N-[5(S)-3-[4-(1-Aminocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0214] [0214]
[0215] To a solution of N-[5(S)-3-[4-(1-carboxycyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (prepared from of N-[5(S)-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (420 mg) in the same manner as described for EXAMPLE 2) in dichloromethane (5 mL) was added triethylamine (224 L) and DPPA (442 mg) at room temperature, and the mixture was stirred at the same temperature for 30 min, then concentrated in vacuo. The resulting residue was diluted with toluene, the mixture was heated at reflux for 2 hours, and then concentrated in vacuo. To a solution of the residue in dioxane (10 mL) was added 10% potassium carbonate solution (10 mL), and the mixture was stirred at room temperature for 1 hour. After dilution the mixture with brine, the mixture was extracted with ethyl acetate. The ethyl acetate solution was extracted with 5% hydrochloric acid. The aqueous extracts were adjusted to pH 10 by the addition of potassium carbonate, diluted with brine, and extracted with ethyl acetate and dichloromethane-methanol (4:1). The combined organic extracts were dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, dichloromethane:methanol=9:1) of the residue gave N-[5(S)-3-[4-(1-aminocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0216] MS (EI + ) m/z: 307 (M + ).
[0217] HRMS (EI + ) for C 15 H 18 FN 3 O 3 (M + ): calcd, 307.1332; found, 307.1329.
EXAMPLE 5
N-[5(S)-3-[3-Fluoro-4-(1-formylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0218] [0218]
[0219] To a solution of N-[5(S)-3-[3-fluoro-4-(1-hydroxymethylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (337 mg) in dimethyl sulfoxide (5 mL) was added 1-hydroxy-1,2-benziodoxol-3(1H)-one 1-oxide (439 mg), and the mixture was stirred at room temperature for 12 hours. After dilution with saturated sodium hydrogencarbonate solution, the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate:methanol=10:1) of the residue gave N-[5(S)-3-[3-fluoro-4-(1-formylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0220] MS (EI + ) m/z: 320 (M + ).
[0221] HRMS (EI + ) for C 16 H 17 FN 2 O 4 (M + ): calcd, 320.1172; found, 320.1190.
EXAMPLE 6
N-[5(S)-3-[3-Fluoro-4-(1-(hydroxyimino)methylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0222] [0222]
[0223] To a solution of hydroxylamine hydrochloride (163 mg) in methanol (10 mL) was added sodium acetate (384 mg), and the mixture was stirred at room temperature for 30 min. To a resulting mixture was added N-[5(S)-3-[3-fluoro-4-(1-formylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (250 mg), the mixture was stirred at room temperature for 30 min, and then concentrated in vacuo. Flash chromatography (silica, dichloromethane:methanol=9:1) of the residue gave N-[5(S)-3-[3-fluoro-4-(1-(hydroxyimino)methylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0224] MS (EI + ) m/z: 335 (M + ).
[0225] HRMS (EI + ) for C 16 H 18 FN 3 O 4 (M + ): calcd, 335.1281; found, 335.1233.
EXAMPLE 7
N-[5 (S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0226] [0226]
[0227] To a solution of N-[5(S)-3-[3-fluoro-4-(1-(hydroxyimino)methylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (160 mg) in tetrahydrofuran (5 mL) was added diisopropyl azodicarboxylate (145 mg) and triphenylphosphine (375 mg) at room temperature, and the mixture was stirred at the same temperature for 10 min. Flash chromatography (silica, ethyl acetate:methanol=19:1) of the mixture gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide. MS (EI + ) m/z: 317 (M + ).
[0228] HRMS (EI + ) for C 16 H 16 FN 3 O 3 (M + ): calcd, 317.1176; found, 317.1177.
EXAMPLE 8
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thioacetamide
[0229] [0229]
[0230] To a solution of N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (120 mg) in toluene was added Lawesson's reagent (153 mg) at 80° C., and the mixture was stirred at the same temperature for 2 hours. Flash chromatography (silica, hexane:ethyl acetate=1:1) of the mixture gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thioacetamide. MS (FAB + ) m/z: 334 (MH + ).
[0231] HRMS (FAB + ) for C 16 H 17 FN 3 O 2 S (MH + ): calcd, 334.1026; found, 334.1043.
EXAMPLE 9
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]methanesulfonylamide
[0232] [0232]
[0233] A suspension of 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (122 mg) and Lindlar catalyst (12 mg) in methanol (5 mL) was hydrogenated at 1 atm for 3 hours at room temperature. After filtration of the catalyst, the filtrate was concentrated in vacuo to give 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one. To a solution of crude 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one thus obtained in dichloromethane (2 mL) was added pyridine (96 mg) and methanesulfonyl chloride (70 mg) at 0° C., and the mixture was stirred at the same temperature for 30 min. The mixture was washed with water and 5% hydrochloric acid, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate) of the residue gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]methanesulfonylamide. MS (EI + ) m/z: 353 (M + ).
[0234] HRMS (EI + ) for C 15 H 16 FN 3 O 4 S (M + ): calcd, 353.0846; found, 353.0869.
EXAMPLE 10
N-[5(S)-3-[4-[(1-t-Butoxycarbonyl)cyclopropan-1-yl]-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0235] [0235]
[0236] Step 1
[0237] 5(R)-Azidomethyl-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3-fluorophenyl]oxazolidin-2-one.
[0238] The title compound 5(R)-azidomethyl-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3,5-difluorophenyl]oxazolidin-2-one (19.5 g) was prepared from t-butyl 1-(4-benzyloxycarbonylamino-2,6-difluorophenyl)-cyclopropane-1-carboxylate (13.6 g) in the same manner as described for EXAMPLE 1.
[0239] Step 2
[0240] N-[5(S)-3-[4-[(1-t-Butoxycarbonyl)cyclopropan-1-yl]-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0241] The title compound N-[5(S)-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (5.90 g) was prepared from 5(R)-azidomethyl-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3,5-difluorophenyl]oxazolidin-2-one (7.57 g) in the same manner as described for EXAMPLE 1.
[0242] MS (EI + ) m/z: 410 (M + ).
[0243] HRMS (EI + ) for C 20 H 24 F 2 N 2 O 5 (M + ): calcd, 410.1653; found, 410.1693.
EXAMPLE 11
N-[5(S)-3-[3,5-Difluoro-4-(1-hydroxymethylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0244] [0244]
[0245] Step 1
[0246] N-[5(S)-3-[4-(1-Carboxycyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0247] The title compound N-[5(S)-3-[4-(1-carboxycyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide was prepared from N-[5(S)-3-[4-[(1-t-butoxycarbonyl)cyclopropan-1-yl]-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (3.00 g) in the same manner as described for EXAMPLE 2.
[0248] MS (EI + ) m/z: 354 (M + ).
[0249] HRMS (EI + ) for C 16 H 16 F 2 N 2 O 5 (M + ): calcd, 354.1027; found, 354.0984.
[0250] Step 2
[0251] N-[5(S)-3-[3,5-Difluoro-4-(1-hydroxymethylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0252] The title compound N-[5(S)-3-[3,5-difluoro-4-(1-hydroxymethylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (2.11 g) was prepared from crude N-[5(S)-3-[4-(1-carboxycyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide thus obtained in step 1 in the same manner as described for EXAMPLE 3.
[0253] MS (EI + ) m/z: 340 (M + ).
[0254] HRMS (EI + ) for C 16 H 18 F 2 N 2 O 4 (M + ): calcd, 340.1235; found, 340.1211.
EXAMPLE 12
N-[5(S)-3-[3,5-Difluoro-4-(1-formylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0255] [0255]
[0256] The title compound N-[5(S)-3-[3,5-difluoro-4-(1-formylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (520 mg) was prepared from N-[5(S)-3-[3,5-difluoro-4-(1-hydroxymethylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (1.00 g) in the same manner as described for EXAMPLE 5.
[0257] MS (EI + ) m/z: 338 (M + ).
[0258] HRMS (EI + ) for C 16 H 16 F 2 N 2 O 4 (M + ): calcd, 338.1078; found, 338.1099.
EXAMPLE 13
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0259] [0259]
[0260] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3,5-difluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (418 mg) was prepared from N-[5(S)-3-[3,5-difluoro-4-(1-formylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (520 mg) in the same manner as described for EXAMPLE 6 and 7. MS (EI + ) m/z: 335 (M + ).
[0261] HRMS (EI + ) for C 16 H 15 F 2 N 3 O 3 (M + ): calcd, 335.1081; found, 335.1080.
EXAMPLE 14
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]difluoroacetamide
[0262] [0262]
[0263] Step 1
[0264] 5(R)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-5-hydroxymethyloxazolidin-2-one.
[0265] The title compound 5(R)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-5-hydroxymethyloxazolidin-2-one (483 mg) was prepared from 1-(4-benzyloxycarbonylamino-2-fluorophenyl)-1-cyclopropanecarbonitrile (638 mg) in the same manner as described for EXAMPLE 1. MS (EI + ) m/z: 276 (M + ).
[0266] HRMS (EI + ) for C 14 H 13 FN 2 O 3 (M + ): calcd, 276.0910; found, 276.0905.
[0267] Step 2
[0268] 5(R)-Azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one.
[0269] The title compound 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (490 mg) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-5-hydroxymethyloxazolidin-2-one (450 mg) in the same manner as described for EXAMPLE 1. MS (EI + ) m/z: 301 (M + ).
[0270] HRMS (EI + ) for C 14 H 12 FN 5 O 2 (M + ): calcd, 301.0975; found, 301.0964.
[0271] Step 3
[0272] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]difluoroacetamide.
[0273] To a solution of crude 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (490 mg) in the same manner as described for EXAMPLE 9) in pyridine (10 mL) was added difluoroacetic anhydride (340 mg) at 0° C., and the mixture was stirred at room temperature for 2 hours. After quenching the reaction by the addition of water, the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous sodium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=1:1) of the residue gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]-difluoroacetamide. MS (EI + ) m/z: 353 (M + ).
[0274] HRMS (EI + ) for C 16 H 14 F 3 N 3 O 3 (M + ): calcd, 353.0987; found, 353.0983.
EXAMPLE 15
5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,2,4-oxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]aminomethyloxazolidin-2-one
[0275] [0275]
[0276] A mixture of 5(R)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-5-hydroxymethyloxazolidin-2-one (250 mg), 3-N-(t-butoxycarbonyl)amino-1,2,4-oxadiazole (252 mg), tetramethylazodicarboxamide (312 mg), and tributylphosphine (0.45 mL) in benzene (10 mL) was heated at 70-80° C. for 7.7 hours. After insoluble materials were filtered off, the filtrate was concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=1:1) of the residue gave 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,2,4-oxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]aminomethyloxazolidin-2-one. MS (EI + ) m/z: 443 (M + ).
[0277] HRMS (EI + ) for C 21 H 22 FN 5 O 5 (M + ): calcd, 443.1605; found, 443.1637.
EXAMPLE 16
5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,2-isoxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]aminomethyloxazolidin-2-one
[0278] [0278]
[0279] The title compound 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,2-isoxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]amino-methyloxazolidin-2-one (364 mg) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-5-hydroxymethyloxazolidin-2-one (250 mg) and 3-N-(t-butoxycarbonyl)aminoisoxazole (250 mg) in the same manner as described for EXAMPLE 15. MS (EI + ) m/z: 442 (M + ).
[0280] HRMS (EI + ) for C 22 H 23 FN 4 O 5 (M + ): calcd, 442.1652; found, 442.1650.
EXAMPLE 17
5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-5-[N-(1,2,4-oxadiazolyl-3-yl)amino]methyloxazolidin-2-one
[0281] [0281]
[0282] To a solution of 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,2,4-oxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]aminomethyloxazolidin-2-one (331 mg) in dichloromethane (8 mL) was added trifluoroacetic acid at 0° C., and the mixture was stirred at the same temperature for 40 min. After quenching the reaction by the addition of saturated sodium hydrogencarbonate solution and 1 N sodium hydroxide solution, the mixture was extracted with dichloromethane. The organic extracts were washed with brine, dried over anhydrous sodium sulfate, filtered, and then concentrated in vacuo. After treating the residue with methanol, the resulting precipitates were collected by filtration to give 5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-5-[N-(1,2,4-oxadiazolyl-3-yl)amino]methyloxazolidin-2-one. Flash chromatography (silica, hexane:ethyl acetate=1:4) of the filtrate gave further amount of the product. MS (EI + ) m/z: 343 (M + ).
[0283] HRMS (EI + ) for C 16 H 14 FN 5 O 3 (M + ): calcd, 343.1081; found, 343.1067.
EXAMPLE 18
5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-5-[N-(1,2-isoxadiazolyl-3-yl)amino]methyloxazolidin-2-one
[0284] [0284]
[0285] The title compound 5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-5-[N-(1,2-isoxadiazolyl-3-yl)amino]methyloxazolidin-2-one (242 mg) was prepared from 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,2-isoxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]aminomethyloxazolidin-2-one (360 mg) in the same manner as described for EXAMPLE 17. MS (EI + ) m/z: 342 (M + ).
[0286] HRMS (EI + ) for C 17 H 15 FN 4 O 3 (M + ): calcd, 342.1128; found, 342.1141.
EXAMPLE 19
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0287] [0287]
[0288] Step 1
[0289] 5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one.
[0290] The title compound 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (6.31 g) was prepared from 1-(4-benzyloxycarbonylaminophenyl)-1-cyclopropanecarbonitrile (8.34 g) in the same manner as described for EXAMPLE 1. MS (EI + ) m/z: 258 (M + ).
[0291] HRMS (EI + ) for C 14 H 14 N 2 O 3 (M + ): calcd, 258.1004; found, 258.1021.
[0292] Step 2
[0293] 5(R)-Azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one.
[0294] The title compound 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (1.30 g) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (1.36 g) in the same manner as described for EXAMPLE 1. MS (EI + ) m/z: 283 (M + ).
[0295] HRMS (EI + ) for C 14 H 12 FN 5 O 2 (M + ): calcd, 283.1069; found, 283.1059.
[0296] Step 3
[0297] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0298] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (388 mg) was prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (634 mg) in the same manner as described for EXAMPLE 1. MS (EI + ) m/z: 299 (M + ).
[0299] HRMS (EI + ) for C 16 H 17 N 3 O 3 (M + ): calcd, 299.1270; found, 299.1281.
EXAMPLE 20
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]thioacetamide
[0300] [0300]
[0301] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]thioacetamide (196 mg) was prepared from N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (212 mg) in the same manner as described for EXAMPLE 8. MS (FAB + ) m/z: 316 (MH + ).
[0302] HRMS (FAB + ) for C 16 H 18 N 3 O 2 S (MN + ): calcd, 316.1120; found, 316.1116.
EXAMPLE 21
5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,2,4-oxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one
[0303] [0303]
[0304] The title compound 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,2,4-oxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one (113 mg) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (260 mg) and 3-t-butoxycarbonylamino-1,2,4-oxadiazole (278 mg) in the same manner as described for EXAMPLE 15.
[0305] MS (EI + ) m/z: 425 (M + ).
[0306] HRMS (EI + ) for C 21 H 23 N 5 O 5 (M + ): calcd, 425.1699; found, 425.1689.
EXAMPLE 22
5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,2-isoxadiazolyl-3-yl)]-3-[4-(1-5cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one
[0307] [0307]
[0308] The title compound 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,2-isoxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one (1.53 g) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (1.00 g) and 3-t-butoxycarbonylamino-1,2-isoxazole (855 mg) in the same manner as described for EXAMPLE 15.
[0309] MS (EI + ) m/z: 424 (M + ).
[0310] HRMS (EI + ) for C 22 H 24 N 4 O 5 (M + ): calcd, 424.1747; found, 424.1765.
EXAMPLE 23
5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,2,4-oxadiazolyl-3-yl)amino]methyloxazolidin-2-one
[0311] [0311]
[0312] The title compound 5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-[N-(1,2,4-oxadiazolyl-3-yl)amino]methyloxazolidin-2-one (55 mg) was prepared from 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,2,4-oxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one (113 mg) in the same manner as described for EXAMPLE 17. MS (FAB + ) m/z: 326 (MH + ).
[0313] HRMS (FAB + ) for C 16 H 16 N 5 O 3 (MH + ): calcd, 326.1253; found, 326.1231.
EXAMPLE 24
5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,2-isoxadiazolyl-3-yl)amino]methyloxazolidin-2-one
[0314] [0314]
[0315] The title compound 5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-[N-(1,2-isoxadiazolyl-3-yl)amino]methyloxazolidin-2-one (1.11 g) was prepared from 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,2-isoxadiazolyl-3-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one (1.53 g) in the same manner as described for EXAMPLE 17. MS (FAB + ) m/z: 325 (MH + ).
[0316] HRMS (FAB + ) for C 17 H 18 N 4 O 3 (MH + ): calcd, 325.1379; found, 325.1287.
EXAMPLE 25
5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,2-isoxadiazolyl-3-yl)oxy]methyloxazolidin-2-one
[0317] [0317]
[0318] To a solution of 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (249 mg) in tetrahydrofuran (15 mL) was added 3-hydroxyisoxazole (106 mg), triphenylphosphine (380 mg), and diisopropyl azodicarboxylate (0.25 mL), the mixture was stirred at room temperature for 50 min, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=1:1) of the residue gave 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-[N-(1,2-isoxadiazolyl-3-yl)oxy]methyloxazolidin-2-one. MS (EI + ) m/z: 325 (M + ).
[0319] HRMS (EI + ) for C 17 H 15 N 3 O 4 (M + ): calcd, 325.1063; found, 325.1078.
EXAMPLE 26
5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,3-thiazolyl-2-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one
[0320] [0320]
[0321] The title compound 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,3-thiazolyl-2-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one (363 mg) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (250 mg) and 2-t-butoxycarbonylamino-1,3-thiazole (252 mg) in the same manner as described for EXAMPLE 15.
[0322] MS (FAB + ) m/z: 441 (MH + ).
[0323] HRMS (FAB + ) for C 22 H 25 N 4 O 4 S (MH + ): calcd, 441.1597; found, 441.1607.
EXAMPLE 27
5(S)-5-[N-(t-Butoxycarbonyl)-N-(1,3,4-thiadiazolyl-2-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one
[0324] [0324]
[0325] The title compound 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,3,4-thiadiazolyl-2-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one (359 mg) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (300 mg) and 2-t-buoxycarbonylamino-1,3,4-thiadiazole (303 mg) in the same manner as described for EXAMPLE 15.
[0326] MS (FAB + ) m/z: 442 (MH + ).
[0327] HRMS (FAB + ) for C 21 H 24 N 5 O 4 S (ME + ): calcd, 442.1549; found, 442.1583.
EXAMPLE 28
5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,3-thiazolyl-2-yl)amino]methyloxazolidin-2-one
[0328] [0328]
[0329] The title compound 5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-[N-(1,3-thiazolyl-2-yl)amino]methyloxazolidin-2-one (190 mg) was prepared from 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,3-thiazolyl-2-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one (360 mg) in the same manner as described for EXAMPLE 17. MS (EI + ) m/z: 340 (M + ).
[0330] HRMS (EI + ) for C 17 H 16 N 4 O 2 S (M + ): calcd, 340.0994; found, 340.0979.
EXAMPLE 29
5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(1,3,4-thiadiazolyl-2-yl)amino]methyloxazolidin-2-one
[0331] [0331]
[0332] The title compound 5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-[N-(1,3,4-thiadiazolyl-2-yl)amino]methyloxazolidin-2-one (194 mg) was prepared from 5(S)-5-[N-(t-butoxycarbonyl)-N-(1,3,4-thiadiazolyl-2-yl)]-3-[4-(1-cyanocyclopropan-1-yl)phenyl]aminomethyloxazolidin-2-one (353 mg) in the same manner as described for EXAMPLE 17. MS (EI + ) m/z: 341 (M + ).
[0333] HRMS (EI + ) for C 16 H 15 N 5 O 2 S (M + ): calcd, 341.0946; found, 341.0945.
EXAMPLE 30
[0334] S-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]dithiocarbamate
[0335] To a solution of crude 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (500 mg) in the same manner as described for EXAMPLE 8) in ethanol (10 mL) and water (2 drops) was added carbon disulfide (0.2 mL) and triethylamine (0.5 mL) at 0° C., the mixture was stirred at the same temperature for 1 hour, and further stirred at room temperature for 1 hour. To the mixture was added methyl iodide (0.11 mL) at 0° C., the mixture was stirred at the same temperature for 65 min, and further stirred at room temperature for 75 min. The resulting precipitates were collected by filtration, washed with methanol to give S-methyl N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]dithiocarbamate. MS (FAB + ) m/z: 366 (MH + ).
[0336] HRMS (FAB + ) for C 16 H 17 FN 3 O 2 S 2 (MH + ): calcd, 366.0746; found, 366.0749.
EXAMPLE 31
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiourea
[0337] [0337]
[0338] Step 1
[0339] N-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]isothiocyanate.
[0340] To a solution of 1,1′-thiocarbonyldi-2(1H)-pyridone (280 mg) in dichloromethane (20 mL) was added a solution of crude 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (300 mg) in the same manner as described for EXAMPLE 9) in dichloromethane (5 mL) at 0° C. for 5 min, and the mixture was stirred at room temperature for 2 hours. The mixture was washed with water and brine, dried over anhydrous sodium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=1:1) of the residue gave N-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]isothiocyanate.
[0341] Rf=0.36 (hexane:ethyl acetate=1:1).
[0342] Step 2
[0343] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiourea.
[0344] A solution of N-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]isothiocyanate (257 mg) in tetrahydrofuran (5 mL) was saturated with ammonia gas at room temperature for 10 min, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=1:2) of the residue gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiourea. MS (FAB + ) m/z: 335 (MH + ).
[0345] HRMS (FAB + ) for C 15 H 16 FN 4 O 2 S (MH + ): calcd, 335.0978; found, 335.0975.
EXAMPLE 32
O-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiocarbonate
[0346] [0346]
[0347] To a solution of sodium hydride (20 mg) in methanol (1 mL) was added a solution of N-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]isothiocyanate (40 mg) in methanol (1 mL) at 0° C., and the mixture was stirred at room temperature for 10 min. After quenching the reaction by the addition of saturated ammonium chloride solution, the resulting precipitates were collected by filtration, washed with water, and then dried to give O-methyl N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiocarbonate (36 mg). MS (EI + ) m/z: 349 (M + ).
[0348] HRMS (EI + ) for C 16 H 16 FN 3 O 3 S (M + ): calcd, 349.0896; found, 349.0930.
EXAMPLE 33
N′-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiourea
[0349] [0349]
[0350] To a solution of methyl isothiocyanate (80 mg) in tetrahydrofuran (4 mL) was added a solution of crude 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (250 mg) in the same manner as described for EXAMPLE 9) in tetrahydrofuran (4 mL) at room temperature, the mixture was stirred at the same temperature for 16.5 hours, and then concentrated in vacuo. Flash chromatography (silica, dichloromethane:methanol=20:1) of the residue gave N′-methyl N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]thiourea (250 mg).
[0351] MS (FAB + ) m/z: 349 (MH + ).
[0352] HRMS (FAB + ) for C 16 H 18 FN 4 O 2 S (MH + ): calcd, 349.1135; found, 349.1129.
EXAMPLE 34
O-Methyl N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]thiocarbonate
[0353] [0353]
[0354] The title compound O-methyl N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]thiocarbonate (272 mg) was prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (300 mg) in the same manner as described for EXAMPLE 31 and 32.
[0355] MS (EI + ) m/z: 331 (M + ).
[0356] HRMS (EI + ) for C 16 H 17 N 3 O 3 S (M + ): calcd, 331.0991; found, 331.1004.
EXAMPLE 35
N′-Cyano N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamidine
[0357] [0357]
[0358] To a solution of crude 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (227 mg) in methanol (10 mL) and tetrahydrofuran (2 mL) was added O-methyl N-cyanoacetamide (118 mg), the mixture was stirred at room temperature for 1 day, and then concentrated in vacuo. After treating the residue with methanol, the resulting precipitates were collected by filtration, washed with methanol to give N′-cyano N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamidine (183 mg).
[0359] MS (FAB + ) m/z: 324 (MH + ).
[0360] HRMS (FAB + ) for C 17 H 18 N 5 O 2 (MH + ): calcd, 324.1460; found, 324.1464.
EXAMPLE 36
N′-Cyano N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamidine
[0361] [0361]
[0362] The title compound N′-cyano N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]acetamidine (93 mg) was prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (121 mg) in the same manner as described for EXAMPLE 35.
[0363] MS (FAB + ) m/z: 342 (MH + ).
[0364] HRMS (FAB + ) for C 17 H 17 FN 5 O 2 (MH + ): calcd, 342.1366; found, 342.1350.
EXAMPLE 37
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole
[0365] [0365]
[0366] To a solution of 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (300 mg) in dioxane (10 mL) was added 2,5-norbornadiene (0.6 mL), the mixture was heated under reflux for 4.5 hours, and then concentrated in vacuo. After dilution of the residue with dichloromethane, the mixture was washed with water, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate) of the residue gave 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole (190 mg).
[0367] MS (EI + ) m/z: 309 (M + ).
[0368] HRMS (EI + ) for C16H15N5O2 (M + ): calcd, 309.1226; found, 309.1200.
EXAMPLE 38
5-Amino-4-cyano-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole
[0369] [0369]
[0370] To a suspension of potassium carbonate (440 mg) in dimethyl sulfoxide (8 mL) was added a solution of 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (300 mg) and malononitrile (105 mg) in dimethyl sulfoxide (10 mL) at room temperature, the mixture was stirred at the same temperature for 32.3 hours. After dilution of the mixture with water, the resulting precipitates were collected by filtration to give 5-amino-4-cyano-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole (223 mg).
[0371] MS (EI + ) m/z: 349 (M + ).
[0372] HRMS (EI + ) for C17H15N7O2 (M + ): calcd, 349.1287; found, 349.1292.
EXAMPLE 39
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-5-methyl-1,2,3-triazole
[0373] [0373]
[0374] A solution of 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (300 mg) and 1-triphenylphosphoranylidene-2-propanone (343 mg) in benzene (25 mL) was heated under reflux for 33 hours, and then concentrated in vacuo. After dilution of the residue with ethyl acetate, the resulting precipitates were collected by filtration to give 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-5-methyl-1,2,3-triazole (230 mg).
[0375] MS (EI + ) m/z: 323 (M + ).
[0376] HRMS (EI + ) for C17H17N5O2 (M + ): calcd, 323.1382; found, 323.1369.
EXAMPLE 40
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-methyl-1,2,3-triazole
[0377] [0377]
[0378] A solution of 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (880 mg) in methanol (20 mL) was added a solution of 1,1-dichloroacetone tosylhydrazone (260 mg) in methanol (20 mL) at 0° C., the mixture was stirred at the same temperature for 1 hour, and then concentrated in vacuo. After dilution of the residue with dichloromethane, the resulting precipitates were filtered off. Flash chromatography (silica, ethyl acetate) of the filtrate gave 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-methyl-1,2,3-triazole (250 mg).
[0379] MS (EI + ) m/z: 323 (M + ).
[0380] HRMS (EI + ) for C17H17N5O2 (M + ): calcd, 323.1382; found, 323.1377.
EXAMPLE 41
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole
[0381] [0381]
[0382] The title compound 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole (284 mg) was prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (300 mg) in the same manner as described for EXAMPLE 37.
[0383] MS (EI + ) m/z: 327 (M + ).
[0384] HRMS (EI + ) for C16H14FN5O2 (M + ): calcd, 327.1132; found, 327.1135.
EXAMPLE 42
[0385] [0385]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,5-triazole
[0386] Step 1
[0387] 5(R)-3-[4-[(1-Cyanocyclopropan-1-yl)phenyl]-5-methanesulfonyloxymethyloxazolidin-2-one.
[0388] To a solution of 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (2.00 g) and triethylamine (2.0 mL) in tetrahydrofuran (40 mL) was added methanesulfonyl chloride (0.75 mL) at 0° C., the mixture was stirred at the same temperature for 25 min. After dilution with ice water, the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Treatment of the residue with ethyl acetate gave 5(R)-3-[4-[(1-cyanocyclopropan-1-yl)phenyl]-5-methanesulfonyloxymethyloxazolidin-2-one (2.51 g).
[0389] Step 2
[0390] 1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,5-triazole.
[0391] To suspension of sodium hydride (120 mg) in dimethylformamide (15 mL) was added 1H-1,2,3-triazole (150 μL), the mixture was stirred at room temperature for 10 min. A solution of 5(R)-3-[4-[(1-cyanocyclopropan-1-yl)phenyl]-5-methanesulfonyloxymethyloxazolidin-2-one (500 mg) in dimethylformamide (15 mL) was added to the resulting mixture, the mixture was stirred at 80° C. for 4.5 hours. After quenching the reaction by adding 10% sodium carbonate solution, the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate) of the residue gave 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,5-triazole (291 mg). MS (EI + ) m/z: 309 (M + ).
[0392] HRMS (EI + ) for C16H15N5O2 (M + ): calcd, 309.1226; found, 309.1208.
EXAMPLE 43
[0393] [0393]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,4-triazole
[0394] To the mixture of 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (50 mg), tetramethylazodicarboxamide (50 mg) and 1,2,4-triazole (16 mg) in benzene (2 mL) was added butylphosphine (0.09 mL), the mixture was stirred at 70° C. for 19 hours, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate:methanol=20:1) of the residue gave 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,4-triazole (47 mg).
[0395] MS (EI + ) m/z: 309 (M + ).
[0396] HRMS (EI + ) for C16H15N5O2 (M + ): calcd, 309.1226; found, 309.1232.
EXAMPLE 44
[0397] [0397]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2-prazole
[0398] The title compound 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2-prazole (240 mg) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (250 mg and pyrazole (80 mg) in the same manner as described for EXAMPLE 43.
[0399] MS (EI + ) m/z: 308 (M + ).
[0400] HRMS (EI + ) for C17H16N4O2 (M + ): calcd, 308.1273; found, 308.1309.
EXAMPLE 45
[0401] [0401]
2-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]tetrazole
[0402] The title compound 2-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]tetrazole (252 mg) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (250 mg) and 1H-tetrazole (88 mg) in the same manner as described for EXAMPLE 43.
[0403] MS (EI + ) m/z: 310 (M + ).
[0404] HRMS (EI + ) for C15H14N6O2 (M + ): calcd, 310.1178; found, 310.1161.
EXAMPLE 46
[0405] [0405]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,3-imidazole
[0406] The title compound 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,3-imidazole (34 mg) was prepared from 5(R)-3-[4-[(1-cyanocyclopropan-1-yl)phenyl]-5-methanesulfonyloxymethyloxazolidin-2-one (70 mg) and imidazole (28 mg) in the same manner as described for EXAMPLE 42.
[0407] MS (EI + ) m/z: 308 (M + ).
[0408] HRMS (EI + ) for C17H16N4O2 (M + ): calcd, 308.1273; found, 308.1288.
EXAMPLE 47
[0409] [0409]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]tetrazole
[0410] The title compound 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]tetrazole (165 mg) was prepared from 5(R)-3-[4-[(1-cyanocyclopropan-1-yl)phenyl]-5-methanesulfonyloxymethyloxazolidin-2-one (600 mg) and 1H-tetrazole (244 mg) in the same manner as described for EXAMPLE 42
[0411] MS (EI + ) m/z: 310 (M + ).
[0412] HRMS (EI + ) for C15H14N6O2 (M + ): calcd, 310.1178; found, 310.1170.
EXAMPLE 48
[0413] [0413]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-hydroxymethyl-1,2,3-triazole and 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-5-hydroxymethyl-1,2,3-triazole
[0414] To a solution of 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (100 mg) in toluene (5 mL) was added propagyl alcohol (23 μL), the mixture was heated under reflux for 36 hours. After dilution of the residue with water, the mixture was extracted with dichloromethane. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate:methanol 20:1) of the residue gave 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-hydroxymethyl-1,2,3-triazole (56 mg) and 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-5-hydroxymethyl-1,2,3-triazole (37 mg).
[0415] 1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-hydroxymethyl-1,2,3-triazole:
[0416] MS (EI + ) m/z: 339 (M + ).
[0417] HRMS (EI + ) for C17H17N5O3 (M + ): calcd, 339.1331; found, 339.1319.
[0418] 1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-5-hydroxymethyl-1,2,3-triazole:
[0419] MS (EI + ) m/z: 339 (M + ).
[0420] HRMS (EI + ) for C17H17N5O3 (M + ): calcd, 339.1331; found, 339.1303.
EXAMPLE 49
[0421] [0421]
t-Butyl 1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxylate
[0422] To a suspension of copper(I) iodide (335 mg) in tetrahydrofuran (100 mL) was added t-butyl prpiolate (3.63 mL), diisopropylethylamine (4.62 mL) and a solution of 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (5.00 g) in tetrahydrofuran (10 mL), the mixture was stirred at room temperature for 2.5 hours, and then concentrated in vacuo. After dilution of the residue with ethyl acetate, the resulting precipitates were filtered off, and then concentrated in vacuo. Treatment of the residue with ethyl acetate gave t-butyl 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxylate (6.85 g).
[0423] MS (EI + ) m/z: 409 (M + ).
[0424] HRMS (EI + ) for C21H23N5O4 (M + ): calcd, 409.1750; found, 409.1729.
EXAMPLE 50
[0425] [0425]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxylic Acid
[0426] The title compound 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxylic acid (3.82 g) was prepared from t-butyl 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxylate (4.45 g) in the same manner as described for EXAMPLE 2.
[0427] MS (FAB + ) m/z: 354 (MH + ).
[0428] HRMS (FAB + ) for C17H16N5O4 (MH + ): calcd, 354.1202; found, 354.1197.
EXAMPLE 51
[0429] [0429]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxamide
[0430] To a solution of 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxylate (600 mg) in dimethylformamide (10 mL) was added N-hydroxysuccinimide (293 mg) and 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (487 mg), the mixture was stirred at room temperature for 5 hours. The resulting solution was added 25% ammonium hydroxide solution (0.58 mL), the mixture was stirred at room temperature for 2 hours, and then concentrated in vacuo. After dilution of the residue with saturated sodium hydrogen carbonate solution and water, the resulting precipitates were collected by filtration to give 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxamide (485 mg).
[0431] MS (EI + ) m/z: 352 (M + ).
[0432] HRMS (EI + ) for C17H16N6O3 (M + ): calcd, 352.1284; found, 352.1290.
EXAMPLE 52
[0433] [0433]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-N-methyl-1,2,3-triazole-4-carboxamide
[0434] The title compound N-methyl 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxamide (356 mg) was prepared from 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxylate (400 mg) and methylamine (2.83 mL, 2.0 M solution in tetrahydrofuran) in the same manner as described for EXAMPLE 51.
[0435] MS (EI + ) m/z: 366 (M + ).
[0436] HRMS (EI + ) for C18H18N6O3 (M + ): calcd, 366.1440; found, 366.1422.
EXAMPLE 53
[0437] [0437]
1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-N,N-dimethyl-1,2,3-triazole-4-carboxamide
[0438] The title compound N,N-dimethyl 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxamide (360 mg) was prepared from 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl] -2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxylate (400 mg), dimethylamine hydrochloride (401 mg) and triethylamine (0.79 mL) in the same manner as described for EXAMPLE 51.
[0439] MS (EI + ) m/z: 380 (M + ).
[0440] HRMS (EI + ) for C19H20N6O3 (M + ): calcd, 380.1597; found, 380.1618.
EXAMPLE 54
[0441] [0441]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxaldehyde
[0442] The title compound 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxaldehyde (95.3 mg) was prepared from 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-hydroxymethyl-1,2,3-triazole (100 mg) in the same manner as described for EXAMPLE 5.
[0443] MS (EI + ) m/z: 337 (M + ).
[0444] HRMS (EI + ) for C17H15N5O3 (M + ): calcd, 337.1175; found, 337.1175.
EXAMPLE 55
[0445] [0445]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-(hydroxyimino)methyl-1,2,3-triazole
[0446] The title compound 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-(hydroxyimino)methyl-1,2,3-triazole (1.00 g) was prepared from 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxaldehyde (1.00 g) in the same manner as described for EXAMPLE 6.
[0447] MS (FAB + ) m/z: 353 (MH + ).
[0448] HRMS (FAB + ) for C17H17N6O3 (MH + ): calcd, 353.1362; found, 353.1381.
EXAMPLE 56
[0449] [0449]
4-Cyano-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole
[0450] The title compound 4-cyano-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole (379 mg) was prepared from 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-(hydroxyimino)methyl-1,2,3-triazole (450 mg) in the same manner as described for EXAMPLE 7.
[0451] MS (EI + ) m/z: 334 (M + ).
[0452] HRMS (EI + ) for C17H14N6O2 (M + ): calcd, 334.1178; found, 334.1160.
EXAMPLE 57
[0453] [0453]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-(methoxyimino)methyl-1 ,2,3-triazole
[0454] The title compound 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-(methoxyimino)methyl-1,2,3-triazole (316 mg) was prepared from 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole-4-carboxaldehyde (300 mg) and O-methylhydroxylamine hydrochloride (223 mg) in the same manner as described for EXAMPLE 6.
EXAMPLE 58
[0455] [0455]
4-Aminomethyl-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole
[0456] Step 1
[0457] 4-Azidomethyl-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole.
[0458] The title compound 4-azidomethyl-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole (1.50 g) was prepared from 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-hydroxymethyl-1,2,3-triazole (1.50 g) in the same manner as described for EXAMPLE 1.
[0459] MS (EI + ) m/z: 364 (M + ).
[0460] HRMS (EI + ) for C17H16N8O2 (M + ): calcd, 364.1396; found, 364.1364.
[0461] Step 2
[0462] 4-Aminomethyl-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole.
[0463] To a solution of 4-azidomethyl-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole (900 mg) in tetrahydrofuran (30 mL) was added triphenylphosphine (842 mg), the mixture was stirred at room temperature for 9.2 hours. The resulting mixture was heated under reflux for 7 hours, and then concentrated in vacuo. After dilution of the residue with 6 N hydrochloric acid and water, the mixture was washed with ethyl acetate. The aqueous solution was made to alkaline by the addition of saturated sodium hydrogencarbonate solution and sodium carbonate. The resulting mixture was extracted with dichloromethane-methanol (5:1). The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo to give 4-aminomethyl-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole (790 mg).
[0464] MS (FAB + ) m/z: 339 (MH + ).
[0465] HRMS (FAB + ) for C17H19N6O2 (MH + ): calcd, 339.1569; found, 339.1562.
EXAMPLE 59
[0466] [0466]
4-Acetoamidomethyl-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole
[0467] To a suspension of 4-aminomethyl-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole (300 mg) in tetrahydrofuran (15 mL) was added a solution of triethylamine (197 mg) in tetrahydrofuran (1 mL) and a solution of acetic anhydride (109 mg) in tetrahydrofuran (1 mL), the mixture was stirred at room temperature for 15 min, and then concentrated in vacuo. Treatment of the residue with diethyl ether gave 4-acetoamidomethyl-1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole (304 mg).
[0468] MS (EI + ) m/z: 380 (M + ).
[0469] HRMS (EI + ) for C19H20N6O3 (M + ): calcd, 380.1597; found, 380.1592.
EXAMPLE 60
[0470] [0470]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-dimethylaminomethyl-1,2,3-triazole
[0471] Step 1
[0472] 1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-methanesulfonyloxymethyl-1,2,3-triazole.
[0473] The title compound 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-methanesulfonyloxymethyl-1,2,3-triazole (979 mg) was prepared from 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-hydroxymethyl-1,2,3-triazole (811 mg) in the same manner as described for EXAMPLE 42.
[0474] Step 2
[0475] 1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-dimethylaminomethyl-1,2,3-triazole.
[0476] To a solution of dimethylamine (2.0 M, 8.38 mL) in tetrahydrofuran was added 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-methanesulfonyloxymethyl-1,2,3-triazole at room temperature for 1 hour, the mixture was stirred at the same temperature for 10 min. The resulting precipitates were collected by filtration. Flash chromatography (NH silica, dichloromethane:methanol=40:1) of the precipitates gave 1-[5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-4-dimethylaminomethyl-1,2,3-triazole (270 mg).
[0477] MS (EI + ) m/z: 366 (M + ).
[0478] HRMS (EI + ) for C19H22N6O2 (M + ): calcd, 366.1804; found, 366.1778.
EXAMPLE 61
[0479] [0479]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]difluoroacetamide
[0480] Step 1
[0481] 5(S)-Aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one.
[0482] The title compound 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (5.31 g) was prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (6.60 g) in the same manner as described for EXAMPLE 58.
[0483] MS (EI + ) m/z: 257 (M + ).
[0484] HRMS (EI + ) for C14H15N3O2 (M + ): calcd, 257.1164; found, 257.1135.
[0485] Step 2
[0486] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]difluoroacetamide.
[0487] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]difluoroacetamide (695 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (600 mg) in the same manner as described for EXAMPLE 14.
[0488] MS (EI + ) m/z: 335 (M + ).
[0489] HRMS (EI + ) for C16H15F2N3O3 (M + ): calcd, 335.1081; found, 335.1080.
EXAMPLE 62
[0490] [0490]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]cyclopropanecarboxamide
[0491] To a solution of 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and cyclopropanecarboxylic acid (65.2 mg) in dichloromethane (10 mL) was added 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (168 mg), the mixture was stirred at room temperature for 12 hours. The mixture was washed with water and saturated sodium hydrogencarbonate solution, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, dichloromethane:methanol=95:5) of the residue gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]cyclopropanecarboxamide (160 mg).
[0492] MS (EI + ) m/z: 325 (M + ).
[0493] HRMS (EI + ) for C18H19N3O3 (M + ): calcd, 325.1426; found, 325.1426.
EXAMPLE 63
[0494] [0494]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]methoxyacetamide
[0495] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]methoxyacetamide (189 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and methoxyacetic acid (68.3 mg) in the same manner as described for EXAMPLE 62.
[0496] MS (EI + ) m/z: 329 (M + ).
[0497] HRMS (EI + ) for C17H19N3O4 (M + ): calcd, 329.1376; found, 329.1378.
EXAMPLE 64
[0498] [0498]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]furan-3-carboxamide
[0499] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]furan-3-carboxamide (183 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and furan-3-carboxylic acid (84.9 mg) in the same manner as described for EXAMPLE 62.
[0500] MS (EI + ) m/z: 351 (M + ).
[0501] HRMS (EI + ) for C19H17N3O4 (M + ): calcd, 351.1219; found, 351.1222.
EXAMPLE 65
[0502] [0502]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]pyrazine-2-carboxamide
[0503] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]pyrazine-2-carboxamide (135 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and pyrazine-2-carboxylic acid (94.1 mg) in the same manner as described for EXAMPLE 62.
[0504] MS (EI + ) m/z: 363 (M + ).
[0505] HRMS (EI + ) for C19H17N5O3 (M + ): calcd, 363.1331; found, 363.1348.
EXAMPLE 66
[0506] [0506]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]isoxazole-5-carboxamide
[0507] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]isoxazole-5-carboxamide (197 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and isoxazole-5-carboxylic acid (85.7 mg) in the same manner as described for EXAMPLE 62.
[0508] MS (EI + ) m/z: 352 (M + ).
[0509] HRMS (EI + ) for C18H16N4O4 (M + ): calcd, 352.1172; found, 352.1179.
EXAMPLE 67
[0510] [0510]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,5-thiadiazole-3-carboxamide
[0511] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,5-thiadiazole-4-carboxamide (186 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and 1,2,5-thiadiazole-3-carboxylic acid (91.0 mg) in the same manner as described for EXAMPLE 62.
[0512] MS (EI + ) m/z: 369 (M + ).
[0513] HRMS (EI + ) for C17H15N5O3S (M + ): calcd, 369.0896; found, 369.0916.
EXAMPLE 68
[0514] [0514]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-(4-methyl-1,3-thiazole)-5-carboxamide
[0515] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-(4-methyl-1,3-thiazole)-5-carboxamide (215 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and 4-methyl-1,3-thiadiazole-5-carboxylic acid (100 mg) in the same manner as described for EXAMPLE 62.
[0516] MS (EI + ) m/z: 382 (M + ).
[0517] HRMS (EI + ) for C19H18N4O3S (M + ): calcd, 382.1100; found, 382.1121.
EXAMPLE 69
[0518] [0518]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]formamide
[0519] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]formamide (167 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (160 mg) and formic acid (34.3 mg) in the same manner as described for EXAMPLE 62.
[0520] MS (EI + ) m/z: 285 (M + ).
[0521] HRMS (EI + ) for C15H15N3O3 (M + ): calcd, 285.1113; found, 285.1104.
EXAMPLE 70
[0522] [0522]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]propionamide
[0523] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]propionamide (184 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (160 mg) and propionic anhydride (162 mg) in the same manner as described for EXAMPLE 14.
[0524] MS (EI + ) m/z: 313 (M + ).
[0525] HRMS (EI + ) for C17H19N3O3 (M + ): calcd, 313.1426; found, 313.1429.
EXAMPLE 71
[0526] [0526]
5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(methoxycarbonyl)]aminomethyloxazolidin-2-one
[0527] The title compound 5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-[N-(methoxycarbonyl)]aminomethyloxazolidin-2-one (181 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (160 mg) and methyl chloroformate (118 mg) in the same manner as described for EXAMPLE 14.
[0528] MS (EI + ) m/z: 315 (M + ).
[0529] HRMS (EI + ) for C16H17N3O4 (M + ): calcd, 315.1219; found, 315.1220.
EXAMPLE 72
[0530] [0530]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]dichloroacetamide
[0531] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]dichloroacetamide (172 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and dichloroacetyl chloride (103 mg) in the same manner as described for EXAMPLE 14.
[0532] MS (EI + ) m/z: 367 (M + ).
[0533] HRMS (EI + ) for C16H15C12N3O3 (M + ): calcd, 367.0490; found, 367.0481.
EXAMPLE 73
[0534] [0534]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]methylthioacetamide
[0535] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]methylthioacetamide (348 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (300 mg) and methylthioacetic acid (149 mg) in the same manner as described for EXAMPLE 62.
[0536] MS (EI + ) m/z: 345 (M + ).
[0537] HRMS (EI + ) for C17H19N3O3S (M + ): calcd, 345.1147; found, 345.1156.
EXAMPLE 74
[0538] [0538]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]cyanoacetamide
[0539] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]cyanoacetamide (179 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and cyanoacetic acid (64.5 mg) in the same manner as described for EXAMPLE 62.
[0540] MS (EI + ) m/z: 324(M + ).
[0541] HRMS (EI + ) for C17H16N4O3 (M + ): calcd, 324.1222; found, 324.1245.
EXAMPLE 75
[0542] [0542]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]methylsulfonylacetamide
[0543] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]methylsulfonylacetamide (199 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and methylsulfonylacetic acid (105 mg) in the same manner as described for EXAMPLE 62.
[0544] MS (EI + ) m/z: 377 (M + ).
[0545] HRMS (EI + ) for C17H19N3O5S (M + ): calcd, 377.1045; found, 377.1035.
EXAMPLE 76
[0546] [0546]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-(2,2-dichloro)cyclopropane-1-carboxamide (Diastereomers A and B)
[0547] The title compounds N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-(2,2-dichloro)cyclopropane-1-carboxamide (diastereomers A (98.7 mg) and B (101 mg)) were prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and 2,2-dichlorocyclopropane-1-carboxylic acid (117 mg) in the same manner as described for EXAMPLE 62.
[0548] Diastereomer A:
[0549] MS (EI + ) m/z: 393 (M + ).
[0550] HRMS (EI + ) for C18H17C12N3O3 (M + ): calcd, 393.0647; found, 393.0666.
[0551] Diastereomer B:
[0552] MS (EI + ) m/z: 393 (M + ).
[0553] HRMS (EI + ) for C18H17C12N3O3 (M + ): calcd, 393.0647; found, 393.0677.
EXAMPLE 77
[0554] [0554]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]methylsulfinylacetamide
[0555] To a solution of N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]methylthioacetamide (160 mg) in dichloromethane (4 mL) was added m-chloroperbenzoic acid (87.9 mg) at 0° C., the mixture was stirred at the same temperature for 2 hours. The mixture was washed with 5% sodium bisulfate solution, 5% sodium hydrogencarbonate solution and brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, dichloromethane:methanol=9:1) of the residue gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]methylsulfinylacetamide (139 mg).
[0556] MS (FAB + ) m/z: 362 (MH + ).
[0557] HRMS (FAB + ) for C17H20N3O4S (MH + ): calcd, 362.1175; found, 362.1163.
EXAMPLE 78
[0558] [0558]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-2(R)-chloropropionamide
[0559] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-2(R)-chloropropionamide (194 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and (R)-chloropropionic acid (82.2 mg) in the same manner as described for EXAMPLE 62.
[0560] MS (EI + ) m/z: 347 (M + ).
[0561] HRMS (EI + ) for C17H18ClN3O3 (M + ): calcd, 347.1037; found, 347.1038.
EXAMPLE 79
[0562] [0562]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-2(S)-chloropropionamide
[0563] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-2(S)-chloropropionamide (193 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (150 mg) and (S)-chloropropionic acid (82.2 mg) in the same manner as described for EXAMPLE 62.
[0564] MS (EI + ) m/z: 347 (M + ).
[0565] HRMS (EI + ) for C17H18ClN3O3 (M + ): calcd, 347.1037; found, 347.1063.
EXAMPLE 80
[0566] [0566]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-N-methylacetamide
[0567] To a solution of N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (140 mg) in tetrahydrofuran (5 mL) was added iodomethane (73 μL) and potassium t-butoxide (78.7 mg) at room temperature, the mixture was stirred at the same temperature for 1 hour. After quenching the reaction by addition of 5% hydrochloric acid, the mixture was extracted with ethyl acetate. The organic extracts were washed with 5% sodium hydrogencarbonate solution, 5% sodium thiosulfate solution and brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate:methanol=19:1) of the residue gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-N-methylacetamide (139 mg).
[0568] MS (EI + ) m/z: 313 (M + ).
[0569] HRMS (EI + ) for C17H19N3O3 (M + ): calcd, 313.1426; found, 313.1433.
EXAMPLE 81
[0570] [0570]
N-Benzoyloxy-N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide and N-benzoyloxy-O-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetimidate
[0571] The title compounds N-benzoyloxy-N-[5(S)-3-[4-(1-cyanocyclopropan-1-5yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (127 mg) and N-benzoyloxy-O-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetimidate (268 mg) were prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (272 mg) and N-benzoyloxyacetamide (179 mg) in the same manner as described for EXAMPLE 25.
[0572] N-Benzoyloxy-N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide:
[0573] MS (EI + ) m/z: 419 (M + ).
[0574] HRMS (EI + ) for C23H21N3O5 (M + ): calcd, 419.1481; found, 419.1505.
[0575] N-Benzoyloxy-O-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetimidate:
[0576] MS (FAB + ) m/z: 420 (MH + ).
[0577] HRMS (FAB + ) for C23H22N3O5 (MH + ): calcd, 420.1559; found, 420.1578.
EXAMPLE 82
[0578] [0578]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-N-hydroxyacetamide
[0579] To a solution of N-benzoyloxy-N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (105 mg) in methanol (10 mL) was added potassium carbonate (34.6 mg), the mixture was sonicated at room temperature for 5 min, and then concentrated in vacuo. Flash chromatography (silica, dichloromethane:methanol=9:1) of the residue gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-N-hydroxyacetamide (57.2 mg).
[0580] MS (EI + ) m/z: 315 (M + ).
[0581] HRMS (EI + ) for C16H17N304 (M + ): calcd, 315.1219; found, 315.1229.
EXAMPLE 83
[0582] [0582]
O-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-N-hydroxyacetimidate
[0583] The title compound O-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-N-hydroxyacetimidate (110 mg) was prepared from N-benzoyloxy-O-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetimidate (235 mg) in the same manner as described for EXAMPLE 82.
[0584] MS (EI + ) m/z: 315 (M + ).
[0585] HRMS (EI + ) for C16H17N304 (M + ): calcd, 315.1219; found, 315.1247.
EXAMPLE 84
[0586] [0586]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]-1-cyanocyclopropane-1-carboxamide
[0587] To a solution of 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (315 mg) and 1-cyanocyclopropane-1-carboxylic acid (131 mg) in dimethylformamide (4 mL) was added diethyl cyanophosphonate (0.21 mL) and triethylamine (0.18 mL) at 0° C., the mixture was stirred at room temperature for 18 hours. After dilution with 1 N hydrochloric acid, the mixture was extracted with ethyl acetate. The organic extracts were washed with water, 1 N sodium hydroxide solution and brine, dried over anhydrous sodium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate =3:10) of the residue gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]-1-cyanocyclopropane-1-carboxamide (306 mg).
[0588] MS (EI + ) m/z: 368 (M + ).
[0589] HRMS (EI + ) for C19H17FN403 (M + ): calcd, 368.1285; found, 368.1260.
EXAMPLE 85
[0590] [0590]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]-1-hydroxycyclopropane-1-carboxamide
[0591] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]-2-oxooxazolidin-5-ylmethyl]-1-hydroxycyclopropane-1-carboxamide (364 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-fluorophenyl]oxazolidin-2-one (426 mg) and 1-hydroxycyclopropane-1-carboxylic acid (163 mg) in the same manner as described for EXAMPLE 84.
[0592] MS (EI + ) m/z: 359 (M + ).
[0593] HRMS (EI + ) for C18H18FN304 (M + ): calcd, 359.1281; found, 359.1305.
EXAMPLE 86
[0594] [0594]
N′-Cyano-N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-S-methylisothiourea
[0595] To a solution of dimethyl N-cyanodithioiminocarbonate (179 mg) in methanol (2 mL) was added a solution of 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (257 mg) in methanol (6 mL), the mixture was stirred at room temperature for 7 hours. The resulting precipitates were collected by filtration and washed with cold methanol to give N′-cyano-N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-S-methylisothiourea (281 mg).
[0596] MS (FAB + ) m/z: 356 (MH + ).
[0597] HRMS (FAB + ) for C17H18N502S (MH + ): calcd, 356.1181; found, 356.1172.
EXAMPLE 87
[0598] [0598]
N′-Cyano-N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]urea
[0599] To a solution of N′-cyano-N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]-S-methylisothiourea (210 mg) in pyridine (4 mL) was added a solution of ammonia (7 N, 20 mL) in methanol, the mixture was allowed to stand at room temperature overnight, and then concentrated in vacuo. Treatment of the residue with cold methanol gave N′-cyano-N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]urea (166 mg).
[0600] MS (FAB + ) m/z: 325 (MH + ).
[0601] HRMS (FAB + ) for C16H17N602 (MH + ): calcd, 325.1413; found, 325.1414.
EXAMPLE 88
[0602] [0602]
5(S)-5-[N-(t-Butoxycarbonyl)-N-(pyridin-2-yl)]aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one
[0603] The title compound 5(S)-5-[N-(t-Butoxycarbonyl)-N-(pyridin-2-yl)]aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (307 mg) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (258 mg) and 2-(t-butoxycarbonyl)aminopyridine (389 mg) in the same manner as described for EXAMPLE 15.
[0604] MS (EI + ) m/z: 434 (M + ).
[0605] HRMS (EI + ) for C24H26N404 (M + ): calcd, 434.1954; found, 434.1973.
EXAMPLE 89
[0606] [0606]
5(S)-3-[4-(1-Cyanocyclopropan-1-yl)phenyl]-5-[N-(pyridin-2-yl)]aminomethyloxazolidin-2-one
[0607] The title compound 5(S)-3-[4-(1-cyanocyclopropan-1-yl)phenyl]-5-[N-(pyridin-2-yl)]aminomethyloxazolidin-2-one (175 mg) was prepared from 5(S)-5-[N-(t-butoxycarbonyl)-N-(pyridin-2-yl)]aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one (335 mg) using a solution of hydrogen chloride (8 M, 5 mL) in methanol instead of trifluoroacetic acid in the same manner as described for EXAMPLE 17.
[0608] MS (FAB + ) m/z: 335 (MH + ).
[0609] HRMS (FAB + ) for C19H19N402 (MH + ): calcd, 335.1508; found, 335.1516.
EXAMPLE90
[0610] [0610]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-methylphenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0611] Step 1
[0612] 5(R)-3-[4-(1-Cyanocyclopropan-1-yl)-3-methylphenyl]-5-hydroxymethyloxazolidin-2-one.
[0613] The title compound 5(R)-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]-5-hydroxymethyloxazolidin-2-one (1.34 g) was prepared from 1-(4-benzyloxycarbonylamino-2-methylphenyl)-1-cyclopropanecarbonitrile (2.48 g) in the same manner as described for EXAMPLE 1.
[0614] MS (EI + ) m/z: 272 (M + ).
[0615] HRMS (EI + ) for C15H16N203 (M + ): calcd, 272.1161; found, 272.1169.
[0616] Step 2
[0617] 5(R)-Azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]oxazolidin-2-one.
[0618] The title compound 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]oxazolidin-2-one (1.04 g) was prepared from 5(R)-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]-5-hydroxymethyloxazolidin-2-one (1.00 g) in the same manner as described for EXAMPLE 1.
[0619] MS (EI + ) m/z: 297 (M + ).
[0620] HRMS (EI + ) for C15H15N502 (M + ): calcd, 297.1226; found, 297.1227.
[0621] Step 3
[0622] 5(S)-Aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]oxazolidin-2-one.
[0623] The title compound 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]oxazolidin-2-one (706 mg) was prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]oxazolidin-2-one (805 mg) in the same manner as described for EXAMPLE 9.
[0624] Rf: 0.19 (silica, dichloromethane:methanol=4:1).
[0625] Step 4
[0626] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-methylphenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0627] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (134-mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]oxazolidin-2-one (120 mg) in the same manner as described for EXAMPLE 14.
[0628] MS (EI + ) m/z: 313 (M + ).
[0629] HRMS (EI + ) for C17H19N303 (M + ): calcd, 313.1426; found, 313.1423.
EXAMPLE 91
[0630] [0630]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)]-3-methylphenyl]-2-oxooxazolidin-5-ylmethyl]propionamide
[0631] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)]-3-methylphenyl]-2-oxooxazolidin-5-ylmethyl]propionamide (139 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)]-3-methylphenyl]oxazolidin-2-one (120 mg) and propionic anhydride (115 mg) in the same manner as described for EXAMPLE 14.
[0632] MS (EI + ) m/z: 327 (M + ).
[0633] HRMS (EI + ) for C18H21N303 (M + ): calcd, 327.1583; found, 327.1571.
EXAMPLE 92
[0634] [0634]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-methylphenyl]-2-oxooxazolidin-5-ylmethyl]cyclopropanecarboxamide
[0635] The title compound N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]-2-oxooxazolidin-5-ylmethyl]cyclopropanecarboxamide (138 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]oxazolidin-2-one (120 mg) in the same manner as described for EXAMPLE 62.
[0636] MS (EI + ) m/z: 339 (M + ).
[0637] HRMS (EI + ) for C19H21N303 (M + ): calcd, 339.1583; found, 339.1580.
EXAMPLE 93
[0638] [0638]
5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-methylphenyl]-5-[N-(methoxycarbonyl)]aminomethyloxazolidin-2-one
[0639] The title compound 5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]-5-[N-(methoxycarbonyl)]aminomethyloxazolidin-2-one (142 mg) was prepared from 5(S)-aminomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]oxazolidin-2-one (120 mg) and methyl chloroformate (51 μL) in the same manner as described for EXAMPLE 14.
[0640] MS (EI + ) m/z: 329 (M + ).
[0641] HRMS (EI + ) for C17H19N304 (M + ): calcd, 329.1376; found, 329.1391.
EXAMPLE 94
[0642] [0642]
1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)-3-methylphenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole
[0643] The title compound 1-[5(R)-3-[4-(1-Cyanocyclopropan-1-yl)-3-methylphenyl]-2-oxooxazolidin-5-ylmethyl]-1,2,3-triazole (187 mg) was prepared from 5(R)-azidomethyl-3-[4-(1-cyanocyclopropan-1-yl)-3-methylphenyl]oxazolidin-2-one (200 mg) in the same manner as described for EXAMPLE 37.
[0644] MS (EI + ) m/z: 323 (M + ).
[0645] HRMS (EI + ) for C17H17N502 (M + ): calcd, 323.1382; found, 323.1369.
EXAMPLE 95
[0646] [0646]
N-[5(S)-3-[3-Bromo-4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0647] Step 1
[0648] 5(R)-3-[3-Bromo-4-(1-Cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one.
[0649] The title compound 5(R)-3-[3-bromo-4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (658 mg) was prepared from 1-(4-benzyloxycarbonylamino-2-bromophenyl)-1-cyclopropanecarbonitrile (1.15 g) using lithium t-butoxide (prepared from t-butanol (298 mg) and n-butyllithium in hexane (2.66 M, 1.3 mL)) in stead of n-butyllithium in the same manner as described for EXAMPLE 1.
[0650] MS (EI + ) m/z: 336 (M + ).
[0651] HRMS (EI + ) for C14H13BrN203 (M + ): calcd, 336.0110; found, 336.0111.
[0652] Step 2
[0653] 5(R)-Azidomethyl-3-[3-bromo-4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one.
[0654] The title compound 5(R)-azidomethyl-3-[3-bromo-4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one was prepared from 5(R)-3-[3-bromo-4-(1-cyanocyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (580 mg) in the same manner as described for EXAMPLE 1. This was used in the next step without further purification.
[0655] Rf: 0.50 (silica, hexane:ethyl acetate=1:2).
[0656] Step 3
[0657] N-[5(S)-3-[3-Bromo-4-(1-Cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0658] To a solution of the above crude 5(R)-azidomethyl-3-[3-bromo-4-(1-cyanocyclopropan-1-yl)phenyl]oxazolidin-2-one in tetrahydrofuran (10 mL) was added triphenylphosphine (541 mg), the mixture was stirred at room temperature for 6 hours. The resulting mixture was added water (155 μL) and then heated at 60° C. for 6 hours. The mixture was adjusted to pH 4 by the addition of 6 N hydrochloric acid at 0° C., diluted with ethyl acetate, and extracted with 5% hydrochloric acid. The aqueous extracts were washed with ethyl acetate, adjusted to pH 9 by the addition of potassium carbonate, and then diluted with tetrahydrofuran (20 mL). The resulting mixture was added acetic anhydride (878 mg), the mixture was stirred at room temperature for 1 hour. The mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate:methanol=20: 1) of the residue gave N-[5(S)-3-[3-bromo-4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (614 mg).
[0659] MS (EI + ) m/z: 377 (M + ).
[0660] HRMS (EI + ) for C16H16BrN303 (M + ): calcd, 377.0375; found, 313.0378.
EXAMPLE 96
[0661] [0661]
N-[5(S)-3-[3-Cyano-4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0662] A mixture of N-[5(S)-3-[3-bromo-4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (100 mg), zinc cyanide (24.8 mg), tris(dibenzylideneacetone)dipalladium(0) (12.1 mg) and (diphenylphosphino)ferrocene (17.6 mg) in N-methylpyrrolidone (5 mL) was heated at 150° C. for 18 hours, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate:methanol=19:1) of the residue gave N-[5(S)-3-[3-cyano-4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (43 mg).
[0663] MS (EI + ) m/z: 324 (M + ).
[0664] HRMS (EI + ) for C17H16N403 (M + ): calcd, 324.1222; found, 324.1247.
EXAMPLE 97
[0665] [0665]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-phenylphenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0666] A mixture of N-[5(S)-3-[3-bromo-4-(1-cyanocyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (90 mg), phenylboronic acid (58.0 mg), tetrakis(triphenylphosphine)palladium(0) (27.5 mg), and 2 M sodium carbonate solution (240 μL) in dioxane (5 mL) was heated at 110° C. for 12 hours, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate:methanol=20:1) of the residue gave N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-phenylphenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (81.4 mg).
[0667] MS (EI + ) m/z: 375 (M + ).
[0668] HRMS (EI + ) for C22H21N303 (M + ): calcd, 375.1583; found, 375.1574.
EXAMPLE 98
[0669] [0669]
N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-(pyridin-3-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide and N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-ethylphenyl]-2-oxooxazolidin-5-ylmethyl]acetamide
[0670] The title compounds N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-(pyridin-3-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (36.2 mg) and N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-ethylphenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (24 mg) were prepared from N-[5(S)-3-[4-(1-cyanocyclopropan-1-yl)-3-bromophenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (150 mg) and diethyl(3-pyridyl)borane (87.5 mg) in the same manner as described for EXAMPLE 97.
[0671] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-(pyridin-3-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide:
[0672] MS (EI + ) m/z: 376 (M + ).
[0673] HRMS (EI + ) for C21H20N403 (M + ): calcd, 376.1535; found, 376.1524.
[0674] N-[5(S)-3-[4-(1-Cyanocyclopropan-1-yl)-3-ethylphenyl]-2-oxooxazolidin-5-ylmethyl]acetamide:
[0675] MS (EI + ) m/z: 327 (M + ).
[0676] HRMS (EI + ) for C18H21N303 (M + ): calcd, 327.1583; found, 327.1576.
EXAMPLE 99
[0677] Step 1
[0678] 5(R)-[4-(1-(2-Methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one.
[0679] The title compound 5(R)-[4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (2.55 g) was prepared from 4-benzyloxycarbonylamino-1-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)benzene (3.00 g) in the same manner as described for EXAMPLE 1.
[0680] MS (EI + ) m/z: 319 (M + ).
[0681] HRMS (EI + ) for C17H21NO5 (M + ): calcd, 319.1420; found, 319.1409.
[0682] Step 2
[0683] 5(R)-[4-(1-(2-Methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]-5-phenylsulfonyloxymethyloxazolidin-2-one.
[0684] To a solution of 5(R)-[4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]-5-hydroxymethyloxazolidin-2-one (2.55 g) and triethylamine (1.7 mL) in tetrahydrofuran (20 mL) was added benzenesulfonyl chloride (1.2 mL) at 0° C., the mixture was stirred at room temperature overnight, and heated at 40° C. for 10 hours. After dilution with water, the mixture was extracted with tetrahydrofuran. The organic extracts were washed with 1 N hydrochloric acid, saturated sodium hydrogencarbonate solution and brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=1:1) of the residue gave 5(R)-[4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]-5-phenylsulfonyloxymethyloxazolidin-2-one (3.05 g).
[0685] MS (EI + ) m/z: 459 (M + ).
[0686] HRMS (EI + ) for C23H25NO7S (M + ): calcd, 459.1352; found, 459.1335.
[0687] Step 3
[0688] 5(R)-Azidomethyl-3-[4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]oxazolidin-2-one.
[0689] The title compound 5(R)-azidomethyl-3-[4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]oxazolidin-2-one (1.49 g) was prepared from 5(R)-[4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]-5-phenylsulfonyloxymethyloxazolidin-2-one (2.00 g) in the same manner as described for EXAMPLE 1.
[0690] MS (EI + ) m/z: 344 (M + ).
[0691] HRMS (EI + ) for C17H20N404 (M + ): calcd, 344.1485; found, 344.1489.
[0692] Step 4
[0693] N-[5(S)-3-[4-(1-Acetylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide.
[0694] A suspension of 5(R)-azidomethyl-3-[4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]oxazolidin-2-one (1.46 g) and Lindlar catalyst (500 mg) in methanol (20 mL) and dichloromethane (4 mL) was hydrogenated at 1 atm for 2.5 hours at room temperature. After filtration of the catalyst, the filtrate was concentrated in vacuo to give 5(S)-aminomethyl-3-[4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]oxazolidin-2-one. To a solution of crude 5(S)-aminomethyl-3-[4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)phenyl]oxazolidin-2-one thus obtained in dichloromethane (20 mL) was added triethylamine (1.2 mL) and acetic anhydride (0.8 mL) at room temperature, and the mixture was stirred at the same temperature for 1 hour, and then concentrated in vacuo. The residue was added acetic acid (30 mL) and water (3 mL), the resulting mixture was stirred at room temperature for 8 hours, and allowed to stand for overnight. After dilution with ethyl acetate, the mixture was washed with saturated sodium hydrogencarbonate solution and brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, ethyl acetate:methanol=20:1) of the residue gave N-[5(S)-3-[4-(1-acetylcyclopropan-1-yl)phenyl]-2-oxooxazolidin-5-ylmethyl]acetamide (800 mg).
[0695] MS (EI + ) m/z: 316 (M + ).
[0696] HRMS (EI + ) for C17H20N204 (M + ): calcd, 316.1423; found, 316.1423.
REFERENCE EXAMPLE 1
2-Fluoro-4-nitrophenylacetic Acid
[0697] To a suspension of sodium hydride (32.7 g) in dimethyl sulfoxide (580 mL) was added diethyl malonate (129 mL) at 0° C. for 40 min, and the mixture was stirred at room temperature for 1.5 hours. 3,4-Difluoronitrobenzene (50.0 g) was added the mixture at 0° C., and the resulting solution was stirred at room temperature for 2 hours. The mixture was poured to 10% ammonium chloride solution, and then extracted with ethyl acetate. The organic extracts were washed with water and brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo to give diethyl 2-fluoro-4-nitrophenyl malonate. A solution of crude diethyl 2-fluoro-4-nitrophenyl malonate thus obtained in acetic acid (456 mL), water (323 mL) and concentrated sulfuric acid (130 mL) was heated under reflux for 14 hours, and then concentrated in vacuo. After dilution the residue with water, the mixture was extracted with ether. The ethereal solution was extracted with 10% potassium carbonate solution. The aqueous extracts were adjusted to pH 2 by the addition of concentrated hydrochloric acid. The resulting precipitates were collected by filtration, washed with water, and then dried in air to give 2-fluoro-4-nitrophenylacetic acid. MS (EI + ) m/z: 199 (M + ).
[0698] HRMS (EI + ) for C 8 H 6 FNO 4 (M + ): calcd, 199.0281; found, 199.0308.
REFERENCE EXAMPLE 2
t-Butyl 2-Fluoro-4-nitrophenylacetate
[0699] To a solution of 2-fluoro-4-nitrophenylacetic acid (24.0 g) in t-butyl alcohol (450 mL) was added di-t-butyl dicarbonate (29.0 g) and (4-dimethylamino)pyridine (1.47 g) at room temperature, and the mixture was stirred at the same temperature for 2 hours. The mixture was added saturated sodium hydrogencarbonate solution, stirred for 30 min, and then extracted with ethyl acetate. The organic extracts were washed with 5% hydrochloric acid and brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=6:1) of the residue gave t-butyl 2-fluoro-4-nitrophenylacetate. MS (FAB + ) m/z: 256 (MH + ).
[0700] HRMS (FAB + ) for C 12 H 15 FNO 4 (MH + ): calcd, 256.0985; found, 256.0989.
REFERENCE EXAMPLE 3
t-Butyl 1-(2-Fluoro-4-nitrophenyl)cyclopropane-1-carboxylate
[0701] To a solution of t-butyl 2-fluoro-4-nitrophenylacetate (11.3 g) in dimethyl sulfoxide (70 mL) was added bis(dimethylamino)methane (6.80 g) and acetic anhydride (14.9 g) at room temperature, and the mixture was stirred at the same temperature for 30 min. The mixture was poured to water, and the mixture was extracted with toluene. The organic extracts were washed with water and brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=9:1) of the residue gave t-butyl 2-(2-fluoro-4-nitrophenyl)acrylate. To a solution of the above t-butyl 2-(2-fluoro-4-nitrophenyl)acrylate and trimethylsulfoxonium iodide (11.7 g) in dimethyl sulfoxide (70 mL) was added potassium t-butoxide (5.96 g) at room temperature, and the mixture was stirred at the same temperature for 1 hour. After quenching the reaction by the addition of 5% hydrochloric acid, the mixture was extracted with ethyl acetate. The organic extracts were washed with 3% sodium thiosulfate solution and brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=9:1) of the residue gave t-butyl 1-(2-fluoro-4-nitrophenyl)cyclopropane-1-carboxylate. MS (EI + ) m/z: 281 (M + ).
[0702] HRMS (EI + ) for C 14 H 16 FNO 4 (M + ): calcd, 281.1063; found, 281.1088.
REFERENCE EXAMPLE 4
t-Butyl 1-(4-Benzyloxycarbonylamino-2-fluorophenyl)cyclopropane-1-carboxylate
[0703] A suspension of t-butyl 1-(2-fluoro-4-nitrophenyl)cyclopropane-1-carboxylate (110 mg) and palladium catalyst (10% on charcoal, 11 mg) in methanol (5 mL) was hydrogenated at 1 atm for 2 hours at room temperature. After filtration of the catalyst, the filtrate was concentrated in vacuo to give t-butyl 1-(4-amino-2-fluorophenyl)cyclopropane-1-carboxylate. To a solution of crude t-butyl 1-(4-amino-2-fluorophenyl)cyclopropane-1-carboxylate thus obtained in tetrahydrofuran (5 mL) was added sodium hydrogencarbonate (39 mg), water (1 mL) and benzyl chloroformate (61L) at room temperature, and the mixture was stirred at the same temperature for 1 hour. After quenching the reaction by the addition of saturated sodium hydrogencarbonate solution, the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=6:1) of the residue gave t-butyl 1-(4-benzyloxycarbonylamino-2-fluorophenyl)cyclopropane-1-carboxylate. MS (EI + ) m/z: 385 (M + ).
[0704] HRMS (EI + ) for C 22 H 24 FNO 4 (M + ): calcd, 385.1689; found, 385.1693.
REFERENCE EXAMPLE 5
2,6-Difluoro-4-nitrophenylacetic Acid
[0705] The title compound 2,6-difluoro-4-nitrophenylacetic acid (16.0 g) was prepared from 3,4,5-trifluoronitrobenzene (14.8 g) and diethyl malonate (35 mL) in the same manner as described for REFERENCE EXAMPLE 1. MS (EI + ) m/z: 217 (M + ).
[0706] HRMS (EI + ) for C 8 H 5 F 2 NO 4 (M + ): calcd, 217.0187; found, 217.0213.
REFERENCE EXAMPLE 6
[0707] t-Butyl 2,6-Difluoro-4-nitrophenylacetate
[0708] The title compound t-butyl 2,6-difluoro-4-nitrophenylacetate (18.5 g) was prepared from 2,6-difluoro-4-nitrophenylacetic acid (16.0 g) in the same manner as described for REFERENCE EXAMPLE 2.
[0709] Rf=0.73 (hexane:ethyl acetate=4:1).
REFERENCE EXAMPLE 7
t-Butyl 2-(2,6-Difluoro-4-nitrophenyl)acrylate
[0710] The title compound t-butyl 2-(2,6-difluoro-4-nitrophenyl)acrylate (18.8 g) was prepared from t-butyl 2,6-difluoro-4-nitrophenylacetate (18.5 g) in the same manner as described for REFERENCE EXAMPLE 3. MS (FAB + ) m/z: 285 (MH + ).
[0711] HRMS (FAB + ) for C 13 H 14 F 2 NO 4 (MH + ): calcd, 285.0891; found, 285.0902.
REFERENCE EXAMPLE 8
t-Butyl 1-(2,6-Difluoro-4-nitrophenyl)cyclopropane-1-carboxylate
[0712] The title compound t-butyl 1-(2,6-difluoro-4-nitrophenyl)cyclopropane-1-carboxylate (145 mg) was prepared from t-butyl 2-(2,6-difluoro-4-nitrophenyl)acrylate (200 mg) in the same manner as described for REFERENCE EXAMPLE 3.
[0713] MS (EI + ) m/z: 299 (M + ).
[0714] HRMS (EI + ) for C 14 H 15 F 2 NO 4 (M + ): calcd, 299.0969; found, 299.0986.
REFERENCE EXAMPLE 9
t-Butyl 1-(4-Benzyloxvcarbonylamino-2,6-difluorophenyl)cyclopropane-1-carboxylate
[0715] The title compound t-butyl 1-(4-benzyloxycarbonylamino-2,6-difluorophenyl)cyclopropane-1-carboxylate (14.9 g) was prepared from t-butyl 1-(2,6-difluoro-4-nitrophenyl)cyclopropane-1-carboxylate (12.3 g) in the same manner as described for REFERENCE EXAMPLE 4. MS (EI + ) m/z: 403 (M + ).
[0716] HRMS (EI + ) for C 14 H 15 F 2 NO 4 (M + ): calcd, 403.1595; found, 403.1586.
REFERENCE EXAMPLE 10
1-(2-Fluoro-4-nitrophenyl)-1-cyclopropylmethanol
[0717] The title compound 1-(2-fluoro-4-nitrophenyl)-1-cyclopropylmethanol (20.7 g) was prepared from t-butyl 2-fluoro-4-nitrophenylacetate (30.2 g) in the same manner as described for EXAMPLE 2 and 3. MS (EI + ) m/z: 211 (M + ).
[0718] HRMS (EI + ) for C 10 H 10 FNO 3 (M + ): calcd, 211.0645; found, 211.0649.
REFERENCE EXAMPLE 11
1-(2-Fluoro-4-nitrophenyl)-1-cyclopropylcarbonitrile
[0719] The title compound 1-(2-fluoro-4-nitrophenyl)-1-cyclopropylcarbonitrile (424 mg) was prepared from 1-(2-fluoro-4-nitrophenyl)-1-cyclopropylmethanol (555 mg) in the same manner as described for EXAMPLE 5, 6 and 7. MS (EI + ) m/z: 206 (M + ).
[0720] HRMS (EI + ) for C 10 H 7 FN 2 O 2 (M + ): calcd, 206.0492; found, 206.0512.
REFERENCE EXAMPLE 12
1-(4-Benzyloxycarbonylamino-2-fluorophenyl)-1-cyclopropanecarbonitrile
[0721] The title compound 1-(4-benzyloxycarbonylamino-2-fluorophenyl)-1-cyclopropanecarbonitrile (642 mg) was prepared from 1-(2-fluoro-4-nitrophenyl)-1-cyclopropylcarbonitrile (420 mg) in the same manner as described for REFERENCE EXAMPLE 4. MS (EI + ) m/z: 310 (M + ).
[0722] HRMS (EI + ) for C 18 H 15 FN 2 O 2 (M + ): calcd, 310.1118; found, 310.1122.
REFERENCE EXAMPLE 13
1-(4-Benzyloxycarbonylaminophenyl)-1-cyclopropanecarbonitrile
[0723] The title compound 1-(4-benzyloxycarbonylaminophenyl)-1-cyclopropanecarbonitrile (8.34 g) was prepared from 1-(4-nitrophenyl)-1-cyclopropylcarbonitrile (5.50 g) in the same manner as described for REFERENCE EXAMPLE 4. MS (EI + ) m/z: 292 (M + ).
[0724] HRMS (EI + ) for C 18 H 16 N 2 O 2 (M + ): calcd, 292.1212; found, 292.1190.
REFERENCE EXAMPLE 14
(2-Methyl-4-nitrophenyl)acetonitrile
[0725] To a suspension of sodium hydride (60% oil dispersion, 6.13 g) in dimethyl sulfoxide (100 mL) was added ethyl cyanoacetate (18.0 g) at 0° C., and the mixture was stirred at room temperature for 2 hours. 2-Methyl-4-nitrofluorobenzene (9.15 g) was added to the mixture, and the resulting solution was stirred at room temperature for 12 hours. After quenching the reaction by the addition of 6 N hydrochloric acid at 0° C., and the mixture was extracted with ether. The ethereal solution was washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo to give ethyl (2-methyl-4-nitrophenyl)cyanoacetate. A solution of crude ethyl (2-methyl-4-nitrophenyl)cyanoacetate thus obtained in dioxane (200 mL) and 6 N hydrochloric acid (200 mL) was heated at 100° C. for 12 hours. After dilution of the mixture with water and sodium chloride, the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=2:1) of the residue gave (2-methyl-4-nitrophenyl)acetonitrile (5.32 g).
[0726] MS (EI + ) m/z: 176 (M + ).
[0727] HRMS (EI + ) for C9H8N202 (M + ): calcd, 176.0586; found, 176.0590.
REFERENCE EXAMPLE 15
1-(2-Methyl-4-nitrophenyl)cyclopropane-1-carbonitrile
[0728] A mixture of (2-methyl-4-nitrophenyl)acetonitrile (100 mg), benzyltriethylammonium chloride (129 mg), dibromoethane (73.4 μL) and 50% sodium hydroxide solution was heated at 70° C. for 1 hour. After quenching the reaction by the addition of concentrated hydrochloric acid at 0° C., and the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=2:1) of the residue gave 1-(2-Methyl-4-nitrophenyl)cyclopropane-1-carbonitrile (92.1 mg).
[0729] MS (EI + ) rn/z: 202 (M + ).
[0730] HRMS (EI + ) for C11H10N202 (M + ): calcd, 202.0742; found, 202.0727.
REFERENCE EXAMPLE 16
1-(4-Benzyloxycarbonylamino-2-methylphenyl)cyclopropane-1-carbonitrile
[0731] The title compound 1-(4-benzyloxycarbonylamino-2-methylphenyl)cyclopropane-1-carbonitrile (5.05 g) was prepared from 1-(2-methyl-4-nitrophenyl)cyclopropane-1-carbonitrile (4.39 g) in the same manner as described for REFERENCE EXAMPLE 4.
[0732] MS (EI + ) m/z: 306 (M + ).
[0733] HRMS (EI + ) for C19H18N202 (M + ): calcd, 306.1368; found, 306.1397.
REFERENCE EXAMPLE 17
(2-Bromo-4-nitrophenyl)acetonitrile
[0734] The title compound (2-bromo-4-nitrophenyl)acetonitrile (1.34 g) was prepared from 2-bromo-4-nitrochlorobenzene (2.36 g) in the same manner as described for REFERENCE EXAMPLE 14.
[0735] MS (EI + ) m/z: 240 (M + ).
[0736] HRMS (EI + ) for C8H5BrN202 (M + ): calcd, 239.9534; found, 239.9562.
REFERENCE EXAMPLE 18
1-(2-Bromo-4-nitrophenyl)cyclopropane-1-carbonitrile
[0737] The title compound 1-(2-bromo-4-nitrophenyl)cyclopropane-1-carbonitrile (29.4 mg) was prepared from (2-bromo-4-nitrophenyl)acetonitrile (50 mg) in the same manner as described for REFERENCE EXAMPLE 15.
[0738] MS (EI + ) m/z: 266 (M + ).
[0739] HRMS (EI + ) for C10H7BrN202 (M + ): calcd, 265.9691; found, 265.9677.
REFERENCE EXAMPLE 19
1-(4-Benzyloxycarbonylamino-2-bromophenyl)cyclopropane-1-carbonitrile
[0740] The title compound 1-(4-benzyloxycarbonylamino-2-bromophenyl)cyclopropane-1-carbonitrile (115 mg) was prepared from 1-(2-bromo-4-nitrophenyl)cyclopropane-1-carbonitrile (100 mg) in the same manner as described for REFERENCE EXAMPLE 4.
[0741] Rf: 0.57 (silica, hexane:ethyl acetate=2:1).
REFERENCE EXAMPLE 20
4-(1-Acetylcyclopropan-1-yl)nitrobenzene
[0742] The title compound 4-(1-acetylcyclopropan-1-yl)nitrobenzene (94.0 mg) was prepared from 4-nitrophenylacetone (100 mg) in the same manner as described for REFERENCE EXAMPLE 15.
[0743] MS (EI + ) m/z: 205 (M + ).
[0744] HRMS (EI + ) for C11H11NO3 (M + ): calcd, 205.0739; found, 205.0729.
REFERENCE EXAMPLE 21
4-(1-(2-Methyl-1.3-dioxolan-2-yl)cyclopropan-1-yl)nitrobenzene
[0745] A solution of 4-(1-acetylcyclopropan-1-yl)nitrobenzene (2.40 g), ethylene glycol (6.5 mL), and pyridinium p-toluenesulfonate (1.47 g) in benzene (120 mL) was heated under reflux with Dean-Stark apparatus for 15 hours. After cooling, dilution with saturated sodium hydrogencarbonate solution, the mixture was extracted with ethyl acetate. The organic extracts were washed with brine, dried over anhydrous magnesium sulfate, filtered, and then concentrated in vacuo. Flash chromatography (silica, hexane:ethyl acetate=4:1) of the residue gave 4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)nitrobenzene (2.83 g).
[0746] MS (EI + ) m/z: 250 (M + ).
[0747] HRMS (EI + ) for C13H16NO4 (M + ): calcd, 250.1079; found, 250.1089.
REFERENCE EXAMPLE 22
4-Benzyloxycarbonylamino-1-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)benzene
[0748] The title compound 4-benzyloxycarbonylamino-1-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)benzene (3.39 g) was prepared from 4-(1-(2-methyl-1,3-dioxolan-2-yl)cyclopropan-1-yl)nitrobenzene (2.50 g) in the same manner as described for REFERENCE EXAMPLE 4.
[0749] MS (EI + ) m/z: 353 (M + ).
[0750] HRMS (EI + ) for C21H23NO4 (M + ): calcd, 353.1627; found, 353.1623.
[0751] The invention has been described with reference to certain preferred embodiments. However, as variations thereon will become obvious to those of skill in the art, the invention is not to be considered as limited thereto.
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This invention relates to new oxazolidinones having a cyclopropyl moiety, which are effective against aerobic and anerobic pathogens such as multi-resistant staphylococci, streptococci and enterococci, Bacteroides spp., Clostridia spp. species, as well as acid-fast organisms such as Mycobacterium tuberculosis and other mycobacterial species.
The compounds are represented by structural formula I:
its enantiomer, diastereomer, or pharmaceutically acceptable salt or ester thereof.
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The present invention relates to a device which may be attached to a wire in order to permit one to turn the wire comfortably. In particular, the device relates to a pin vise.
BACKGROUND OF THE INVENTION
Modern angiographic practice calls for the extensive use of guidewires during the catheterization of human arteries and arterial branches. A typical steerable guide wire consists of a flexible distal section, usually a spring, connected to a long slender section of wire or tubing which is manipulated for axial advancement and retraction, and rotational torque transmission. This combination of features allows the guidewire to negotiate through the compound curves involved in the human arterial system, and when finally in place, to act as a guide for flexible diagnostic and therapeutic catheters which are slipped over it.
Since the proximal ends of the guidewires are typically small diameter wire or tubing (often hard-drawn stainless steel) and have a hard, polished, surface, they are very difficult to grasp securely. Medical device manufacturers currently provide a variety of so-called "pin vises", or "torquers", or "handles" which are intended to grip and manipulate the wires, but they all suffer from one or more deficiencies.
SUMMARY OF THE INVENTION
The present invention is a pin vise which may be attached to a medical guidewire. The pin vise comprises an elongated, cylindrical body portion having a slot whose cross-section is shaped to receive a guidewire and a means for holding said guidewire. It also comprises a slider portion adapted to be received within the the elongated slot in the body portion. The slider portion includes means for moving the slider portion and means for holding the guidewire. The means for holding said guidewire is adapted to frictionally coact with the guidewire and with the body portion.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the pin vise of the present invention;
FIG. 2 is a longitudinal section of the pin vise of FIG. 1 with the slider attached to a guidewire;
FIG. 3 is a longitudinal section of the pin vise of FIG. 1 with the bottom of the slider just contacting the guidewire;
FIG. 4 is a longitudinal section of the pin vise of FIG. 1 with the thumbpiece of the slider depressed;
FIG. 5 is a front view of the pin vise of the present invention;
FIG. 6 is a cross-sectional view of the pin vise of the present invention; and
FIG. 7 is a detailed view of the slider.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring generally to FIG. 1, the pin vise 10 of the preferred embodiment is made of a lightweight, sterilizable plastic, such as Ultem™, making it ideally suited to use as disposable medical device.
The pin vise 10 is comprised of two parts, the body 12 and the slider 14, which separate for side mount applications, and which mate using an arrangement employing a T-slot 16 (shown in cross section in FIG. 6). The T-slot 16 runs the entire length of the body 12, it accommodates the slider 14, and it provides the structure necessary to oppose the clamp forces when a wire 18 (see FIG. 4) is being gripped. In the bottom of the T-slot 16 is a groove 20, which runs at a fixed depth for most of its length, but inclines upward near the front 22 of the body 12. This incline is the site where the wire 18 is wedged by a wedge blade 24 on a thumbpiece 26 of the slider 14. The widths of the groove 20 and blade 24 are chosen to accommodate a variety of commercial guide wire sizes. By way of example, they will accommodate a 0.009" diameter guide wire.
The thumbpiece 26 protrudes above the body 12 and is used to advance or retract the slider 14. The thumbpiece 26 acts also as a pushbutton when the pin vise 10 is used in the "inching" mode described below. The thumbpiece 26 is joined to the block via a spring 28 comprised of a thin, limber segment of plastic or metal which has a preformed curve formed into it.
The spring 28 serves two purposes. It provides a constant frictional drag between the slider 14 and the body 12 in order to prevent the slider 14 from falling out of the body 12 during handling. The frictional drag is imposed when the naturally curved slider 14 is inserted into the body 12, where it is forced to follow the T-slot groove 16 and assume a straight, rather than a curved configuration. It acts as a flexible hinge when the pin vise 10 is used in the "inch" mode as explained below. In this situation, the thumbpiece 26 is positioned at some distance from the front end 22 of the pin vise 10, and pressed down or released in order to grip the wire 18 in a momentary fashion.
The pin vise body 12 is substantially cylindrical in shape, and has a surface finish on its bottom which provides a secure grip in the hand even in the presence of blood, saline or contrast agents. A finger stop 30 is provided at the front to prevent slippage and to overcome any tendency of the device 10 to roll when placed on an inclined surface. The finger stop 30 allows the user to identify the front of the unit 10 udner subdued light conditions, such as exist in the typical angio suite. A "V-notch" opening 32 on the front 22 of the unit 10 aids in wire loading and prevents inadvertent loading of the slider 14 from the wrong end.
The guidewire is either end loaded or side loaded. When the guidewire is end loaded, the thumbpiece 26 is moved back to a point about 1 cm from the front 22 of the body 12, and released. The end of the wire 18 is placed in the groove 18 ahead of the thumbpiece 26 and advanced so as to pass under the thumbpiece 26 and block and extend from the end of the pin vise 10. The end of the wire 18 can then be grasped and the pin vise 10 slid down to the point of use.
When the guidewire 18 is side loaded, the slider 14 is removed from the body 12, and set aside. The body 12 is placed adjacent to the wire 18 at the point of use, and the wire 18 is gently guided into the groove 20 along the entire length of the body 12. The slider 14 is then inserted into the body 12 and advanced to the operating position.
The pin vise has two modes of operation, the "lock" mode and the "inch" mode. In the "lock" mode, the wire 18 is inserted by either of the above two methods, and the pin vise 10 is positioned on the wire 18 at the point of use. At this point, the configuration of the pin vise 10 is as shown in FIG. 3, and since the blade 24 below the thumbpiece 26 is not in contact with the wire 18, the wire 18 is free to move and the pin vise 10 is in the released position. Now the thumbpiece 26 is advanced towards the front 22 of the pin vise 10, and the incline of the blade binds the wire 18 against the incline 34 in the body 12, as shown in FIG. 2. When the thumbpiece 26 is pressed firmly forwards, it locks by friction in the forward position and securely grips the wire 18. The pin vise 10 can now be advanced, retracted, and rotated to manipulate the guidewire 18 as necessary. Since the grip is locked, it is not necessary to maintain pressure on the thumbpiece 26 while rotating the pin vise 10. This is a significant feature for user convenience. The thumbpiece 26 can be moved forward and back to grip and release the wire 18 as necessary during the procedure.
In the "inch" mode, the wire is inserted by either of the previously described two methods, and the pin vise 10 is positioned at the point of use. At this point, the configuration of the pin vise 10 is as shown in FIG. 3, and since the blade 24 below the thumbpiece 26 is not in contact with the wire 18, the wire 18 is free to move, and the pin vise 10 is in the released position. Now the thumbpiece 26 is depressed (not advanced) to grip the wire in a momentary fashion, so the wire can be advanced incrementally, an inch or so at a time. After the wire 18 is advanced, the thumbpiece 26 depressed again, and so on. Using this method, a guidewire 18 can be advanced readily, even against resistance, without risk.
In the preferred embodiment of the invention, the slider 14 is a one piece unit, preferably molded, and the spring 28 is between the block 36 and the thumbpiece is precurved as shown in FIG. 7. When the slider 14 is inserted into the body 12, the spring 28 is forced into a nearly straight configuration. Since the block 36 is relatively long, and its "T" 38 matches the body "T" closely, the spring 28 tends to use the block 36 as a reference, and attempts to lift the thumbpiece 26 in the T-slot 16. Since the thumbpiece "T" 40 is made thinner in section than the body "T" 38, it has clearance beneath, as shown in FIG. 5, which allows it to act as spring-return pushbutton in the "inch" mode. The spring 28 must be carefully designed to give the proper return force to the thumbpiece 26 for best operator feel. If molded of Ultem, which has a modulus of 430,000 psi, a beam deflection calculation shows that a spring 1" long 1" long×0.180" wide and 0.037" thick, with a preformed offset of 0.100" would have a deflection force of approximately 45 grams. This valve would give a suitable return force. In practice, a tapered, or a "wasp waist" spring shape could be used for minimum material and optimum strain distribution considerations.
In the preferred embodiment of the invention, the incline 34 on the body 12 (as shown in FIG. 2) and the incline 42 on the thumbpiece 26 (as shown in FIG. 7) are approximately 2.5 degrees. These valves give the proper wedging and gripping action on a stainless steel guidewire 18 over a wide range of sizes, exploiting the coefficient of friction between Ultem™ and stainless (about 0.45) and at the same time insures that the thumbpiece 26 will stick in the "lock" mode when firmly advanced against the wire 18, exploiting the coefficient of friction between Ultem™ and Ultem™ (about 0.45).
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The pin vise is usable in connection with guidewire of the type used in medical applications, i.e., for guiding catheters. The pin vise is constructed from two parts which are assembled together to provide a handle over a guidewire.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent Application No. 2007-0034424, filed on Apr. 6, 2007, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] The present invention relates to a washing machine and a method of washing. More particularly, the present invention relates to a washing machine comprising a sterilizer that sterilizes washing water and a circulator that circulates the washing water in the sterilizer.
[0004] 2. Description of the Related Art
[0005] In general, a washing machine washes the laundry in a washing tub by stirring the laundry together with washing water mixed with detergent.
[0006] Such a washing machine comprises a body forming an external appearance, a water reservoir installed in the body and containing washing water, a detergent supply apparatus that mixes detergent with water supplied from an exterior and supplies the water to the water reservoir.
[0007] Recently, an Ag solution supply apparatus, which supplies Ag solution by dissolving Ag ions exhibiting antibiotic and sterilization functions in washing water, has been added to the washing machine in order to wash the laundry and sterilize bacteria existing in the washing water and the laundry.
[0008] The Ag solution supply apparatus comprises one pair of Ag electrodes to which voltage is applied, and supplies Ag ions, which are generated by an Ag plate during electrolysis when the washing water passes through the Ag electrodes, to a water reservoir.
[0009] The Ag solution supply apparatus provided in the washing machine is installed on a water supply path, which supplies the washing water to the water reservoir, together with a detergent dissolver, and supplies the Ag ions to the washing water supplied to the water reservoir. However, the Ag solution supply apparatus cannot supply the Ag ions any more after the water supply is terminated, so antibiotic and sterilization functions cannot be continuously exhibited during washing and rinsing processes.
[0010] Further, the density of the Ag ions, which are generated by the Ag solution supply apparatus and provided to the washing water, is gradually reduced through reaction with other ions existing in the washing water, so the sterilization effect may be reduced. If many Ag ions are supplied to the washing water in consideration of the fact, consumption amount of Ag in the Ag plate may be increased, resulting in reduction of the life span of the Ag plate.
SUMMARY
[0011] Accordingly, one or more embodiments of the present invention provide a washing machine capable of continuously exhibiting antibiotic and sterilization functions during washing and rinsing processes.
[0012] One or more embodiments of the present invention also provide a washing machine capable of reducing consumption amount of Ag in an Ag plate.
[0013] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
[0014] The foregoing and/or other aspects of embodiments of the present invention are achieved by providing a washing machine including a water reservoir to contain washing water, a sterilizer sterilizing the washing water through an electrolysis process, and a circulator circulating the washing water in the sterilizer.
[0015] The sterilizer comprises a first electrode including Ag and a second electrode including a metal having an ionization tendency lower than the ionization tendency of Ag.
[0016] The second electrode may comprise Ti.
[0017] The second electrode may also comprise Pt or Ir coated on a surface thereof.
[0018] The washing machine further comprises a power supply that supplies electric current to the first and second electrodes, and a controller that switches polarity of the electric current applied to the first and second electrodes.
[0019] The controller operates in a first mode, in which the first electrode becomes an anode and the second electrode becomes a cathode, or a second mode in which the second electrode becomes an anode and the first electrode becomes a cathode.
[0020] The circulator comprises a circulation pipe, which forms a circulation path such that the washing water is circulated in the water reservoir, and a circulation pump that pumps the washing water in the circulation path.
[0021] The circulation pipe may be provided along a circumference of the water reservoir.
[0022] The water reservoir comprises an inlet to introduce the washing water to the circulation path, and an outlet to discharge the washing water having passed the circulation path to the water reservoir.
[0023] The outlet may be provided at an upper portion of the water reservoir.
[0024] The outlet may be provided with an injection nozzle that injects the washing water such that the washing water is uniformly spread in the water reservoir.
[0025] The washing machine may further comprise a salt supply unit that supplies salt to the washing water.
[0026] The salt supply unit may be provided in a detergent supply apparatus that supplies detergent to the water reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0028] FIG. 1 is a schematic view illustrating an internal structure of a washing machine including a sterilizer used in embodiments of the present invention; FIG. 2 is an exploded perspective view showing the construction of the sterilizer in FIG. 1 ; and
[0029] FIG. 3 is a schematic view showing an internal structure of the washing machine in FIG. 1 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0030] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
[0031] FIG. 1 is a schematic view showing an internal structure of a washing machine according to an embodiment of the present invention.
[0032] The washing machine comprises a body 1 forming an external appearance, a water reservoir 2 installed in the body 1 , and a drum 3 rotatably installed in the water reservoir 2 .
[0033] A door 4 is installed in the front of the body 1 to open and close the opened front of the body 1 . Water supply valves 5 , which are connected to an external water supply source, and a detergent supply apparatus 6 are installed at the upper portion of the water reservoir 2 , in which the detergent supply apparatus 6 dissolves detergent in water supplied through the water supply valves 5 and supplies the water to the water reservoir 2 .
[0034] The detergent supply apparatus 6 comprises a housing 6 a and a detergent box 6 b detachably provided in the housing 6 a.
[0035] A circulation pipe 7 that forms a circulation path is installed at the outer side of the water reservoir 2 such that the washing water can be circulated in the water reservoir 2 . A circulation pump 8 is installed on the circulation path formed by the circulation pipe 7 .
[0036] A three-way valve 9 is installed at the lower portion of the water reservoir 2 in order to switch a path between a drain pipe 12 , which drains the washing water from the water reservoir 2 , and the circulation pipe 7 .
[0037] The circulation pipe 7 interconnects the upper and lower portions of the water reservoir 2 such that the washing water in the lower portion of the water reservoir 2 can be moved to the upper portion of the water reservoir 2 . At this time, the circulation pump 8 pumps the washing water, which is supplied to the circulation pump 8 from the lower portion of the water reservoir 2 along the circulation pipe 7 , such that the washing water can be discharged from the upper portion of the water reservoir 2 .
[0038] A sterilizer 100 is installed above the circulation pump 8 to exhibit sterilization function by generating Ag ions through an electrolysis operation or activating the generated Ag ions.
[0039] FIG. 2 is an exploded perspective view showing the construction of the sterilizer in FIG. 1 .
[0040] The sterilizer 100 comprises a storage container 110 having an inlet 110 a , which has an opened upper surface and introduces washing water inside the sterilizer 100 , and an outlet 110 b that discharges the washing water.
[0041] A circulation pipe is connected between the inlet 110 a and the outlet 110 b , a cover 120 is installed at the opened upper surface of the storage container 110 , and first and second electrodes 130 and 140 are installed at the cover 120 in order to form electrodes for electrolysis.
[0042] The first and second electrodes 130 and 140 are installed in the path in the storage container 110 through slots 120 a and 120 b formed in the cover 120 , and are immersed when the washing water passes through the storage container 110 .
[0043] Further, the first and second electrodes 130 and 140 have a plate shape as shown in FIG. 2 , face each other, and are arranged in parallel with the flowing direction of the washing water in the storage container 110 .
[0044] As the first and second electrodes 130 and 140 have a plate shape, the contact area with the washing water can be increased. However, in other embodiments, the electrodes may also have a bar shape.
[0045] The first and second electrodes 130 and 140 may comprise Ag and Ti, respectively. In addition to Ti, the second electrode 140 may also comprise other metals featuring an ionization tendency lower than that of Ag.
[0046] When the second electrode 140 comprises Ti, metals (e.g. Pt and Ir) having an ionization tendency lower than that of Ag may be coated on the surface of the second electrode 140 through plating in order to improve the corrosion-resistance.
[0047] FIG. 3 is a schematic view showing an internal structure of the washing machine in FIG. 1 .
[0048] The water reservoir 2 is installed in the body 1 of the washing machine, and the drum 3 is installed in the water reservoir 2 .
[0049] The water supply valves 5 that supply water to the water reservoir 2 are connected to the detergent supply apparatus 6 through a water supply pipe 11 at the upper portion of the water reservoir 2 , and an outlet 3 b and an inlet 3 a are formed at the upper and lower portions of the water reservoir 2 , respectively.
[0050] The circulation pipe 7 that forms a circulation path 20 by interconnecting the outlet 3 b and the inlet 3 a is connected to the outer side of the water reservoir 2 , and the circulation pump 8 and the sterilizer 100 are connected to the circulation path 20 .
[0051] The inlet 3 a is used as a waterway to drain the washing water in the water reservoir 2 , and the three-way valve 9 is installed at the lower portion of the inlet 3 a to switch the path such that the washing water introduced through the inlet 3 a can be sent to the drain pipe 12 or the circulation pipe 7 .
[0052] An injection nozzle 21 is installed at the outlet 3 b such that the drained washing water can be spread over the wide range. The outlet 3 b and the injection nozzle 21 are installed at the upper portion of the water reservoir 2 , so that the washing water passing through the sterilizer 100 can be uniformly spread in the drum 3 and the water reservoir 2 when the washing water is discharged into the water reservoir 2 .
[0053] As the washing or rinsing process starts, washing water is filled in the water reservoir 2 up to a predetermined water level, and the sterilizer 100 is positioned higher than the water level of the washing water. Accordingly, the electrodes 130 and 140 in the sterilizer 100 are not immersed in the washing water in a state when the circulation pump 8 is not operating, so that the sterilizer 100 can be prevented from being contaminated due to water remaining after the washing or rinsing process. In addition, even if the locking state of the door is released due to the abnormal operation of the washing machine, or other problems occur, electric shock can be prevented.
[0054] The two electrodes 130 and 140 of the sterilizer 100 are connected to a power supply 30 such that power can be supplied to the electrodes 130 and 140 . The power supply 30 converts electric current such that DC power can be supplied to the electrodes 130 and 140 .
[0055] The polarity of the DC power supplied to the electrodes 130 and 140 can be changed by a controller 40 that controls the power supply 30 .
[0056] The sterilizer 100 operates in two modes. In the first mode, the first electrode 130 serves as an anode because positive (+) polarity of the DC power is connected to the first electrode 130 by the controller 40 and the second electrode 140 serves as a cathode because negative (−) polarity of the DC power is connected to the second electrode 140 . In the second mode, the polarity of the electrode is inversed as compared to the first mode, so the first electrode 130 serves as the cathode and the second electrode 140 serves as the anode.
[0057] In detail, in the first mode, the first electrode 130 comprising Ag serves as the anode to emit Ag ions into the washing water. That is, the first electrode 130 and the second electrode 140 become the anode and the cathode, respectively, so electric current flows in the two electrodes. In addition, Ag is electrolyzed in the first electrode 130 , so Ag ions in Ag + state are generated and supplied to the circulated washing water.
[0058] In the second mode, the polarities of the first and second electrodes 130 and 140 are inversed as compared with the first mode, so the second electrode 140 comprising Ti becomes the anode, and the first electrode 130 (Ag electrode) becomes the cathode.
[0059] In such a case, the Ag ions are not emitted through the first electrode 130 and electrolysis of the electrode is not performed in the second electrode 140 . Accordingly, ions (e.g. Ti + ) are not generated in the second electrode 140 , and electric current flows between the first electrode 130 and the second electrode 140 due to an electrolyte contained in the washing water or ions generated by the detergent.
[0060] In such a second mode, ions for sterilization are not directly generated, but ions contained in the washing water are activated. That is, compound in the neutral state contained in the washing water can be ionized through the electrolysis operation.
[0061] In particular, when Ag ions are emitted into the washing water in the first mode, if the Ag ions are reduced in the sterilization process and become electrically neutral, the sterilization effect is discontinued. Thus, the Ag ions in the neutral state are restored into Ag ions through the electrolysis operation.
[0062] In the second mode, the bacteria contained in the washing water are sterilized by the electric current flowing between the first electrode 130 and the second electrode 140 . That is, the cell membrane of the bacteria contained in the washing water is partially destroyed by the electric current or pores may be formed in the cell membrane while the washing water is passing between the first electrode 130 and the second electrode 140 .
[0063] The cell membrane of the bacteria subject to the electric current is destroyed and disappears. Even if the bacteria do not disappear, the Ag ions can easily penetrate into the bacteria. If the Ag ions have been emitted into the washing water in the first mode, the bacteria disappear due to penetration of the Ag ions.
[0064] The effect on the bacteria due to the electric current flowing between the first electrode 130 and the second electrode 140 is increased in proportion to the density of the electric current flowing between the two electrodes 130 and 140 , that is, the electric current per unit area.
[0065] The sterilization function in the first and second modes as described above can be variously applied throughout the entire washing process, and embodiments regarding the sterilization function will be described.
[0066] In one embodiment, the sterilizer 100 operates in the first mode in order to emit Ag ions, and the first mode is switched to the second mode after a predetermined time period passes.
[0067] This can be commonly applied to the washing and rinsing processes. In FIG. 3 , in a state where the washing water is supplied to the water reservoir 2 through the water supply valves 5 and the detergent supply apparatus 6 , as the three-way valve 9 connects the inlet 3 a to the circulation path 20 to form the circulation path 20 , and the circulation pump 8 operates, the washing water is circulated through the circulation path 20 and the sterilizer 100 connected to the circulation path 20 .
[0068] As the sterilizer 100 operates in the first mode, the Ag ions are emitted into the washing water through the first electrode 130 , and the washing water containing the Ag ions are injected into the water reservoir 2 and the drum 3 through the injection nozzle 21 , thereby exhibiting the antibiotic and sterilization functions.
[0069] After a predetermined time period passes, the sterilizer 100 operates in the second mode. That is, the cell membrane of the bacteria is subject to the electric current flowing between the two electrodes 130 and 140 , so the bacteria is destroyed or disappears due to the Ag ions. Further, Ag, which has been emitted in the first mode and reduced through the sterilization process of the bacteria or other methods, is activated into Ag ions in the second mode.
[0070] The consumed Ag ions are restored through the procedure as described above, so that the operation time of the first mode can be shortened, and thus the consumption amount of Ag can be reduced in the first electrode.
[0071] In another embodiment, the sterilizer 100 operates in sequence of the second mode and the first mode. The reason of primarily operating the sterilizer 100 in the second mode is that the Ag ions emitted during the washing process may be affected by the high-density detergent dissolved in the washing water and other ions, and the sterilization function of the Ag ions may be interrupted. Thus, the sterilizer 100 operates in the second mode during the washing process such that the sterilization function due to the electric current between the first electrode 130 and the second electrode 140 can be exhibited, and then the sterilizer 100 operates in the first mode during the rinsing process, in which the density of the detergent is reduced, such that the Ag ions can be supplied to the washing water.
[0072] In further another embodiment, the washing machine can operate in a washing mode, in which the water reservoir and the drum are washed, separately from the washing and rinsing processes.
[0073] The washing mode corresponds to a dedicated washing process of removing biofilms formed in the water reservoir and the drum due to the propagation of bacteria. That is, in a state where washing water is supplied to the water reservoir without the laundry, the circulation pump 8 operates to circulate the washing water and the sterilizer 100 operates in the second mode or the first mode.
[0074] In order to improve the washing effect by the circulated washing water, a salt supply unit (not shown) can be provided to supply salt to the supplied water. The salt supply unit can be additionally provided to the washing machine, or can also be provided to the detergent box 6 b of the detergent supply apparatus 6 (see FIG. 1 ).
[0075] As the salt is dissolved in the washing water, HOCl is generated through an electrolysis process. Since reaction and generation conditions for generation of the HOCl are well known to the skilled in the art, details thereof will be omitted here.
[0076] The HOCl generated in the sterilizer exhibits the sterilization function derived from the strong oxidation power, so that biofilms can be effectively prevented from being generated or can be removed by cleaning the water reservoir 2 and the drum 3 using the HOCl.
[0077] According to the washing machine of the present invention as described above, the sterilization effect can be maximized by using a small quantity of Ag and can be continued throughout the entire washing process, so that not only harmful microorganisms contained in the laundry but also microorganisms remaining or growing in the washing machine can be sterilized using the circulator, and thus the laundry can be prevented from being secondarily contaminated.
[0078] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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Disclosed is an apparatus and method for machine washing that includes a sterilizer capable of continuously exhibiting antibiotic and sterilization functions during washing and rinsing processes and reducing the consumption amount of Ag. The washing machine comprises a water reservoir to contain washing water, a sterilizer sterilizing the washing water through an electrolysis process, and a circulator circulating the washing water in the sterilizer.
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This invention relates to a quick connect branch connector for use in plumbing systems. While not limited thereto, the invention relates to a quick connect branch connector of particular utility in assembling a fire extinguishing sprinkler system. While of particular utility in that application, the quick connect branch connector of the invention finds utility in any other application in which it is desired to connect a plumbing branch to a main pipe line.
BACKGROUND OF THE ART
Branch connections as commonly known are provided by a plumbing tee and by threading pipes into the branches of the tee.
Also known in the art are branch connectors that can be secured to a main plumbing line by straps or other fittings, and which communicate with the main plumbing line through a hole drilled through the exterior surface of the main pipe line, the branch connector being sealed to the outer surface of the main line.
Such branch connectors have been successfully employed in the fabrication of fire extinguishing sprinkler systems. However, the known branch connectors are encumbered with the disadvantage that two hands must be employed for assembling the branch connector onto the main pipe, this involving the holding of the branch connector in one hand while the securing strap is attached to the branch connector. While this poses no particular problem in locations that are readily accessible, it does pose considerable problems in the assembly of such branch connectors in difficult locations, such as high above a workshop floor, which is a typical location of such sprinkler heads.
Branch connectors that are a snap-fit onto the main pipeline have been previously proposed. Typical of such snap-on branch connectors are ones manufactured by Spraying Systems Co. of Wheaton, Ill., U.S.A. and by Uni-Spray of Waterloo, Ontario, Canada.
The snap-fit branch connectors manufactured by those firms are employed for the securement of spray nozzles to a low pressure pipeline. While the snap-fit branch connectors referred to are eminently suited to their intended purpose, which is one in which relatively low pressures exist in the pipeline, they are not suited to their employment in fire extinguishing systems.
In a fire extinguishing system, the sprinkler heads are exposed to a continuous high static pressure within the pipeline, which exists at all times and possibly for many years, and until such time that the sprinkler heads are actuated by a fire condition.
The prior known quick connect branch connectors each employ spring clips that can be snapped over the main pipeline, and, which maintain the quick connect branch connector attached to the main pipeline exclusively by the stored spring force in the spring clips.
As will be apparent, the pressure at which the connection will fail is determined by the spring force that can be exerted on the connectors by the spring clips. Thus, the use of such known quick connect branch connectors is limited to relatively low pressure applications for supporting spray nozzles that are exposed to dynamic pressure loading. In a fire extinguishing system the sprinkler heads are continuously exposed to a high static pressure loading of a much greater magnitude than that encountered in a spraying system.
Further considerations present themselves in the assembly of fire extinguishing sprinkler systems. A major one of those considerations is that the sprinkler heads must be attached to the main pipeline in a manner that prohibits accidental or intentional removal of the sprinkler head at the time the main pipeline is under pressure. This consideration, of course, applies in all other plumbing applications in which the pipeline is under pressure, particularly in the event that noxious or hazardous fluids are being conveyed by the pipeline.
Object of the Invention
The object of this invention is to provide a quick connect branch connector for use in any plumbing application, and in particular for use in the construction of fire extinguishing systems, in which the branch connector is capable of withstanding high static pressures without failing, and is incapable of accidental and unintentional release from the pipeline with which it is associated. Another object of this invention is to preserve the advantages of known quick connect branch connectors in their ability for them to be snap-fitted onto the main pipeline in a maneuver that easily can be effected by a single hand, even in difficult locations. The branch connector can then be permanently affixed to the associated pipeline, any attempts at removal of the connector then requiring the premeditated use of an appropriate tool.
Summary of the Invention
According to the present invention, a quick connect branch connector is provided by a saddle for attachment to an associated pipeline, the saddle incorporating a nipple for penetration into the associated pipeline through a hole formed therein, the nipple being surrounded by a sealing gasket.
The saddle is provided with a spring clip that is hingedly connected to the saddle and which is configured for it to snap over and closely embrace the associated pipeline in order to maintain the saddle initially attached to the associated pipeline.
The end of the spring clip remote from the hinged interconnection with the saddle is then permanently secured to that side of the saddle opposite to the hinged connection in a manner that requires a tool in order to effect the securement. As a consequence, the use of a similar or identical tool is required in order to effect the release of the branch connector from the associated pipeline, thus prohibiting accidental and unintentional release of the branch connector.
The securement of both ends of the spring clip to the saddle acts to draw the spring clips into clamping engagement with the associated pipe, thus providing a permanent interconnection between the pipe and the branch connector that relies on the tensional stress produced in the spring clip, and which does not in any way rely on the compressive spring strength thereof.
In this manner, a positive and permanent interconnection can be made between the branch connector and the associated pipe, with the advantages of initially securing the branch connector to the associated pipe in an entirely stable manner, thus freeing both of the hands of the installer for effecting the subsequent final connection of the branch connector to the associated pipe.
Conveniently, the main supply pipe is pre-drilled prior to its installation in the sprinkler system, subsequent to which the quick connect connectors can be permanently affixed to the main supply pipe.
Preferably, but not essentially, sprinkler heads are formed integrally with the branch connectors, or, are preassembled onto the branch connectors prior to their installation on the main supply pipe, thus eliminating the skill and dexterity required in installing the sprinkler heads in difficult locations, such as in elevated or cramped conditions.
DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings, which illustrate preferred embodiments of the invention, and in which:
FIG. 1 is a front elevation of one embodiment of the quick connect branch connector of the invention;
FIG. 2 is a side elevation thereof, the quick connect branch connector being shown assembled with a conventional sprinkler head;
FIG. 3 is a side elevation of the quick connect branch connector shown in an opened position, preparatory to its being snapped over a conventional pipe;
FIG. 4 is an underside plan view of another embodiment of quick connect branch connector of the invention;
FIG. 5 is a side elevation of the branch connector of FIG. 4;
FIG. 6 is an exploded perspective view of another embodiment of quick connect branch connector of the invention;
FIG. 7 is a side view of the connector of FIG. 6 when in an assembled condition;
FIG. 8 is a plan view of another embodiment of quick connect branch connector of the invention;
FIG. 9 is a side view of the connector of FIG. 8;
FIG. 10 is a perspective view of the connector of FIGS. 8 and 9 when in an open condition prior to assembly onto a pipe; and,
FIG. 11 is a perspective view of the spring clip taken from a different position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring firstly to FIG. 1, the quick connect branch connector of the present invention includes a saddle 10 having a central through bore 12 that extends from the lower face 13 of the connector to the upper face thereof where it emerges at 14 between a pair of arcuate lugs 16 that are adapted to be received within a lateral bore formed in a pipe (not shown).
The upper surface 18 of the saddle is configured for it to embrace the outer surface of the pipe, the upper surface being recessed for it to receive a sealing gasket 20 for engagement with the pipe periphery to provide a fluid tight seal between the saddle upper surface and the exterior of the pipe. As is shown in FIGS. 2 and 3, the upper portion of the saddle extends laterally to both sides thereof in order to provide a hinge post 22 on one side thereof and a bolting pad 24 on the opposite side.
A spring clip 26 is pivotally mounted on the hinge posts 22 by means of loops 28, the spring clip being generally of U-shape when viewed in plan, the respective arms of the spring clip merging into an eyelet portion 30. The spring clip 26 is formed of one continuous length of stiff but resilient wire that provides for gripping engagement over a pipe.
As will be observed more particularly in FIG. 3, the spring clip 26 is of greater arcuate extent than one half of the periphery of the pipe, whose axis is indicated at 32, in order that the spring clip must be forced over the pipe and clipped thereon, the spring clip at that time providing a hanger for the saddle 10. The saddle can then be released by the workman in preparation for the step of assembly, the saddle at that time remaining suspended from the pipe by means of the spring clip 26.
The workman is then free to use both hands in order to rotate the spring clip around the pipe axis to bring the lugs 16 of the saddle into proper alignment with the hole bored in the pipe, subsequent to which the saddle can be rotated upwardly about the hinge post 22, to bring the lugs 16 into engagement within the hole formed in the pipe. Once the lugs are engaged within the hole in the pipe, then, further movement of the saddle 10 is precluded, in that it is held against rotation around the pipe by the engagement of the lugs 16 within the hole.
The spring clip 26 and saddle 10 are then moved to position the eyelet 30 and the bolt hole 34 in alignment. A bolt 36 is then inserted through the eyelet 30 and is threaded into the bolt hole 34, at which time the bolt can be finger tightened until the head of the bolt tightens down on the eyelet 30. The bolt can then be tightened down fully by the use of a wrench in order to bring the sealing gasket 20 into intimate sealing contact with the pipe exterior, and, to tension the spring clip 26 about the pipe periphery, thus placing the spring clip 26 under a tensile hoop stress, that is translated into a compressive seating engagement of the saddle 10 on the pipe periphery and final compression of the sealing gasket 20.
In this condition of assembly, removal of the branch connector from the pipe cannot occur accidentally or unintentionally. Removal of the branch connector from the pipe only can be accomplished by the use of a wrench employed to loosen and remove the bolt 36.
Thus, all of the advantages of the known quick connectors are accomplished, and, in addition, all of the disadvantages of the known connectors are eliminated, it being impossible to dislodge the branch connector from the pipe without having first intentionally removed the bolt.
The quick connect branch connector of the present invention, when in a fully asssssembled condition does not rely on the compressive spring strength of the spring clip 26 to hold it in position and provide the required seating pressure for the sealing gasket. The spring clip 26, when placed under a tensile hoop stress by the bolt 36, ceases to function in the capacity of a spring clip, and instead, functions in the capacity of a rigid tie strap.
In FIG. 2 of the drawings the quick connect branch connector of the invention is shown in combination with a conventional sprinkler head 38.
Conveniently, the sprinkler head 38 can be fully assembled onto the saddle 10 prior to the branch connector being applied and secured to the pipe. This eliminates assembly of the sprinkler head 38 onto the saddle 10 after it has been applied to the pipe, the location of the saddle 10 at that time possibly being a most inconvenient one in which to effect an assembly operation.
While the quick connect branch connector of the invention has been shown in association with a sprinkler head, it will be fully understood that any other fitting could be used in association with the branch connector, for example, a spray nozzle, a pressure release valve, a pressure indicating gauge, a faucet, or, a branch line of piping.
Conveniently the saddle 10 is formed as a one-piece casting of ductile iron. For other applications it can be formed form brass or copper, or, as a molding of reinforced plastics material, depending upon the application to which it is to be subjected.
While the hinged posts 22 have been shown as being cast integrally with the saddle 10, they could be provided by a rod inserted into a bore in the saddle.
Referring now to FIGS. 4 and 5, the saddle is indicated at 40 and the spring clip at 42. The saddle and the spring clip are similar to those employed in the embodiment of FIGS. 1, 2, 3, the manner of securement of the spring clip 42 being somewhat different. Instead of providing a threaded bore, such as the threaded bore 34 in FIGS. 2 and 3, the saddle is provided with a bifurcated lug 44 having a slot dimensioned to receive the shank of a bolt 46. The shank of the bolt 46 passes through a nut 48 having laterally extending posts 50 that extend over a looped portion 52 of the spring clip.
In this manner, the nut 48 and the bolt 46 can be preassembled to the spring clip 42, which holds the nut and bolt captive, while allowing the nut and the bolt to swing about the axis of the posts 50. This permits the spring clip 42 to be snapped over the pipe periphery, the nut and the bolt then swung outwardly about the axis of the posts 50, and, the saddle 40 then swung upwardly and the bolt 46 passed into the bifurcated lug 44. This maneuver also can be performed using a single hand. The nut 46 is then tightened down using a wrench in order to draw the spring clip 42 into clamping engagement with the pipe, further tightening down of the bolt resulting in the spring clip 42 being placed under a tensile hoop stress, and in this manner providing a permanent securement of the branch connector to the pipe that only be released by the use of a wrench in a premeditated manner.
FIGS. 6 and 7 illustrate a modification of the embodiment of FIGS. 4 and 5. In this embodiment, the saddle 60 is provided with posts 62 that extend laterally of the saddle as in the embodiment of FIGS. 4 and 5.
The spring clip, indicated generally at 64, includes arcuate portions 65 that are interconnected by a laterally extending portion 66 that extends between looped portions 67 providing transitions between the portions 66 and the portions 65. The spring clip 64 is assembled onto the saddle 60 by passing the arcuate portions 65 downwardly on opposite sides of the saddle and then rotating the spring clip 64 to bring the longitudinally extending portion 66 into overlying relation with the upper surface of the saddle, at which point the spring clip member 64 becomes captive on the saddle but swingable about the axis of the posts 62.
The free ends 68 of the spring clip 64 extend outwardly and generally parallel to the longitudinally extending portion 66. The ends 68 are then moved towards each other and passed through the bore of a nut 70 having axially extending channels 72 formed therein at diametrically opposite positions. The ends 68 are then allowed to spring outwardly for them to become captive under the lower surface of the nut 70, subsequent to which a bolt 74 is threaded into the bore of the nut, in this manner preventing removal of the ends of the spring clip. The bolt 74 is then swung into a bifurcated lug 76 in the saddle 60 and the bolt tightened down to place the spring clip under tension and in clamping engagement with the exterior of the pipe.
FIGS. 8-11 illustrate another embodiment of the invention in which the required tensile hoop stress in the spring clip is produced by means other than a bolt.
In this embodiment the saddle 80 is similarly formed with posts 82 providing hinged connections for the ends 84 of a spring clip 86.
At its opposite lateral side, the saddle 80 is formed with camming lugs 88 that define a channel 90 for the reception of a transversely extending portion 92 of the spring clip 86.
At each of its axial ends, the intermediate portion 92 is formed as a V-shaped spring member having arms 94 and 96 that are capable of producing a considerable tensile stress in the spring clip 86 upon assembly of the connector.
Assembly of the connector onto a pipe is effected by swinging the spring clip upwardly to position the intermediate portion 92 in front of the camming lugs 88, subsequent to which a screwdriver or flat metal bar is inserted beneath the intermediate portion 92 and into a slot 98 provided between the camming lugs 88. The screwdriver is then employed to lever the intermediate portion 92 upwardly and over the camming lugs 88, at which time the intermediate portion 92 snaps into the channel 90 under the influence of the spring force exerted by the spring arms 94 and 96. In accomplishing this operation, the spring arms 94 and 96 will be moved to a somewhat straightened position in which they provide a considerable spring force which acts both to maintain the intermediate portion 92 clamped within the channel 90, and also, to place the arcuate portions 86 of the spring clip under very considerable tensile hoop stress acting to clamp the spring clip and the saddle directly onto the outer surface of the associated pipe, shown at 100 in FIG. 8.
In all instances the spring clip members 26, 42, 64 and 86 are formed from a high-strength rod or thick wire of a spring steel material of considerable tensile strength, thus enabling the spring clip members to perform the dual function of a spring clip that initially clips the branch connector onto the pipe prior to securement of the branch connector to the pipe, and which then, upon securement of the spring clip to the opposite end of the saddle acts as a clamping member capable of accommodating considerable tensile hoop stress in order to effect a permanent securement of the branch connector to the pipe.
In all instances a tool must be employed in order to detach the branch connector from the pipe, thus eliminating the possibility of accidental and unintentional detachment of the branch connector from the pipe.
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A quick connect branch connector includes a saddle to which one end of a spring clip is hingedly connected, a traction device being provided at the opposite end of the spring clip for cooperation with the saddle, whereby the spring clip can be placed under tensile hoop stress in encircling relation with a pipe.
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CROSS REFERENCE OF RELATED APPLICATION
[0001] This is a Continuation-In-Part application of a non-provisional application having an application Ser. No. 11/403,295 and a filing date of Apr. 12, 2006.
BACKGROUND OF THE PRESENT INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to a waste bag dispenser, and more particularly to a pet waste bags dispenser for pet waste bags, wherein the pet waste bags dispenser comprises a pouch structure for storing the pet waste bags, such that the pet waste bags can be dispensed conveniently, and the waste bag dispenser is easy to carry around, easy to store, light in weight, easy to manufacture and has a low manufacturing cost.
[0004] 2. Description of Related Arts
[0005] Many people around the world have pets, especially those in developed countries. And people in the developed world are known to be very conscious about health and environment, which makes pet owners very careful about not leaving behind pet wastes when walking their pets. In fact, many developed countries have laws and regulations regarding pet wastes. Pet owners can receive citations when they get caught for not cleaning up after the pets.
[0006] Due to an advance in technology, as well as wealth, cleaning up pet wastes has advanced from using magazine pages and newspaper to using products specifically produced for picking up pet wastes.
[0007] Waste bags dispensers are already available in the market. However, such dispensers are heavy and bulky, making carrying around and storing difficult. They also consist of a lot of material and parts that may not be quite necessary. Such waste of material in turn creates a waste to the environment, which is not desired by most people.
[0008] In view of the above drawbacks, waste bags dispensers that are easy to store, and to use, cheaper to manufacture and consist of less parts has to be provided.
SUMMARY OF THE PRESENT INVENTION
[0009] A main object of the present invention is to provide a pet waste bag dispenser for dispensing pet waste bags, comprising a pouch body having a bag cavity provided for pet waste bags to be placed therewithin, a pouch cover provided for covering the bag cavity, preventing the waste bags from falling off the waste bags dispenser, means for detachably attaching the front cover edge of the pouch cover on the front wall of the pouch body, and a bag dispenser such that the waste bags are dispensed without the pouch cover being lifted up.
[0010] Another object of the present invention is to provide a pet waste bag dispenser, wherein the bag dispenser is on a front wall of the pouch body, such that the waste bags are dispensed with or without the pouch cover being closed.
[0011] Another object of the present invention is to provide a pet waste bag dispenser, further has a pouch carrier for easy carrying around and accessing of the waste bags in the pet waste bag dispenser.
[0012] Another object of the present invention is to provide a pet waste bag dispenser, wherein the pouch carrier forms a detachable loop for looping the pet waste bag dispenser onto a desired object.
[0013] Another object of the present invention is to provide a pet waste bag dispenser, wherein the pouch body has an elastic element for the pouch body to accommodate any amount of waste bags being placed within the dispenser cavity, wherein the pouch body will expand slightly when more waste bags are placed within the dispenser cavity, and will bind the waste bags even when there are a few waste bags placed within the dispenser cavity, such that the waste bags will not move around within the waste dispenser cavity.
[0014] Another object of the present invention is to provide a pet waste bag dispenser, so as to dispense rolls of waste bags.
[0015] Another object of the present invention is to provide a pet waste bag dispenser wherein all elements of the dispenser are undetachably attached together so as to achieve all of the above objectives with no detachable parts, such that the storage and usage of the waste bags dispenser are more efficient and effective.
[0016] Accordingly, in order to accomplish the above objects, the present invention provides a pet waste bag dispenser for pet waste bag, comprising:
[0017] a pouch body having a front wall, a rear wall and two sidewalls to form a bag cavity for storing the waste bag therein and a top opening communicating with the bag cavity; and
[0018] a pouch cover, having a front cover edge, extended from the rear wall of the pouch body;
[0019] means for detachably attaching the front cover edge of the pouch cover on the front wall of the pouch body, wherein the pouch cover is frontwardly folded to cover the top opening of the pouch body so as to enclose the bag cavity for retaining the waste bags therein; and
[0020] a bag dispenser provided on the front wall of the pouch body at a position below the front cover edge of the pouch cover when the pouch cover is detachably attached on the front wall, wherein the bag dispenser is adapted for allowing the waste bags to be dispensed out of the bag cavity when the bag cavity is enclosed by the pouch cover.
[0021] These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a perspective view of the pet waste bag dispenser according to the preferred embodiment of the present invention.
[0023] FIG. 2 is a cross-sectional view of the pet waste bag dispenser according to the above preferred embodiment of the present invention.
[0024] FIG. 3 is a perspective view of the pet waste bag dispenser according to the preferred embodiment of the present invention.
[0025] FIG. 4 is a cross-sectional view of the pet waste bag dispenser according to the above preferred embodiment of the present invention.
[0026] FIG. 5A is a perspective view of the bag roll wherein the waste bags are detachably connected.
[0027] FIG. 5B is a perspective view of the bag roll wherein each bag is rolled into the bag roll with a portion overlapped with the previous and the next bags.
[0028] FIG. 6 is a perspective view of an alternative embodiment of the present invention, the top opening of the bag is made of two elastic edges.
[0029] FIG. 7 is a perspective view of the waste bag which can be sealed by pulling the edge through the sealing slit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Referring to FIG. 1 of the drawings, a pet waste bags dispenser for pet waste bags according to a preferred embodiment of the present invention is illustrated, wherein the pet waste bags dispenser comprises a pouch body 10 , a pouch cover 20 , means 30 for detachably attaching the front cover edge of the pouch cover on the wall of the pouch body, and a bag dispenser 40 .
[0031] The pouch body has a front wall 10 , a rear wall 11 and two sidewalls 12 , to form a bag cavity 14 . The bag cavity 14 is provided for waste bag 5 to be stored therein. The pouch body also has a top opening 15 for communicating with the bag cavity 14 , such that the waste bags can be refilled into the bag cavity 14 through the top opening 15 .
[0032] According to the preferred embodiment of the present invention, the waste bags dispenser is designed for a roll of rectangular shaped bags, such that the waste bags can easily be dispensed continuously.
[0033] The pouch cover 20 is provided for covering a top opening 15 of the bag cavity 14 , so as to protect the waste bags 5 placed within the bag cavity 14 through the top opening 15 , prevent the waste bags 5 from falling off the bag cavity 14 , or from damages. The pouch cover 20 is extended from the rear wall 11 of the pouch body 10 , and has a front cover edge 21 .
[0034] In order to ensure that the top opening 15 is to remain closed, the pet waste bag dispenser has means 30 for detachably attaching the front cover edge 21 of the pouch cover 20 on the front wall 13 of the pouch body 10 , wherein the pouch cover 20 is frontwardly folded to cover the top opening 15 of the pouch body 10 so as to enclose the bag cavity 14 and retaining the waste bags 5 therein.
[0035] It is worth mentioning that, the pouch cover 20 does not need to be separately formed, reducing the number of manufacturing procedures and less material will be used. Also, the means 30 ensures that the pouch cover 20 will not accidentally open up and let the waste bags 5 to spill out of the bag cavity 14 .
[0036] According to the preferred embodiment of the present invention, the means 30 comprises a first fastener 31 and a second fastener 32 , wherein the first fastener 31 is provided on the front wall 11 of the pouch body 10 above the bag dispenser, and the second fastener 32 is provided on the pouch cover 20 and is arranged to detachably fasten with the first fastener 31 such that the pouch cover 20 is retained in a closed position. Of course, the means 30 can be other connectors too, including button snap, button and hole, and other detachable adhesive means.
[0037] It should be noted that, according to the preferred embodiment of the present invention, the first fasteners 31 and second fasteners 32 are a pair of hook and loop fasteners respectively.
[0038] The bag dispenser 40 is provided for the waste bags 5 inside the bag cavity 14 to be dispensed out of the waste bags dispenser. According the preferred embodiment of the invention, the bag dispenser 40 is provided on the front wall 11 of the pouch body 10 preferably at a position below the front cover edge 21 of the pouch cover 20 when the pouch cover 20 is detachably attached on the front wall 11 .
[0039] The bag dispenser 40 is adapted for allowing the waste bags 5 to be dispensed out of the bag cavity 14 when the bag cavity 14 is enclosed by the pouch cover 20 , such that the waste bags 5 can be pulled out of the bag cavity 14 without having to use both hands to hold on to the waste bag dispenser or to have to open up the pouch cover 20 to reach the waste bags 5 in the bag cavity 14 , allowing a user to effortlessly utilize the waste bags 5 , when he/she might not have both hands free.
[0040] According to the preferred embodiment of the present invention, the bag dispenser 40 of the waste bags dispenser contains a dispensing slit 41 , which is transversely formed on the front wall 11 of the pouch body 10 for the waste bag 5 to slide out of the bag cavity 14 through the dispensing slit 41 .
[0041] It should be noted that the dispensing slit 41 has a width larger than a width of the waste bag 5 in a folded manner while the waste bag is rolled to be stored in the bag cavity 14 , or else the waste bags 5 may not easily dispensed out of the bag cavity 14 .
[0042] It is worth mentioning that the pet waste bags dispenser, including the pouch body 10 and the pouch cover 20 , is made of a collapsible material, which enables the pet waste bag dispenser, when empty, to be easily folded, occupying less space and effectively stored inside the pocket of the user. It means that when the user stores the waste bags dispenser inside his pocket, there will be no bulging, and therefore no one can see it.
[0043] The pet waste bag dispenser further comprises pouch carrier 50 provided for the waste bags dispenser be carried around. The pouch carrier 50 enables the user to link the waste bags dispenser to a foreign object which allows the user to easily obtain a waste bag 5 from the waste bags dispenser without having to hold on to the pet waste bag dispenser.
[0044] By allowing the user to obtain a waste bag 5 from the waste bags dispenser with only one hand, without having to hold on to the waste bags dispenser, ensures that the user does not have to loose concentration in watching his or her dog wile obtaining a waste bag 5 . Imagine if a user has to hold the waste bags dispenser with both hands while trying to hold on to the leash of the dog, him or her may easily loose the leash of the dog and create hazard to both the dog and other pedestrians around.
[0045] The pouch carrier 50 comprises a carrier strap 51 , which is attached to the pouch cover 20 and a fastener element 52 provided on the carrier strap 51 in such a manner that two free ends 511 of the carrier strap 51 are detachably attached to form a carry loop for the pouch body 10 to be carried.
[0046] Referring to FIG. 2 of the drawings, according to the preferred embodiment of the present invention, in order to flexibly and comfortably accommodate different amount of waste bags 5 within the bag cavity 14 , the pouch body 10 further comprises an elastic element 16 , which is provided on the pouch body 10 at the top opening 15 . The effect of having the elastic element 16 is to shrink a size of the top opening 15 for securely retaining the waste bag 5 within the bag cavity 14 .
[0047] Also according to the preferred embodiment of the present invention, the elastic element 16 comprises two elastic bands 161 . The elastic bands 161 are provided along top edges 131 of the sidewalls 13 respectively, so as to substantially pull the front wall 11 and the rear wall 12 towards each other so as to form the bag cavity 14 having a trapezoid cross section.
[0048] Basically, when there are fewer waste bags 5 in the pouch body 10 , the flexible elastic element 16 prevents the waste bags 5 from falling out off the bag cavity 14 due to the emptiness within the bag cavity 14 . And, when there are many waste bags 5 in the pouch body 10 , the elastic element 16 expands to bind around the waste bags 5 within the pouch body 10 , such that the waste bags 5 will not ooze out of the bag cavity 14 simply because the bag cavity 14 is fuller.
[0049] The waste bags dispenser can be useful not only for pet's waste, but also for many other purposes. For example, the bags can be used to carry diapers or sanitary napkins.
[0050] Referring to FIG. 3 of the drawings, a pet waste bags dispenser for pet waste bags according to a preferred embodiment of the present invention is illustrated, wherein the pet waste bags dispenser comprises a pouch body 10 ′, a pouch cover 20 ′, means 30 ′ for detachably attaching the front cover edge of the pouch cover on the wall of the pouch body, a bag dispenser 40 ′, and plurality of waste bags 5 ′.
[0051] The pouch body has a front wall 11 ′, a rear wall 12 ′ and two sidewalls 13 ′, to form a bag cavity 14 ′. The bag cavity 14 ′ is provided for waste bag 5 ′ to be stored therein. The pouch body 10 ′ also has a top opening 15 ′ for communicating with the bag cavity 14 ′, such that the waste bags can be refilled into the bag cavity 14 ′ through the top opening 15 ′.
[0052] The pouch cover 20 ′ is provided for covering a top opening 15 ′ of the bag cavity 14 ′, so as to protect the waste bags 5 ′ placed within the bag cavity 14 ′ through the top opening 15 ′, prevent the waste bags 5 ′ from falling off the bag cavity 14 ′, or from damages. The pouch cover 20 ′ is extended from the rear wall 11 ′ of the pouch body 10 ′, and has a front cover edge 21 ′.
[0053] The top opening 15 ′ is made of elastic material to remain closed, and is easy to be opened for refilling waste bags 5 ′. In a preferred embodiment, the top opening comprises a front edge 151 ′, a rear edge 152 ′, and two elastic sides 153 ′. During normal time the top opening is remaining closed. The two elastic sides 153 ′ shrink and pull the front edge 151 ′ and the rear edge 152 ′ towards each other by elastic force to close the pouch body 10 ′. To open the top opening 15 ′, just pull the front edge 151 ′ and the rear edge 152 ′ away from each other, and the front edge 151 ′, the rear edge 152 ′, with the elastic sides 153 ′ form an open area for the pouch body 10 ′.
[0054] Referring to FIG. 6 , in an alternative embodiment, the top opening 15 ′ comprises two straight edges 154 ′. These two elastic edges 154 ′ are placed facing each other parallely. The ends of one elastic edge 154 ′ are connected with the ends of another elastic edge 154 ′ relatively. So in normal time these two elastic edges 154 ′ attached with each other and close the top opening 15 ′. While the elastic edges 154 ′ are made of elastic material and can be bent in a curve. When pull the two elastic edges 154 ′ away from each other, the top opening 15 ′ will be opened. And when release, the two elastic edges 154 ′ will return to the original shape and attach each other to close the top opening 15 ′ by elastic force.
[0055] In an alternative embodiment, the whole edge of the top opening 15 ′ is made of elastic material. During normal time, the top opening 15 ′ is closed with the edge shrinking together by elastic fore. When stretch the edge of the top opening 15 ′, the top opening 15 ′ is opened.
[0056] In order to ensure that the top opening 15 ′ is to remain closed, the pet waste bag dispenser has means 30 ′ for detachably attaching the front cover edge 21 ′ of the pouch cover 20 ′ on the front wall 13 ′ of the pouch body 10 ′, wherein the pouch cover 20 ′ is frontwardly folded to cover the top opening 15 ′ of the pouch body 10 so as to enclose the bag cavity 14 ′ and retaining the waste bags 5 ′ therein.
[0057] It is worth mentioning that, the pouch cover 20 ′ does not need to be separately formed, reducing the number of manufacturing procedures and less material will be used. Also, the means 30 ′ ensures that the pouch cover 20 ′ will not accidentally open up and let the waste bags 5 ′ to spill out of the bag cavity 14 ′.
[0058] According to the preferred embodiment of the present invention, the means 30 ′ comprises a first fastener 31 ′ and a second fastener 32 ′, wherein the first fastener 31 ′ is provided on the front wall 11 ′ of the pouch body 10 ′ above the bag dispenser, and the second fastener 32 ′ is provided on the pouch cover 20 ′ and is arranged to detachably fasten with the first fastener 31 ′ such that the pouch cover 20 ′ is retained in a closed position. Of course, the means 30 ′ can be other connectors too, including button snap, button and hole, and other detachable adhesive means.
[0059] It should be noted that, according to the preferred embodiment of the present invention, the first fasteners 31 ′ and second fasteners 32 ′ are a pair of hook and loop fasteners respectively.
[0060] The bag dispenser 40 ′ is provided for the waste bags 5 ′ inside the bag cavity 14 ′ to be dispensed out of the waste bags dispenser. According the preferred embodiment of the invention, the bag dispenser 40 ′ is provided on the front wall 11 ′ of the pouch body 10 preferably at a position below the front cover edge 21 ′ of the pouch cover 20 ′ when the pouch cover 20 ′ is detachably attached on the front wall 11 ′.
[0061] The bag dispenser 40 ′ is adapted for allowing the waste bags 5 ′ to be dispensed out of the bag cavity 14 ′ when the bag cavity 14 is enclosed by the pouch cover 20 ′, such that the waste bags 5 ′ can be pulled out of the bag cavity 14 ′ without having to use both hands to hold on to the waste bag dispenser or to have to open up the pouch cover 20 ′ to reach the waste bags 5 ′ in the bag cavity 14 ′, allowing a user to effortlessly utilize the waste bags 5 ′, when he/she might not have both hands free.
[0062] According to the preferred embodiment of the present invention, the bag dispenser 40 ′ of the waste bags dispenser contains a dispensing slit 41 ′, which is transversely formed on the front wall 11 ′ of the pouch body 10 ′ for the waste bag 5 ′ to slide out of the bag cavity 14 ′ through the dispensing slit 41 ′. The bag dispenser 40 ′ also comprises a front edge 42 ′ and a back edge 43 ′ along the dispensing slit 41 ′ and form the dispensing slit 41 ′ wherein the front edge 42 ′ and the back edge 43 ′ are overlapped in such a manner the front edge 42 ′ covers the back edge 43 ′. As a result, the dispensing slit 41 ′ does not expose the waste bags 5 ′ inside the pouch body 10 ′ directly to the air. First, the overlapped edges prevent dirt, water or other unwanted stuff entering into the pouch body 10 ′; second, the overlapped edges fold the waste bags when it is pulling out, this increases the friction force and prevent more waste bags being pulled out, and keep a portion of the next waste bag 5 ′ remaining in the slit 41 ‘for the user’s convenience to pull out next time, other wise the next waste bag 5 ′ can be rolled back into to pouch body 10 ′, or pulled out together with the previous waste bag 5 ′.
[0063] It should be noted that the dispensing slit 41 ′ has a width larger than a width of the waste bag 5 ′ in a folded manner while the waste bag is rolled to be stored in the bag cavity 14 , or else the waste bags 5 ′ may not easily dispensed out of the bag cavity 14 ′.
[0064] It is worth mentioning that the pet waste bags dispenser, including the pouch body 10 ′ and the pouch cover 20 ′, is made of a collapsible material, which enables the pet waste bag dispenser, when empty, to be easily folded, occupying less space and effectively stored inside the pocket of the user. It means that when the user stores the waste bags dispenser inside his pocket, there will be no bulging, and therefore no one can see it.
[0065] The pet waste bag dispenser further comprises pouch carrier 50 ′ provided for the waste bags dispenser be carried around. The pouch carrier 50 ′ enables the user to link the waste bags dispenser to a foreign object which allows the user to easily obtain a waste bag 5 ′ from the waste bags dispenser without having to hold on to the pet waste bag dispenser.
[0066] By allowing the user to obtain a waste bag 5 ′ from the waste bags dispenser with only one hand, without having to hold on to the waste bags dispenser, ensures that the user does not have to loose concentration in watching his or her dog wile obtaining a waste bag 5 ′. Imagine if a user has to hold the waste bags dispenser with both hands while trying to hold on to the leash of the dog, him or her may easily loose the leash of the dog and create hazard to both the dog and other pedestrians around.
[0067] The pouch carrier 50 ′ comprises a carrier strap 51 ′, which is attached to the pouch cover 20 ′ and a fastener element 52 ′ provided on the carrier strap 51 ′ in such a manner that two free ends 511 ′ of the carrier strap 51 ′ are detachably attached to form a carry loop for the pouch body 10 ′ to be carried.
[0068] Referring to FIG. 4 of the drawings, according to the preferred embodiment of the present invention, in order to flexibly and comfortably accommodate different amount of waste bags 5 ′ within the bag cavity 14 ′, the pouch body 10 ′ further comprises an elastic element 16 ′, which is provided on the pouch body 10 ′ at the top opening 15 ′. The effect of having the elastic element 16 ′ is to shrink a size of the top opening 15 ′ for securely retaining the waste bag 5 ′ within the bag cavity 14 ′.
[0069] Also according to the preferred embodiment of the present invention, the elastic element 16 ′ comprises two elastic bands 161 ′. The elastic bands 161 ′ are provided along top edges 131 ′ of the sidewalls 13 ′ respectively, so as to substantially pull the front wall 11 ′ and the rear wall 12 ′ towards each other so as to form the bag cavity 14 ′ having a trapezoid cross section.
[0070] Basically, when there are fewer waste bags 5 ′ in the pouch body 10 ′, the flexible elastic element 16 ′ prevents the waste bags 5 ′ from falling out off the bag cavity 14 ′ due to the emptiness within the bag cavity 14 ′. And, when there are many waste bags 5 ′ in the pouch body 10 ′, the elastic element 16 ′ expands to bind around the waste bags 5 ′ within the pouch body 10 ′, such that the waste bags 5 ′ will not ooze out of the bag cavity 14 ′ simply because the bag cavity 14 ′ is fuller.
[0071] Referring to FIG. 5 , the waste bags are installed inside the pouch body 10 ′ in a predetermined manner for the sake of easy pulling out continuously. In the first embodiment as illustrated in FIG. 5A , all the waste bags are detachably connected continuously, and are rolled together into a bag roll 51 ′. The bag roll 51 ′ is transversely stored in the bag cavity 14 ′ with the roll axes parallel to the dispensing slit 41 ′. The end of the rolling bags is slid out of the pouch body 10 ′ thought the dispensing slit 41 ′, so the user can reach the waste bag without opening the pouch body 10 ′. Since the waste bags 5 ′ are detachably connected, when one waste bag 5 ′ is pulled out, a portion of the bag roll 51 ′ is pulled out accordingly. When the waste bag 5 ′ is detached, a portion of the end of the bag roll 51 ′ remains outside of the pouch body 10 ′ though the dispensing slit 41 ′, so next time, the next waste bag 5 ′ will be easy to pull out. In the preferred embodiment, the waste bags 5 ′ are prefabricated in a continuous sheet, the connection of every two bags are pre-punched or half cut so the waste bags can be detached from the sheet.
[0072] Referring to FIG. 5B , in the second embodiment, the waste bags 5 ′ are rolled into a bag roll 52 ′ wherein each bag is rolled into the bag roll with a portion overlapped with the previous and the next bags. So when one waste bag 5 ′ is pulled out from the dispensing slit 41 ′, a portion of the next bag is pulled out too, and the bag roll 52 ′ is rolled inside the bag cavity 14 ′ accordingly.
[0073] In order to smaller the width of the waste bags to save space, all bags are tree-folded. So in both embodiments, the width of the bag roll is one third of the real width of the waste bags.
[0074] Each waste bag 5 ′ further comprises an opening 53 ′, a bag wall 54 ′, and a sealing slit 55 ′ for sealing the waste bag 5 ′ easily. Referring to FIG. 6 , the sealing slit 55 ′ is cut in U-shape on the bag wall 54 ′ near the opening 53 ′ of the waste bag 5 ′. The upper edge 551 ′ of the sealing slit 55 ′ can be lift up to make a through hole on the bag wall 53 ′. When the waste bag 5 ′ needs to be sealed, the edge of the opening 53 ′ which is opposite to the sealing slit 55 ′ is pulled through the sealing slit 55 ′ from one side to another, then the opening 53 ′ of the waste bag 5 ′ is squeezed and sealed. The sealing slit 55 ′ holds the edge of the opening 53 ′ for fastening. In this way, no other fasteners, such as rubber band, thread, or clamps are needed for sealing the waste bag 5 ′.
[0075] One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
[0076] It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
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A pet waste bags dispenser provided for dispensing animal waste bags, having a collapsible container, a dispenser cavity cover and a dispensing means, wherein the dispensing means allows waste bags placed within the waste bags dispenser to be dispensed to a user easily and conveniently. The collapsible waste bags dispenser is made of a collapsible material, such that the dispenser is easy to store, light in weight, simple to manufacture, and has the flexibility to contain different amounts of waste bags within the collapsible container, wherein rolls of or individually wrapped waste bags are allowed to be dispensed. The collapsible waste bags dispenser further has external connecting means for connecting the waste bags dispenser to a foreign object, so as to facilitate the user to easily obtain a waste bag from the dispenser.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. provisional application serial No. 60/201,389 filed May 3, 2000; the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention generally relates to security devices and, more particularly, to a six-sided box having a hinged lid for storing DVD and CD jewel boxes. Specifically, the invention relates to a security storage container having a lock slide that is used to securely lock jewel boxes inside the security box. The overall dimensions of the security box are only slightly larger than the overall dimensions of the jewel box in order to save valuable shelf space.
[0004] 2. Background Information
[0005] Lightweight inexpensively molded plastic containers have been used in recent times to display items of recorded media for sale. Retail sales establishments desire containers to be lockable to prevent unauthorized removal of the items of recorded media from the containers. The containers themselves, or the items of recorded media, preferably hold an EAS (Electronic Article Surveillance) tag that will sound an alarm if a thief removes the EAS tag from the retail establishment. The lock on the container prevents the thief from removing the EAS tag or from removing the item of recorded media from the security box.
[0006] Many different security boxes are known in the art and various types of locking mechanisms are used to maintain the security devices in the locked position. Although existing security storage containers function for their intended purposes, there remains room in the art for an improved design. The art generally desires the overall dimensions of the security storage container to be only slightly larger than the item of recorded media so that the retail establishment does not have to add an excessive amount of shelf space to use the security boxes. Retail establishments also desire security boxes that are easy to unload so that the retail clerk does not have to spend excessive time unlocking and unloading the security storage container. Another problem in the art is that security storage containers are typically loaded with automated machinery. The design of the security storage container must allow items of recorded media to be automatically loaded into the security storage container by automated equipment. The design of the security storage container must also allow the device to be closed and locked after it is loaded.
SUMMARY OF THE INVENTION
[0007] The invention provides a security box for holding items of recorded media wherein the security box includes a base and a lid having first and second ends. The lid and base are connected by hinges at one end with a lock slide being carried by the base at the other end. The lock slide engages the lid when the lid is in the closed position and the lock slide is in the locked position to prevent the lid from moving to the open position.
[0008] The invention also provides a locking arrangement wherein at least one tooth on the lid passes through an opening in the base that is then blocked by the lock slide when the lock slide is moved to the locked position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The preferred embodiment of the invention, illustrative of the best mode in which applicant contemplated applying the principles of the invention, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended Claims.
[0010] [0010]FIG. 1 is a perspective view of the security storage container of the present invention in an open position;
[0011] [0011]FIG. 2 is a perspective view of the security storage container of the present invention with the lid being closed;
[0012] [0012]FIG. 3 is a perspective view of the security storage container of the present invention with the lid closed and the lock slide being in the closed position;
[0013] [0013]FIG. 4 is a top perspective view of the lock slide of the security storage container;
[0014] [0014]FIG. 5 is a bottom perspective view of the lock slide of the security storage container;
[0015] [0015]FIG. 6 is a top sectional view taken through the lock slide showing the lid and the lock slide in unlocked positions;
[0016] [0016]FIG. 7 is a view similar to FIG. 6 showing the lid in a closed position and the lock slide in an unlocked position;
[0017] [0017]FIG. 8 is a view similar to FIG. 6 showing the lid in the closed position and the lock slide in the locked position;
[0018] [0018]FIG. 9 is a top plan view of the security storage container showing the lock slide in an unlocked position and the locking tab in an unlocked position;
[0019] [0019]FIG. 10 is a side sectional view showing the lock slide and locking tab in unlocked positions;
[0020] [0020]FIG. 11 is an enlarged view of the encircled portion of FIG. 10;
[0021] [0021]FIG. 12 is a view similar to FIG. 9 showing the lock slide and locking tab in a locked position;
[0022] [0022]FIG. 13 is a view similar to FIG. 10 showing the lock slide and locking tab in a locked position;
[0023] [0023]FIG. 14 is an enlarged view of the encircled portion of FIG. 13;
[0024] [0024]FIG. 15 is a view similar to FIG. 10 showing the security storage container aligned with a key;
[0025] [0025]FIG. 16 is a view similar to FIG. 15 showing the security storage container engaged with the key and the magnet of the key moving the locking tab to the unlocked position;
[0026] [0026]FIG. 17 is a view similar to FIG. 15 showing the key moving the lock slide to the unlocked position; and
[0027] [0027]FIG. 18 is a view similar to FIG. 17 showing an alternative lock arrangement with dual locking members.
[0028] Similar numbers refer to similar parts throughout the specification.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] The security storage container of the present invention is indicated generally by the numeral 10 in the accompanying drawings. Security storage container 10 generally includes a base 12 and a lid 14 that is connected to base 12 by a pair of hinges 16 . Lid 14 moves between open and closed positions. A storage compartment is defined between lid 14 and base 12 when lid 14 is in the closed position. A lock slide 18 is carried by base 12 and moveable between locked and unlocked positions. Lock slide 18 is configured to lock lid 14 in the closed position to prevent unauthorized access to the storage compartment.
[0030] The operation of security storage container 10 may be generally viewed in FIGS. 1 - 3 . In FIG. 1, lid 14 is entirely open to a position where it may be loaded with an item of recorded media such as a CD or DVD jewel box. In FIG. 2, lid 14 is being moved toward the closed position as indicated by arrows 20 . In this position, lock slide 18 is moved to the unlocked position. In FIG. 3, lid 14 is in the closed position and lock slide 18 has been moved to the locked position as indicated by arrow 22 . In this position, a key 24 (FIGS. 15 - 17 ) is required to open security storage container 10 to remove its contents. The use and function of key 24 will be described below in detail.
[0031] Base 12 generally includes a top wall 30 , a pair of sidewalls 32 extending generally perpendicular from top wall 30 , and a back wall 34 . Back wall 34 is generally planar and extends between sidewalls 32 and top wall 30 . In other embodiments of the invention, back wall 34 may include openings that allow the manufacturer to reduce the amount of material used to form security storage container 10 . In the preferred embodiment of the invention, each wall 30 , 32 , and 34 may be fabricated from a transparent material to allow the consumer to view the contents of security storage container 10 . In another preferred embodiment, top wall 30 may be fabricated from an opaque material that prevents a shoplifter from viewing the lock mechanism of security storage container 10 .
[0032] Lid 14 generally includes a bottom wall 36 , a pair of sidewalls 38 extending generally perpendicular from bottom wall 36 , and a front wall 40 extending between bottom wall 36 and side walls 38 . As with base 12 , walls 36 , 38 , and 40 of lid 14 are preferably fabricated from a transparent material to allow the consumer to view the contents of security storage container 10 . Front wall 40 is preferably a solid wall but may also include openings to reduce the overall amount of material used to form security storage container 10 .
[0033] Each side wall 38 is inset from the outer edge of front wall 40 and bottom wall 36 to form a ledge 42 having a width substantially equal to the thickness of side wall 32 of base 12 . Ledge 42 receives side wall 32 when lid 14 is in the closed position as depicted in FIGS. 2 and 3. Walls 38 are spaced apart a distance substantially equal to the length or width dimension of a standard item of recorded media such as a CD or DVD jewel box such that the overall width of security storage container 10 is only larger than the width or length of the item of recorded media by the thickness of both side walls 38 and both side walls 32 .
[0034] Each side wall 32 includes a finger access depression 44 that allows the user of security storage container 10 to easily grasp ledge 42 when lid 14 is in the closed position. Finger access depressions 44 thus allow the retail clerk to easily open lid 14 once security storage container 10 is unlocked.
[0035] Each hinge 16 includes a hinge pin extending between a pair of protuberances 46 that extend from back wall 34 and bottom wall 36 . In order to reduce shipping space and to allow security storage container 10 to nest together, the bottom of front wall 40 and the front edge of bottom wall 36 are provided with indentions 48 sized to receive protrusions 46 when two security storage containers 10 are stacked together.
[0036] Lid 14 additionally includes a plurality of first teeth 50 . Teeth 50 preferably extend substantially parallel to front wall 40 and are disposed substantially evenly between side walls 38 . Teeth 50 are preferably offset from the front surface of front wall 40 as shown in FIG. 6. The offset may be achieved by providing an offset wall 52 connected to front wall 40 and side walls 38 .
[0037] Base 12 includes a plurality of second teeth 54 extending downwardly from the front edge of top wall 30 . Each second tooth 54 is slightly wider than each first tooth 50 as depicted in FIG. 6. Teeth 54 are staggered with respect to teeth 50 allowing first teeth 50 to pass through the openings 56 between second teeth 54 . First teeth 50 do not engage the edges of second teeth 54 because opening 56 are wider than the width of each first tooth 50 .
[0038] Slide 18 includes a main wall 60 , a back slide wall 62 , and a plurality of slide teeth 64 spaced from back slide wall 62 . Slide teeth 64 and back slide wall 62 each extending the same direction from main wall 60 and are substantially parallel. Slide teeth 64 are preferably disposed at the same spacing as second teeth 54 and are preferably the same width as second teeth 54 . As such, opening 56 is formed when slide 18 is in the unlocked position. When slide 18 is moved to the locked position as depicted in FIG. 8, each opening 56 is closed by slide teeth 64 . As shown in FIG. 8, teeth 50 are offset far enough to allow slide teeth 64 to slide between teeth 50 and teeth 54 so as to lock teeth 50 in position by preventing teeth 50 from moving back through openings 56 . Main wall 60 includes a key opening 66 that is aligned with a second key opening 68 formed in top wall 30 of base 12 . Second key opening 68 is elongated such that key opening 66 may be accessed through second key opening 68 when slide 18 is in both the locked and unlocked positions.
[0039] Slide 18 further includes a locking channel 70 that receives a locking member 72 when slide 18 is in the locked position as depicted in FIGS. 13 and 14. Locking member 72 is preferably fabricated from a material that may be moved in a magnetic field. Locking member 72 is preferably resiliently biased toward locking channel 70 so that locking member 72 automatically moves into locking channel 70 when slide 18 is moved to the locked position. Locking member 72 may be attached to top wall 30 by any of a variety of appropriate connectors.
[0040] Slide 18 is carried by base 12 on at least a pair of supports 80 . Supports 80 are preferably disposed on back wall 34 . Supports 80 allow slide 18 to move back and forth between the locked and unlocked position. In the locked position, the inner end 82 of slide 18 preferably engages sidewall 32 as shown in FIGS. 13 and 15. In the unlocked position, the outer end 84 of slide 18 engages sidewall 32 as shown in FIG. 17. In the unlocked position of slide 18 , a portion of main wall 60 protrudes through sidewall 32 so that slide 18 may be easily moved from the unlocked position to the locked position. The protruding portion of main wall 60 allows slide 18 to be locked by automated equipment after an item of recorded media has been loaded into the storage compartment of security storage container 10 .
[0041] In operation, an item of recorded media such as a DVD or CD jewel box is loaded into the storage compartment of container 10 by placing the item of recorded media in either base 12 or lid 14 and then closing lid 14 as depicted in FIG. 2. Once lid 14 is closed, slide 18 is moved from the unlocked position to the locked position as depicted in FIG. 3. In this position, teeth 64 close openings 56 to trap teeth 50 in a locked position. Security storage container 10 is now locked with the item of recorded media securely held inside security storage container 10 where a shoplifter cannot remove an EAS tag from the item of recorded media while allowing the consumer to view substantially the entire surface area of the item of recorded media. The loading and locking process may be easily achieved by automated equipment because of the relatively simple movements required to load, close, and lock security storage container 10 .
[0042] When a store clerk is selling the item of recorded media to the consumer, the store clerk must open security storage container 10 and remove the item of recorded media. The store clerk is provided with a key 24 having a magnet 90 and an unlocking pin 92 . Magnet 90 and unlocking pin 92 are spaced apart so that they align with openings 66 , 68 , and locking member 72 when security storage container 10 is brought into contact with key 24 . The store clerk places key 24 onto security storage container 10 as depicted in FIG. 16 such that locking pin 92 engages key opening 66 and magnet 90 pulls locking member 72 toward key 24 to an unlocked position. Key 24 is then moved in the direction indicated by arrow 94 in FIG. 17 to move slide 18 to the unlocked position. Lid 14 may then be opened and the item of recorded media removed and sold to the consumer. In other embodiments of the invention, key 24 may be mounted to a counter top and security storage container 10 moved with respect to key 24 .
[0043] As shown in FIG. 18, another embodiment of storage container 10 may include a pair of locking members 72 that cooperate together to provide a secure locking arrangement to container 10 . In this embodiment, key 24 includes two magnets 90 with one magnet being aligned with each locking member 72 .
[0044] The present invention thus provides an improved security storage box for use with items of recorded media. Of course, the security box may be used with other items of merchandise. The security box of the invention provides a container that has overall container that are only slightly larger than the overall dimensions of the item of recorded media being held in the box. The locking mechanism of the security box may be locked and unlocked with automated equipment because the motions required to close and lock the box are relatively simple. The box allows the front, rear, bottom, and sides of the item of recorded media to be viewed by the consumer when the walls are fabricated from a transparent material. The device is easy to unlock by retail store clerk and frustrate shoplifters by hiding the lock slide within the box and providing no areas that may be easily attacked with a pry bar.
[0045] Accordingly, the improved security box for recorded media apparatus is simplified, provides an effective, safe, inexpensive, and efficient device which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.
[0046] In the foregoing description, certain terms have been used for brevity, clearness, and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
[0047] Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
[0048] Having now described the features, discoveries, and principles of the invention, the manner in which the security box for recorded media is constructed and used, the characteristics of the construction, and the advantageous new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts, and combinations are set forth in the appended claims.
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A security box for holding items of recorded media includes a base and a lid hinged together between open and closed positions. At the end of the base opposite the hinged connection with the lid, a lock slide is positioned and movable between locked and unlocked positions. The lid includes a tooth that passes through an opening in the base as the lid is pivoted between the open and closed positions. The lock slide includes a tooth that moves between the tooth of the lid and the opening of the base when the lock slide is in the locked position.
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TECHNICAL FIELD
[0001] The present application is a continuation in part of U.S. patent application Ser. No. 15/258,453.
BACKGROUND
[0002] Deep fryers generally utilize substantial quantities cooking oils. These oils typically are expensive. Also, these oils may present storage and disposal problems. Additionally, the more there are of these oils, the more difficult they may be to handle. Examples shown herein, among other advantages, may reduce the amount of cooking oils utilized in deep frying articles. Such examples may also show how to more easily store and handle deep fryer cooking oil.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Various embodiments will become better understood with regard to the following description, appended claims and accompanying drawings wherein:
[0004] FIG. 1 is a perspective of embodiment 601 .
[0005] FIG. 2 is a perspective of embodiment 601 , with outer enclosure 604 removed.
[0006] FIG. 3 is a perspective of embodiment 601 , with outer enclosure 604 and cooking vessel 606 removed.
[0007] FIG. 4 is a perspective of embodiment 601 , with outer enclosure 604 , cooking vessel 606 , control box/heat coil 608 , and lid 610 removed.
[0008] FIG. 5 is a exploded perspective of embodiment 601 .
[0009] FIG. 6 is a perspective of embodiment 601 , including also: oil storage container 612 , filter media support 616 , and oil storage container lid 618 , in their assembled storage condition.
[0010] FIG. 7 is an exploded perspective view of embodiment 601 , including also: oil storage container 612 , filter media 614 , filter media support 616 , and oil storage container lid 618 , in their assembled storage condition.
[0011] FIG. 8 is an exploded perspective view of: oil storage container 612 , filter media 614 , filter media support 616 , and oil storage container lid 618 , in their oil storage condition.
[0012] FIG. 9 is a perspective of embodiment 601 , in its draining condition.
[0013] FIG. 10 is an exploded perspective of food support 620 , including: left food support dynamic side wall 622 , right food support dynamic side wall 624 , left food support handle 626 , right food support handle 628 . In addition, FIG. 10 shows wire basket 630 , and wire basket lid 632 .
[0014] FIG. 11 is a perspective view of food support 620 , with wire basket 630 mounted within it, and wire basket lid 632 mounted within wire basket 630 , as a nonlimiting and nonexhaustive example, during cooking, or at other times.
[0015] FIG. 12 is a perspective of a first example 634 of wire basket lid 632 , mounted within wire basket 630 .
[0016] FIG. 13 is a perspective of a second example 635 of wire basket lid 632 , mounted within wire basket 630 .
[0017] FIG. 14 is an exploded perspective of food support 620 , including lid 610 .
[0018] FIG. 14A is a detail of FIG. 14 , as indicated in FIG. 14 .
[0019] FIG. 15 is a front view of food support 620 , including lid 610 , article 634 , displacement/cooking chamber 636 , chamber plug 638 .
[0020] FIG. 16 is a front view taken from the same point as FIG. 15 , and showing most of the same elements, but with displacement/cooking chamber 636 penetrating inside of article 634 .
[0021] FIG. 17 is identical to FIG. 16 , except article 634 with inserted displacement/cooking chamber 636 , is lowered into food support 620 .
[0022] FIG. 18 is identical to FIG. 17 , except lid 630 is mounted on to the tops of left food support handle 626 and right food support handle 628 .
[0023] FIG. 19 is a perspective of embodiment 601 , showing the section plane of FIG. 20 .
[0024] FIG. 20 is a section view of FIG. 19 , as indicated in FIG. 19 .
[0025] FIG. 21 is a perspective of embodiment 601 , showing the section plane of FIG. 22 .
[0026] FIG. 22 is a section view of FIG. 21 , as indicated in FIG. 21 .
[0027] FIG. 23 is an exploded perspective of displacement/cooking chamber 636 and chamber plug 638 .
[0028] FIG. 24 is a perspective of cooking vessel 606 .
[0029] FIG. 25 is a detail perspective of FIG. 26 , as indicated in FIG. 26 .
[0030] FIG. 26 is a perspective of food support 620 , with left food support handle 626 position to be mounted within bracket 714 .
[0031] FIG. 27 a perspective taken from the same viewpoint as FIG. 26 , with left food support handle 626 mounted within bracket 714 .
[0032] FIG. 28 is a perspective of embodiment 716 , with domed lid 718 inverted, as a nonlimiting and nonexhaustive example, to make embodiment 716 more compact for shipment, storage, or other purposes.
[0033] FIG. 29 is a perspective taken from the same viewpoint as FIG. 28 , with domed lid 718 upright, as it might be positioned during cooking, or at other times.
[0034] FIG. 30 is a perspective taken from the same viewpoint as FIG. 29 , but including article to be cooked 730 , and including domed lid 718 and outer enclosure 728 being removed.
[0035] FIG. 31 is a perspective taken from the same viewpoint as FIG. 30 , but further including cooking vessel 726 being removed.
[0036] FIG. 32 is a perspective taken from the same viewpoint as FIG. 29 , and with FIG. 32 indicating where the section view of FIG. 33 was taken.
[0037] FIG. 33 is a section view of embodiment 716 , as indicated in FIG. 32 .
[0038] FIG. 34 is a perspective exploded view of embodiment 716 .
DETAILED DESCRIPTION
Detailed Description—Embodiment 601 —FIGS. 1 Through 27 :
[0039] Referring especially to FIG. 5 , as well as other drawings herein, embodiment 601 generally comprises: lid 610 , displacement/cooking chamber 636 , (optionally) chamber plug 638 , food support 620 , control box/heat coil 608 , cooking vessel 606 and outer enclosure 604 .
[0040] Using embodiment 601 may be done, as a nonlimiting and nonexhaustive example, utilizing the following steps:
1) Placing outer enclosure 604 on a horizontal support surface. 2) Placing cooking vessel 606 within outer enclosure 604 . 3) Dropping heat coil 640 into cooking vessel 608 , and mounting rigidly attached control box 642 to control box mount 644 , which is disposed on the upper portion of right rear side of enclosure 604 . 4) Placing a predetermined amount of cooking oil into cooking vessel 606 , and adjusting controls on control box 642 to activate heat coil 640 , and thus heat up the cooking oil to cooking temperatures 5) Optionally, placing items to be cooked, as a nonlimiting and nonexhaustive example stuffing, into displacement/cooking chamber 636 , and capping displacement/cooking chamber 636 with chamber plug 636 . Embodiment 601 may be used without chamber plug 636 when not cooking items within displacement/cooking chamber 636 . 6) Optionally, and including where article 634 is a fowl, placing displacement/cooking chamber 636 inside the empty gut cavity of article 634 , which is shown as a fowl (transition from FIG. 15 to FIG. 16 ). When displacement/cooking chamber 636 is placed inside the gut cavity of article 634 , it may support article 634 in an upright position. It may also serve as a carving stand when resting on a horizontal support surface. When you 7) Dropping the above assemblage into food support 620 , which, because of the base of displacement/cooking chamber 636 resting and putting downward pressure on flexing center strip 646 , causes left food support dynamic side wall 622 , and right food support dynamic side wall 624 to converge 648 toward one another and contain article 634 (transition from FIGS. 16 to 17 ). 8) Mounting lid 610 on the upper portions of left food support handle 626 and right support handle 624 ( FIG. 14, 14A , and transition from FIG. 17 to FIG. 18 ). 9) Lowering the entire above assemblage into cooking vessel 606 , and leaving it there long enough for cooking to occur (transition from FIG. 18 to FIG. 19 ). 10) After cooking, raising the entire assemblage out of cooking vessel 606 and removing article 634 from food support 620 . Optionally, pulling out chamber plug 638 from displacement/cooking chamber 636 and removing the, now cooked, contents. Serving article 634 , optionally using displacement/cooking chamber 636 as a vertical carving stand.
[0051] Right food support dynamic side wall 624 and left food support dynamic side wall 622 , may be converge 648 to a generally vertical disposition, as shown in FIGS. 17 and 18 , when lid 610 is affixed to the upper ends of both left food support handle 626 and right food support handle 628 .
[0052] Independent of this, right food support dynamic side wall 624 and left food support dynamic side wall 622 , may converge 648 simply by the camming action between the outer surfaces of right food support dynamic side wall 624 and left food support dynamic side wall 622 , and upper rim 664 of cooking vessel 606 as food support 620 is lowered into cooking vessel 606 . Particularly where large foods are involved, such as, by way of a nonlimiting and nonexhaustive example, a large Thanksgiving day size turkey. This forceful converging 648 camming action may help provide the compressive forces to place such a large food within the narrow confines of cooking vessel 606 .
[0053] Right food support dynamic side wall 624 and left food support dynamic side wall 622 , may be fabricated utilizing any suitable construction. As both a nonlimiting and non-exhaustive example, each may be stamped in aluminum and have a non-stick inner surface to help with easy cleaning, and the easy release and removal of article 634 (such as the fowl illustrated) from food support 620 .
[0054] Flexing center strip 646 , as a nonlimiting and nonexhaustive example, may be fabricated from resilient aluminum which is biased to the disposition shown in FIGS. 15 and 16 , and is riveted to left food support dynamic side wall 622 and right food support dynamic side wall 624 .
[0055] As an alternative to this construction, flexing center strip may be biased inward so that left food support dynamic side wall 622 and right food support dynamic side wall 624 must be parted to allow the insertion of article 634 .
[0056] As yet another alternative, a common hinge with limited travel, which is either not biased or biased inward or outward, utilizing an auxiliary spring, might be used for center strip 646 .
[0057] As yet another alternative flexing center strip 646 might be rigid, not allowing movement of support dynamic side wall 622 and right food support dynamic side wall 624 .
[0058] As one further alternative, food support 620 might be constructed as a unitary piece, with or without a V-shaped gap between left food support dynamic side wall 622 and right food support dynamic side wall 624 .
[0059] As yet one further alternative, food support 620 might be constructed as a tapered or an un-tapered unitary bucket, with or without a nonstick coating on its interior.
[0060] Spacing protrusions 706 ( FIGS. 14 and 15 ) on the exterior surfaces of dynamic side walls 622 and 624 , are configured to create a minimum predetermined space between the exterior surfaces of dynamic side walls 622 and 624 , and the interior surfaces of cooking vessel 606 . This at least allows the circulation of hot liquid, so that dynamic side walls 622 and 624 may be at virtually the same temperature as the hot liquid within cooking vessel 606 . This, in combination with circulation holes 708 ( FIG. 5 ), and nonstick surfaces on surfaces which touch and/or don't touch articles being cooked 634 , may help achieve even browning of articles 634 being cooked.
[0061] All of the above constructions might benefit from nonstick coatings on any portions which make and/or don't make contact with article 634 . This is at least both because it may help even browning, as mentioned above, and because ease of cleaning may be enhanced.
[0062] As both a nonlimiting and nonexhaustive example, displacement/cooking chamber 636 , might be drawn in aluminum and might also be nonstick coded at lease for easy cleaning and/or for other reasons.
[0063] Chamber plug 638 , as both a nonlimiting and nonexhaustive example, might be injection molded from silicone rubber, or other food safe, high temperature elastomers, or from other suitable materials.
[0064] Referring to FIG. 23 , chamber plug 638 has lower peripheral ring 650 , which is integral and reinforces most of the the lower edge of of chamber plug 638 , except where it is interrupted by gap 652 . Gap 652 allows pressure within displacement/cooking chamber 636 to be released in a one-way, outward fashion, and also prevents cooking oil from entering into displacement/cooking chamber 636 , when pressure is lowered within displacement/cooking chamber 636 as during cooling or at other times.
[0065] Finger grip tab 654 may be pulled by the user to release vacuum within displacement/cooking chamber 636 to make it easier to remove chamber plug 638 , or for other reasons. Finger grip tab 654 may also aid in pulling chamber plug 638 out from the base of displacement/cooking chamber 636 .
[0066] As nonlimiting and non-exhaustive alternatives to the above construction for displacement/cooking chamber 636 , it may be constructed from wires, like a round top birdcage, or from perforated metal, or be solid, without an interior cavity, or may be a permanently sealed container, like a sealed tin can filled with air, oil, or other suitable material, or may be of other desirable construction.
[0067] As best shown in FIGS. 21 and 22 , as well as other figures herein, when lid 610 is mounted during cooking, or at other times, it's annular peripheral downward directed rim 656 is spaced between the upper rim 686 of outer enclosure 604 and the upper rim 664 of cooking vessel 606 , with annular air gap 658 between downward directed rim 656 and upper rim 664 of cooking vessel 606 , and annular air gap 660 between peripheral downward directed rim 656 and the upper portion of outer enclosure 604 .
[0068] This arrangement helps direct steam and debris downward into space 662 formed between the outer walls of cooking vessel 606 and the inner walls of outer enclosure 604 . By doing this, steam may be condensed and cooled before exiting embodiment 601 .
[0069] This may help condense and trap debris before it enters the immediate environment surrounding embodiment 601 . This in turn may help reduce odors and greasy kitchen surfaces normally associated with frying.
[0070] Further, should foam and/or hot bubbles and/or hot oil and/or other materials rise to the level of upper rim 664 of cooking vessel 606 , rather than spitting them out into the immediate environment surrounding embodiment 601 , downward directed rim 656 , by interrupting the space between upper rim 664 of cooking vessel 606 and upper rim 686 of outer enclosure 604 , blocks outward egress and forces all such materials into space 662 where they can be trapped in outer enclosure 604 , which is liquid tight, for later disposal, and/or reuse, and/or for other purposes.
[0071] Control box/heat coil 608 has user operated latch 666 ( FIG. 21 ), which prevents control box/heat coil 608 from being removed from outer enclosure 604 until user operated latch 666 is activated.
[0072] When oil is cooled down, the user may tip embodiment 601 forward toward 45° offset pouring rim 672 ( FIGS. 19 and 20 ), and dump the oil within cooking vessel 606 , for disposal, and/or storage, and/or reuse, and/or for other purposes, as a nonlimiting and nonexhaustive example, into oil storage container 612 ( FIGS. 6, 7, and 8 ). Cold pins 668 , and thermostatic probe 670 , each are fixedly coupled to the top of control box 642 ( FIG. 5 ), and loop over upper rim 664 of cooking vessel 606 , thus they prevent it from sliding forward when embodiment 601 is tipped. This may happen until latch 666 is activated, and control box/heat coil 608 is removed from outer enclosure 604 , which allows cooking vessel 606 to be removed from outer enclosure 604 .
[0073] This arrangement of locking cooking vessel 606 inside of outer enclosure 604 , allows simultaneous pouring of oil within cooking vessel 606 and oil, water, and/or debris, within outer enclosure 604 , simply by tipping embodiment 601 forward. Thus it also helps prevent a user accidentally leaving oil, water, and/or debris in the bottom outer enclosure 604 , after embodiment 601 has been used for cooking.
[0074] Openings 674 ( FIG. 19 ), disposed most of the way around the base of outer enclosure 604 , except below 45° offset pouring rim 672 ( FIGS. 19 and 20 ), provide both an additional outlet for steam and/or exhaust beyond that provided by annular air gap 660 , and openings 674 may also provide additional cooling for outer enclosure 604 .
[0075] Referring to FIG. 24 , as well as other figures herein, cooking vessel 606 is contoured to efficiently utilize cooking oil when cooking articles, including fowl, as well as other articles. Cooking vessel 606 is also configured to help minimize countertop space usage. To achieve these goals, cooking vessel 606 's midriff tapers inward, such that its girth 680 , measured 20% down from its upper rim 676 is shown as being 110% of its girth 682 measured 20% up from its base 678 . This proportional relationship most advantageously accomplishes its goals with ratios above 105%. To help these goals still further, cooking vessel 606 is shown as having a height 684 which is roughly 145% of its width 686 . This proportional relationship most advantageously accomplishes its goals with ratios above 130%. Utilization of displacement/cooking chamber 636 , where appropriate, further helps to achieve the above goals of minimal countertop space utilization and reduced cooking oil usage.
[0076] Cooking vessel 606 is generally tubular, with an integral bottom. It's tubular cross-section may be of any suitable configuration, including polygon (triangular, square, diamond, pentagonal, hexagonal, etc.), irregular polygon, regular or irregular polygonal with rounded corners, regularly curved (such as circular, as shown, elliptical, etc.), any combination of the above for the top, middle, and/or lower portions of cooking vessel 606 , or any other suitable configuration.
[0077] Embodiment 601 is most advantageously limited to 16 inches in overall height. This is because, in the US market, 16 inches is generally considered to be the minimal standard height for cabinets above kitchen countertop surfaces.
[0078] To help achieve this maximum height goal, as best shown in FIGS. 3 and 5 , heat coil 640 is configured in a manner which disposes it in close proximity to outer lower outer wall 688 , of cooking vessel 606 , while leaving the center of heat coil 640 open, and thus not adding to the overall height of embodiment 601 . As an example, article 634 , disposed inside of food support 620 , may be lowered directly on the floor of cooking vessel 606 , instead of resting on, or being raised up by, a portion of a heat coil.
[0079] Cooking vessel 606 is supported by, and positioned within outer enclosure 604 , by upper rim 664 of cooking vessel 606 being supported on its underside by cooking vessel mounting brackets 690 , disposed on the upper interior of outer enclosure 604 (best shown in FIG. 5 ).
[0080] Left food support handle 626 and right food support handle 628 are detachable from left food support dynamic side wall 622 and right food support dynamic side wall 624 respectively, as best shown in FIGS. 25 through 27 . As an example, mounting left food support handle 626 to left food support dynamic side wall 622 may be accomplished by pushing end 710 up 712 into bracket 714 , where it is secured by both friction and by snap action caused by dimple 716 ( FIG. 25 ). Detaching left food support handle 626 from left food support dynamic side wall 622 may be accomplished by striking the top of handle 626 downward. Detaching the handles may be desirable for shipping, storage, or for other purposes.
[0081] FIG. 9 illustrates how right food support handle 628 (and mirrored by left support handle 626 ) may hold food support 620 in a raised position above the oil level within cooking vessel 606 , so that article 634 may be drained of cooking oil, or for other purposes, including, but not limited to, utilizing embodiment 601 for food steaming, by replacing cooking oil in cooking vessel 606 with water, and also potentially using wire basket 632 to hold articles to be steamed.
[0082] Oil storage, between uses, is a known problem for most food fryers, both, at least, because of inconvenience, and/or also because it may take up valuable countertop and/or refrigerator space.
[0083] For short durations, cooking oil may be left within embodiment 601 , while, as a nonlimiting and non-exhaustive example, embodiment 601 remains resting on a countertop.
[0084] With extended periods between fryer uses, oil may be stored in its original container. In many cases, because of original container sizes, it may be difficult to store in a refrigerator, or on a countertop, or in a cabinet. In many cases also, pouring oil from the fryer back into the original container, may be difficult.
[0085] Further, oil ages and becomes unusable, at least partially because of charred particles within the oil and other contaminants. Filtering such particles and contaminants may make extended oil usage possible.
[0086] FIGS. 6, 7, and 8 , address the directly above issues. Oil storage container 612 is configured to efficiently store within most refrigerators, and/or cabinets. Its square shape, and relatively shallow height aid in this efficiency.
[0087] Also, oil storage container 612 , when not containing oil, may be stored by telescoping it over the bottom of embodiment 601 as shown in FIGS. 6, and 7 . As also shown in FIGS. 6, and 7 , oil storage container lid 618 filter media support 616 , and optionally filter media 614 may be efficiently nested and stored below oil container 612 .
[0088] Referring in particular to FIG. 8 , filter media support 616 , while disposed below and supporting filter media 614 , may rest on upper rim surfaces 692 , disposed on the upper portions of oil storage container 612 ( FIG. 8 ). In this disposition, oil may be poured on to filter media 614 where the oil is filtered before entering oil container 612 . As mentioned, this may help prolong the useful life of the oil.
[0089] Oil storage container lid 618 may be mounted to the top opening of oil storage container 612 , to contain orders, promote freshness, and/or for other purposes. This may be done if filter media support 616 and optionally filter media 614 are mounted within oil storage container 612 , or if they are ab sent.
[0090] Troughs 694 ( FIG. 7 ) intended outward from the interior of oil storage container 612 , aid in the easy pouring of liquids contained within oil storage container 612 , as nonlimiting and nonexhaustive examples, back into its original container, for disposal, or back into cooking vessel 606 for cooking, and or for pouring liquids contained within storage container 612 elsewhere.
[0091] Troughs 694 may also provide convenient handholds during container movement, while pouring, or at other times.
[0092] Embodiment 601 , may be used to cook a broad variety of foods, including, but not limited to, those which are best deep fried in a fry basket. FIGS. 10 through 13 illustrate, as nonlimiting and nonexhaustive examples, screen and/or perforated metal, and/or sheet metal fry baskets which are compatible with use within food support 620 and cooking vessel 606 . With the substitution of water for oil within cooking vessel 606 , these fry baskets may be also adaptable for food steaming as well ( FIG. 9 ).
[0093] Wire basket 630 may support within it, one or more wire basket lids 632 , disposed horizontally flat, or at user directed angles, by resilient wire member 696 , or resilient wire member 698 , disengaging the side walls of wire basket 630 when finger holds 700 are depressed 702 , and by re-engaging wire basket 630 when finger holds 700 are released, as shown in dotted lines in FIGS. 12 and 13 . Using more than one wire basket lids 632 , within wire basket 630 , may allow stacking or layering of similar or dissimilar items, within wire basket 630 .
[0094] Also, two or more wire basket 630 s may be stacked within food support 624 during cooking.
[0095] As a non-limiting and nonexhaustive example, central portions 704 of resilient wire members 696 and 698 may be welded or otherwise fixedly coupled to the upper surface of wire basket 632 .
[0096] Wire basket 630 and wire basket lids 634 and 636 are configured for convenient one hand operation.
Detailed Description—Embodiment 716 —FIGS. 28 Through 34 :
[0097] Referring especially to FIG. 34 , as well as to other figures herein, embodiment 716 , as apparent, shares many construction details with embodiment 601 . Embodiment 716 Is generally comprised of: domed lid 718 , displacement/mounting stand 720 , food support 722 , cooking vessel 726 , and outer enclosure 728 .
[0098] Embodiment 716 may be used, as a nonlimiting and nonexhaustive example, to cook articles using a two-step immersion process, as described in U.S. Pat. No. 8,309,151, claims 1 and 6, FIGS. 142 to 145.
[0099] Generally speaking, and as a nonlimiting and nonexhaustive example, a user cooking an article within embodiment 716 may employ the following steps:
Placing Cooking Vessel 726 within outer enclosure 728 . Mounting control box heat coil 608 . Filling cooking vessel 726 with a predetermined amount of cooking liquid, Activating control box/he coil 608 to heat the cooking liquid. Mounting article to be cooked 730 within food support 722 . As a nonlimiting and nonexhaustive example, if article to be cooked 730 is a fowl, and if the fowl is being mounted in a breast up position, as shown in FIG. 34 , placing displacement/mounting stand 720 within the empty gut cavity of the fowl. and placing the assembly on the floor of food support 722 , causing left food support dynamic side wall 732 , and right food support dynamic side wall 734 to converge 736 toward one another, analogous to transition from FIG. 16 to FIG. 17 . Or, if the fowl is being mounted in a breast down position for the first immersion into the cooking liquid, simply placing the fowl within food support 722 in a breast down position, with or without mounting displacement/mounting stand 720 being inserted into the fowl. Placing domed lid 718 on top of article to be cooked 730 and immersing the assembly, except for domed lid 718 , in the hot cooking liquid long enough for the fowl to be cooked. Removing the fowl from the cooking liquid and inverting it. Placing domed lid 718 on top of article to be cooked 730 , and immersing the fowl back in the cooking liquid long enough for the fowl to be cooked an additional time. Removing the fowl from the cooking liquid and serving it. Again, displacement/mounting stand 720 may be used as a carving stand during serving.
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Reduced cooking liquid usage deep fryers, particularly adapted to cooking fowl, as well as other articles. Cooking liquid storage and filtering apparatus. Heating element structure configured to reduce the overall height of a deep fryer. Food support apparatus which simplify food handling. Cooking vessel configurations configured to reduce cooking liquid usage. Volume displacement members which may reduce cooking liquid usage. Fry basket construction. Food support and containment structures. Cooking liquid overflow safety structures. Passive condensation exhaust filtering. Apparatus allowing the cooking of stuffing and/or other articles, while deep frying a fowl or other articles. Removable dual food support handles. Food support apparatus for deep fryers which deep fry only a portion of unitary food article at one time.
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RELATED APPLICATIONS
This application is a continuation of U.S. Ser. No. 10/691,105 filed Oct. 22, 2003 now abandoned. It is also a continuation-in-part of U.S. Ser. No. 10/895,500 filed Jul. 21, 2004 now U.S. Pat. No. 6,997,490, which claims the priority of U.S. Provisional Ser. No. 60/489,031 filed Jul. 22, 2003.
TECHNICAL FIELD
The present invention relates to the bumper and fascia components of a motor vehicle, more particularly the bumper energy absorber and the upper fascia support components, and more particularly to a load isolator for conjoining, yet load isolating, the bumper energy absorber and the upper fascia support components.
BACKGROUND OF THE INVENTION
Motor vehicles include an energy absorber at the front and rear bumper for purposes of crash energy absorption. Additionally, motor vehicles utilize an upper fascia support in the form of brackets, flanges or braces to support and align attached parts such as head/tail lamps, hood/tailgate/trunk lid bumper pads, etc. with the sheet metal body and frame of the vehicle. The energy absorbers and the upper fascia support members are separate components, requiring separate manufacturing, shipping, material handling, and motor vehicle installation.
Motor vehicle manufacturers have long been faced with the challenge of achieving ever tighter fits between components and attached parts, while ever controlling costs and increasing production efficiency. In this regard, it would be very beneficial if somehow the upper fascia support could provide attachment locations for various attached parts so that they would be precisely located relative to the motor vehicle. Further in this regard, it would also be very beneficial if the energy absorber and the upper fascia support could be integrated, provided the problem of load induced deformations, due to, for example, those arising out of impact or thermal origins, could somehow be overcome.
SUMMARY OF THE INVENTION
The present invention is an integrated upper fascia support member and bumper energy absorber, wherein the upper fascia support member is structured to provide attachments for various attached parts of a motor vehicle, and wherein the upper fascia support member is integrally connected to the bumper energy absorber of the motor vehicle via a load isolator.
The integrated upper fascia support member and bumper energy absorber according to the present invention has a single piece construction, wherein the upper fascia support member is integrally connected to the bumper energy absorber by a load isolator which undergoes deformation in the event a predetermined threshold level of load is applied to either one of the upper fascia support member and the bumper energy absorber relative to the other such as to cause relative movement therebetween. The preferred composition and manufacture of the present invention is a single piece molded polymeric motor vehicle component, preferably formed by an injection molding process.
The preferred motor vehicle locations of the present invention are at the front or rear ends thereof. In this regard, the constituents of the integrated single piece component which constitutes the integrated upper fascia support member and bumper energy absorber according to the present invention serve synergistically, as follows. The bumper energy absorber forms a part of the bumper which is attached to the structure of the motor vehicle. The bumper energy absorber deforms so as to provide crash management by energy absorption of a low speed vehicle impact. The upper fascia support member attaches to the vehicle sheet metal structure and provides support and precise location of (i.e., setting the gap with regard to) various attached parts, as for example hood/tailgate/trunk lid over-slam bumper pads, head/tail lights, front grill, radiator, etc. When placed at the front end of the motor vehicle, the upper fascia support member integrates head light attachment provisions and hood bumper pads so as to achieve a good fit with respect to the hood, fenders and grille. The load isolator provides two functions: 1) connecting the upper fascia support member to the bumper energy absorber in a fixed position relative to each other (assuming relative loading is below a predetermined threshold, and 2) management of a load applied, relatively, to one of the upper fascia support member and the bumper energy absorber such as to cause relative movement therebetween, from adversely affecting the other, as for example, keeping vehicle damage to a minimum in the event of an untoward impact event.
The load isolation is preferably in the form of a plurality of load isolation arms, wherein the load isolation arms may have a certain shape selected from a range of possible shapes, as for example: an S-shape, a V-shape, a U-shape, a semicircular shape, or an irregular shape, as for example a single loop shape or a multiple loop shape. The number, placement, width, thickness and shape of the load isolator arms is predetermined to accommodate a specific vehicular application. Load isolation as between the upper fascia support member and the bumper energy absorber can be accomplished by elastic deformation of the load isolation arms of the load isolator, wherein the deformation may be in the form of bending or bending and breaking of the load isolation arms, as for example during an untoward vehicle impact.
From the foregoing, it will be appreciated that the integrated bumper energy absorber and upper fascia support member according to the present invention provides improved appearance due to a tighter fit of vehicular components and attached parts, yet eliminates the need of separate components and reduces piece cost through tooling savings, manufacturing, shipping, processing and material management. Consequently, the assembly plants manufacturing motor vehicles equipped with the present invention achieve higher quality and improved productivity.
Accordingly, it is an object of the present invention to provide an integrated upper fascia support member and bumper energy absorber, wherein the upper fascia support member is structured to provide support for various attached parts of a motor vehicle, and wherein the universal upper fascia support member is integrally connected to the bumper energy absorber of the motor vehicle via a load isolator.
This and additional objects, features and advantages of the present invention will become clearer from the following specification of a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an integrated upper fascia and bumper energy absorber according to the present invention having an S-shaped load isolator, shown adapted for location at the front end of a motor vehicle.
FIG. 2 is a side view of the integrated upper fascia and bumper energy absorber as shown at FIG. 1 , now shown schematically installed at the front end of a motor vehicle.
FIG. 2A is a side view of the integrated upper fascia and bumper energy absorber according to the present invention, as shown at FIG. 2 , wherein now the bumper energy absorber has suffered an impact and been displaced rearwardly such as to cause deformation of the load isolator.
FIG. 2B is a side view of the integrated upper fascia and bumper energy absorber according to the present invention, as shown at FIG. 2 , wherein now the upper fascia support member has suffered an impact and been displaced rearwardly such as to cause deformation of the load isolator.
FIG. 2C is a side view of the integrated upper fascia and bumper energy absorber according to the present invention, as shown at FIG. 2 , wherein now a load applied to the bumper energy absorber has caused it to move vertically toward the upper fascia support member such as to cause deformation of the load isolator.
FIG. 3A is a side view of the integrated upper fascia and bumper energy absorber according to the present invention having V-shaped load isolator, showing a schematic installation at the front end of a motor vehicle.
FIG. 3B is a side view of the integrated upper fascia and bumper energy absorber according to the present invention, as shown at FIG. 3A , wherein now the bumper energy absorber has suffered an impact and been displaced rearwardly such as to cause deformation of the load isolator.
FIGS. 4A through 4C each show a side view of the integrated upper fascia and bumper energy absorber according to the present invention, showing a schematic installation at the front end of a motor vehicle, wherein the load isolator is, respectively, U-shaped, semicircularly shaped, and irregularly shaped.
FIG. 5 is a perspective view of an integrated upper fascia and bumper energy absorber according to the present invention similar to that shown in FIG. 1 , wherein now an S-shaped load isolator has additional (intermediate and outboard) load isolator arms.
FIG. 6 is a perspective view of an integrated upper fascia and bumper energy absorber according to the present invention having an S-shaped load isolator, shown adapted for location at the rear end of a motor vehicle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the Drawing, FIG. 1 depicts a view of an integrated upper fascia and bumper energy absorber 10 according to the present invention. It will be seen that there is unity of construction, in that the integrated upper fascia and bumper energy absorber 10 is an integrated, integral single piece component having essentially three sections: an upper fascia support member 12 , a bumper energy absorber 14 and a load isolator 16 which integrally connects the upper fascia support member to the bumper energy absorber. The preferred composition and manufacture of the integrated upper fascia and bumper energy absorber 10 is a single piece molded polymeric motor vehicle component, preferably formed by an injection molding process. The integrated upper fascia and bumper energy absorber 10 may be installed on a motor vehicle at either the front end of the vehicle, as shown at FIG. 1 , or rear end of the vehicle, as shown at FIG. 6 .
As shown schematically at FIG. 2 , the bumper energy absorber 14 may be overmolded or otherwise covered by an external bumper 18 , wherein the bumper is attached to a structural member 20 of the motor vehicle. The purpose of the bumper energy absorber is to provide a structure which undergoes deformation in the event of a low speed vehicle impact so as to provide crash management by energy absorption.
As also shown schematically at FIG. 2 , the upper fascia support member 12 attaches to the vehicle sheet metal structure 22 and provides support and precise attachment locations 24 of (i.e., setting the gap with regard to) various attached parts, as for example hood over-slam bumper pads attachment locations 24 a , head light attachment locations 24 b , front grill attachment locations 24 c and radiator bracket attachment locations 24 d . When placed at the front end of the motor vehicle (as shown at FIG. 2 ), the upper fascia support member integrates the attachment locations 24 so as to achieve a good fit with respect to the hood, fenders and grille.
The load isolator 16 is structured so that, in the uninstalled state, it will keep the upper fascia support member in a fixed position relative to the bumper energy absorber provided a load above a predetermined threshold is not applied, relatively, to one or the other. Upon installation in a motor vehicle, the load isolator 16 will deform by bending or by bending and breaking in the event a load sufficient to move the upper fascia support member relative to the bumper energy absorber occurs in an axial direction X, a vertical direction V, or a direction which is some combination thereof. It is preferred in this regard for the load isolator 16 to be in the form of a plurality of load isolator arms, as for example a pair of outboard load isolator arms 16 a , 16 b , as shown at FIG. 1 , or as for another non-limiting example a pair of outboard load isolator arms 16 a ′, 16 b ′ in association with a pair of inboard isolation arms 16 c , 16 d , which are differently configured from the outboard load isolator arms, as shown at FIG. 5 .
Each of the upper fascia support member 12 , bumper energy absorber 14 and load isolator 16 may be composed of different material even though they are integrally joined together as a single piece component. In the event the load isolator 16 is composed of the same material as that of the upper fascia support member 12 (which is generally rigid due to its selected thickness), and the bumper energy absorber 14 (which is configured so as to absorb crash energy as it deforms for impacts above a certain predetermined crash load threshold), because of the selected number, selected relative spacing, selected shape, selected width and selected thickness of the load isolator arms, they deform when a load is applied such that the upper fascia support member 12 or the bumper energy absorber 14 is moved out of original position with respect to the other, as could happen in an impact event or unequal vehicular component expansions of a thermal origin. Examples of relative movements are shown in FIGS. 2A through 3B .
In FIG. 2A , the bumper energy absorber has been impacted so as to push it rearward relative to its original position, indicated by plane A in FIG. 2 , with respect to the upper fascia support member. In this regard, an S-shaped load isolator 16 has deformably stretched to accommodate this relative movement. In FIG. 2B , the upper fascia support member 12 has been impacted so as to push it rearward relative to its original position at plane A with respect to the bumper energy absorber 14 . In this regard, the S-shaped load isolator 16 has deformably stretched in an opposite direction from that of FIG. 2A in order to accommodate this relative movement. In FIG. 2C , the bumper energy absorber 14 has been subjected to a load which has moved it vertically out of its original installation position toward the upper fascia support member 12 , wherein the S-shaped load isolator 16 has compressibly deformed to accommodate this relative movement. It is clear from the foregoing that a vertical separation increase between the upper fascia support member and the bumper energy absorber would result in a deformable stretching of the load isolator.
In FIG. 3B , the bumper energy absorber 14 has been impacted so as to push it rearward relative to its original position, indicated by plane A′ in FIG. 3A with respect to the upper fascia support member 12 . In this regard, a V-shaped load isolator 16 has deformably stretched, and then deformably broken, to accommodate this relative movement.
For comparative purposes, FIG. 4A depicts the integrated upper fascia and bumper energy absorber 10 shown schematically installed at the front end of a motor vehicle, wherein the load isolator 16 is U-shaped; FIG. 4B depicts the integrated upper fascia and bumper energy absorber 10 shown schematically installed at the front end of a motor vehicle, wherein the load isolator 16 is semicircularly shaped; and FIG. 4C depicts the integrated upper fascia and bumper energy absorber 10 shown schematically installed at the front end of a motor vehicle, wherein the load isolator 16 is irregularly shaped.
Now referring to FIGS. 1 , 5 and 6 , it will be understood that the number, placement, width, thickness and shape of the load isolator arms is predetermined to accommodate a specific vehicular application, as for example the front or rear of a vehicle, or whether the vehicle is a truck or passenger car.
Form the foregoing, it is clear that the integrated bumper energy absorber and upper fascia support member 10 provides improved appearance due to a tighter fit of vehicular components and attached parts, yet eliminates the need of separate components and reduces piece cost through tooling savings, manufacturing, shipping, processing and material management. Consequently, the assembly plants manufacturing motor vehicles equipped with the present invention achieve higher quality and improved productivity.
Some notable aspects of the present invention are: the load isolator can be uniform or can differently structured by location; the load isolator material can be the same as the bumper energy absorber material or can be a different material; the load isolator can run continually between the upper fascia support member or can be arranged discretely in the form of load isolator arms; the load isolator arms may have the same shape thickness and width, or may be different; any load (i.e., of thermal or impact origin) is isolated by the load isolator between the upper fascia support member and the bumper energy absorber, yet the load isolator provides connection and relative positional orientation between the upper fascia support member and the bumper energy absorber during processing, assembling, shipping, and installing in a motor vehicle; and the upper fascia support member may carry the bumper pads required to achieve a desired hood over-slam.
To those skilled in the art to which this invention appertains, the above described preferred embodiment may be subject to change or modification. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims.
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An integrated, single piece upper fascia support member and bumper energy absorber, wherein the upper fascia support member is structured to provide attachments for various attached parts of a motor vehicle, and wherein the upper fascia support member is integrally connected to the bumper energy absorber of the motor vehicle via a load isolator. The load isolator connects the upper fascia support member to the bumper energy absorber in a fixed position relative to each other (assuming relative loading is below a predetermined threshold) and manages a load applied, relatively, to one of the upper fascia support member and the bumper energy absorber such as to cause relative movement, from adversely affecting the other, as, for example, keeping vehicle damage to a minimum in the event of an untoward impact event.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 11/298,324, filed Dec. 8, 2005, which is a continuation of U.S. patent application Ser. No. 10/622,320, filed Jul. 17, 2003, now U.S. Pat. No. 7,205,305, which is a continuation of U.S. patent application Ser. No. 09/336,266, filed Jun. 18, 1999, now U.S. Pat. No. 6,608,060, which is a continuation of International Application No. PCT/US97/23392, filed Dec. 17, 1997, which is a continuation-in-part of U.S. patent application Ser. No. 08/862,925, filed Jun. 10, 1997, now U.S. Pat. No. 6,147,080, which is a continuation-in-part of U.S. patent application Ser. No. 08/822,373, filed Mar. 20, 1997, now U.S. Pat. No. 5,945,418, which claims the benefit of U.S. Provisional Application No. 60/034,288, filed Dec. 18, 1996, now abandoned, the disclosures of which are each incorporated herein by reference in their entireties.
TECHNICAL FIELD OF INVENTION
The present invention relates to inhibitors of p38, a mammalian protein kinase involved cell proliferation, cell death and response to extracellular stimuli. The invention also relates to methods for producing these inhibitors. The invention also provides pharmaceutical compositions comprising the inhibitors of the invention and methods of utilizing those compositions in the treatment and prevention of various disorders.
BACKGROUND OF THE INVENTION
Protein kinases are involved in various cellular responses to extracellular signals. Recently, a family of mitogen-activated protein kinases (MAPK) have been discovered. Members of this family are Ser/Thr kinases that activate their substrates by phosphorylation [B. Stein et al., Ann. Rep. Med. Chem., 31, pp. 289-98 (1996)]. MAPKs are themselves activated by a variety of signals including growth factors, cytokines, UV radiation, and stress-inducing agents.
One particularly interesting MAPK is p38. p38, also known as cytokine suppressive anti-inflammatory drug binding protein (CSBP) and RK, was isolated from murine pre-B cells that were transfected with the lipopolysaccharide (LPS) receptor CD14 and induced with LPS. p38 has since been isolated and sequenced, as has the cDNA encoding it in humans and mouse. Activation of p38 has been observed in cells stimulated by stresses, such as treatment of lipopolysaccharides (LPS), UV, anisomycin, or osmotic shock, and by cytokines, such as IL-1 and TNF.
Inhibition of p38 kinase leads to a blockade on the production of both IL-1 and TNF. IL-1 and TNF stimulate the production of other proinflammatory cytokines such as IL-6 and IL-8 and have been implicated in acute and chronic inflammatory diseases and in post-menopausal osteoporosis [R. B. Kimble et al., Endocrinol., 136, pp. 3054-61 (1995)].
Based upon this finding it is believed that p38, along with other MAPKs, have a role in mediating cellular response to inflammatory stimuli, such as leukocyte accumulation, macrophage/monocyte activation, tissue resorption, fever, acute phase responses and neutrophilia. In addition, MAPKs, such as p38, have been implicated in cancer, thrombin-induced platelet aggregation, immunodeficiency disorders, autoimmune diseases, cell death, allergies, osteoporosis and neurodegenerative disorders. Inhibitors of p38 have also been implicated in the area of pain management through inhibition of prostaglandin endoperoxide synthase-2 induction. Other diseases associated with IL-1, IL-6, IL-8 or TNF overproduction are set forth in WO 96/21654.
Others have already begun trying to develop drugs that specifically inhibit MAPKs. For example, PCT publication WO 95/31451 describes pyrazole compounds that inhibit MAPKs, and in particular p38. However, the efficacy of these inhibitors in vivo is still being investigated.
Accordingly, there is still a great need to develop other potent, p38-specific inhibitors that are useful in treating various conditions associated with p38 activation.
SUMMARY OF THE INVENTION
The present invention solves this problem by providing compounds which demonstrate strong and specific inhibition of p38.
These compounds have the general formula:
wherein each of Q 1 , and Q 2 are independently selected from 5-6 membered aromatic carbocyclic or heterocyclic ring systems, or 8-10 membered bicyclic ring systems comprising aromatic carbocyclic rings, aromatic heterocyclic rings or a combination of an aromatic carbocyclic ring and an aromatic heterocyclic ring.
The rings that make up Q 1 are substituted with 1 to 4 substituents, each of which is independently selected from halo; C 1 -C 3 alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; O—(C 1 -C 3 ) -alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; CN; N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
The rings that make up Q 2 are optionally substituted with up to 4 substituents, each of which is independently selected from halo; C 1 -C 3 straight or branched alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; O—(C 1 -C 3 )-alkyl; O—(C 1 -C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR 2 ; NR 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; R 3 ; OR 3 ; NHR 3 ; SR 3 ; C(O)R 3 ; C(O)N(R′)R 3 ; C(O)OR 3 ; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; N═CH—N(R′) 2 ; or CN.
R′ is selected from hydrogen, (C 1 -C 3 )-alkyl; (C 2 -C 3 )-alkenyl or alkynyl; phenyl or phenyl substituted with 1 to 3 substituents independently selected from halo, methoxy, cyano, nitro, amino, hydroxy, methyl or ethyl.
R 3 is selected from 5-6 membered aromatic carbocyclic or heterocyclic ring systems.
R 4 is (C 1 -C 4 )-alkyl optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 ; or a 5-6 membered carbocyclic or heterocyclic ring system optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 .
X is selected from —S—, —O—, —S(O 2 )—, —S(O)—, —S(O 2 )—N(R 2 )—, —N(R 2 )—S(O 2 )—, —N(R 2 )—C(O)O—, —O—C(O)—N(R 2 ), —C(O)—, —C(O)O—, —O—C(O)—, —C(O)—N(R 2 )—, —N(R 2 )—C(O)—, —N(R 2 )—, —C(R 2 ) 2 —, or —C(OR 2 ) 2 —.
Each R is independently selected from hydrogen, —R 2 , —N(R 2 ) 2 , —OR 2 , SR 2 , —C(O)—N(R 2 ) 2 , —S(O 2 )—N(R 2 ) 2 , or —C(O)—OR 2 , wherein two adjacent R are optionally bound to one another and, together with each Y to which they are respectively bound, form a 4-8 membered carbocyclic or heterocyclic ring;
R 2 is selected from hydrogen, (C 1 -C 3 )-alkyl, or (C 2 -C 3 )-alkenyl; each optionally substituted with —N(R′) 2 , —OR′, SR′, —C(O)—N(R′) 2 , —S(O 2 )—N(R′) 2 , —C(O)—OR′, or R 3 .
Y is N or C;
A, if present, is N or CR′;
n is 0 or 1;
R 1 is selected from hydrogen, (C 1 -C 3 )-alkyl, OH, or O—(C 1 -C 3 )-alkyl.
In another embodiment, the invention provides pharmaceutical compositions comprising the p38 inhibitors of this invention. These compositions may be utilized in methods for treating or preventing a variety of disorders, such as cancer, inflammatory diseases, autoimmune diseases, destructive bone disorders, proliferative disorders, infectious diseases, viral diseases and neurodegenerative diseases. These compositions are also useful in methods for preventing cell death and hyperplasia and therefore may be used to treat or prevent reperfusion/ischemia in stroke, heart attacks, organ hypoxia. The compositions are also useful in methods for preventing thrombin-induced platelet aggregation. Each of these above-described methods is also part of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides inhibitors of p38 having the general formula:
wherein each of Q 1 , and Q 2 are independently selected from 5-6 membered aromatic carbocyclic or heterocyclic ring systems, or 8-10 membered bicyclic ring systems comprising aromatic carbocyclic rings, aromatic heterocyclic rings or a combination of an aromatic carbocyclic ring and an aromatic heterocyclic ring.
The rings that make up Q 1 are substituted with 1 to 4 substituents, each of which is independently selected from halo; C 1 -C 3 alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; O—(C 1 -C 3 ) -alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; CN; N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
The rings that make up Q 2 are optionally substituted with up to 4 substituents, each of which is independently selected from halo; C 1 -C 3 straight or branched alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; O—(C 1 -C 3 )-alkyl; O—(C 1 -C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; R 3 ; OR 3 ; NHR 3 ; SR 3 ; C(O)R 3 ; C(O)N(R′)R 3 ; C(O)OR 3 ; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; N═CH—N(R′) 2 ; or CN.
R′ is selected from hydrogen, (C 1 -C 3 )-alkyl; (C 2 -C 3 )-alkenyl or alkynyl; phenyl or phenyl substituted with 1 to 3 substituents independently selected from halo, methoxy, cyano, nitro, amino, hydroxy, methyl or ethyl.
R 3 is selected from 5-6 membered aromatic carbocyclic or heterocyclic ring systems.
R 4 is (C 1 -C 4 )-alkyl optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 ; or a 5-6 membered carbocyclic or heterocyclic ring system optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 .
X is selected from —S—, —O—, —S(O 2 )—, —S(O)—, —S(O 2 )—N(R 2 )—, —N(R 2 )—S(O 2 )—, —N(R 2 )—C(O)O—, —O—C(O)—N(R 2 ), —C(O)—, —C(O)O—, —O—C(O)—, —C(O)—N(R 2 )—, —N(R 2 )—C(O)—, —N(R 2 )—, —C(R 2 ) 2 —, or —C(OR 2 ) 2 —.
Each R is independently selected from hydrogen, —R 2 , —N(R 2 ) 2 , —OR 2 , SR 2 , —C(O)—N(R 2 ) 2 , —S(O 2 )—N(R 2 ) 2 , or —C(O)—OR 2 , wherein two adjacent R are optionally bound to one another and, together with each Y to which they are respectively bound, form a 4-8 membered carbocyclic or heterocyclic ring;
When the two R components form a ring together with the Y components to which they are respectively bound, it will obvious to those skilled in the art that a terminal hydrogen from each unfused R component will be lost. For example, if a ring structure is formed by binding those two R components together, one being —NH—CH 3 and the other being —CH 2 —CH 3 , one terminal hydrogen on each R component (indicated in bold) will be lost. Therefore, the resulting portion of the ring structure will have the formula —NH—CH 2 —CH 2 —CH 2 —.
R 2 is selected from hydrogen, (C 1 -C 3 )-alkyl, or (C 2 -C 3 )-alkenyl; each optionally substituted with —N(R′) 2 , —OR′, SR′, —C(O)—N(R′) 2 , —S(O 2 )—N(R′) 2 , —C(O)—OR′, or R 3 .
Y is N or C;
A, if present, is N or CR′;
n is 0 or 1;
R 1 is selected from hydrogen, (C 1 -C 3 )-alkyl, OH, or O—(C 1 -C 3 )-alkyl. It will be apparent to those of skill in the art that if R 1 is OH, the resulting inhibitor may tautomerize resulting in compounds of the formula:
which are also p38 inhibitors of this invention.
According to another preferred embodiment, Q 1 is selected from phenyl or pyridyl containing 1 to 3 substituents, wherein at least one of said substituents is in the ortho position and said substituents are independently selected from chloro, fluoro, bromo, —CH 3 , —OCH 3 , —OH, —CF 3 , —OCF 3 , —O(CH 2 ) 2 CH 3 , NH 2 , 3,4-methylenedioxy, —N(CH 3 ) 2 , —NH—S(O) 2 -phenyl, —NH—C(O)O—CH 2 -4-pyridine, —NH—C(O)CH 2 -morpholine, —NH—C(O)CH 2 —N(CH 3 ) 2 , —NH—C(O)CH 2 -piperazine, —NH—C(O)CH 2 -pyrrolidine, —NH—C(O)C(O)-morpholine, —NH—C(O)C(O)-piperazine, —NH—C(O)C(O)-pyrrolidine, —O—C(O)CH 2 —N(CH 3 ) 2 , or —O— (CH 2 ) 2 —N(CH 3 ) 2 .
Even more preferred are phenyl or pyridyl containing at least 2 of the above-indicated substituents both being in the ortho position.
Some specific examples of preferred Q 1 are:
Most preferably, Q 1 is selected from 2-fluoro-6-trifluoromethylphenyl, 2,6-difluorophenyl, 2,6-dichlorophenyl, 2-chloro-4-hydroxyphenyl, 2-chloro-4-aminophenyl, 2,6-dichloro-4-aminophenyl, 2,6-dichloro-3-aminophenyl, 2,6-dimethyl-4-hydroxyphenyl, 2-methoxy-3,5-dichloro-4-pyridyl, 2-chloro-4,5 methylenedioxy phenyl, or 2-chloro-4-(N-2-morpholino-acetamido)phenyl.
According to a preferred embodiment, Q 2 is phenyl or pyridyl containing 0 to 3 substituents, wherein each substituent is independently selected from chloro, fluoro, bromo, methyl, ethyl, isopropyl, —OCH 3 , —OH, —NH 2 , —CF 3 , —OCF 3 , —SCH 3 , —C(O)OH, —C(O)OCH 3 , —CH 2 NH 2 , —N(CH 3 ) 2 , —CH 2 -pyrrolidine and —CH 2 OH.
Some specific examples of preferred Q 2 are:
unsubstituted 2-pyridyl or unsubstituted phenyl.
Most preferred are compounds wherein Q 2 is selected from phenyl, 2-isopropylphenyl, 3,4-dimethylphenyl, 2-ethylphenyl, 3-fluorophenyl, 2-methylphenyl, 3-chloro-4-fluorophenyl, 3-chlorophenyl, 2-carbomethoxylphenyl, 2-carboxyphenyl, 2-methyl-4-chlorophenyl, 2-bromophenyl, 2-pyridyl, 2-methylenehydroxyphenyl, 4-fluorophenyl, 2-methyl-4-fluorophenyl, 2-chloro-4-fluorphenyl, 2,4-difluorophenyl, 2-hydroxy-4-fluorphenyl or 2-methylenehydroxy-4-fluorophenyl.
According to yet another preferred embodiment,
X is —S—, —O—, —S(O 2 )—, —S(O)—, —NR—, —C(R 2 )— or —C(O)—. Most preferably, X is S.
According to another preferred embodiment, n is 1 and A is N.
According to another preferred embodiment, each Y is C.
According an even more preferred embodiment,
each Y is C and the R attached to those Y components is selected from hydrogen or methyl.
Some specific inhibitors of this invention are set forth in the table below.
TABLE 1
Formula Ia and Ib Compounds.
cpd
#
structure
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
According to another embodiment, the present invention provides methods of producing inhibitors of p38 of the formula (Ia) depicted above. These methods involve reacting a compound of formula II:
wherein each of the variables in the above formula are the same as defined above for the inhibitors of this invention, with a leaving group reagent of formula IIa:
wherein R′ is as defined above, or a leaving group reagent of formula IIb:
wherein each of L 1 , L 2 , and L 3 independently represents a leaving group.
The leaving group reagent used in this reaction is added in excess, either neat or with a co-solvent, such as toluene. The reaction is carried out at a temperature of between 25° C. and 150° C.
Leaving group reagents of formula IIa that are useful in producing the p38 inhibitors of this invention include dimethylformamide dimethylacetal, dimethylacetamide dimethylacetal, trimethyl orthoformate, dimethylformamide diethylacetal and other related reagents. Preferably the leaving group reagent of formula IIa used to produce the inhibitors of this invention is dimethylformamide dimethylacetal.
Leaving group reagents of formula IIb that are useful in producing the p38 inhibitors of this invention include phosgene, carbonyldiimidazole, diethyl carbonate and triphosgene.
More preferred methods of producing the compounds of this invention utilize compounds of formula II wherein each of the variables are defined in terms of the more preferred and most preferred choices as set forth above for the compounds of this invention.
Because the source of R 1 is the leaving group reagent (C—R′ or C═O), its identity is, of course, dependent on the structure of that reagent. Therefore, in compounds where R 1 is OH, the reagent used must be IIb. Similarly, when R 1 is H or (C 1 -C 3 )-alkyl, the reagent used must be IIa. In order to generate inhibitors wherein R′ is O—(C 1 -C 3 )-alkyl, a compound wherein R 1 is OH is first generated, followed by alkylation of that hydroxy by standard techniques, such as treatment with Na hydride in DMF, methyl iodide and ethyl iodide.
The immediate precursors to the inhibitors of this invention of formula Ia (i.e., compounds of Formula II) may themselves be synthesized by either of the synthesis schemes depicted below:
In Scheme 1, the order of steps 1) and 2) can be reversed. Also, the starting nitrile may be replaced by a corresponding acid or by an ester. Alternatively, other well-known latent carboxyl or carboxamide moieties may be used in place of the nitrile (see scheme 2). Variations such as carboxylic acids, carboxylic esters, oxazolines or oxizolidinones may be incorporated into this scheme by utilizing subsequent deprotection and functionalization methods which are well known in the art
The base used in the first step of Scheme 1 (and in Scheme 2, below) is selected from sodium hydride, sodium amide, LDA, lithium hexamethyldisilazide, sodium hexamethyldisilazide or any number of other non-nucleophilic bases that will deprotonate the position alpha to the nitrile.
Also, the addition of HX-Q 2 in the single step depicted above may be substituted by two steps—the addition of a protected or unprotected X derivative followed by the addition of a Q 2 derivative in a subsequent step.
In Scheme 2, Z is selected from COOH, COOR′, CON(R′) 2 , oxazoline, oxazolidinone or CN. R′ is as defined above.
According to another embodiment, the present invention provides methods of producing inhibitors of p38 of the formula (Ib) depicted above. These methods involve reacting a compound of formula III:
wherein each of the variables in the above formula are the same as defined above for the inhibitors of this invention, with a leaving group reagent of formula:
as described above.
Two full synthesis schemes for the p38 inhibitors of formula (Ib) of this invention are depicted below.
In scheme 3, a Q 1 , substituted derivative may be treated with a base such as sodium hydride, sodium amide, LDA, lithium hexamethyldisilazide, sodium hexamethyldisilazide or any number of other non-nucleophilic bases to deprotonate the position alpha to the Z group, which represents a masked amide moiety. Alternatively, Z is a carboxylic acid, carboxylic ester, oxazoline or oxazolidinone. The anion resulting from deprotonation is then contacted with a nitrogen bearing heterocyclic compound which contains two leaving groups, or latent leaving groups, in the presence of a Palladium catalyst. One example of such compound may be 2,6-dichloropyridine.
In step two, the Q 2 ring moiety is introduced. This may be performed utilizing many reactions well known in the art which result in the production of biaryl compounds. One example may be the reaction of an aryl lithium compound with the pyridine intermediate produced in step 1. Alternatively, an arylmetallic compound such as an aryl stannane or an aryl boronic acid may be reacted with the aryl halide portion of the pyridine intermediate in the presence of a Pd o catalyst.
In step 3 the Z group is deprotected and/or functionalized to form the amide compound. When Z is a carboxylic acid, carboxylic ester, oxazoline or oxazolidinone, variations in deprotection and functionalization methods which are well known in the art are employed to produce the amide. Finally in step 4, the amide compound is cyclized to the final product utilizing reagents such as DMF acetal or similar reagents either neat or in an organic solvent.
Scheme 4 is similar except that the a biaryl intermediate is first generated prior to reaction with the Q1 starting material.
According to another embodiment, the invention provides inhibitors of p38 similar to those of formulae Ia and Ib above, but wherein the C═N in the ring bearing the Q 1 substituent is reduced. These inhibitors have the formula:
wherein A, Q 1 , Q 2 , R′, R′, X, Y and n are defined in the same manner as set forth for compounds of formulae Ia and Ib. These definitions hold for all embodiments of each of these variables (i.e., basic, preferred, more preferred and most preferred). R 5 is selected from hydrogen, —CR′ 2 OH, —C(O)R 4 , —C(O)OR 4 , —CR′ 2 OPO 3 H 2 , and salts of —PO 3 H 2 .
When R 5 is not hydrogen, the resulting compounds are expected to be prodrug forms which should be cleaved in vivo to produce a compound wherein R 5 is hydrogen.
According to other preferred embodiments, in compounds of formula Ic, A is preferably nitrogen, n is preferably 1, and X is preferably sulfur. In compounds of formula Ic or Id, Q 1 and Q 2 are preferably the same moieties indicated above for those variables in compounds of formulae Ia and Ib.
Compounds of formulae Ic and Id may be prepared directly from compounds of formulae Ia or Ib which contain a hydrogen, C 1 -C 3 alkyl or C 2 -C 3 alkenyl or alkynyl at the R 1 position (e.g., where R 1 =R′). The synthesis schemes for these compounds is depicted in Schemes 5 and 6, below.
In these schemes, compounds of formula Ia or Ib are reduced by reaction with an excess of diisobutylaluminum hydride, or equivalent reagent to yield the ring reduced compounds of formula Ic or Id, respectively.
The addition of an R 5 component other than hydrogen onto the ring nitrogen is achieved by reacting the formula Ic or Id compounds indicated above with the appropriate reagent(s). Examples of such modifications are provided in the Example section below.
Some specific inhibitors of this invention of formula Ic are set forth in the table below.
TABLE 2
Formula Ic Compounds.
cpd
#
structure
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
According to yet another embodiment, the invention provides p38 inhibitors of the formulae:
wherein A, Q 1 , Q 2 , R′, X, Y and n are defined in the same manner as set forth for compounds of formulae Ia and Ib. These definitions hold for all embodiments of each of these variables (i.e., basic, preferred, more preferred and most preferred). More preferably, in compounds of formula Ie, Q 2 is unsubstituted phenyl.
Q 3 is a 5-6 membered aromatic carbocyclic or heterocyclic ring system, or an 8-10 membered bicyclic ring system comprising aromatic carbocyclic rings, aromatic heterocyclic rings or a combination of an aromatic carbocyclic ring and an aromatic heterocyclic ring. The rings of Q 3 are substituted with 1 to 4 substituents, each of which is independently selected from halo; C 1 -C 3 alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; O—(C 1 -C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; CN; N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
According to one preferred embodiment, Q 3 is substituted with 2 to 4 substituents, wherein at least one of said substituents is present in the ortho position relative to the point of attachment of Q 3 to the rest of the inhibitor. When Q 3 is a bicyclic ring, the 2 substituents in the ortho position are present on the ring that is closest (i.e., directly attached) to the rest of the inhibitor molecule. The other two optional substituents may be present on either ring. More preferably, both such ortho positions are occupied by one of said substituents.
According to another preferred embodiment, Q 3 is a monocyclic carbocyclic ring, wherein each ortho substituent is independently selected from halo or methyl. According to another preferred embodiment, Q 3 contains 1 or 2 additional substituents independently selected from NR′ 2 , OR′, CO 2 R′CN, N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
Preferably, Q 3 is selected from any of the Q 3 moieties present in the Ie compounds set forth in Table 3, below, or from any of the Q 3 moieties present in the Ig compounds set forth in Table 4, below.
Those of skill will recognize compounds of formula Ie as being the direct precursors to certain of the formula Ia and formula Ic p38 inhibitors of this invention (i.e., those wherein Q 1 =Q 3 ). Those of skill will also recognize that compounds of formula Ig are precursors to certain of the formula Ib and Id p38 inhibitors of this invention (i.e., those wherein Q 1 =Q 3 ). Accordingly, the synthesis of formula Ie inhibitors is depicted above in Schemes 1 and 2, wherein Q 1 is replaced by Q 3 . Similarly, the synthesis of formula Ig inhibitors is depicted above in Schemes 3 and 4, wherein Q 1 is replaced by Q 3 .
The synthesis of formula If and formula Ih inhibitors is depicted below in Schemes 7 and 8.
Scheme 8 depicts the synthesis of compounds of type Ih. For example, treating an initial dibromo derivative, such as 2,6 dibromopyridine, with an amine in the presence of a base such as sodium hydride yields the 2-amino-6-bromo derivative. Treatment of this intermediate with a phenylboronic acid analog (a Q2-boronic acid) such as phenyl boronic acid in the presence of a palladium catalyst gives the disubstituted derivative which can then be acylated to the final product. The order of the first two steps of this synthesis may be reversed.
Without being bound by theory, applicants believe that the diortho substitution in the Q 3 ring of formula Ie and Ig inhibitors and the presence of a nitrogen directly attached to the Q 1 ring in formula If and Ih inhibitors causes a “flattening” of the compound that allows it to effectively inhibit p38.
A preferred formula Ie inhibitor of this invention is one wherein A is carbon, n is 1, X is sulfur, each Y is carbon, each R is hydrogen, Q 3 is 2,6-dichlorophenyl and Q 2 is phenyl, said compound being referred to as compound 201. A preferred formula Ig inhibitor of this invention is one wherein Q 3 is 2,6-dichlorophenyl, Q 2 is phenyl, each Y is carbon and each R is hydrogen. This compound is referred to herein as compound 202. Other preferred formula Ig compounds of this invention are those listed in Table 4, below.
Preferred Ih compounds of this invention are those depicted in Table 5, below. Other preferred Ih compounds are those wherein Q 1 is phenyl independently substituted at the 2 and 6 positions by chloro or fluoro; each Y is carbon; each R is hydrogen; and Q 2 is 2-methylphenyl, 4-fluorophenyl, 2,4-difluorophenyl, 2-methylenehydroxy-4-fluorophenyl, or 2-methyl-4-fluorophenyl.
Some specific inhibitors of formulae Ie, Ig and Ih are depicted in the tables below.
TABLE 3
Formula Ie Inhibitors.
cmpd
#
structure
201
203
204
205
206
207
208
209
TABLE 4
Formula Ig Inhibitors.
cpd
#
structure
202/ 301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
1301
TABLE 5
Compound Ih Inhibitors.
cpd
#
structure
401
402
403
404
405
406
407
408
409
410
411
412
The activity of the p38 inhibitors of this invention may be assayed by in vitro, in vivo or in a cell line. In vitro assays include assays that determine inhibition of either the kinase activity or ATPase activity of activated p38. Alternate in vitro assays quantitate the ability of the inhibitor to bind to p38 and may be measured either by radiolabelling the inhibitor prior to binding, isolating the inhibitor/p38 complex and determining the amount of radiolabel bound, or by running a competition experiment where new inhibitors are incubated with p38 bound to known radioligands.
Cell culture assays of the inhibitory effect of the compounds of this invention may determine the amounts of TNF, IL-1, IL-6 or IL-8 produced in whole blood or cell fractions thereof in cells treated with inhibitor as compared to cells treated with negative controls. Level of these cytokines may be determined through the use of commercially available ELISAs.
An in vivo assay useful for determining the inhibitory activity of the p38 inhibitors of this invention is the suppression of hind paw edema in rats with Mycobacterium butyricum -induced adjuvant arthritis. This is described in J. C. Boehm et al., J. Med. Chem., 39, pp. 3929-37 (1996), the disclosure of which is herein incorporated by reference. The p38 inhibitors of this invention may also be assayed in animal models of arthritis, bone resorption, endotoxin shock and immune function, as described in A. M. Badger et al., J. Pharmacol. Experimental Therapeutics, 279, pp. 1453-61 (1996), the disclosure of which is herein incorporated by reference.
The p38 inhibitors or pharmaceutical salts thereof may be formulated into pharmaceutical compositions for administration to animals or humans. These pharmaceutical compositions, which comprise and amount of p38 inhibitor effective to treat or prevent a p38-mediated condition and a pharmaceutically acceptable carrier, are another embodiment of the present invention.
The term “p38-mediated condition”, as used herein means any disease or other deleterious condition in which p38 is known to play a role. This includes, conditions which are known to be caused by IL-1, TNF, IL-6 or IL-8 overproduction. Such conditions include, without limitation, inflammatory diseases, autoimmune diseases, destructive bone disorders, proliferative disorders, infectious diseases, neurodegenerative diseases, allergies, reperfusion/ischemia in stroke, heart attacks, angiogenic disorders, organ hypoxia, vascular hyperplasia, cardiac hypertrophy, thrombin-induced platelet aggregation, and conditions associated with prostaglandin endoperoxide synthase-2.
Inflammatory diseases which may be treated or prevented include, but are not limited to acute pancreatitis, chronic pancreatitis, asthma, allergies, and adult respiratory distress syndrome. Autoimmune diseases which may be treated or prevented include, but are not limited to, glomerulonephritis, rheumatoid arthritis, systemic lupus erythematosus, scleroderma, chronic thyroiditis, Graves' disease, autoimmune gastritis, diabetes, autoimmune hemolytic anemia, autoimmune neutropenia, thrombocytopenia, atopic dermatitis, chronic active hepatitis, myasthenia gravis, multiple sclerosis, inflammatory bowel disease, ulcerative colitis, Crohn's disease, psoriasis, or graft vs. host disease.
Destructive bone disorders which may be treated or prevented include, but are not limited to, osteoporosis, osteoarthritis and multiple myeloma-related bone disorder.
Proliferative diseases which may be treated or prevented include, but are not limited to, acute myelogenous leukemia, chronic myelogenous leukemia, metastatic melanoma, Kaposi's sarcoma, and multiple myeloma.
Angiogenic disorders which may be treated or prevented include solid tumors, ocular neovasculization, infantile haemangiomas.
Infectious diseases which may be treated or prevented include, but are not limited to, sepsis, septic shock, and Shigellosis.
Viral diseases which may be treated or prevented include, but are not limited to, acute hepatitis infection (including hepatitis A, hepatitis B and hepatitis C), HIV infection and CMV retinitis.
Neurodegenerative diseases which may be treated or prevented by the compounds of this invention include, but are not limited to, Alzheimer's disease, Parkinson's disease, cerebral ischemias or neurodegenerative disease caused by traumatic injury.
“p38-mediated conditions” also include ischemia/reperfusion in stroke, heart attacks, myocardial ischemia, organ hypoxia, vascular hyperplasia, cardiac hypertrophy, and thrombin-induced platelet aggregation.
In addition, p38 inhibitors in this invention are also capable of inhibiting the expression of inducible pro-inflammatory proteins such as prostaglandin endoperoxide synthase-2 (PGHS-2), also referred to as cyclooxygenase-2 (COX-2). Therefore, other “p38-mediated conditions” are edema, analgesia, fever and pain, such as neuromuscular pain, headache, cancer pain, dental pain and arthritis pain.
The diseases that may be treated or prevented by the p38 inhibitors of this invention may also be conveniently grouped by the cytokine (IL-1, TNF, IL-6, IL-8) that is believed to be responsible for the disease.
Thus, an IL-1-mediated disease or condition includes rheumatoid arthritis, osteoarthritis, stroke, endotoxemia and/or toxic shock syndrome, inflammatory reaction induced by endotoxin, inflammatory bowel disease, tuberculosis, atherosclerosis, muscle degeneration, cachexia, psoriatic arthritis, Reiter's syndrome, gout, traumatic arthritis, rubella arthritis, acute synovitis, diabetes, pancreatic β-cell disease and Alzheimer's disease.
TNF-mediated disease or condition includes, rheumatoid arthritis, rheumatoid spondylitis, osteoarthritis, gouty arthritis and other arthritic conditions, sepsis, septic shock, endotoxic shock, gram negative sepsis, toxic shock syndrome, adult respiratory distress syndrome, cerebral malaria, chronic pulmonary inflammatory disease, silicosis, pulmonary sarcoisosis, bone resorption diseases, reperfusion injury, graft vs. host reaction, allograft rejections, fever and myalgias due to infection, cachexia secondary to infection, AIDS, ARC or malignancy, keloid formation, scar tissue formation, Crohn's disease, ulcerative colitis or pyresis. TNF-mediated diseases also include viral infections, such as HIV, CMV, influenza and herpes; and veterinary viral infections, such as lentivirus infections, including, but not limited to equine infectious anemia virus, caprine arthritis virus, visna virus or maedi virus; or retrovirus infections, including feline immunodeficiency virus, bovine immunodeficiency virus, or canine immunodeficiency virus.
IL-8 mediated disease or condition includes diseases characterized by massive neutrophil infiltration, such as psoriasis, inflammatory bowel disease, asthma, cardiac and renal reperfusion injury, adult respiratory distress syndrome, thrombosis and glomerulonephritis.
In addition, the compounds of this invention may be used topically to treat or prevent conditions caused or exacerbated by IL-1 or TNF. Such conditions include inflamed joints, eczema, psoriasis, inflammatory skin conditions such as sunburn, inflammatory eye conditions such as conjunctivitis, pyresis, pain and other conditions associated with inflammation.
In addition to the compounds of this invention, pharmaceutically acceptable salts of the compounds of this invention may also be employed in compositions to treat or prevent the above-identified disorders.
Pharmaceutically acceptable salts of the compounds of this invention include those derived from pharmaceutically acceptable inorganic and organic acids and bases. Examples of suitable acid salts include acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, bisulfate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, formate, fumarate, glucoheptanoate, glycerophosphate, glycolate, hemisulfate, heptanoate, hexanoate, hydrochloride, hydrobromide, hydroiodide, 2-hydroxyethanesulfonate, lactate, maleate, malonate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, nitrate, oxalate, palmoate, pectinate, persulfate, 3-phenylpropionate, phosphate, picrate, pivalate, propionate, salicylate, succinate, sulfate, tartrate, thiocyanate, tosylate and undecanoate. Other acids, such as oxalic, while not in themselves pharmaceutically acceptable, may be employed in the preparation of salts useful as intermediates in obtaining the compounds of the invention and their pharmaceutically acceptable acid addition salts. Salts derived from appropriate bases include alkali metal (e.g., sodium and potassium), alkaline earth metal (e.g., magnesium), ammonium and N—(C 1-4 alkyl) 4+ salts. This invention also envisions the quaternization of any basic nitrogen-containing groups of the compounds disclosed herein. Water or oil-soluble or dispersible products may be obtained by such quaternization.
Pharmaceutically acceptable carriers that may be used in these pharmaceutical compositions include, but are not limited to, ion exchangers, alumina, aluminum stearate, lecithin, serum proteins, such as human serum albumin, buffer substances such as phosphates, glycine, sorbic acid, potassium sorbate, partial glyceride mixtures of saturated vegetable fatty acids, water, salts or electrolytes, such as protamine sulfate, disodium hydrogen phosphate, potassium hydrogen phosphate, sodium chloride, zinc salts, colloidal silica, magnesium trisilicate, polyvinyl pyrrolidone, cellulose-based substances, polyethylene glycol, sodium carboxymethylcellulose, polyacrylates, waxes, polyethylene-polyoxypropylene-block polymers, polyethylene glycol and wool fat.
The compositions of the present invention may be administered orally, parenterally, by inhalation spray, topically, rectally, nasally, buccally, vaginally or via an implanted reservoir. The term “parenteral” as used herein includes subcutaneous, intravenous, intramuscular, intra-articular, intra-synovial, intrasternal, intrathecal, intrahepatic, intralesional and intracranial injection or infusion techniques. Preferably, the compositions are administered orally, intraperitoneally or intravenously.
Sterile injectable forms of the compositions of this invention may be aqueous or oleaginous suspension. These suspensions may be formulated according to techniques known in the art using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose, any bland fixed oil may be employed including synthetic mono- or di-glycerides. Fatty acids, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically-acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions may also contain a long-chain alcohol diluent or dispersant, such as carboxymethyl cellulose or similar dispersing agents which are commonly used in the formulation of pharmaceutically acceptable dosage forms including emulsions and suspensions. Other commonly used surfactants, such as Tweens, Spans and other emulsifying agents or bioavailability enhancers which are commonly used in the manufacture of pharmaceutically acceptable solid, liquid, or other dosage forms may also be used for the purposes of formulation.
The pharmaceutical compositions of this invention may be orally administered in any orally acceptable dosage form including, but not limited to, capsules, tablets, aqueous suspensions or solutions. In the case of tablets for oral use, carriers which are commonly used include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions are required for oral use, the active ingredient is combined with emulsifying and suspending agents. If desired, certain sweetening, flavoring or coloring agents may also be added.
Alternatively, the pharmaceutical compositions of this invention may be administered in the form of suppositories for rectal administration. These can be prepared by mixing the agent with a suitable non-irritating excipient which is solid at room temperature but liquid at rectal temperature and therefore will melt in the rectum to release the drug. Such materials include cocoa butter, beeswax and polyethylene glycols.
The pharmaceutical compositions of this invention may also be administered topically, especially when the target of treatment includes areas or organs readily accessible by topical application, including diseases of the eye, the skin, or the lower intestinal tract. Suitable topical formulations are readily prepared for each of these areas or organs.
Topical application for the lower intestinal tract can be effected in a rectal suppository formulation (see above) or in a suitable enema formulation. Topically-transdermal patches may also be used.
For topical applications, the pharmaceutical compositions may be formulated in a suitable ointment containing the active component suspended or dissolved in one or more carriers. Carriers for topical administration of the compounds of this invention include, but are not limited to, mineral oil, liquid petrolatum, white petrolatum, propylene glycol, polyoxyethylene, polyoxypropylene compound, emulsifying wax and water. Alternatively, the pharmaceutical compositions can be formulated in a suitable lotion or cream containing the active components suspended or dissolved in one or more pharmaceutically acceptable carriers. Suitable carriers include, but are not limited to, mineral oil, sorbitan monostearate, polysorbate 60, cetyl esters wax, cetearyl alcohol, 2-octyldodecanol, benzyl alcohol and water.
For ophthalmic use, the pharmaceutical compositions may be formulated as micronized suspensions in isotonic, pH adjusted sterile saline, or, preferably, as solutions in isotonic, pH adjusted sterile saline, either with or without a preservative such as benzylalkonium chloride. Alternatively, for ophthalmic uses, the pharmaceutical compositions may be formulated in an ointment such as petrolatum.
The pharmaceutical compositions of this invention may also be administered by nasal aerosol or inhalation. Such compositions are prepared according to techniques well-known in the art of pharmaceutical formulation and may be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other conventional solubilizing or dispersing agents.
The amount of p38 inhibitor that may be combined with the carrier materials to produce a single dosage form will vary depending upon the host treated, the particular mode of administration. Preferably, the compositions should be formulated so that a dosage of between 0.01-100 mg/kg body weight/day of the inhibitor can be administered to a patient receiving these compositions.
It should also be understood that a specific dosage and treatment regimen for any particular patient will depend upon a variety of factors, including the activity of the specific compound employed, the age, body weight, general health, sex, diet, time of administration, rate of excretion, drug combination, and the judgment of the treating physician and the severity of the particular disease being treated. The amount of inhibitor will also depend upon the particular compound in the composition.
According to another embodiment, the invention provides methods for treating or preventing a p38-mediated condition comprising the step of administering to a patient one of the above-described pharmaceutical compositions. The term “patient”, as used herein, means an animal, preferably a human.
Preferably, that method is used to treat or prevent a condition selected from inflammatory diseases, autoimmune diseases, destructive bone disorders, proliferative disorders, infectious diseases, degenerative diseases, allergies, reperfusion/ischemia in stroke, heart attacks, angiogenic disorders, organ hypoxia, vascular hyperplasia, cardiac hypertrophy, and thrombin-induced platelet aggregation.
According to another embodiment, the inhibitors of this invention are used to treat or prevent an IL-1, IL-6, IL-8 or TNF-mediated disease or condition. Such conditions are described above.
Depending upon the particular p38-mediated condition to be treated or prevented, additional drugs, which are normally administered to treat or prevent that condition may be administered together with the inhibitors of this invention. For example, chemotherapeutic agents or other anti-proliferative agents may be combined with the p38 inhibitors of this invention to treat proliferative diseases.
Those additional agents may be administered separately, as part of a multiple dosage regimen, from the p38 inhibitor-containing composition. Alternatively, those agents may be part of a single dosage form, mixed together with the p38 inhibitor in a single composition.
In order that the invention described herein may be more fully understood, the following examples are set forth. It should be understood that these examples are for illustrative purposes only and are not to be construed as limiting this invention in any manner.
Example 1
Synthesis of p38 Inhibitor Compound 1
Examples of the synthesis of several compounds of formula Ia are set forth in the following 4 examples.
A.
To a slurry of sodium amide, 90% (1.17 g., 30 mmol) in dry tetrahydrofuran (20 ml) we added a solution of benzyl cyanide (2.92 g., 25.0 mmol) in dry tetrahydrofuran (10 ml) at room temperature. The mixture was stirred at room temperature for 30 minutes. To the reaction mixture we added a solution of 3,6-dichloropyridazine (3.70 g., 25.0 mmol) in dry tetrahydrofuran (10 ml). After stirring for 30 minutes, the reaction mixture was diluted with an aqueous saturated sodium bicarbonate solution. The reaction mixture was then extracted with ethyl acetate. The layers were separated and the organic was washed with water, brine, dried over magnesium sulfate, filtered and concentrated in vacuo.
The residue was purified by chromatography on silica gel (eluant: 30% ethyl acetate in n-hexane) to give 3.71 g. (16.20 mmol ˜54%) of product as a white solid.
B.
To a slurry of sodium hydride, 95% (0.14 g., 6.0 mmol) in dry tetrahydrofuran (10 ml) we added thiophenol (0.66 g, 6.0 ml.) at room temperature. The reaction mixture was then stirred for 10 minutes. To the reaction mixture we added a solution of the product from step A., above (1.31 g., 5.72 mmol) in absolute ethanol (20 ml.). The reaction mixture was then brought to reflux and stirred there for one hour. The cool reaction mixture was concentrated in vacuo. The residue was diluted with a 1N sodium hydroxide solution (10 ml), then extracted with methylene chloride. The organic phase was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo.
The residue was purified by chromatography on silica gel (eluant: 20% ethyl acetate in n-hexane) to give 0.66 g. (2.19 mmol ˜40%) of product as a white solid.
C.
A mixture of the product from step B. (0.17 g., 0.69 mmol) and concentrated sulfuric acid (5 ml) was heated to 100° C. for one hour. The solution was cooled and adjusted to pH 8 with a saturated sodium bicarbonate solution. The reaction mixture was extracted with methylene chloride. The organic layer was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo to give 0.22 g. (0.69 mmol ˜100%) of compound pre-1 as an orange oil. 1 H NMR (500 MHz, CD3OD) d7.7 (d), 7.5 (d), 7.4 (m), 7.3-7.2 (m).
D.
A solution of pre-1 from step C. (0.22 g., 0.69 mmol) and N,N-dimethylformamide dimethylacetal (0.18 g., 1.5 mmol) in toluene (5 ml) was heated at 100° C. for one hour. Upon cooling, the resulting solid was filtered and dissolved in warm ethyl acetate. The product was precipitated with the dropwise addition of diethyl ether. The product was then filtered and washed with diethyl ether to give 0.038 g. of compound 1 as a yellow solid. 1 H NMR (500 MHz, CDCl3) d8.63 (s), 7.63-7.21 (m), 6.44 (d).
Example 2
Synthesis of p38 Inhibitor Compound 2
A.
The first intermediate depicted above was prepared in a similar manner as in Example 1A, using 4-fluorophenylacetonitrile, to afford 1.4 g (5.7 mmol, ˜15%) of product.
B.
The above intermediate was prepared in a similar manner as in Example 1B. This afforded 0.49 g (1.5 mmol, 56%) of product.
C.
The above intermediate was prepared in a similar manner as Example 1C. This afforded 0.10 g (0.29 mmol, 45%) of compound pre-2. 1 H NMR (500 MHz, CDCl3) d 7.65-7.48 (m), 7.47-7.30 (m), 7.29-7.11 (m), 7.06-6.91 (m), 5.85 (s, br).
D.
Compound 2 (which is depicted in Table 1) was prepared from pre-2 in a similar manner as in Example 1D. This afforded 0.066 g of product. 1 H NMR (500 MHz, CDCl3) δ 8.60 (s), 7.62-7.03 (m), 6.44 (d)).
Example 3
Synthesis of p38 Inhibitor Compound 6
A.
The first intermediate in the preparation of compound 6 was prepared in a manner similar to that described in Example 1A, using 2,6-dichlorophenyl-acetonitrile, to afford 2.49 g (8.38, 28%) of product.
B.
The next step in the synthesis of compound 6 was carried out in a similar manner as described in Example 1B. This afforded 2.82 g (7.6 mmol, 91%) of product.
C.
The final intermediate, pre-6, was prepared in a similar manner as described in Example 1C. This afforded 0.89 g (2.3 mmol, 85%) of product. 1 H NMR (500 MHz, CD3OD) δ 7.5-7.4 (dd), 7.4 (m), 7.3 (d), 7.2 (m), 7.05 (d).
D.
The final step in the synthesis of compound 6 (which is depicted in Table 1) was carried out as described in Example 1D. This afforded 0.06 g of product. 1 H NMR (500 MHz, CDCl3) δ 8.69 (s), 7.65-7.59 (d), 7.58-7.36 (m), 7.32-7.22 (m), 6.79 (d), 6.53 (d).
Example 4
Preparation of p38 Inhibitor Compound 5
A.
The first intermediate in the synthesis of compound 5 was prepared in a similar manner as described in Example 1A, using 2,4-dichlorophenylacetonitrile, to afford 3.67 g (12.36 mmol, 49%) of product.
B.
The second intermediate was prepared in a similar manner as described in Example 1B. This afforded 3.82 g (9.92 mmol, 92%) of product.
C.
The final intermediate, pre-5, was prepared in a similar manner as described in Example 1C. This afforded 0.10 g (0.24 mmol, 92%) of product. 1 H NMR (500 MHz, CD3OD) δ 7.9 (d), 7.7 (d), 7.6-7.5 (dd), 7.4-7.3 (m), 2.4 (s).
D.
The final step in the preparation of compound 5 (which is depicted in Table 1) was carried out in a similar manner as described in Example 1D. This afforded 0.06 g of product. 1 H NMR (500 MHz, CDCl3) d 8.64 (s), 7.51-7.42 (m), 7.32-7.21 (m), 6.85 (d), 6.51 (d), 2.42 (s).
Other compounds of formula Ia of this invention may be synthesized in a similar manner using the appropriate starting materials.
Example 5
Preparation of A p38 Inhibitor Compound of Formula Ib
An example of the synthesis of a p38 inhibitor of this invention of the formula Ib is presented below.
A.
To a slurry of sodium amide, 90% (1.1 eq) in dry tetrahydrofuran was added a solution of 2,6-dichlorobenzyl cyanide (1.0 eq) in dry tetrahydrofuran at room temperature. The mixture was stirred at room temperature for 30 minutes. To the reaction mixture was added a solution of 2,6-dichloropyridine (1 eq) in dry tetrahydrofuran. The reaction was monitored by TLC and, when completed the reaction mixture was diluted with an aqueous saturated sodium bicarbonate solution. The reaction mixture was then extracted with ethyl acetate. The layers were separated and the organic layer was washed with water, brine, dried over magnesium sulfate, filtered and concentrated in vacuo. The residue was purified by chromatography on silica gel to yield pure product.
B.
To a solution of 4-fluoro-bromobenzene (1 eq) in dry tetrahydrofuran at −78° C. was added t-butyllithium (2 eq, solution in hexanes). The reaction mixture was then stirred for 30 minutes. To the reaction mixture was added a solution of the product from Step A (1 eq) in dry THF. The reaction mixture was then monitored and slowly brought to room temperature. The reaction mixture was quenched with water then extracted with methylene chloride. The organic phase was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo. The residue was purified by chromatography on silica gel to yield the product.
C.
A mixture of the product step B and concentrated sulfuric acid was heated to 100° C. for one hour. The solution was cooled and adjusted to pH 8 with a saturated sodium bicarbonate solution. The reaction mixture was extracted with methylene chloride. The organic layer was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo to give product. The final product was purified by silica gel flash chromatography
D.
A solution of the product Step C (1 eq) and N,N-Dimethylformamide dimethylacetal (2 eq) in toluene is heated at 100° C. for one hour. Upon cooling, the resulting mixture is filtered and dissolved in warm ethyl acetate. The product is precipitated with the dropwise addition of diethyl ether. The product is then filtered and washed with diethyl ether to give a p38 inhibitor of formula Ib. The final product is further purified by silica gel chromatography.
Other compounds of formula Ib of this invention may be synthesized in a similar manner using the appropriate starting materials.
Example 6
Synthesis of p38 Inhibitor Compound 103
This example sets forth a typical synthesis of a compound of formula Ic.
A.
The p38 inhibitor compound 12 is prepared essentially as set forth for in Example 4, except that 4-fluorothiophenyl is utilized in step B.
B.
Compound 12 was dissolved in dry THF (5 ml) at room temperature. To this solution we added diisobutylaluminum hydride (1M solution in toluene, 5 ml, mmol) and the reaction was stirred at room temperature for 1 hour. The reaction mix was then diluted with ethyl acetate and quenched by the addition of Rochelle salt. The layers were separated and the organic layer was isolated, washed with water, washed with brine, dried over magnesium sulfate and filtered to yield crude compound 103. The crude product was chromatographed on silica gel eluting with 2% methanol in methylene chloride. Pure compound 103 was thus obtained (210 mg, 50% yield): 1H NMR (500 Mhz, CDCl3) 7.51 (m, 1H), 7.38 (d, 2H), 7.20 (t, 2H), 7.08 (t, 2H), 6.70 (broad s, 1H), 6.30 (dd, 2H), 5.20 (s, 2H).
Example 7
Synthesis of p38 Inhibitor Compound 201
A.
The starting nitrile shown above (5.9 g, 31.8 mmol) was dissolved in DMF (20 ml) at room temperature. Sodium hydride (763 mg, 31.8 mmol) was then added, resulting in a bright yellow-colored solution. After 15 minutes a solution of 2,5 dibromopyridine (5.0 gr., 21.1 mmol) in DMF (10 ml) was added followed by Palladium tetrakis (triphenylphosphine) (3 mmol). The solution was then refluxed for 3 hrs. The reaction was cooled to room temperature and diluted with ethyl acetate. The organic layer was then isolated, washed with water and then with brine, dried over magnesium sulfate, filtered and evaporated in vacuo to a crude oil. Flash column chromatography eluting with 10% ethyl acetate in hexane afforded product (5.8 g, 84%) as an off white solid.
B.
The bromide produced in step A (194.8 mg, 0.57 mmol) was dissolved in xylene (15 ml). To this solution we added thiophenylstannane (200 μl, 587 mmol) and palladium tetrakis (triphenylphosphine) (25 mg). The solution was refluxed overnight, cooled, filtered and evaporated in vacuo. The crude product was chromatographed on silica gel, eluting with methylene chloride, to yield pure product (152 mg, 72%) as a yellow oil.
C.
The nitrile produced in step B (1.2 g, 3.37 mmol) was dissolved in glacial acetic acid (30 ml). To this solution we added water (120 μl, 6.67 mmol) followed by titanium tetrachloride (760 μl, 6.91 mmol), which resulted in an exotherm. The solution was then refluxed for two hours, cooled and poured into 1N HCl. The aqueous layer was extracted with methylene chloride. The organic layer was backwashed with 1N NaOH, dried over magnesium sulfate and filtered over a plug of silica gel. The plug was first eluted with methylene chloride to remove unreacted starting materials, and then with ethyl acetate to yield compound 201. The ethyl acetate was evaporated to yield pure compound 201 (1.0 g, 77%).
Example 8
Synthesis of p38 Inhibitor Compound 110
A.
The starting nitrile (3.76 g, 11.1 mmol) was first dissolved in glacial acetic acid (20 ml). To this solution we added titanium tetrachloride (22.2 mmol) and water (22.2 mmol) and heated the solution to reflux for 1 hour. The reaction mixture was then cooled and diluted in water/ethyl acetate. The organic layer was then isolated, washed with brine and dried over magnesium sulfate. The organic layer was then filtered and evaporated in vacuo. The resulting crude product was chromatographed on silica gel eluting with 5% methanol in methylene chloride to afford pure product as a yellow foam (2.77 g, 70%)
B.
The amide produced in step A (1.54 g, 4.3 mmol) was dissolved in toluene (20 ml). We then added N,N-dimethylformamide dimethylacetal (1.53 g, 12.9 mmol), heated the resulting solution for 10 minutes then allowed it to cool to room temperature. The reaction was then evaporated in vacuo and the residue was chromatographed on silica gel eluting with 2-5% methanol in methylene chloride. The recovered material was then dissolved in hot ethyl acetate. The solution was allowed to cool resulting in the crystallization of pure product as a yellow solid (600 mg, 40%). Additional material (˜800 mg) was available from the mother liquor.
C.
The bromide from step B (369 mg, 1 mmol) was dissolved in THF (10 ml). We then added Diisobutylaluminum hydride (1.0M solution, 4 mmol), stirred the reaction at room temperature for 10 minutes, and then quenched the reaction with methanol (1 ml). A saturated solution of Rochelle salts was then added and the mixture was extracted with ethyl acetate. The organic layer was isolated, dried over magnesium sulfate, evaporated and the residue was chromatographed on silica gel eluting with 1-3% methanol in methylene chloride to afford a bright orange solid (85 mg, 23% yield).
D.
The bromide produced in step C (35.2 mg, 0.1 mmol) was dissolved in xylene (12 ml). To this solution we added thiophenol (0.19 mmol) followed by tributyltin methoxide (0.19 mmol). The resulting solution was heated to reflux for 10 minutes, followed by the addition of palladium tetrakis(triphenylphosphine) (0.020 mmol). The reaction was heated and monitored for the disappearance of the bromide starting material. The reaction was then cooled to room temperature and passed through a plug of silica gel. The plug was eluted initially with methylene chloride to remove excess tin reagent and then with 5% methanol in ethyl acetate to elute the p38 inhibitor. The filtrate was concentrated and then re-chromatographed on silica gel using 5% methanol in ethyl acetate as eluant affording pure compound 110 (20 mg, 52%).
Example 9
Synthesis of p38 Inhibitor Compound 202
A.
The starting nitrile (2.32 g, 12 mmol) was dissolved in DMF (10 ml) at room temperature. Sodium hydride (12 mmol) was then added resulting in a bright yellow colored solution. After 15 minutes, a solution of 2,6 dibromopyridine (2.36 gr., 10 mmol) in DMF (5 ml) was added, followed by Palladium tetrakis (triphenylphosphine) (1.0 mmol). The solution was then refluxed for 3 hours. The reaction was next cooled to room temperature and diluted with ethyl acetate. The organic layer was isolated, washed with water and brine, dried over magnesium sulfate, filtered and evaporated in vacuo to a crude oil. Flash column chromatography eluting with 10% ethyl acetate in hexane afforded product (1.45 g, 42%) as a white solid.
B.
The bromo compound produced in step A (1.77 g, 5.2 mmol) was dissolved in toluene (20 ml) and the resulting solution was degassed. Under a nitrogen atmosphere, a solution of phenylboronic acid (950 mg, 7.8 mmol) in ethanol (4 ml) and a solution of sodium carbonate (1.73 g, 14 mmol) in water (4 ml) were added. The reaction mixture was heated to reflux for one hour and then was cooled to room temperature. The reaction was diluted with ethyl acetate and washed with water and brine. The organic layer was then dried with magnesium sulfate, filtered and concentrated in vacuo. The residue was purified on silica gel eluting with 30% ethyl acetate in hexane to afford product as a white solid (1.56 g, 88%).
C.
The nitrile from step B (700 mg, 2.07 mmol) was dissolved in concentrated sulfuric acid (10 ml) and heated to 80° C. for 1 hour. The reaction was then cooled to room temperature and the pH was adjusted to 8 using 6N sodium hydroxide. The mixture was next extracted with ethyl acetate. The organic layer was isolated, dried with magnesium sulfate and evaporated in vacuo to yield compound 202 as a yellow foam (618 mg, 84%).
Example 10
Synthesis of Compound 410
A.
In a flame-dried 100 ml round-bottomed flask, 2.28 g (93.8 mmol) of magnesium chips were added to 50 ml of anhydrous tetrahydrofuran. One crystal of iodine was added forming a light brown color. To the solution was added 1.5 ml of a 10.0 ml (79.1 mmol) sample of 2-bromo-5-fluorotoluene. The solution was heated to reflux. The brown color faded and reflux was maintained when the external heat source was removed indicating Grignard formation. As the reflux subsided, another 1.0-1.5 ml portion of the bromide was added resulting in a vigorous reflux. The process was repeated until all of the bromide had been added. The olive-green solution was externally heated to reflux for one hour to ensure complete reaction. The solution was cooled in an ice-bath and added via syringe to a solution of 9.3 ml (81.9 mmol) of trimethyl borate in 100 ml of tetrahydrofuran at −78° C. After the Grignard reagent had been added, the flask was removed from the cooling bath and the solution was stirred at room temperature overnight. The grayish-white slurry was poured into 300 ml of H 2 O and the volatiles were evaporated in vacuo. HCl (400 ml of 2N solution) was added and the milky-white mixture was stirred for one hour at room temperature. A white solid precipitated. The mixture was extracted with diethyl ether and the organic extract was dried (MgSO 4 ) and evaporated in vacuo to afford 11.44 g (94%) of the boronic acid as a white solid.
B.
In a 100 ml round-bottomed flask, 7.92 g (33.4 mmol) of 2,6-dibromopyridine was dissolved in 50 ml of anhydrous toluene forming a clear, colorless solution. 4-fluoro-2-methylbenzene boronic acid (5.09 g, 33.1 mmol) produced in step A was added forming a white suspension. Thallium carbonate (17.45 g, 37.2 mmol) was added followed by a catalytic amount (150 mg) of Pd(PPh 3 ) 4 . The mixture was heated to reflux overnight, cooled, and filtered over a pad of silica gel. The silica was washed with CH 2 Cl 2 and the filtrate was evaporated to afford a white solid. The solid was dissolved in a minimal amount of 50% CH 2 Cl 2 /hexane and chromatographed on a short column of silica gel using 30% CH 2 Cl 2 /hexane to afford 6.55 g (74%) of the 2-bromo-6-(4-fluoro-2-methylphenyl)pyridine as a white solid.
C.
In a 50 ml round-bottomed flask, 550 mg (2.07 mmol) of 2-bromo-6-(4-fluoro-2-methylphenyl)pyridine produced in step B was dissolved in 30 ml of anhydrous tetrahydrofuran forming a clear, colorless solution. 2,6-difluoroaniline (2.14 ml, 2.14 mmol) was added followed by 112 mg (2.79 mmol) of a 60% NaH suspension in mineral oil. Gas evolution was observed along with a mild exotherm. The solution was heated to reflux overnight and then cooled. The reaction mixture was poured in 10% NH 4 Cl and extracted with CH 2 Cl 2 . The organic extract was dried (MgSO 4 ) and evaporated in vacuo to afford a brown oil that was a mixture of the product and starting material. The material was chromatographed on a short column of silica gel using 50% CH 2 Cl 2 /hexane to afford 262 mg (40%) of 2-(2,6-difluorophenyl)-6-(4-fluoro-2-methylphenyl)pyridine as a colorless oil.
D.
In a 100 ml round-bottomed flask, 262 mg (834 mmol) of 2-(2,6-difluorophenyl)-6-(4-fluoro-2-methylphenyl)pyridine produced in step C was dissolved in 30 ml of anhydrous CHCl 3 forming a clear, colorless solution. Chlorosulfonyl isocyanate (1.0 ml, 11.5 mmol) was added and the light yellow solution was stirred at room temperature overnight. Water (˜30 ml) was added causing a mild exotherm and vigorous gas evolution. After stirring overnight, the organic layer was separated, dried (MgSO 4 ) and evaporated in vacuo to afford a brown oil that was a mixture of the product and starting material. The material was chromatographed on a short column of silica gel using 10% EtOAc/CH 2 Cl 2 . The recovered starting material was re-subjected to the reaction conditions and purified in the same manner to afford a total of 205 mg (69%) of the urea as a white solid.
Example 11
Synthesis of Compound 138
Compound 103 (106 mg, 0.25 mmol) was dissolved in THF (0.5 ml) and to this solution was added triethylamine (35 μl, 0.25 mmol) followed by and excess of formaldehyde (37% aqueous solution, 45 mg). The reaction was allowed to stir at room temperature overnight. The reaction mixture was then rotovapped under reduced pressure and the residue was dissolved in methylene chloride and applied to a flash silica gel column. The column was eluted with 2% methanol in methylene chloride to yield pure product (78 mg, 70% yield).
Example 12
Synthesis of Prodrugs of Compound 103
A.
Compound 138 (1 equivalent) is dissolved in methylene chloride and to this solution is added triethylamine (1 equivalent) followed by dibenzylphosphonyl chloride (1 equivalent). The solution is stirred at room temperature and monitored by TLC for consumption of starting material. The methylene chloride layer is then diluted with ethyl acetate and washed with 1N HCl, saturated sodium bicarbonate and saturated NaCl. The organic layer is then dried, rotovapped and the crude product is purified on silica gel. The pure product is then dissolved in methanol and the dibenzyl esters are deprotected with 10% palladium on charcoal under a hydrogen atmosphere. When the reaction is monitored as complete, the catalyst is filtered over celite and the filtrate is rotovapped to yield the phosphate product.
B.
Compound 103 (210 mg, 1.05 mmol) was dissolved in THF (2 ml) and cooled to −50° C. under a nitrogen atmosphere. To this solution was added lithium hexamethyldisilazane (1.1 mmol) followed by chloroacetyl chloride (1.13 mmol). The reaction was removed from the cooling bath and allowed to warm to room temperature, after which time the reaction was diluted with ethyl acetate and quenched with water. The organic layer was washed with brine, dried and rotovapped to dryness. The crude product was flash chromatographed on silica gel using 25% ethyl acetate in hexane as eluant to yield 172 mg (70%) of pure desired product, which was used as is in the next reactions.
C.
The chloroacetyl compound is dissolved in methylene chloride and treated with an excess of dimethyl amine. The reaction is monitored by TLC and when complete all volatiles are removed to yield desired product.
Example 13
Synthesis of Compounds 34 and 117
A.
The nitrile from Example 5, step A (300 mg, 1.0 mmol) was dissolved in ethanol (10 ml) and to this solution was added thiourea (80.3 mg, 1.05 mmol). The reaction was brought to reflux for 4 hours at which point TLC indicated that all starting material was consumed. The reaction was cooled and all volatiles were removed under reduced pressure, and the residue was dissolved in acetone (10 ml).
To this solution was then added 2,5-difluoronitrobenzene (110 μl, 1.01 mmol) followed by potassium carbonate (200 mg, 1.45 mmol) and water (400 μl). The reaction was allowed to stir at room temperature overnight. The reaction was then diluted with methylene chloride (25 ml) and filtered through a cotton plug. All volatiles were removed under reduced pressure and the residue was flashed chromatographed on silica gel eluting with a gradient from 10%-25% ethyl acetate in hexane to yield the desired product (142 mg, 33%).
B.
The nitrile product from Step A (142 mg, 0.33 mmol) was mixed with concentrated sulfuric acid (2 ml), heated to reflux for 1 hour and then allowed to cool to room temperature. The mixture was then diluted with ethyl acetate and carefully neutralized with saturated potassium carbonate solution (aqueous). The layers were separated and the organic layer was washed with water, brine and dried over magnesium sulfate. The mixture was filtered and evaporated to dryness. The residue was used in the next step without further purification (127 mg, 85% yield).
C.
The amide from the step B (127 mg, 0.28 mmol) was dissolved in THF (3 ml) and to this solution was added dimethylformamide dimethylacetal (110 μl, 0.83 mmol). The reaction was heated to reflux for 5 minutes then cooled to room temperature. All volatiles were removed in vacuo and the residue was flash chromatographed on silica gel eluting with 2.5% methanol in methylene chloride to yield pure desired compound 34 (118 mg, 92%).
D.
A solution of nickel dichloride hexahydrate (103 mg, 0.44 mol) in a mixture of benzene/methanol (0.84 mL/0.84 ml) was added to a solution of compound 34 (100.8 mg, 0.22 mmol) in benzene (3.4 ml) and this solution was cooled to 0° C. To this solution was then added sodium borohydride (49 mg, 1.3 mmol). The reaction was stirred while allowing to warm to room temperature. The reaction was evaporated in vacuo and the residue was flash chromatographed eluting with 2% methanol in methylene chloride to yield pure desired product, compound 117 (21 mg, 25% yield).
Example 14
Synthesis of Compounds 53 and 142
A.
The product indicated in the above reaction was synthesized using the procedure in example 1 step B using chloropyridazine (359 mg, 1.21 mmol) and 2,4 difluorothiophenol (176 mg, 1.21 mmol). The product was obtained after flash silica gel chromatography (451 mg, 92%).
B.
The above reaction was carried out as described in Example 1, step C, using 451 mg of starting material and 5 ml of concentrated sulfuric acid to yield the indicated product (425 mg, 90%).
C.
The reaction above was carried out as described in Example 1, step D, using starting amide (410 mg, 0.96 mmol) and dimethylformamide dimethylacetal (3 mmol). The reaction was heated at 50° C. for 30 minutes and worked up as described previously. Compound 53 was obtained (313 mg, 75%).
D.
Compound 34 (213, 0.49 mmol) was dissolved in THF (10 ml), cooled to 0° C. and to this solution was added Borane in THF (1M, 0.6 mmol). The reaction was stirred for 30 minutes quenched with water and diluted with ethyl acetate. The organic layer was washed with water and brine, dried and rotovapped. The residue was purified on silica gel eluting with a gradient of 1% to 5% methanol in methylene chloride to afford compound 142 (125 mg, 57%).
Example 15
Cloning of p38 Kinase in Insect Cells
Two splice variants of human p38 kinase, CSBP1 and CSBP2, have been identified. Specific oligonucleotide primers were used to amplify the coding region of CSBP2 cDNA using a HeLa cell library (Stratagene) as a template. The polymerase chain reaction product was cloned into the pET-15b vector (Novagen). The baculovirus transfer vector, pVL-(His)6-p38 was constructed by subcloning a XbaI-BamHI fragment of pET15b-(His)6-p38 into the complementary sites in plasmid pVL1392 (Pharmingen).
The plasmid pVL-(His)6-p38 directed the synthesis of a recombinant protein consisting of a 23-residue peptide (MGSS HHHHHH SSG LVPRGS HMLE, where LVPRGS represents a thrombin cleavage site) fused in frame to the N-terminus of p38, as confirmed by DNA sequencing and by N-terminal sequencing of the expressed protein. Monolayer culture of Spodoptera frugiperda (Sf9) insect cells (ATCC) was maintained in TNM-FH medium (Gibco BRL) supplemented with 10% fetal bovine serum in a T-flask at 27° C. Sf9 cells in log phase were co-transfected with linear viral DNA of Autographa califonica nuclear polyhedrosis virus (Pharmingen) and transfer vector pVL-(His)6-p38 using Lipofectin (Invitrogen). The individual recombinant baculovirus clones were purified by plaque assay using 1% low melting agarose.
Example 16
Expression and Purification of Recombinant p38 Kinase
Trichoplusia ni (Tn-368) High-Five™ cells (Invitrogen) were grown in suspension in Excel-405 protein free medium (JRH Bioscience) in a shaker flask at 27° C. Cells at a density of 1.5×10 6 cells/ml were infected with the recombinant baculovirus described above at a multiplicity of infection of 5. The expression level of recombinant p38 was monitored by immunoblotting using a rabbit anti-p38 antibody (Santa Cruz Biotechnology). The cell mass was harvested 72 hours after infection when the expression level of p38 reached its maximum.
Frozen cell paste from cells expressing the (His) 6 -tagged p38 was thawed in 5 volumes of Buffer A (50 mM NaH2PO4 pH 8.0, 200 mM NaCl, 2 mM β-Mercaptoethanol, 10% Glycerol and 0.2 mM PMSF). After mechanical disruption of the cells in a microfluidizer, the lysate was centrifuged at 30,000×g for 30 minutes. The supernatant was incubated batchwise for 3-5 hours at 4° C. with Talon™ (Clontech) metal affinity resin at a ratio of 1 ml of resin per 2-4 mgs of expected p38. The resin was settled by centrifugation at 500×g for 5 minutes and gently washed batchwise with Buffer A. The resin was slurried and poured into a column (approx. 2.6×5.0 cm) and washed with Buffer A+5 mM imidazole.
The (His) 6 -p38 was eluted with Buffer A+100 mM imidazole and subsequently dialyzed overnight at 4° C. against 2 liters of Buffer B, (50 mM HEPES, pH 7.5, 25 mM β-glycerophosphate, 5% glycerol, 2 mM DTT). The His 6 tag was removed by addition of at 1.5 units thrombin (Calbiochem) per mg of p38 and incubation at 20° C. for 2-3 hours. The thrombin was quenched by addition of 0.2 mM PMSF and then the entire sample was loaded onto a 2 ml benzamidine agarose (American International Chemical) column.
The flow through fraction was directly loaded onto a 2.6×5.0 cm Q-Sepharose (Pharmacia) column previously equilibrated in Buffer B+0.2 mM PMSF. The p38 was eluted with a 20 column volume linear gradient to 0.6M NaCl in Buffer B. The eluted protein peak was pooled and dialyzed overnight at 4° C. vs. Buffer C (50 mM HEPES pH 7.5, 5% glycerol, 50 mM NaCl, 2 mM DTT, 0.2 mM PMSF).
The dialyzed protein was concentrated in a Centriprep (Amicon) to 3-4 ml and applied to a 2.6×100 cm Sephacryl S-100HR (Pharmacia) column. The protein was eluted at a flow rate of 35 ml/hr. The main peak was pooled, adjusted to 20 mM DTT, concentrated to 10-80 mgs/ml and frozen in aliquots at −70° C. or used immediately.
Example 17
Activation of p38
P38 was activated by combining 0.5 mg/ml p38 with 0.005 mg/ml DD-double mutant MKK6 in Buffer B+10 mM MgCl2, 2 mM ATP, 0.2 mM Na2VO4 for 30 minutes at 20° C. The activation mixture was then loaded onto a 1.0×10 cm MonoQ column (Pharmacia) and eluted with a linear 20 column volume gradient to 1.0 M NaCl in Buffer B. The activated p38 eluted after the ADP and ATP. The activated p38 peak was pooled and dialyzed against buffer B+0.2 mM Na2VO4 to remove the NaCl. The dialyzed protein was adjusted to 1.1M potassium phosphate by addition of a 4.0M stock solution and loaded onto a 1.0×10 cm HIC (Rainin Hydropore) column previously equilibrated in Buffer D (10% glycerol, 20 mM β-glycerophosphate, 2.0 mM DTT)+1.1MK2HPO4. The protein was eluted with a 20 column volume linear gradient to Buffer D+50 mM K2HPO4. The double phosphorylated p38 eluted as the main peak and was pooled for dialysis against Buffer B+0.2 mM Na2VO4. The activated p38 was stored at −70° C.
Example 18
P38 Inhibition Assays
A. Inhibition of Phosphorylation of EGF Receptor Peptide
This assay was carried out in the presence of 10 mM MgCl2, 25 mM β-glycerophosphate, 10% glycerol and 100 mM HEPES buffer at pH 7.6. For a typical IC50 determination, a stock solution was prepared containing all of the above components and activated p38 (5 nM). The stock solution was aliquotted into vials. A fixed volume of DMSO or inhibitor in DMSO (final concentration of DMSO in reaction was 5%) was introduced to each vial, mixed and incubated for 15 minutes at room temperature. EGF receptor peptide, KRELVEPLTPSGEAPNQALLR, a phosphoryl acceptor in p38-catalyzed kinase reaction (1), was added to each vial to a final concentration of 200 μM. The kinase reaction was initiated with ATP (100 μM) and the vials were incubated at 30° C. After 30 minutes, the reactions were quenched with equal volume of 10% trifluoroacetic acid (TFA).
The phosphorylated peptide was quantified by HPLC analysis. Separation of phosphorylated peptide from the unphosphorylated peptide was achieved on a reverse phase column (Deltapak, 5 μm, C18 100D, part no. 011795) with a binary gradient of water and acteonitrile, each containing 0.1% TFA. IC50 (concentration of inhibitor yielding 50% inhibition) was determined by plotting the % activity remaining against inhibitor concentration.
B. Inhibition of ATPase Activity
This assay was carried out in the presence of 10 mM MgCl2, 25 mM β-glycerophosphate, 10% glycerol and 100 mM HEPES buffer at pH 7.6. For a typical Ki determination, the Km for ATP in the ATPase activity of activated p38 reaction was determined in the absence of inhibitor and in the presence of two concentrations of inhibitor. A stock solution was prepared containing all of the above components and activated p38 (60 nM). The stock solution was aliquotted into vials. A fixed volume of DMSO or inhibitor in DMSO (final concentration of DMSO in reaction was 2.5%) was introduced to each vial, mixed and incubated for 15 minutes at room temperature. The reaction was initiated by adding various concentrations of ATP and then incubated at 30° C. After 30 minutes, the reactions were quenched with 50 μl of EDTA (0.1 M, final concentration), pH 8.0. The product of p38 ATPase activity, ADP, was quantified by HPLC analysis.
Separation of ADP from ATP was achieved on a reversed phase column (Supelcosil, LC-18, 3 μm, part no. 5-8985) using a binary solvent gradient of following composition: Solvent A-0.1 M phosphate buffer containing 8 mM tetrabutylammonium hydrogen sulfate (Sigma Chemical Co., catalogue no. T-7158), Solvent B-Solvent A with 30% methanol.
Ki was determined from the rate data as a function of inhibitor and ATP concentrations. The results for several of the inhibitors of this invention are depicted in Table 6 below:
TABLE 6
Compound
K i (μM)
1
>20
2
15
3
5.0
5
2.9
6
0.4
Other p38 inhibitors of this invention will also inhibit the ATPase activity of p38.
C. Inhibition of IL-1, TNF, IL-6 and IL-8 Production in LPS-Stimulated PBMCs
Inhibitors were serially diluted in DMSO from a 20 mM stock. At least 6 serial dilutions were prepared. Then 4× inhibitor stocks were prepared by adding 4 μl of an inhibitor dilution to 1 ml of RPMI1640 medium/10% fetal bovine serum. The 4× inhibitor stocks contained inhibitor at concentrations of 80 μM, 32 μM, 12.8 μM, 5.12 μM, 2.048 μM, 0.819 μM, 0.328 μM, 0.131 μM, 0.052 μM, 0.021 μM etc. The 4× inhibitor stocks were pre-warmed at 37° C. until use.
Fresh human blood buffy cells were separated from other cells in a Vacutainer CPT from Becton & Dickinson (containing 4 ml blood and enough DPBS without Mg 2+ /Ca 2+ to fill the tube) by centrifugation at 1500×g for 15 min. Peripheral blood mononuclear cells (PBMCs), located on top of the gradient in the Vacutainer, were removed and washed twice with RPMI1640 medium/10% fetal bovine serum. PBMCs were collected by centrifugation at 500×g for 10 min. The total cell number was determined using a Neubauer Cell Chamber and the cells were adjusted to a concentration of 4.8×10 6 cells/ml in cell culture medium (RPMI1640 supplemented with 10% fetal bovine serum).
Alternatively, whole blood containing an anti-coagulant was used directly in the assay.
We placed 100 μl of cell suspension or whole blood in each well of a 96-well cell culture plate. Then we added 50 μl of the 4× inhibitor stock to the cells. Finally, we added 50 μl of a lipopolysaccharide (LPS) working stock solution (16 ng/ml in cell culture medium) to give a final concentration of 4 ng/ml LPS in the assay. The total assay volume of the vehicle control was also adjusted to 200 μl by adding 50 μl cell culture medium. The PBMC cells or whole blood were then incubated overnight (for 12-15 hours) at 37° C./5% CO2 in a humidified atmosphere.
The next day the cells were mixed on a shaker for 3-5 minutes before centrifugation at 500×g for 5 minutes. Cell culture supernatants were harvested and analyzed by ELISA for levels of IL-1b (R & D Systems, Quantikine kits, #DBL50), TNF-∀ (BioSource, #KHC3012), IL-6 (Endogen, #EH2-IL6) and IL-8 (Endogen, #EH2-IL8) according to the instructions of the manufacturer. The ELISA data were used to generate dose-response curves from which IC50 values were derived.
Results for the kinase assay (“kinase”; subsection A, above), IL-1 and TNF in LPS-stimulated PBMCs (“cell”) and IL-1, TNF and IL-6 in whole blood (“WB”) for various p38 inhibitors of this invention are shown in Table 7 below:
cell
cell
WB
WB
WB
cmpd
kinase
IL-1
TNF
IL-1
TNF
IL-6
#
IC50
IC50
IC50
IC50
IC50
IC50
2
+
N.D.
N.D.
N.D.
N.D.
N.D.
3
+
N.D.
N.D.
N.D.
N.D.
N.D.
5
+
N.D.
N.D.
N.D.
N.D.
N.D.
6
++
++
+
N.D.
N.D.
N.D.
7
+
+
+
N.D.
N.D.
N.D.
8
+
+
+
N.D.
N.D.
N.D.
9
+
+
+
N.D.
N.D.
N.D.
10
+
N.D.
N.D.
N.D.
N.D.
N.D.
11
+
+
+
N.D.
N.D.
N.D.
12
++
++
++
+
+
+
13
+
+
+
N.D.
N.D.
N.D.
14
+
++
+
N.D.
N.D.
N.D.
15
+
++
++
N.D.
N.D.
N.D.
16
++
+
++
N.D.
N.D.
N.D.
17
+
+
+
N.D.
N.D.
N.D.
18
+
+
+
N.D.
N.D.
N.D.
19
+
+
+
N.D.
N.D.
N.D.
20
++
+
+
N.D.
N.D.
N.D.
21
++
++
+
N.D.
N.D.
N.D.
22
+
+
+
N.D.
N.D.
N.D.
23
++
++
+
+
+
+
24
++
++
++
+
+
N.D.
25
++
++
+
N.D.
N.D.
N.D.
26
+
+++
++
+
+
+
27
++
+
+
+
+
+
28
++
++
++
N.D.
N.D.
N.D.
29
++
++
++
N.D.
N.D.
N.D.
30
+
+
+
+
N.D.
N.D.
31
+
+
+
N.D.
N.D.
N.D.
32
++
+
++
+
+
+
33
++
++
++
+
+
+
34
+
+
+
N.D.
N.D.
N.D.
35
++
++
+
+
+
+
36
+
+
+
+
+
+
37
++
++
+
+
+
+
38
+++
+++
++
++
++
++
39
++
+
+
N.D.
N.D.
N.D.
40
++
++
+
N.D.
N.D.
N.D.
41
+++
+++
+++
N.D.
N.D.
N.D.
42
+
N.D.
N.D.
N.D.
N.D.
N.D.
43
++
+
+
N.D.
N.D.
N.D.
44
++
+
+
N.D.
N.D.
N.D.
45
++
N.D.
N.D.
N.D.
N.D.
N.D.
46
++
+
+
N.D.
N.D.
N.D.
47
++
++
+
N.D.
N.D.
N.D.
48
++
++
+
N.D.
N.D.
N.D.
49
++
+++
+
+
+
+
50
+
N.D.
N.D.
N.D.
N.D.
N.D.
51
++
N.D.
N.D.
N.D.
N.D.
N.D.
52
++
N.D.
N.D.
N.D.
N.D.
N.D.
53
+++
+++
+++
+++
+++
+++
101
++
+++
+++
+
+
++
102
+++
+++
+++
+
++
++
103
+++
+++
+++
+
++
++
104
++
++
++
+
+
+
105
++
+
+
N.D.
N.D.
N.D.
106
+++
+++
+++
+
++
++
107
++
+
+
N.D.
N.D.
N.D.
109
+++
+++
+++
+
+
++
108
+++
++
+++
++
+++
+++
110
++
+
+
N.D.
N.D.
N.D.
111
++
+
+
N.D.
N.D.
N.D.
112
++
++
+
+
+
+
113
+++
+++
++
+
+
+
114
+++
+++
+++
++
++
+++
115
+++
+++
+++
+
+
+
116
+++
+++
++
+
+
+
117
+++
+++
+++
++
++
+++
118
++
++
++
+
+
+
119
++
N.D.
N.D.
N.D.
N.D.
N.D.
120
N.D.
++
+
+
+
+
121
+++
+++
++
+
+
+
122
++
++
+
+
+
+
123
++
++
++
+
+
+
124
+
+
+
N.D.
N.D.
N.D.
125
+++
+++
+++
+
+
+
126
+
++
+
N.D.
N.D.
N.D.
127
+++
+++
+++
++
++
+++
128
+
+
+
N.D.
N.D.
N.D.
129
+++
+++
+++
++
+
++
130
+++
++
+
N.D.
N.D.
N.D.
131
+++
+++
+++
N.D.
N.D.
N.D.
132
+++
+++
++
N.D.
N.D.
N.D.
133
+++
+++
+++
N.D.
N.D.
N.D.
134
+++
++
+
N.D.
N.D.
N.D.
135
+++
++
+
+
+
+
136
+++
+++
+++
+
+
++
137
+++
+++
++
+
+
++
138
++
+++
++
+
+
+++
139
+++
+++
+
+
+
+
140
+++
+++
+++
++
+
++
141
+++
+++
+++
+
+
+
142
+++
+++
+++
+++
+++
+++
143
+++
+++
++
+
+
+
144
+++
+++
++
+
+
++
145
+++
+++
+++
+++
+++
+++
201
++
+
+
+
+++
+
203
+
N.D.
N.D.
N.D.
N.D.
N.D.
204
+
N.D.
N.D.
N.D.
N.D.
N.D.
205
+
N.D.
N.D.
N.D.
N.D.
N.D.
206
++
+
+
N.D.
N.D.
N.D.
207
+
N.D.
N.D.
N.D.
N.D.
N.D.
208
N.D.
++
N.D.
N.D.
N.D.
N.D.
209
N.D.
+
N.D.
N.D.
N.D.
N.D.
202/301
+++
++
++
+
+
+
302
+++
+++
++
+
+
+
303
+
+
+
+
+
+
304
+
+
+
+
+
+
305
+++
+++
+
+
+
+
306
++
++
+
+
+
+
307
+++
++
+
+
+
+
308
+
N.D.
N.D.
N.D.
N.D.
N.D.
309
++
++
++
+
+
+
310
++
+
+
N.D.
N.D.
N.D.
311
++
+
+
N.D.
N.D.
N.D.
312
+++
++
+
+
+
+
313
++
+
+
N.D.
N.D.
N.D.
314
+
N.D.
N.D.
N.D.
N.D.
N.D.
315
+
N.D.
N.D.
N.D.
N.D.
N.D.
316
+
N.D.
N.D.
N.D.
N.D.
N.D.
317
+
+
+
N.D.
N.D.
N.D.
318
++
N.D.
N.D.
N.D.
N.D.
N.D.
319
+
N.D.
N.D.
N.D.
N.D.
N.D.
320
+++
++
++
N.D.
N.D.
N.D.
321
+
N.D.
N.D.
N.D.
N.D.
N.D.
322
++
+
+
N.D.
N.D.
N.D.
323
++
++
++
N.D.
N.D.
N.D.
324
++
++
+
N.D.
N.D.
N.D.
325
+++
+++
++
+
+
+
326
+
N.D.
N.D.
N.D.
N.D.
N.D.
327
++
N.D.
N.D.
N.D.
N.D.
N.D.
328
+
N.D.
N.D.
N.D.
N.D.
N.D.
329
++
++
+
+
+
+
330
+
N.D.
N.D.
N.D.
N.D.
N.D.
331
+
N.D.
N.D.
N.D.
N.D.
N.D.
332
++
++
+
+
+
+
333
++
+
+
N.D.
N.D.
N.D.
334
+
N.D.
N.D.
N.D.
N.D.
N.D.
335
++
+
+
+
+
+
336
+
N.D.
N.D.
N.D.
N.D.
N.D.
337
+
N.D.
N.D.
N.D.
N.D.
N.D.
338
+
N.D.
N.D.
N.D.
N.D.
N.D.
339
+
N.D.
N.D.
N.D.
N.D.
N.D.
340
+
N.D.
N.D.
N.D.
N.D.
N.D.
341
++
++
++
N.D.
N.D.
N.D.
342
+
N.D.
N.D.
N.D.
N.D.
N.D.
343
+
N.D.
N.D.
N.D.
N.D.
N.D.
344
+
N.D.
N.D.
N.D.
N.D.
N.D.
345
+
N.D.
N.D.
N.D.
N.D.
N.D.
346
++
+
+
+
+
+
347
+
N.D.
N.D.
N.D.
N.D.
N.D.
348
+
N.D.
N.D.
N.D.
N.D.
N.D.
349
+
++
+
+
+
+
350
+
++
+
N.D.
N.D.
N.D.
351
+
+
+
N.D.
N.D.
N.D.
352
+
+
N.D.
N.D.
N.D.
N.D.
353
++
+
+
N.D.
N.D.
N.D.
354
+
N.D.
N.D.
N.D.
N.D.
N.D.
355
+
N.D.
N.D.
N.D.
N.D.
N.D.
356
+
N.D.
N.D.
N.D.
N.D.
N.D.
357
+
N.D.
N.D.
N.D.
N.D.
N.D.
358
++
+
+
N.D.
N.D.
N.D.
359
+
N.D.
N.D.
N.D.
N.D.
N.D.
360
+
N.D.
N.D.
N.D.
N.D.
N.D.
361
++
++
+
N.D.
N.D.
N.D.
362
+++
++
++
+
+
+
363
+++
+++
++
+
+
+
364
+++
+++
++
+
+
+
365
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
366
+
N.D.
N.D.
N.D.
N.D.
N.D.
367
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
368
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
369
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
370
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
371
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
372
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
373
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
374
++
N.D.
N.D.
N.D.
N.D.
N.D.
375
+++
N.D.
N.D.
N.D.
N.D.
N.D.
376
+++
N.D.
N.D.
N.D.
N.D.
N.D.
377
+++
N.D.
N.D.
N.D.
N.D.
N.D.
378
+++
N.D.
N.D.
N.D.
N.D.
N.D.
379
+++
N.D.
N.D.
N.D.
N.D.
N.D.
380
++
N.D.
N.D.
N.D.
N.D.
N.D.
381
++
N.D.
N.D.
N.D.
N.D.
N.D.
382
+++
N.D.
N.D.
N.D.
N.D.
N.D.
383
+++
N.D.
N.D.
N.D.
N.D.
N.D.
384
++
N.D.
N.D.
N.D.
N.D.
N.D.
385
++
N.D.
N.D.
N.D.
N.D.
N.D.
386
+
N.D.
N.D.
N.D.
N.D.
N.D.
387
+
N.D.
N.D.
N.D.
N.D.
N.D.
388
+++
N.D.
N.D.
N.D.
N.D.
N.D.
389
++
N.D.
N.D.
N.D.
N.D.
N.D.
390
+
N.D.
N.D.
N.D.
N.D.
N.D.
391
++
N.D.
N.D.
N.D.
N.D.
N.D.
392
++
N.D.
N.D.
N.D.
N.D.
N.D.
393
++
N.D.
N.D.
N.D.
N.D.
N.D.
394
+++
N.D.
N.D.
N.D.
N.D.
N.D.
395
+++
N.D.
N.D.
N.D.
N.D.
N.D.
396
+++
N.D.
N.D.
N.D.
N.D.
N.D.
397
+
N.D.
N.D.
N.D.
N.D.
N.D.
398
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
399
+++
N.D.
N.D.
N.D.
N.D.
N.D.
1301
+++
N.D.
N.D.
N.D.
N.D.
N.D.
401
+++
++
++
+
+
+
402
+++
+++
+++
+
+
+
403
+++
+++
+++
+
+
++
404
+++
+++
+++
+
+
+
405
+++
+++
++
N.D.
N.D.
N.D.
406
++
++
+
N.D.
N.D.
N.D.
407
++
++
+
N.D.
N.D.
N.D.
408
+++
+++
++
N.D.
N.D.
N.D.
409
+++
+++
+++
+
+
++
410
+++
+++
+++
++
++
++
411
+++
+++
+++
+
+
+
412
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
For kinase IC50 values, “+++” represents <0.1 μM, “++” represents between 0.1 and 1.0 μM, and “+” represents >1.0 μM. For cellular IL-1 and TNF values, “+++” represents <0.1 μM, “++” represents between 0.1 and 0.5 μM, and “+” represents >0.5 μM. For all whole blood (“WB”) assay values, “+++” represents <0.25 μM, “++” represents between 0.25 and 0.5 μM, and “+” represents >0.5 μm. In all assays indicated in the table above, “N.D.” represents value not determined.
Other p38 inhibitors of this invention will also inhibit phosphorylation of EGF receptor peptide, and the production of IL-1, TNF and IL-6, as well as IL-8 in LPS-stimulated PBMCs or in whole blood.
D. Inhibition of IL-6 and IL-8 Production in IL-1-Stimulated PBMCs
This assay was carried out on PBMCs exactly the same as above except that 50 μl of an IL-1b working stock solution (2 ng/ml in cell culture medium) was added to the assay instead of the (LPS) working stock solution.
Cell culture supernatants were harvested as described above and analyzed by ELISA for levels of IL-6 (Endogen, #EH2-IL6) and IL-8 (Endogen, #EH2-IL8) according to the instructions of the manufacturer. The ELISA data were used to generate dose-response curves from which IC50 values were derived.
Results for p38 inhibitor compound 6 are shown in Table 8 below:
TABLE 8 Cytokine assayed IC 50 (μM) IL-6 0.60 IL-8 0.85
E. Inhibition of LPS-Induced Prostaglandin Endoperoxide Synthase-2 (PGHS-2, or COX-2) Induction in PBMCs
Human peripheral mononuclear cells (PBMCs) were isolated from fresh human blood buffy coats by centrifugation in a Vacutainer CPT (Becton & Dickinson). We seeded 15×10 6 cells in a 6-well tissue culture dish containing RPMI 1640 supplemented with 10% fetal bovine serum, 50 U/ml penicillin, 50 μg/ml streptomycin, and 2 mM L-glutamine. Compound 6 (above) was added at 0.2, 2.0 and 20 μM final concentrations in DMSO. Then we added LPS at a final concentration of 4 ng/ml to induce enzyme expression. The final culture volume was 10 ml/well.
After overnight incubation at 37° C., 5% CO 2 , the cells were harvested by scraping and subsequent centrifugation, then the supernatant was removed, and the cells were washed twice in ice-cold DPBS (Dulbecco's phosphate buffered saline, BioWhittaker). The cells were lysed on ice for 10 min in 50 μl cold lysis buffer (20 mM Tris-HCl, pH 7.2, 150 mM NaCl, 1% Triton-X-100, 1% deoxycholic acid, 0.1% SDS, 1 mM EDTA, 2% aprotinin (Sigma), 10 μg/ml pepstatin, 10 μg/ml leupeptin, 2 mM PMSF, 1 mM benzamidine, 1 mM DTT) containing 1 μl Benzonase (DNAse from Merck). The protein concentration of each sample was determined using the BCA assay (Pierce) and bovine serum albumin as a standard. Then the protein concentration of each sample was adjusted to 1 mg/ml with cold lysis buffer. To 100 μl lysate an equal volume of 2×SDS PAGE loading buffer was added and the sample was boiled for 5 min. Proteins (30 μg/lane) were size-fractionated on 4-20% SDS PAGE gradient gels (Novex) and subsequently transferred onto nitrocellulose membrane by electrophoretic means for 2 hours at 100 mA in Towbin transfer buffer (25 mM Tris, 192 mM glycine) containing 20% methanol. The membrane was pretreated for 1 hour at room temperature with blocking buffer (5% non-fat dry milk in DPBS supplemented with 0.1% Tween-20) and washed 3 times in DPBS/0.1% Tween-20. The membrane was incubated overnight at 4° C. with a 1:250 dilution of monoclonal anti-COX-2 antibody (Transduction Laboratories) in blocking buffer. After 3 washes in DPBS/0.1% Tween-20, the membrane was incubated with a 1:1000 dilution of horseradish peroxidase-conjugated sheep antiserum to mouse Ig (Amersham) in blocking buffer for 1 h at room temperature. Then the membrane was washed again 3 times in DPBS/0.1% Tween-20 and an ECL detection system (SuperSignal™ CL-HRP Substrate System, Pierce) was used to determine the levels of expression of COX-2.
Results of the above mentioned assay indicate that compound 6 inhibits LPS induced PGHS-2 expression in PBMCs.
While we have hereinbefore presented a number of embodiments of this invention, it is apparent that our basic construction can be altered to provide other embodiments which utilize the methods of this invention.
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The present invention relates to inhibitors of p38, a mammalian protein kinase involved cell proliferation, cell death and response to extracellular stimuli. The invention also relates to methods for producing these inhibitors. The invention also provides pharmaceutical compositions comprising the inhibitors of the invention and methods of utilizing those compositions in the treatment and prevention of various disorders.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present invention claims priority to U.S. application Ser. No. 13/362,467 entitled “Electrospinning Process for Manufacture of Multi-Layered Structures,” filed Jan. 31, 2012.
[0002] This invention was made with Government support under 70NANB11H004 awarded by the National Institute of Standards and Technology (NIST). The Government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The present invention generally relates to fiber structures and methods of forming fiber structures using wedge-shaped vessels.
BACKGROUND
[0004] Macro-scale structures formed from concentrically-layered nanoscale or microscale fibers (“core-sheath fibers”) are useful in a wide range of applications including drug delivery, tissue engineering, nanoscale sensors, self-healing coatings, and filters. On a commercial scale, the most commonly used techniques for manufacturing core-sheath fibers are extrusion, fiber spinning, melt blowing, and thermal drawing. None of these methods, however, are ideally suited to producing drug-loaded core-sheath fibers, as they all utilize high temperatures which may be incompatible with thermally labile materials such as drugs or polypeptides. Additionally, fiber spinning, extrusion and melt-blowing are most useful in the production of fibers with diameters greater than ten microns.
[0005] Core-sheath fibers can be produced by electrospinning, in which an electrostatic force is applied to a polymer solution to form very fine fibers. Conventional electrospinning methods utilize a charged needle to supply a polymer solution, which is then ejected in a continuous stream toward a grounded collector. After removal of solvents by evaporation, a single long polymer fiber is produced. Core-sheath fibers have been produced using emulsion-based electrospinning methods, which exploit surface energy to produce core-sheath fibers, but which are limited by the relatively small number of polymer mixtures that will emulsify, stratify, and electrospin. Core-sheath fibers have also been produced using coaxial electrospinning, in which concentric needles are used to eject different polymer solutions: the innermost needle ejects a solution of the core polymer, while the outer needle ejects a solution of the sheath polymer. This method is particularly useful for fabrication of core-sheath fibers for drug delivery in which the drug-containing layer is confined to the center of the fiber and is surrounded by a drug-free layer. However, both emulsion and coaxial electrospinning methods can have relatively low throughput, and are not ideally suited to large-scale production of core-sheath fibers. To increase throughput, coaxial nozzle arrays have been utilized, but such arrays pose their own challenges, as separate nozzles may require separate pumps, the multiple nozzles may clog, and interactions between nozzles may lead to heterogeneity among the fibers collected. Another means of increasing throughput, which utilizes a spinning drum immersed in a bath of polymer solution, has been developed by the University of Liberec and commercialized by Elmarco, S.R.O. under the mark Nanospider®. The Nanospider® improves throughput relative to other electrospinning methods, but it is not currently possible to manufacture core-sheath fibers using the Nanospider®. There is, accordingly, a need for a mechanically simple, high-throughput means of manufacturing core-sheath fibers.
SUMMARY OF THE INVENTION
[0006] The present invention addresses the need described above by providing systems and methods for high-throughput production of core-sheath fibers.
[0007] In one aspect the present invention relates to an apparatus used for the electrospinning of core-sheath structures such as fibers. The apparatus comprises first and second wedge-shaped vessels, each having a slit at an apex. The first vessel is disposed inside of the second vessel such that each of the slits of the vessels is aligned. The apparatus includes means for applying a voltage source to one or more materials contained within fluid reservoirs that are in fluid communication with the wedge-shaped vessels. The apparatus also includes means for pumping fluid from one or both of the reservoirs to the wedge-shaped vessels.
[0008] Another aspect the present invention relates to a method of forming a structure comprising a core including a first material and a sheath including a second material around said core. The method comprises the steps of providing an apparatus comprising first and second wedge-shaped vessels, each having a slit at an apex thereof where the first vessel is disposed inside of the second vessel such that the first and second slits are aligned. The method further comprises the step of introducing first and second materials, at least one of which is electrically conductive, into the first and second wedge-shaped vessels. The method further comprises the step of applying a voltage of between 1 and 100 kV to at least one of the first and second materials, and pumping the first and second fluids from the fluid reservoirs to the wedge-shaped vessels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In the drawings, like reference characters generally refer to the same parts throughout the different views. Drawings are not necessarily to scale, as emphasis is placed on illustration of the principles of the invention.
[0010] FIG. 1 is a schematic illustration of a portion of an electrospinning apparatus according to an embodiment of the invention.
[0011] FIG. 2 includes photographs of portion of an electrospinning apparatus according to certain embodiments of the invention.
[0012] FIG. 3 includes photographs of electrospinning apparatus of the invention in use.
[0013] FIG. 4 is a close up photograph of a Taylor cone from an operating electrospinning apparatus of the invention.
[0014] FIG. 5 includes scanning electron micrographs of electrospun core-sheath and homogeneous fibers formed on apparatuses of the invention.
[0015] FIG. 6 includes photographs and schematic illustrations of apparatuses utilizing pneumatic fluid supplies according to certain embodiments of the invention.
[0016] FIG. 7 includes schematic illustrations and photographs of apparatuses utilizing pneumatic fluid supplies according to certain embodiments of the invention.
[0017] FIG. 8 includes schematic illustrations of hydraulically-driven and mechanically-driven fluid supplies according to certain embodiments of the invention.
[0018] FIG. 9 includes photographs and schematic illustrations of gravity-driven fluid supplies according to certain embodiments of the invention.
[0019] FIG. 10 includes photographs of apparatuses in accordance with the invention having varying geometries (linear and round) and varying slit arrangements (single slits, many holes, few holes).
[0020] FIG. 11 includes photographs of diffusers in accordance with the invention.
[0021] FIG. 12 includes photographs of even polymer solution flows achieved with a change of the direction of flow in accordance with certain embodiments of the invention.
[0022] FIG. 13 includes photographs and schematic drawings of an electrospinning apparatus of the invention having a circular slit.
[0023] FIG. 14 includes cumulative dexamethasone release data from core-sheath fibers formed under varying flows of sheath polymer solution.
[0024] FIG. 15 includes schematic depictions of apparatuses according to embodiments of the invention.
[0025] FIG. 16 includes schematic depictions of apparatuses according to embodiments of the invention.
[0026] FIG. 17 includes schematic depictions of apparatuses according to embodiments of the invention.
[0027] FIG. 18 includes a schematic depiction of an angle in a wedge-shaped vessel according to certain embodiments of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The present invention relates to electrospun fibers, including drug-containing electrospun fibers, that are produced in a high yield manner. The fibers are formed into a core-sheath configuration, such that in cross section, the fiber includes a central core as an inner radial portion surrounded by a sheath having an outer radial portion, as is known in the art. Fibers of the present invention preferably have a total diameter of no more than about 20 microns.
[0029] Examples of biodegradable polymers that can be used with the present invention to form the core and/or sheath portions of a fiber include: polyesters, such as poly(ε-caprolactone), polyglycolic acid, poly(L-lactic acid), poly(DL-lactic acid); copolymers thereof such as poly(lactide-co-ε-caprolactone), poly(glycolide-co-ε-caprolactone), poly(lactide-co-glycolide), copolymers with polyethylene glycol (PEG); branched polyesters, such as poly(glycerol sebacate); polypropylene fumarate); poly(ether esters) such as polydioxanone; poly(ortho esters); polyanhydrides such as poly(sebacic anhydride); polycarbonates such as poly(trimethylcarbonate) and related copolymers; polyhydroxyalkanoates such as 3-hydroxybutyrate, 3-hydroxyvalerate and related copolymers that may or may not be biologically derived; polyphosphazenes; poly(amino acids) such as poly (L-lysine), poly (glutamic acid) and related copolymers. Examples of other dissolvable or resorbable polymers include polyethylene glycol and poly(ethylene glycol-propylene glycol) copolymers that are known as pluronics and reverse pluronics.
[0030] Examples of biologically derived restorable polymers that can be used with the present invention include: polypeptides such as collagen, elastin, albumin and gelatin; glycosaminoglycans such as hyaluronic acid, chondroitin sulfate, dermatan sulfate, keratan sulfate, heparan sulfate and heparin; chitosan and chitin; agarose; wheat gluten; polysaccharides such as starch, cellulose, pectin, dextran and dextran sulfate; and modified polysaccharides such as carboxymethylcellulose and cellulose acetate.
[0031] Examples of non-biodegradable polymers that can be used with the present invention include: nylon 4, 6; nylon 6; nylon 6,6; nylon 12; polyacrylic acid; polyacrylonitrile; poly(benzimidazole) (PBI); poly(etherimide) (PEI); poly(ethylenimine); poly(ethylene terephthalate); polystyrene; poly(styrene-block-isobutylene-block-styrene); polysulfone; polyurethane; polyurethane urea; polyvinyl alcohol; poly(N-vinylcarbazole); polyvinyl chloride; poly (vinyl pyrrolidone); poly(vinylidene fluoride); poly(tetrafluoroethylene) (PTFE); polysiloxanes; and poly (methyl methacrylate).
[0032] Electrospun core-sheath fibers and other structures produced by the systems and methods of the invention may optionally include any suitable drug, compound, adjuvant, etc. and may be used for any indication that may occur to one skilled in the art. In preferred embodiments, the drug or other material chosen is insoluble in the polymers and solvents comprising the core polymer solution, or the concentration of drug or material used exceeds the solubility limit of the drug or material in the polymers or solvents. Without limiting the foregoing, general categories of drugs that are useful include, but are not limited to: opioids; ACE inhibitors; adenohypophoseal hormones; adrenergic neuron blocking agents; adrenocortical steroids; inhibitors of the biosynthesis of adrenocortical steroids; alpha-adrenergic agonists; alpha-adrenergic antagonists; selective alpha-two-adrenergic agonists; androgens; anti-addictive agents; antiandrogens; antiinfectives, such as antibiotics, antimicrobals, and antiviral agents; analgesics and analgesic combinations; anorexics; antihelminthics; antiarthritics; antiasthmatic agents; anticonvulsants; antidepressants; antidiabetic agents; antidiarrheals; antiemetic and prokinetic agents; antiepileptic agents; antiestrogens; antifungal agents; antihistamines; antiinflammatory agents; antimigraine preparations; antimuscarinic agents; antinauseants; antineoplastics; antiparasitic agents; antiparkinsonism drugs; antiplatelet agents; antiprogestins; antipruritics; antipsychotics; antipyretics; antispasmodics; anticholinergics; antithyroid agents; antitussives; azaspirodecanediones; sympathomimetics; xanthine derivatives; cardiovascular preparations, including potassium and calcium channel blockers, alpha blockers, beta blockers, and antiarrhythmics; antihypertensives; diuretics and antidiuretics; vasodilators, including general coronary, peripheral, and cerebral; central nervous system stimulants; vasoconstrictors; hormones, such as estradiol and other steroids, including corticosteroids; hypnotics; immunosuppressives; muscle relaxants; parasympatholytics; psychostimulants; sedatives; tranquilizers; nicotine and acid addition salts thereof; benzodiazepines; barbiturates; benzothiadiazides; beta-adrenergic agonists; beta-adrenergic antagonists; selective beta-one-adrenergic antagonists; selective beta-two-adrenergic antagonists; bile salts; agents affecting volume and composition of body fluids; butyrophenones; agents affecting calcification; catecholamines; cholinergic agonists; cholinesterase reactivators; dermatological agents; diphenylbutylpiperidines; ergot alkaloids; ganglionic blocking agents; hydantoins; agents for control of gastric acidity and treatment of peptic ulcers; hematopoietic agents; histamines; 5-hydroxytryptamine antagonists; drugs for the treatment of hyperlipiproteinemia; laxatives; methylxanthines; monoamine oxidase inhibitors; neuromuscular blocking agents; organic nitrates; pancreatic enzymes; phenothiazines; prostaglandins; retinoids; agents for spasticity and acute muscle spasms; succinimides; thioxanthines; thrombolytic agents; thyroid agents; inhibitors of tubular transport of organic compounds; drugs affecting uterine motility; anti-vasculogenesis and angiogenesis; vitamins; and the like; or a combination thereof.
[0033] The invention includes means for co-localizing sheath and core polymer solutions at multiple sites of Taylor cone formation during an electrospinning process so that core-sheath fibers are produced. In certain embodiments, devices of the invention comprise a hollow vessel having a lengthwise slit therethrough, through which a solution of the core polymer can be introduced. Flow of both core and sheath polymer solutions is initiated and an electric field is introduced. These steps are performed in any suitable order: for example, in some embodiments, flow of the core polymer solution is initiated, a field is introduced and Taylor cones and electrospinning jets comprising core polymer solution are formed; then sheath polymer flow is initiated such that the sheath polymer is incorporated into Taylor cones and electrospinning jets. In other embodiments, the sheath polymer flow is initiated first, then the field is introduced and, after formation of Taylor cones and electrospinning jets, the core polymer flow is initiated. In still other embodiments, both polymer solutions are provided simultaneously, then the field is introduced, etc.
[0034] Application of an electric field of sufficient strength to apparatuses of the invention leads to formation of Taylor cones and electrospinning jets in the polymer solution or solutions. In some embodiments, Taylor cones and electrospinning jets are formed in the core polymer solution 230 , then the sheath polymer solution 260 is added alongside or above the core polymer solution 230 so that the sheath polymer solution 260 is drawn up into Taylor cones 240 and electrospinning jets 241 . In preferred embodiments, Taylor cones and jets are formed in the sheath polymer solution 260 and the core polymer solution 230 is added, preferably beneath the sheath polymer solution 260 , so that it is incorporated or pulled into electrospinning jets. As illustrated in FIG. 1 , this can be achieved, in preferred embodiments, by using an apparatus 200 comprising nested wedge-shaped vessels 210 , 270 in which an inner vessel 210 is positioned within an outer vessel 270 . A first slit 220 is located at one apex of the inner wedge shaped vessel; 210 , and a second, larger wedge-shaped vessel 270 is arranged so that a second slit 271 is aligned with the first slit 220 and a gap exists between the inner wedge-shaped vessel 210 and the outer wedge-shaped vessel 270 , permitting a solution of sheath polymer solution 260 to flow around the inner wedge shaped vessel 210 . The wedge-shaped vessels 210 , 270 may be oriented so that the slit is aligned with a vertical plumb line, or it may be angled with respect to a vertical plumb line so that extra core polymer solution 230 or extra sheath polymer solution 260 can run-off, preventing formation of inhomogeneities such as globs in the resulting fibers or other structures. The arrangement of the slit 271 of the bath 270 to the slit 220 of the inner vessel 210 is illustrated in FIG. 2 , which shows the slit 271 substantially surrounding the slit 220 . FIG. 3 shows multiple core-sheath Taylor cones 240 and electrospinning jets 241 emanating from the slit 270 when the apparatus is in use. A close-up image of a core-sheath Taylor cone is shown in FIG. 4 . The wedge shaped vessels, in preferred embodiments, include side walls that are angled 30° from the vertical, as shown in FIG. 18 .
[0035] The vessels 210 , 270 are made of a conducting material such as stainless steel, copper, bronze, brass, gold, silver, platinum, and other metals and alloys. Slits 220 , 271 preferably have a width sufficient to permit formation of Taylor cones 240 , generally between 0.01 and 20 millimeters, and preferably between 0.1 to 5 millimeters. The length of vessels 210 , 270 is preferably between 5 centimeters and 50 meters, and more preferably between 10 centimeters and 2 meters.
[0036] Metals used to form portions of apparatuses of the invention may be polished, brushed, cast, etched (by acid or other chemical or mechanically) or unfinished. The metal finish may be chosen to affect an aspect of the performance of the apparatus; for example, the inventors have found that using polished brass improves the flow of polymer solution. Alternatively, non-metal materials or insulating materials may be used to form all or a part of the components used within the apparatuses of the present invention.
[0037] The materials used to form the core and sheath portions of the fibers formed in the present invention are placed into solution before being introduced into the apparatuses that are used for fiber formation. The core polymer solution preferably has a viscosity of between 1 and 100,000 centipoise, and is preferably pumped through the inner vessel 210 at rates of between 0.01 and 1000 milliliters per hour per centimeter, more preferably between 5 and 200 milliliters per hour per centimeter. A voltage, preferably between 1 and 250 kV, more preferably between 20-100 kV, is applied. The positive electrode of the power supply is preferably connected to one or both of the vessels 210 , 270 such that a potential exists between one or both of the vessels and a grounded collector that is placed at a distance. In alternate embodiments the collector is oppositely charged relative to the polymer solution(s). In some embodiments, the collector 250 includes one or more grounded or oppositely charged points (for example, two grounded points separated by a space), and fibers collect around the one or more points and/or between them. Upon application of a sufficient voltage, Taylor cones 240 and electrospinning jets 241 will form at the exposed surface of core and/or sheath polymer solution(s) 230 , 260 and the jets will attract towards the collector.
[0038] In preferred embodiments, core and/or sheath polymer solutions 230 , 260 are provided to the interior and exterior, respectively, of the vessel 210 at the slit 220 in a steady, laminar fashion such that fluid velocity and pressure of the core and/or sheath polymers 230 , 260 are constant across the width of the slit 230 over time. Such steady, laminar flow can be achieved by a variety of methods, which may be used alone or combined, and the inventors have found that driving polymer flow pneumatically, hydraulically, mechanically (piston-driven) or by gravity can result in a suitably consistent supply of the required fluids; this aim can also be met by employing flow directing structures such as diffusers in flow paths for the core and sheath polymers 230 , 260 .
[0039] With respect to pneumatic driving of fluids, FIG. 6 shows apparatuses of the invention utilizing reservoirs 231 , 261 for core polymer solution 230 and sheath polymer solution 260 , respectively. Each of the reservoirs includes one or more gas inputs 280 , each of which preferably located opposite a conduit 232 , 262 for the core and sheath polymer solutions 230 , 260 , respectively. For example, in the embodiments of FIG. 6 , gas is provided via inputs 280 at the top of the reservoirs 231 , 261 , and polymer solutions exit via conduits 232 , 262 at the bottom of the reservoirs. The conduits of the apparatus 200 preferably have a width that is roughly the same as a width of the slit 220 , thus minimizing the formation of spreading flows and eddies that may result in variances of fluid velocity or pressure across the width of the slit 220 . In some embodiments, turbulent and/or uneven flows are minimized by removing sharp angles or curves from the flow paths from the reservoirs 231 , 261 through the conduits 232 , 262 to the slit 220 ; the flow paths may be, in some embodiments, substantially linear. It will be appreciated that solutions can also be injected through the inputs 280 leading to reservoirs 231 , 261 and 280 to permit continuous electrospinning.
[0040] Any suitable gas may be used to drive the flow of core and/or sheath fluids 230 , 260 , including air, but in preferred embodiments a non-reactive or inert gas is used such as nitrogen, helium, argon, krypton, xenon, carbon dioxide, helium, nitrous oxide, oxygen, combinations thereof and the like. The gas used to drive flows is optionally insoluble in the solvents used in the core or sheath polymer solutions 230 , 260 to prevent the formation of gas bubbles during electrospinning. Additional steps may be taken to prevent bubble formation during electrospinning, including de-gassing the core and sheath polymer solutions 230 , 260 prior to use and separating the gas used to drive fluid flows from the polymer solutions 230 , 260 through the use of an impermeable membrane or piston. In some embodiments, an inflatable balloon is used to displace polymer solutions 230 , 260 from the reservoirs 231 , 261 . The reservoirs 231 , 261 and the gas inputs 280 are preferably sufficiently airtight to prevent leakage at the gas pressures used.
[0041] As shown in FIG. 7 , pneumatic driving mechanisms may include pressure regulators ( FIG. 7A ) to ensure that gas is provided at a constant pressure, which in turn will advantageously permit the maintenance of even fluid flows during electrospinning In some embodiments, pneumatic pressure is generated through the use of a piston 285 to compress a fixed volume of gas in an airtight vessel such as a polymer solution reservoir. Finally as shown in FIG. 7C-D , in some embodiments, multiple air inlets 280 are used to ensure pneumatic pressure is applied evenly across the width of the reservoir 231 / 261 and, in turn, that the fluid velocity and pressure is kept even across the width of the slit 220 .
[0042] With respect to hydraulic driving of fluids, as shown in FIG. 8 A-B, in preferred embodiments a fluid 281 such as water will be used to displace a piston 285 which then displaces a polymer solution such as the core polymer solution 230 toward the slit 220 . As discussed above, the piston 285 preferably moves through a reservoir or a conduit having a width approximately equal to a width of the slit 220 , and the piston 285 itself preferably has a width substantially equal to the width of the slit 220 . Also as discussed above, an inlet for the fluid 281 and the piston 285 can be disposed within a reservoir opposite a conduit, or in any other suitable arrangement.
[0043] In some embodiments, the piston includes one or more sealing features 286 such as gaskets or O-rings to prevent the driving fluid from mingling with the polymer solution. This aim may also be achieved in some embodiments by tailoring the surfaces of the piston 285 and/or the reservoir to repel the fluid 281 used to drive the piston 285 —for example, in embodiments where water is used to drive the piston 285 , the piston and the wall of the reservoir may include hydrophobic surfaces to prevent the migration of water past the piston.
[0044] With respect to piston-driven fluids, piston 285 may be made of any suitable material, including plastics, metals and combinations thereof. In some embodiments, the piston 285 is made of a material that is the same as or similar to a material included in the vessel 210 ; in other embodiments, the piston is non-conductive and/or includes a dielectric material. The piston preferably includes a material that is non-reactive with the polymer solutions 230 , 260 . The piston and/or the reservoir may include a coating or surface to render it non-reactive and/or to prevent a gas or liquid used to drive the piston from mingling with the polymer solution. The piston and/or the reservoir may also include a coating to minimize friction between the piston and the walls of the reservoir to prevent binding between the piston to the walls and variation in fluid velocities and pressures delivered to the slit 220 .
[0045] Pistons may be driven pneumatically, hydraulically (as discussed above) or by mechanical actuators such as screw actuators or linear actuators. Multiple pistons may be used to drive core polymer solution 230 and sheath polymer solution 260 . As shown in FIG. 8E , in some embodiments, sheath polymer solution is driven by multiple pistons 285 A which are coupled to one-another to ensure the supply of sheath polymer solution is consistent on either side of the slit 220 .
[0046] Pressure diffusers can be used to even out flow across a vessel and/or a slit for electrospinning Pressure diffusers, as the term is used herein, refers to structures that obstruct at least a portion of a flow path to re-direct a relatively narrow stream of fluid over a larger area. A pressure diffuser may include holes, slits, or other apertures to permit fluid to flow through the diffuser. A diffuser may also include angled, curved, or beveled surfaces to force fluid contacting such surfaces to flow in desired directions around the diffuser. One or more diffusers can be arranged, in parallel or in series, across a flow path to more fully diffuse the flow of a solution. The diffuser can include surfaces parallel to, perpendicular to, or otherwise angled to a desired direction of flow. A selection of diffusers compatible with the invention are illustrated in FIG. 11 .
[0047] With respect to gravity-driven fluid flows, in such embodiments, a reservoir such as a core polymer solution reservoir 231 will be positioned above the hollow vessel 210 and the slit 220 , such that the polymer solution 230 / 260 will flow downward by gravity from the reservoir toward the slit. The apparatus 200 includes a vent or valve through which air can enter the reservoir 231 / 261 to occupy space vacated by polymer solution 230 / 260 as it flows toward the slit 220 .
[0048] In some embodiments, the polymers used in the present invention include additives such as drug particles, metallic or ceramic particles to yield fibers having a composite structure.
[0049] Other suitable vessel geometries may be used in accordance with the present invention, including round designs as shown in FIG. 13 and as described in Example 8. The methods and apparatuses described above can be adapted and/or combined to form core-sheath fibers using a round vessel having a round slit. Core polymers and sheath polymers can be provided to the slit in a round vessel using nested annular flow paths, as is illustrated in FIG. 13E ; these annular flow paths are compatible with piston-driven, hydraulically-driven, or pneumatically driven polymer systems described above.
[0050] In addition, although the disclosure focuses on systems and methods utilizing a single lengthwise slit, any suitable aperture geometry may be used, including without limitation multiple short slits, holes, curved slits, slits and holes together, etc. Similarly, the invention includes systems and methods utilizing complex three-dimensional arrangements, such as that shown in FIG. 15 , utilizing multiple disks 350 , each disk containing three troughs in a manner similar to that shown in FIG. 5 - a central trough 310 for the core polymer solution 220 flanked by troughs 320 , 330 for the sheath polymer solution 260 . In the system of FIG. 15 , the core and sheath polymer solutions are supplied by a central line 360 connected to each disk. Upon application of an electrical field, Taylor cone formation and formation of electrospinning jets occurs in a radially outward direction, and the resulting fibers are collected on a grounded collector 370 disposed circumferentially about and at a suitable distance from the disks 350 .
[0051] Preferred embodiments of the invention utilize elongate areas including slits for electrospinning. Using elongate areas rather than, say, radially symmetrical or square areas advantageously permits multiple solutions or materials to be continuously and evenly supplied to sites of Taylor cone and electrospinning jet formation such that they are closely apposed, yet remain separate. In non-elongate areas such as squares, Taylor cones and electrospinning jets that form in the center of the area tend to deplete the supply of materials or polymer solutions in the center of the area, which materials cannot be replaced as efficiently and evenly while remaining in an unmixed fashion as is possible in narrower, more elongate areas. In addition, the use of elongate areas provides a straightforward path to scaling-up fiber production: as the long dimension of the elongate area increases, it is possible to form more Taylor cones and electrospinning jets within the area, yet by keeping a short dimension relatively constant, materials and polymer solution can be rapidly supplied from alongside or underneath the area to prevent depletion. Suitable dimensions for slits in apparatuses of the invention are disclosed in Examples 7 and 8, below.
[0052] The systems and methods described herein can be adapted to form structures other than core-sheath fibers. For example, core-sheath particles may be formed using core and/or sheath polymer solutions with low viscosity. Upon introduction on an electric field, Taylor cones and structures similar to electrospinning jets (which are referred to as “spray jets” herein) will form. Due to the low viscosity of the solutions, the spray jets will break-up midstream leading to particle formation. Optionally, vibration can be used to disrupt the flow of the core and/or sheath solutions to further encourage the formation of spray jets and/or particles.
[0053] The invention also includes combinations of the systems and methods described above. For example, structures incorporating multiple sheath polymers can be formed using a vessel/bath setup as described above in combination with a syringe pump to provide a second sheath polymer solution to sites of Taylor cone formation.
[0054] In some embodiments, one or more of the core polymer solution and the sheath polymer solution is delivered in a pulsatile manner to create fibers with gradients of core densities and/or sheath thicknesses.
[0055] The invention includes systems and methods in which limited or no structure is used to separate core and sheath polymer solutions 220 , 260 . As shown in FIG. 16C , multiple polymer solutions may mix poorly such that little or no structural separation between core and sheath polymer solutions 220 , 260 is necessary to form structures with distinct cores and sheaths. In the embodiment depicted in FIGS. 16A-B , core polymer solution 220 is provided at discrete points within an electrospinning vessel; the remainder of the vessel is filled with sheath polymer solution, and a field is then applied to initiate electrospinning.
[0056] The devices and methods of the present invention may be further understood according to the following non-limiting examples:
Example 1
Electrospinning Conditions for Various Slit/Hole Geometries
[0057] Slit-surfaces of various geometries were fabricated and the formation of electrospinning jets from these surfaces was demonstrated. FIG. 10 shows slit-surfaces that are (A) continuously linear, (B) continuously circular, (C) continuously linear with holes, and (D) non-continuous holes. The respective dimensions of slits or holes and the electrospinning conditions used therefore are presented in Table 1, below:
[0000]
TABLE 1
GEOMETRIES AND ELECTROSPINNING CONDITIONS
FOR APPARATUSES SHOWN IN FIG. 10:
Slit
Apparatus
Polymer
Slit
Electric
Geometry
Geometry
solution
dimensions
Flow rate
Flow Source
field
Continuously
Wedge
6 wt % PLGA
0.5 mm ×
60 ml/hr
Underneath
40 kV
linear
75/25 in TFE
35 mm
Continuously
Annular or
2 wt % PLGA
1 mm ×
120 ml/hr
Underneath
40 kV
circular
Showerhead
85/15 in
80 mm
Chloroform/
Methanol(6:1)
Continuously
Tube
2.5 wt % PLGA
8 cm long
30 ml/hr
Ends
40 kV
linear with
85/15 in
holes
Chloroform/
Methanol(6:1)
Non-
Tube
2.5 wt % PLGA
5 cm long
20 ml/hr
Ends
40 kV
continuous
85/15 in
holes
Chloroform/
Methanol(6:1)
Example 2
Achieving Even Flow of Polymer Solutions Using Mechanical Piston
[0058] Even flow of polymer solution to a slit was achieved by the use of a mechanical piston. FIG. 17A-B depicts the apparatus used. The wedge-shaped slit fixture is attached to a chamber connected to a piston that is mechanically driven using a syringe pump. As the piston moves forward, it pushes solution uniformly towards the slit. Using a flow rate of 50 ml/h and a voltage of 50 kV, multiple electrospinning jets emerged along the entire length of the slit as shown in 25 C.
Example 3
Achieving Even Flow of Polymer Solutions Using Pressure Diffusers
[0059] Even flow of polymer solution to the slit was achieved by incorporating pressure diffusers to divert momentum of fluid flow across the slit. Shown in FIG. 11 are examples of such diffusers. In FIG. 11A , the diffuser is a triangular fixture that contains holes across its length to allow polymer solution to flow through. To demonstrate its ability to divert fluid flow, the diffuser was press-fit inside a container such that flow of solution is forced through its holes rather than around. As shown in FIG. 11B , a dyed solution of PLGA in chloroform:methanol that was pumped into the container from one inlet source encounters the diffuser, spreads across the length of the chamber, and then flows through the holes of the diffuser. The result is a more even distribution of fluid flow across the length of the chamber. Similarly, FIG. 11C shows a circular shaped pressure diffuser that contains holes across its surface. As shown in FIG. 11D series of these diffusers were press fit into a tube and filled with non-dyed polymer solution of PLGA in chloroform:methanol. A dyed solution of the same solution was then pumped into the tube from one inlet source at the bottom. Similar as before, the solution encounters the diffusers, spreads across the area of the tube, and then passes through the holes of the diffuse. The result is a more even distribution of fluid flow across the tube. Pressure diffusers can be incorporated into the apparatus of the invention to achieve even flow of polymer to the slit surface.
Example 4
Achieving Even Flow of Polymer Solutions Using Polymer Solution Re-Direction
[0060] Another method for even flow can be achieved by redirecting polymer solution to flow in the opposite direction of initial direction. Shown in FIG. 20 is an experiment in which a 2 wt % PEO solution in 60:40 (by vol) ethanol:water is pumped through a tube that faces down inside a container. The tube is placed 10 mm away from the bottom of the container and fluid flow is set at 50 ml/h. The solution contains a blue dye to visualize the fluid flow pattern. As demonstrated, solution initially travels in the downward direction and upon encountering the wall of the container, proceeds to spread across the bottom and rise up uniformly. This diversion of momentum of fluid flow concept can be incorporated into the apparatus of the invention to achieve even flow of polymer to the slit surface.
Example 5
Electrospinning of Core-Sheath Fibers Using Direct Feed of Polymer Solutions
[0061] Core-sheath fibers were manufactured using an apparatus according to the embodiment of FIGS. 1 and 2 . The apparatus consists of an inner trough with a slit width of 0.5 mm, while the width of the outer trough is 2 mm. The length of the entire slit is 7 cm. These wedge-shaped slits were affixed to a base fixture that allowed polymer solution to be directly delivered from inlet ports originating from the underside of the fixture.
[0062] A sheath solution 260 of 2.8 wt % 85/15 PLGA in 6:1 (by vol) chloroform/methanol and a core solution 230 of 2.8 wt % 85/15 PLGA in 6:1 (by vol) chloroform/methanol containing 30% wt % dexamethasone drug with respect to PLGA was used. The sheath flow rate was set at 100 ml/h while the core flow rate was set at 50 ml/h. A voltage of 50 kV was applied.
Example 6
Electrospinning of Core-Sheath Fibers Using Pneumatic Feed of Polymer Solutions
[0063] Core-sheath fibers were manufactured using an apparatus according to the embodiment of FIGS. 1-2 and 6 . The apparatus consists of an inner trough capable of holding 50 mls of polymer solution and outer troughs capable of holding 100 mls of sheath polymer solution. The slit width of the inner trough is 0.5 mm, while the width of the outer trough is 2 mm. The length of the slit is 3.5 cm. Polymer solution was delivered to the respective slits via pneumatic actuation using a syringe pump and empty syringe. A sheath solution of 6 wt % PLGA in hexafluoroisopropanol (HFIP) was delivered at 60 mL/min and a core solution 230 of 15 wt % PCL in 6:1 (by vol) chloroform/methanol containing 30% wt % dexamethasone drug with respect to PCL was delivered at a rate of 10 mL/min. A voltage of 50-60 kV was applied and numerous core-sheath jets were emitted from the slit-surface of the apparatus and fibers were collected. FIG. 3 shows multiple core-sheath Taylor cones 240 and electrospinning jets 241 emanating from the slit 270 when the apparatus is in use. The core-sheath structure of the resulting fibers was confirmed by scanning electron microscopy, as shown in FIGS. 5A-D , which includes multiple scanning electron micrographs of fibers 100 having distinct cores 120 comprising dexamethasone particles and sheaths 130 . FIG. 5E shows a control fiber made from a single PLGA/PCL/dexamethasone blend which does not exhibit the core-sheath structure.
Example 7
Electrospinning of Core-Sheath Fibers Using Pneumatic Feed of Polymer Solutions
[0064] Fibers with various core-sheath structures were fabricated using an apparatus according to the embodiment of FIGS. 1-2 and 6 . Core-sheath structure was varied by varying the outer sheath flow rate while keeping the core flow rate constant. The sheath solution 260 consisted of 6 wt % PLGA in hexafluoroisopropanol (HFIP) while the core solution 230 consisted of 15 wt % PCL in 6:1 (by vol) chloroform/methanol containing 30% wt % dexamethasone drug with respect to PCL. The core flow rate was kept constant at 20 ml/h while the sheath flow rate was adjusted to either 40 or 100 ml/h. A control fiber made from a PLGA/PCL/dexamethasone blend was also fabricated. To evaluate the different core-sheath structures, elution of the dexamethasone drug from fibers was evaluated. As shown in FIG. 22 , varying the sheath flow rate had the effect of varying the release kinetics of dexamethasone. Without wishing to be bound to any any theory, the inventors hypothesize that greater sheath flow rates led to thicker sheaths, which restricted diffusion of drug from fiber cores more completely than in fibers formed in conditions of lower sheath flow.
Example 8
Electrospinning from Circular Fixture
[0065] An apparatus incorporating a round slit rather than a linear one has been used. A showerhead fixture was modified, replacing a center piece with a plug to form a circumferential slit. When a 1 wt % PLGA solution was provided to the slit, multiple Taylor cones and electrospinning jets were observed, as shown in FIGS. 13 A and D.
[0066] The term “and/or” is used throughout this application to mean a non-exclusive disjunction. For the sake of clarity, the term A and/or B encompasses the alternatives of A alone, B alone, and A and B together. The aspects and embodiments of the invention disclosed above are not mutually exclusive, unless specified otherwise, and can be combined in any way that one skilled in the art might find useful or necessary.
[0067] The term “elongate” is used throughout this application to refer to structures having at least two dimensions, one dimension being longer, and preferably substantially longer, than the other(s). For the sake of clarity, the term “elongate” encompasses structures that are linear, cylindrical, cuboidal, curved, curvilinear, toroidal, annular, angled, rectangular, etc. and any structure that could be formed by bending or curving one of the elongate structures listed above.
[0068] While several embodiments of the present invention have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the present invention. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the invention may be practiced otherwise than as specifically described and claimed. The present invention is directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present invention.
[0069] The breadth and scope of the invention is intended to cover all modifications and variations that come within the scope of the following claims and their equivalents:
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Devices and methods for high-throughput manufacture of concentrically layered nanoscale and microscale fibers by electrospinning are disclosed. The devices include a hollow tube having a lengthwise slit through which a core material can flow, and can be configured to permit introduction of sheath material at multiple sites of Taylor cone formation formation.
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FIELD OF THE INVENTION
[0001] The subject invention relates to a jacketed power module that is attachable to an equipment panel. The power module may include a conductive jacket electrically connected to a conductive panel.
BACKGROUND OF THE INVENTION
[0002] It is known in the power connector technology to provide an electrical connector for a power connection through the enclosure of equipment. The equipment is typically provided with a conductive shell into which all of the hardware is mounted. The power module is typically provided as a socket which is mounted to a cutout in the rear panel of the equipment. An electrical extension cord is then plugged into the socket where contacts of the cord electrically connect terminals in the power module socket to provide power to the equipment.
[0003] It is also known to common a conductive jacket of the module to the conductive panel of the desktop computer. This is shown in Applicant's SRB series modules.
[0004] It is also generally known in the connector art to common a shield of an electrical connector to a conductive panel, by way of contacts on the shield to increase the conductivity between the shield and the panel, see for example, U.S. Pat. No. 5,752,854. Such contacts however, may become plastically deformed or may provide only point contacts between the shield and the panel.
SUMMARY OF THE INVENTION
[0005] The objects have been accomplished by providing a power module comprising an insulating housing; electrical terminals positioned in the housing; a jacket surrounding at least a portion of the insulating housing; and a spring positioned intermediate the housing and the jacket, spring loading the housing and the jacket in opposite directions along a substantially common axis.
[0006] In another aspect, a power module comprises an insulating housing; electrical terminals positioned in the housing, comprised of at least one ground terminal; a jacket surrounding at least a portion of the insulating housing; and a spring positioned intermediate the housing and the jacket, the spring commoning the ground terminal to the jacket.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a front perspective view of the power module of the present invention;
[0008] FIG. 2 is an exploded view of the module of FIG. 1 ;
[0009] FIGS. 3 and 4 are front and rear perspective views respectively, of an insulating housing used in the power module;
[0010] FIGS. 5 and 6 show front and rear view respectively, of the outer jacket for use with the power module of FIG. 1 ;
[0011] FIG. 7 shows a perspective view of the grounding spring;
[0012] FIG. 8 shows a side plan view of the grounding spring shown in FIG. 7 ;
[0013] FIG. 9 shows a partially fragmented view of the power module of FIG. 1 ;
[0014] FIG. 10 is a cross-sectional view through lines 10 - 10 of FIG. 1 ; and
[0015] FIG. 11 shows a cross-sectional view similar to that of FIG. 10 where the power module is connected to a conductive panel.
DETAILED DESCRIPTION
[0016] With reference to FIGS. 1 and 2 , power module 2 is generally comprised of an insulating housing 4 , a jacket 6 , power terminals 8 , a ground terminal 10 , a spring 12 , where the power module 2 is connectable to power conductors 14 , and to a ground conductor 16 , where the power conductors and the ground conductor form a power cable. With the above elements generally described, each of the elements will now be described in greater detail.
[0017] With reference now to FIGS. 1 , 3 and 4 , insulating housing 4 will be described in greater detail. Insulating housing 4 is comprised of an insulating flange 20 and an insulating body portion 22 . As shown best in FIGS. 1 and 3 , insulating housing 4 includes a front face 24 having a socket portion 26 extending therein which houses power terminals 8 and ground terminal 10 . With respect to FIG. 4 , the opposite end of body portion 22 shows bosses 28 and 30 , where boss 30 provides a planar surface 32 providing an end face. With reference still to FIG. 4 , bosses 28 circumscribe terminal receiving openings 36 for receipt of the power terminals 8 . Boss 30 circumscribes terminal receiving opening 38 for receipt of ground terminal 10 . Finally flange 20 defines a rearwardly facing surface 40 which, as will be described in greater detail later, is profiled for abutment against a panel.
[0018] With respect again to FIG. 2 , power terminals 8 and ground terminal 10 will be described in greater detail. Power terminals 8 include a male tab portion 50 , a wire-wrap portion 52 and an intermediate portion 54 . Ground terminal 10 includes male tab portion 60 and a rear contact portion 62 .
[0019] With respect now to FIGS. 5 and 6 , jacket 6 will be described in greater detail. It should be appreciated that jacket 6 may be comprised of many materials, as further described herein. However as shown jacket 6 is conductive, and is generally comprised of a conductive body portion 70 and a conductive flange portion 72 . As best shown in FIGS. 5 and 9 , body portion 70 includes an outer peripheral wall 74 having an inwardly directed strap portion 76 , which could be stamped from the jacket itself. Meanwhile, flange portion 72 includes a forwardly facing surface 78 which circumscribes a substantial portion of body portion 70 and is located opposite the rearwardly facing insulating surface 40 , when in the position shown in FIG. 1 . As shown in FIG. 6 , jacket 6 also includes a rear wall 80 having apertures 82 .
[0020] With reference now to FIGS. 7 and 8 , spring 12 is shown to include a flat spring portion 90 having an aperture 92 therethrough, a spring leg 94 having a retention member 96 and a wire-wrap portion 98 . Spring 12 could also be comprised of many different materials, but as shown is conductive. As such, spring 12 is a grounding spring, and is used in a dual sense; that is, spring 12 functions as a spring load feature, as well as a commoning mechanism to common the conductive jacket 6 and the ground terminal 10 . With the above described components, the assembly of the connector will now be described.
[0021] Power terminals 8 are first inserted in their respective passageways 36 into the position shown in FIG. 9 . Ground terminal 10 is then insertable into its respective opening 38 , and as installed, rear contact portion extends beyond planar surface 32 . Spring 12 may now be positioned such that aperture 92 ( FIG. 7 ) overlies rear contact portion 62 , and such that flat spring portion 90 ( FIG. 7 ) lies substantially flat against planar surface 32 ( FIG. 4 ). These two may now be soldered together to electrically and mechanically join the two. However, while solder is described herein, any number of connections may be made such as interference fit, welding, retention lances, and the like. The wire-wrap terminal portions 52 and 98 may now be connected to their associated insulated conductors in a known manner.
[0022] Jacket is now received over insulating body portion 22 whereupon spring leg 94 is receivable into strap portion 76 and whereby retention member 96 latches spring leg 94 in place. In the event that jacket 6 and spring 12 are both conductive, the strap portion 76 and spring leg 94 may also be soldered for further electrical and mechanical connection.
[0023] It should be appreciated that the insulating housing 4 and jacket 6 are connectable along a common axis, and that grounding spring 12 spring loads conductive flange 76 towards insulating flange 20 along the common axis. Thus, any movement of jacket 6 away from insulating body 4 attempts to “lift” grounding spring 12 , and more particularly flat spring portion 90 , off of its boss portion 30 , and attempts to pull the two back together.
[0024] For example, and as shown in FIG. 10 , module 2 is shown prior to connection to a panel. In this condition, flange 72 , and more particularly surface 78 ( FIG. 5 ) is positioned proximate to rearwardly facing surface 40 . However, when the jacket and the insulating housing 4 , are positioned within a cutout of a panel 100 as shown in FIG. 11 , flat spring portion 90 of spring 12 lifts off of planar surface 32 of boss 30 . Thus, when the module 2 is assembled to a panel cutout, with a panel positioned between the surfaces 40 , 78 , flange 72 is spring loaded against its counterpart panel.
[0025] It should be appreciated that only one embodiment of the invention has been depicted and the power module could take on many forms. For example, the jacket 6 could alternatively be comprised of an insulating material such as plastic, or alternatively, could be plated plastic. Also, spring many be nonconductive and only used for the spring load feature. A nonconductive spring could be used with a conductive or nonconductive jacket, or a conductive spring could be used with either conductive or nonconductive jacket.
[0026] Furthermore, the grounding spring could be of any shape and/or configuration, and need not be positioned flat against the boss 30 . Moreover, the jacket 6 , grounding spring 12 , and ground terminal 8 , could be all stamped and/or formed from a single piece of common material.
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A panel mounted power module is disclosed having an insulating housing and a conductive jacket. The insulating housing and the conductive jacket have corresponding flanges which oppose each other and are profiled to trap therebetween a panel. The power module includes a spring positioned between the insulating housing and conductive jacket, to spring load the flanges towards each other. The power module has at least one ground terminal and the spring commons the ground terminal and the conductive jacket together.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from U.S. Provisional Application No. 61/784,891, filed on Mar. 14, 2013, the disclosure of which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The present disclosure relates generally to electronic equipment or devices. In particular, the present disclosure relates to electromagnetic protection of electronic equipment, such as power utility electronic equipment, supervisory control & data acquisition (SCADA) systems, communications systems, data processing systems or other semiconductor-based electronic systems.
BACKGROUND
Electronic equipment, including equipment based on semiconductor technology, is susceptible to damage or binary state upsets from High Altitude Electromagnetic Pulse (HEMP or EMP), Intentional Electromagnetic Interference (IEMI) and RF interference. For example, stored data in modern electronic data systems, control systems and recording systems can be upset, scrambled or lost by EMP, IEMI or RF energy. At higher energy levels of EMP, IEMI or RF power the semiconductor devices within electronics units can be destroyed.
Damage based on exposure to electromagnetic fields is not limited to semiconductor-based electronic systems. For example, EMP and IEMI events can cause interference or upset and or damage to electrical equipment, causing that equipment to malfunction or rendering it nonoperational. Electrical equipment can also be destroyed by strong electromagnetic pulse (EMP), intentional electromagnetic interference (IEMI) or high power RF radiation. The detailed characteristics of EMP radiation are described in Military Standard 188-125, entitled “High Altitude Electromagnetic Pulse Protection for Ground Based C4I Facilities Performing Critical, Time-Urgent Missions”. The detailed characteristics of IEMI are described in IEC Standard 61000-2-13, “High-power electromagnetic (HPEM) environments-Radiated and conducted.”
In general, EMP/IEMI/RF events typically take one of two forms. First, high-field events correspond to short-duration, high electromagnetic field events (e.g., up to and exceeding 100 kilovolts per meter), and typically are of the form of short pulses of narrow-band or distributed signals (e.g., in the frequency range of typically 14 kHz to 10 GHz). These types of events typically generate high voltage differences in equipment, leading to high induced currents and burnout of electrical components. Second, low-field events (e.g., events in the range of 0.01 to 10 volts per meter) are indications of changing electromagnetic environments below the high field damaging environments, but still of interest in certain applications. Low field events can also cause upsets in the binary states of digital electronic equipment yielding non-functioning electrical or computing equipment.
Existing electromagnetic protection schemes are typically used to protect against a narrow range of threats. The protection schemes built into electronic systems or cabinets are generally developed to address a certain possible issue, and are not useful to address other electromagnetic interference issues. Although attempts have been made to “harden” or protect, certain military systems against these threats, many commercial electronic systems or cabinets remain unprotected. However, these existing “hardening” solutions are cost-prohibitive to apply to a wide range of electronics, exposing critical assets to possible damage. Additionally, existing solutions provide some amount of shielding, but are not designed to accommodate all of the cooling and access considerations required of many modern electronic system or cabinets. Additionally, earlier shielding attempts could at times limit the functionality of electronics included in such systems, since at times power or other signals would be entirely disrupted to avoid damage or upsets to internal electronics. Still further, many attempts to create shielding enclosures fail because of the strict manufacturing tolerances required to ensure that the enclosures can maintain a seal from outside sources of EMP/IEMI/RF signals. Because the vast majority of electronics remain unprotected from EMP/IEMI/RF events, a widespread outage or failure due to electromagnetic interference could have disastrous effects.
For these and other reasons, improvements are desirable.
SUMMARY
In accordance with the following disclosure, the above and other issues are addressed by the following:
In a first aspect, a shielding arrangement for electronic equipment is disclosed. The shielding arrangement includes a shielding enclosure having an interior volume, the interior volume defining a protected portion, the shielding enclosure further having one open side. The shielding arrangement further includes an enclosure frame welded to the open side of the shielding enclosure, and a door assembly having an opened and closed position, the door assembly providing access to at least the protected portion of the shielding enclosure and being secured to the enclosure. The door assembly includes a metal frame, a metal outer wall, a shielding curtain moveably attached to the metal frame, and an inflatable member positioned along a perimeter of the metal frame and between the metal frame and the shielding curtain. The inflatable member is selected and positioned to, when inflated, apply a uniform pressure to the shielding curtain toward the enclosure frame to form a seal when the door assembly is in the closed position.
In a second aspect, a method of shielding electronic equipment within an enclosure includes positioning electronic equipment within an interior volume of a shielding enclosure having an opening providing access to the interior volume, the opening surrounded by an enclosure frame. The method further includes closing a door to the shielding enclosure, thereby closing off the opening, and engaging one or more latches to affix the door in a closed position, the door including a shielding curtain positioned across the opening. The method also includes inflating an inflatable member positioned along a perimeter of the door frame, the thereby applying a uniform pressure to the shielding curtain toward the enclosure frame to form a seal therebetween.
In a third aspect, a door assembly for shielding electronic equipment includes a metal frame, a metal outer wall, a shielding curtain moveably attached to the metal frame, and a hollow, inflatable member positioned along a perimeter of the metal frame and between the metal frame and the shielding curtain.
In a fourth aspect, a latch for a door assembly includes a first mounting plate having a first plurality of hollow cylinders, positioned along an edge of the first mounting plate, wherein the first plurality of hollow cylinders each includes a gap in at least a portion of the hollow cylinders. The latch further includes a second mounting plate having a second plurality of hollow cylinders positioned along an edge of the second mounting plate, the second plurality of hollow cylinders offset from the first plurality of hollow cylinders such that, when the first and second mounting plate are aligned, the first and second plurality of hollow cylinders form a column of alternating hollow cylinders from the first and second pluralities of hollow cylinders. The latch further includes a latch hinge including a plurality of pins extending from a locking flange and movable between engaged and disengaged positions by sliding the latch hinge in a direction parallel with an axis through the column of alternating hollow cylinders. In the engaged position, the plurality of pins of the latch hinge are at least partially positioned within hollow cylinders of the first and second pluralities of hollow cylinders and a portion of the latch hinge connecting the plurality of pins to the locking flange extends through the gap in each of the first hollow cylinders. In the disengaged position, the plurality of pins of the latch hinge are positioned within the first plurality of hollow cylinders.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a shielding cabinet arrangement including an EMP/IEMI/RF protected enclosure providing protection against both radiated and conducted electromagnetic energy;
FIG. 2 shows an alternative rectangular enclosure embodiment;
FIG. 3 shows a latching hinge to connect the enclosure door and enclosure body shown in FIG. 1 ;
FIG. 4 illustrates an example embodiment of the enclosure door components of the arrangement of FIG. 1 ;
FIG. 5 illustrates a door tubular frame structure and a metal frame bracket;
FIG. 6 shows the door assembly including an inflatable member;
FIG. 7 shows the door components along with a shielding metal curtain hanging from hanger bolts;
FIG. 8 shows a cross-sectional view of the door assembly;
FIG. 9 shows an exploded view of the components of the shielding door assembly.
FIG. 10A shows a view of a hinge assembly useable to attach a door to an enclosure according to example aspects of the present disclosure;
FIG. 10B shows the hinge assembly of FIG. 10A in a locked position;
FIG. 10C shows the hinge assembly of FIG. 10A in an unlocked position; and
FIG. 10D shows the hinge assembly of FIG. 10A in a detachable arrangement used as a latch.
DETAILED DESCRIPTION
Various embodiments of the present invention will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the invention, which is limited only by the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the claimed invention.
In general the present disclosure describes, generally, shielded enclosures, such as electronic cabinets, that are capable of providing shielding from various types of electromagnetic events capable of upsetting and or damaging electronic equipment. In some of the various embodiments described herein, the shielded enclosures can be, for example, constructed of steel or aluminum that is sealed with welded seams and an inflatable member for sealing a metal cover, front panel or other closure surface. The shielded enclosures provide attenuation of radiated electromagnetic energy, such that harmful signals essentially cannot penetrate the enclosure. The shielded enclosures disclosed herein can also, in some embodiments, include electrical filters that provide a path for signals to enter and exit the enclosure, but greatly attenuate the unwanted electromagnetic conducted energy, which typically occurs at higher frequencies. Additionally, in some embodiments the shielded enclosures includes honeycomb waveguide air vents that also provide attenuation of radiated electromagnetic waves/energy, which also reduce unwanted EMP, IEMI and RF energy entering the enclosure, and reduce the risk of damage or upsets to electronic equipment within such electronic cabinets in a cost-effective and compact structure, while concurrently meeting management access and airflow management requirements of electronics systems.
In some embodiments, the present disclosure relates to a low cost and practical method to protect electronic equipment, including SCADA systems, Electrical utility breaker equipment, and communications systems from EMP, IEMI and RF weapons. Using the systems and methods of the present disclosure, SCADA, electrical utility breaker and communications electronics can be better protected from being destroyed or disabled by EMP, IEMI or RF weapons than unprotected equipment. According to various embodiments, the electronics are placed in an EMP/IEMI/RF shielded enclosure, and electrical or other communicative interfaces are sealed and filtered to prevent entry into that enclosure of unwanted signals to interfere with the electronic equipment. Signal filters (housed within one or more containers) are configured to filter out and remove all high frequency, for example greater than typically 14 kHz for EMP and greater than 1 MHz for IEMI, electromagnetic energy. In a first example embodiment shown in FIG. 1 , an enclosure 2 for an electronic device(s) is shown, which provides shielding from potentially damaging EMP/IEMI/RF signals. In the embodiment shown, the enclosure 2 includes a shielded enclosure 4 . The shielded enclosure 4 has an interior volume formed from a protected region 6 . In certain embodiments the shielded enclosure 4 has dimensions comprising of a length (e.g., about 2 to 5 feet), width (e.g., about 2 to 3 feet) and height (e.g., about 2 to 7 feet). The shielded enclosure 4 generally provides attenuation of potentially harmful electromagnetic signals for at least components placed within the protected region 6 . In various embodiments, the shielded enclosure 4 can be constructed from conductive materials, such as a metal (e.g., sheet metal or aluminum) having a thickness generally sufficient to attenuate electromagnetic signals to acceptable levels. In an example embodiment, the shielded enclosure 4 provides 80 dB or more of attenuation.
Generally, the shielded enclosure 4 can contain electronics that include digital or analog electronics; however, other types of electronics systems, including mixed digital/analog electronics could be used as well. In some example embodiments, the electronics can include digital or analog electronics, fiber to electrical signal converters, and power supplies. The electronics are shielded from the potentially harmful electromagnetic signals, and therefore are placed within the protected region 6 . In the context of the present disclosure, the electromagnetic signals that are intended to be shielded are high energy signals, typically having magnitudes and frequencies in typical communication ranges experienced by electronic systems. For example, the short duration, high energy signals provided by EMP/IEMI/RF events are shielded. In some embodiments it is recognized that electronics maintained within the protected region 6 will generally require power and/or communicative connections. Accordingly, in some embodiments, a plurality of filters are positioned at least partially within the protected region 6 , and configured to filter out signals outside of an expected frequency or magnitude range. Also in some embodiments, filters can provide filtration of electrical or communicative signals, and filters can provide filtration and “cleaning” of a power signal. In various embodiments, the filters could be, for example, band-pass, low-pass, or common mode filters, or even a surge arrester. Other types of filters could be included as well. In certain embodiments, the signal output by the power filter is passed to a power supply, which regulates the received, filtered power signal (e.g., a DC or AC signal) and provides a power signal (e.g., a direct current signal at a predetermined voltage desired by the electronics).
In certain embodiments, the enclosure 4 can also contain fiber-optic equipment; accordingly, a waveguide beyond cutoff can be included, and a fiber-optic cable can be extended from external to the enclosure, through an unprotected region, and into the protected region 6 (e.g., to a fiber converter). The waveguide beyond cutoff can be configured to allow optical signals of a predetermined frequency to pass from the unprotected portion to the protected portion, while filtering undesirable signals of different frequency or magnitude.
Furthermore, it is recognized that in many circumstances, the electronics included within an enclosure 4 may require airflow, for example for cooling purposes. In certain embodiments, the enclosure 4 includes a plurality of vents (not shown) through the enclosure 4 which allow airflow from external to the enclosure to pass into the protected region 6 . In certain embodiments, the vents can be positioned in alignment to allow a flow-through, aligned configuration. In alternative embodiments, different positions of vents could be used. Each of the vents can include a waveguide beyond cutoff having one or more honeycomb-shaped or otherwise stacked shapes and arranged apertures configured to shield the interior volume of the enclosure 2 , including the protected region 6 , from exposure to electromagnetic signals exceeding a predetermined acceptable magnitude and frequency. For example, signals up to 10 GHz and up to exceeding about 14 kHz, or about 100 kilovolts per meter, can be filtered by correctly selected sizes of waveguide apertures. Example vents, as well as additional features relating to electromagnetically-shielding enclosures and methods for sealing such enclosures, are provided in co-pending U.S. patent application Ser. No. 13/285,581, filed on Oct. 31, 2011, the disclosure of which is hereby incorporated by reference in its entirety.
In the preferred embodiment, the shielded enclosure 4 has an enclosure frame 8 welded around the perimeter of the shielded enclosure 4 . The enclosure frame 8 is secured to shielded enclosure 4 with a high quality weld such that cracks and pin holes are avoided so that IEMI and EMP energy is prevented from entering the enclosure 4 . In certain embodiments, the enclosure frame 8 can be made from steel, having a nickel or nickel-based coating. The enclosure frame 8 can also be constructed to have a planar and smooth front surface, for example by applying a surface grind operation thereto. The enclosure frame 8 having a shielded door assembly 10 secured to a side of the enclosure frame 8 by a plurality of latch hinges 12 . The shielded door 10 provides a high attenuation of electro-magnetic energy, IEMI and EMP, when the door is in its closed position energy will not enter the protected region 6 .
In certain embodiments the door assembly 10 is comprised of a tubular door frame 14 having a shielding curtain 16 attached to the interior side of the door frame 14 , closest to the protectable region 6 . In some embodiments, the interior side of the door frame 14 can also be constructed to have a planar and smooth surface finish, for example by applying a surface grind operation thereto. In certain embodiments, the shielding curtain 16 can be made of steel and be nickel coated. Also, in some embodiments, the shielding curtain may also be constructed to have a planar and smooth surface finish, for example by applying a surface grind operation thereto. When the door is closed, the curtain 16 mates with the nickel coated enclosure frame 8 , such that the mating surfaces will provide a high attenuation seal to prevent IEMI and EMP energy from entering the protected region 6 . Details regarding this mating arrangement are provided in further detail below.
In a second possible embodiment, such as is shown in FIG. 2 , below, an electrically conductive or RF material can be used around the perimeter of the enclosure frame 8 to provide a gasket seal between the enclosure frame 8 and the door curtain 16 . This gasket material around the perimeter of the enclosure frame 8 could be several millimeters in thickness and have a width of one to three inches. This gasket material could be glued in place onto the enclosure frame 8 . An additional metal frame could be placed around either the outer or inner perimeter of the gasket material to provide a physical stop such that the gasket material would be accurately compressed to within a specified tolerance to achieve high electromagnetic (RF/IEMI/EMP) attenuation.
FIG. 2 shows an alternative rectangular shaped shielded enclosure 100 , according to a second possible embodiment. The shielded enclosure 100 has an interior volume formed from a protected region 102 and an unprotected region 106 . In comparison to enclosure 2 of FIG. 1 , enclosure 100 is designed to be a generally larger enclosure, having dimensions at an upper end of the above-described range.
The shielded enclosure 100 has an interior volume formed from a protected region 102 and an unprotected region 104 . The unprotected enclosure 104 can be sealed with an electrically conductive or RF gasket around the perimeter of the unprotected enclosure 104 . The unprotected portion 104 can house the various signal or Ethernet signal filters for signal inputs and outputs from the enclosure, as necessary based on the type of electronics included in the overall arrangement 100 . In certain embodiments, the enclosure 100 can also contain fiber-optic equipment; accordingly, a waveguide beyond cutoff can be included, and a fiber-optic cable can be extended from external to the enclosure, through the unprotected region 104 , and into the protected region 102 (e.g., to a fiber converter). Additionally, vents, such as those discussed above, could be included as well.
In the embodiment shown, the shielded enclosure 100 has an enclosure frame 106 welded around the perimeter of the shielded enclosure 100 . The enclosure frame 106 being secured to shielded enclosure 100 with a high quality weld such that cracks and pin holes are avoided so that RF, IEMI and EMP energy is prevented from entering the enclosure 100 . As noted above, enclosure frame 106 can also be constructed to have a planar and smooth front surface, for example by applying a surface grind operation thereto. In certain embodiments, the enclosure frame 106 can be made from steel and have a nickel coating.
The enclosure frame 106 has a shielded door assembly 108 secured to a side of the enclosure frame by a plurality of latch hinges 12 . The shielded door assembly 108 provides a high attenuation of electro-magnetic energy, RF, IEMI and EMP, such that when the door is in its closed position energy will not enter the protected region 102 . In certain embodiments the door assembly 108 is comprised of a tubular frame 112 having a shielding curtain 114 attached to the interior side closest to the protectable region 102 . In certain embodiments, the shielding curtain 114 can be made of steel and be Nickel coated such that when it mates with the nickel coated enclosure frame 106 the mating surfaces will provide a high attenuation seal to prevent IEMI and EMP energy from entering the protected region 102 .
In some embodiments, an electrically conductive or RF gasket material 116 can be used around the perimeter of the enclosure frame 106 to provide a gasket seal between the enclosure frame 106 and the shielding curtain 114 . This gasket material 116 around the perimeter of the enclosure frame 106 could be several millimeters in thickness and have a width of one to three inches. The gasket material 116 could be glued or otherwise affixed in place, onto the enclosure frame 106 . An additional metal frame (not shown) could be placed around either the outer or inner perimeter of the gasket material 116 to provide a physical stop such that the gasket material 116 would be accurately compressed to within a specified tolerance to achieve high electromagnetic (RF/IEMI/EMP) attenuation when the door of the enclosure is in a closed position.
FIG. 3 shows a detailed view of the latch hinge 12 shown in FIGS. 1 and 2 . In certain embodiments the latch hinges 12 may be located on the sides of the enclosure frame 8 , on the top and bottom of the enclosure frame 8 , or both. The latch hinge 12 includes two mounting plates 18 , 20 : a first mounting plate 18 is mounted to the metal tubular door frame 14 and the second mounting plate 20 is mounted to the enclosure frame 8 . In certain embodiments, the mounting plate 20 secured on the enclosure frame 8 includes a plurality of vertical hollow cylinders 22 , typically steel or other durable material, spaced along the edge closest to the door opening. The mounting plate 18 can also include a plurality of vertical hollow cylinders 24 located closest to the enclosure opening. The vertical hollow cylinders 24 on the door mounting plate 18 are complementary to the vertical hollow cylinders 22 on the enclosure frame mounting plate 20 such that when the door is in the closed position the vertical hollow cylinders 22 , 24 align in a vertical stack of alternating hollow cylinders. Such an arrangement allows for a pin to be placed between the hollow cylinders 22 , 24 so that door frame 14 and enclosure frame 8 can rotate relative one another via a fixed axis of rotation.
In some embodiments and as best shown in FIG. 10A , the door frame mounting plate 18 or the enclosure frame mounting plate 20 can include a latch 26 . The latch 26 includes a plurality of pins 28 positioned to align with the vertical stack hollow cylinders 22 , 24 . In the embodiment shown, the latch 26 has three positions: open, closed and locked. In the open position, the pins 28 on the latch 26 are in a retracted position generally removed from the vertical hollow cylinders 22 , 24 (as seen in FIG. 10D ). To move to the closed position, the latch 26 is rotated in an outward direction (e.g., toward one of the mounting plates 18 , 20 ). When rotating the latch 26 to a predetermined position, the pins 28 slide vertically downward in the vertical hollow cylinders 22 , 24 of the mounting plates 18 , 20 (as seen in FIG. 10B ). This is due to the portion of the latch 26 extending from the pins aligning with an open portion, or gap, in the hollow cylinders 22 , 24 . Once the door frame 14 is in a closed position, and the mounting plates 18 , 20 are mated together and the latch pins 28 slides into the gap in vertical hollow cylinders 22 , 24 . In this “engaged” position the pins 28 reside at least partially within both hollow cylinders 22 , 24 . By way of contrast, in the open position, the pins 28 will reside only within one of the pluralities of hollow cylinders (e.g., hollow cylinders 22 ).
To achieve the locked position, both the latch 26 and the mated mounting plate are adapted to have a locking flanges 30 , 31 to accept an external lock (e.g. lock 50 ) so that the bolt on the external lock passes through both locking flanges 30 , 31 . In the locked position, the mounting plates 18 , 20 are pivotably connected such that the mounting plates and latch 26 operate as a hinge. To open the door assembly 10 , a user will disengage at least one such latch hinge 12 on one side of the frame, allowing a latch hinge on an opposite side to act as a hinge and pivot the door open (or, alternatively, to disengage all latch hinges 12 , thereby removing the shielded door assembly 108 from the enclosure frame 106 altogether to access the protected region 102 . To accomplish disengagement of a latch hinge 12 , the latch 26 is lifted and rotated away from the enclosure 4 , as shown in FIG. 10C, 10D ). This will disengage the pins 28 . Such an arrangement allows for the user of the enclosure 4 to open the door assembly 10 from either side of the enclosure 4 , and in certain embodiments the door 10 may be opened upwards or downwards when latch hinges 12 are located on the top and bottom of the enclosure 4 . In still further embodiments, the latch hinges 12 can all be disengaged and the shielded door assembly 108 can be removed altogether from the enclosure frame 106 .
Now referring to FIGS. 4-9 , specific features of a door assembly are shown. The features of the door assembly are discussed in connection with door assembly 10 of FIG. 1 ; however, it is understood that equivalent features could be incorporated into door assemblies adapted for use with enclosures of various sizes, including the enclosure 100 shown in FIG. 2 . Additionally the features of the door assembly as illustrated in FIGS. 4-9 can be used either with or without use of a gasket, such as the gasket 116 shown in connection with FIG. 2 , above.
As shown in FIG. 4 , in certain embodiments the structure of the door assembly 10 is comprised of a metal tubular door frame 14 to achieve high stiffness. Attached to the metal tubular door frame 14 is an outer wall 32 , which may be welded to the metal tubular door frame 14 .
FIG. 5 shows an extruded metal frame bracket 34 fastened to the metal door frame 14 . In the embodiment shown, the frame bracket 34 is constructed from aluminum and has a channel 36 disposed around the perimeter of the frame bracket 34 . However, in alternative embodiments, other materials could also be used. Still further, in some embodiments the structure of the metal frame bracket 34 can be incorporated into the metal tubular door frame 14 itself.
In FIG. 6 , an inflatable member 38 is shown positioned within the channel 36 . In some embodiments, the inflatable member 38 may be secured to the frame bracket 34 by glue or epoxy. In some embodiments the inflatable member 38 has a hollow central cavity, and is inflatable by an inflation device (e.g. device 52 ) or other means for pressurizing the inflatable member, such as a compressor or pressurized gas bottle. In some embodiments the inflation device can be a compressor connected to an external power source. In other embodiments disposable gas canisters can be used so that external power is not required to inflate the inflatable member. The compressor or pressurized gas bottle can be adapted to supply a fixed amount of compressed gas or air to ensure that the inflatable member 38 is not over inflated or under inflated. In certain embodiments, the inflatable member 38 will be inflated to 10 psi. In some embodiments, the compressor or pressurized gas bottle can be located inside of the shielded enclosure 2 . For example, the compressor or pressurized gas bottle may be located inside the door frame 14 , between the shielding curtain 16 and outer wall 32 . In other embodiments, the compressor or pressurized gas bottle may be located external of the shielded enclosure 2 .
FIG. 7 shows a shielding metal curtain 16 hanging from a plurality of hanging bolts 40 secured to the frame bracket 34 . In certain embodiments the hanging bolts 40 include a threaded portion that can be threaded in the frame bracket 34 and a collar portion of which the metal curtain 16 is adapted to slide upon.
FIG. 8 shows a cross-sectional view of the door assembly 10 . When in their secured position, the hanging bolts 40 do not tightly press the metal curtain 16 against the frame bracket 34 . Rather, the metal curtain 16 is free to slide upon the hanging bolt 40 over a distance A. In some embodiments the hanging bolts 40 may have a diameter smaller than that of the diameter of the holes in the metal curtain 16 so that the metal curtain may hang loosely on the hanging bolts 40 . This particular sizing allows for the expanding and contracting of the metal curtain 16 in the event of temperature changes. In addition, by relaxing the tolerances between the hanging bolts 40 and the metal curtain 16 , manufacturing becomes more affordable as the parts do not need to be as manufactured with a high degree of precision. In the preferred embodiment, the shielding metal curtain 16 is comprised of a flat metal sheet of steel that can be nickel coated to achieve low corrosion characteristics. A shielding metal curtain 16 is used to achieve a high attenuation seal around the entire perimeter of the door closure surface. It is noted that although metal curtain 16 is discussed in the context of FIG. 7 , equivalent teachings are applicable to curtain 118 of FIG. 2 .
In use, when the door assembly 10 and latch hinges 12 are in their respective closed positions, a user can activate the compressor or pressurized gas bottle to inflate the inflatable member 38 . When inflated, the inflatable member 38 expands and forces the shielding metal curtain 16 over a distance A against the enclosure frame 8 . Once the inflatable member 38 is inflated to the desired pressure the shielding metal curtain 16 is tightly pressed against the enclosure frame 8 with a uniform pressure around the door perimeter therefore sealing against the shielded enclosure 4 .
As noted above, the enclosure frame 8 can be ground to form a smooth and planar outer surface for mating with the shielding curtain 16 , such as by applying a surface grind operation. In addition, in some embodiments, the interior of the door frame 14 and the shielding curtain 16 may also be ground to have a smooth and planar surface to ensure effective mating between the door frame 14 , the shielding curtain 16 , and the enclosure frame 8 . Surface finishes for the enclosure frame 8 , the interior of the door frame 14 , and the shielding curtain 16 can range from less than about 1 RMS to about 250 RMS. In some embodiments, less than about 1 RMS surface finish may be accomplished with electro-less nickel plating, electro polishing or other method. In such cases, the enclosure frame can be attached to the enclosure generally either prior to or after such a grinding process is performed. However, and with respect to mating of the shielding curtain 16 and enclosure frame 8 when the door assembly 10 is in a closed position, in example embodiments, the shielding curtain 16 can be at least partially flexible, such that, when the inflatable member 38 expands, the shielding curtain 16 can be at least partially deformed to seal against the enclosure frame 8 .
Shown in FIG. 9 is an exploded view of the complete door assembly 10 . The frame bracket 34 is attached to the door frame 14 . The inflatable member 38 is positioned inside the channel 36 of the frame bracket 34 . Attached to the frame bracket is metal shielding curtain 16 by way of hanging bolts 40 .
Referring to FIGS. 1-9 generally, it is noted that, in the context of the present disclosure, the protective enclosures described herein are designed to accommodate a level of manufacturing variability, in that differences in manufacturing that would cause misalignment of a door assembly and door opening (thereby possibly leaving open a gap through which such EMP or IEMI signals could pass) are accommodated by way of the adjustably-positioned inner door panel and, in general, the door assemblies 10 , 108 . This allows for creation of enclosures that would otherwise be too large to apply high-manufacturing tolerance techniques, such as a “skin cut” for flatness after fabrication.
In addition, and still referring to FIGS. 1-9 overall, some embodiments of the electromagnetically protected electronic enclosure described above may provide one or more of the following advantages. First, the enclosure can be produced with more relaxed manufacturing tolerances on the shielding curtain because the pressure from the inflatable member will seal the enclosure. Second, the enclosure is forgiving of large departures from flatness on the shielding enclosure, due to the adaptability of the inflatable member, shielding metal curtain, and optional gasket. Third, the manufacturing costs may be lower than other electromagnetic protection enclosures, for example due to simple manufacturability. Fourth, various alternative sizes of doors or door frames are possible. Still other advantages may exist.
The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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Methods and devices for shielding electronic equipment within an enclosure are disclosed. One method includes positioning electronic equipment within an interior volume of a shielding enclosure having an opening providing access to the interior volume, the opening surrounded by an enclosure frame. The method further includes closing a door to the shielding enclosure, thereby closing off the opening, and engaging one or more latches to affix the door in a closed position, the door including a shielding curtain positioned across the opening. The method also includes inflating an inflatable member positioned along a perimeter of the door frame, thereby applying a uniform pressure to the shielding curtain toward the enclosure frame to form a seal therebetween.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention lies within the art of launching a trailerable boat. The specific field is with regard to trailerable ocean boats incorporating a deep “V” with a steep forward entry. With this hull design the bow is forward of the buoyancy level of the typical 12½ percent descent of launch ramps, making the launch and or retrieval difficult without subjecting the tow vehicle, boat, or even the launch facilities to potential damage.
2. Prior Art
The prior art consists of, and includes the designs of trailers with one or more hinge points to break the trailer horizontal beam to enable a lower trailer to hull support position to aid floatation. Another describes a telescopic center beam that when extended, allows a deeper launch, allowing the boat to float off the trailer. Another describes a device to raise and lower the trailer tongue to aid the launch.
The inventor has found, that when the stern, of a trailerable boat becomes buoyant, due to launch ramp depth, that adding a rotational component, of a replicated, sea swell type motion to mechanically lift the bow, aft or forward in the longitudinal axis, creates the equivalency of total buoyancy enabling a safe successful launch, and or retrieval, without compromise.
SUMMARY OF THE INVENTION
In summation, this invention complements a transport trailer, specifically designed to support a boat hull, by installing a powered pivotal support system to the forward trailer frame, to mechanically lift the trailer bound bow, of a boat, into, and out of, deeper buoyant water.
DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood by reference to the description below taken in conjunction with the accompanying drawings wherein:
FIG. 1 shows a perspective view of a transport trailer with boat hull, and powered pivotal launch and retrieval/positioning system in the transport mode.
FIG. 2 shows a perspective view of the powered pivotal launch and retrieval/positioning system in the launch mode.
FIG. 3 shows a perspective view of the powered pivotal launch and retrieval/positioning system as launched.
FIG. 4 shows a perspective view of the hull being positioned for retrieval.
FIG. 5 shows a perspective view of the “A” frame weldment in the top dead center retrieval mode.
FIG. 6 shows a detailed plain cross sectional view, 6 - 6 of FIG. 1 .
FIG. 7 shows a sectional view along and in the direction of lines/arrows 7 - 7 of FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Looking at FIG. 1 , it can be seen that a boat 14 is mounted in a stowage position aboard a trailer frame 11 of a boat transport trailer 10 . Looking more particularly at the boat trailer 10 , it can be seen that the bow 14 a of the boat is secured to the boat trailer 10 from the bow eye 12 location. Looking more particularly at FIG. 6 , a view along line 6 - 6 of FIG. 1 , it can be seen the bow eye 12 is attached to the bow 14 a with two fastening studs 15 that are respectively threaded into the bow eye 12 , and secured with hex nuts 18 bearing on washer 20 inside of the boat hull 14 .
Looking at FIG. 1 it can be seen that trailer 10 includes a pivotable frame 24 , which may sometimes be referred to as a weldment. Frame 24 has a wide end 24 a and a narrow end 24 b (wide and narrow relative to each other), and when frame 24 is in the form of an A-frame, the narrow end 24 b may be referred to as the apex end. The narrow end 24 b of the frame includes connector 25 ( FIG. 2 ) for securing the bow eye 12 to the trailer 10 . The wide end 24 a of a frame 24 is pivotally attached to a portion of the trailer frame 11 towards the front of the trailer 10 . The frame 24 may pivot from a first position, angled towards the front of the trailer 10 ( FIG. 1 ), to a generally vertical position known as “top dead center” or “TDC” ( FIGS. 2 , 5 ), to a second position, angled towards the rear of the trailer 10 ( FIG. 3 ). In the alternative, the frame 24 may pivot from the second position, angled towards the rear of the trailer 10 ( FIG. 4 ), to the “top dead center” or “TDC” positions ( FIGS. 2 , 5 ), to the first position, angled towards the front of the trailer ( FIG. 1 ).
The front of the trailer 10 includes a motive power source for pivoting the frame 24 from the first position towards the second position and from the second position towards the first position. To pivot the frame 24 from the first position towards the second position, the motive power source includes a powered cylinder assembly 22 , further described below, and having an extendible push rod 36 supporting a push fork 28 on the push rod 36 ′s free end. To pivot the frame 24 from the second position towards the first position, the motive power source includes a winch 44 , further described below.
Looking at FIG. 1 , it can be seen that the powered cylinder assembly 22 forms a strut to a quadrilateral formed by trailer 10 , frame 24 , winch support 42 , and winch belt assembly 46 , to prevent vertical movement of the bow eye 12 . Powered cylinder assembly 22 may include a pressurized fluid supply, such as a portable air supply 50 , pneumatically connected to a control regulator 48 . The gas output of the regulator 48 is connected to a pressure cylinder 23 . By adjusting regulator 48 , pressure cylinder 23 can be used to extend push rod 36 out of pressure cylinder 23 to rotate the frame 24 towards the second position (see arrow in FIG. 3 ) and its TDC position as described below.
Looking at FIG. 1 it can be seen that the frame 24 , powered cylinder assembly 22 with push rod 36 , and the trailer frame, form a triangular support apex.
Looking at FIG. 6 and FIG. 7 it can be seen that connector 25 comprises a bilateral connector fork having spaced apart connector fork arms 25 a . Each connector fork arm 25 a has a connector fork slot 25 b . The bow eye 12 is positioned between the connector fork arms 25 a . Looking at FIG. 6 it can be seen, that a horizontal push/pull bar 30 is centered within the bow eye 12 and fixed within the bow eye 12 . A resilient damping material 26 eliminates chatter during towing, to mediate shock, and to evenly distribute loads during rotation. Horizontal push/pull bar 30 , is received in the connector fork slots 25 b in the connector fork arms 25 a to secure the boat 14 to the frame 24 via the bow eye 12 .
Similarly, push fork 28 , connected to the free end of rod 36 of the powered cylinder assembly 22 , comprises a bilateral push fork having spaced apart push fork arms 28 a . Each push fork arm 28 a has a push fork slot 28 b therethrough; the push fork slots 28 b being coaxial. To connect the boat 14 , the frame 24 , and the push fork 28 , as shown in FIG. 6 and FIG. 7 , the bow eye 12 is positioned between the connector fork arms 25 a and the connector fork arms 25 a positioned between the push fork arms 28 a . The horizontal push/pull bar 30 , is received in the slots 25 b , 28 b in the two sets of arms 25 a , 28 a , and the bow eye 12 to secure the boat 14 to the frame 24 and the push fork 28 .
Looking at FIG. 2 , it can be seen that the triangular yoke 35 , and the winch belt 46 has been removed from the horizontal push/pull bar 30 .
To prevent unintentional loss of the push/pull bar 30 should it become unfixed from its position in bow eye 12 , a security lanyard (not shown) can be secured to port side slot 43 of the horizontal push/pull bar 30 .
In a first mode of operation, the boat 14 is moved from a stowage position ( FIG. 1 ) on the trailer 10 and released into the water. In particular, as shown in FIG. 2 , pressure cylinder assembly 22 is pressurized by control regulator 48 , connected to portable air supply 50 . This causes pressure cylinder 23 to extend outwardly rod 36 , causing the frame 24 to move from the first position, towards the TDC position, moving the boat upwardly and away from the front of the trailer, towards the rear of the trailer. When frame 24 reaches and passes TDC, push/pull bar 30 the boat 14 , the frame 24 , and the push fork 28 separate from each other via slots 25 b , 28 b . However, as shown by the arrow in FIG. 3 , gravity will take over and act on the bow 14 a and frame 24 and the bow 14 a and frame 24 will continue to fall rearward where, looking at FIG. 3 , it can be seen the powered cylinder 23 , the frame and the hull completely separate, by the continued downward and rearward motion of the bow 14 a and frame 24 , strictly due to gravitational assist. The boat 14 is thus released into the water.
In a second mode of operation, the boat 14 is to be retrieved from the water and moved into the stowage position on the trailer 10 . In particular, looking at FIG. 4 , it can be seen that the trailer 10 and boat hull 14 are in the retrieval mode. As shown in FIG. 6 , a two piece triangular yoke 35 , has been attached to the ends of horizontal push/pull bar 30 , the winch belt 46 has, been joined to the yoke by shackle 38 , and secured with shackle pin 40 . Looking more particularly at FIG. 4 it can be seen a lift strap 47 is attached to winch belt 46 , and to the frame 24 , that during retrieval, retraction of belt 46 and strap 47 provide an upward lift of the connector fork 25 thereof to receive the horizontal push/pull bar 30 within slots 25 b (see arrow). Continued advancement will enable the start of the longitudinal lift of bow 14 a and frame 24 toward the TDC position. Looking at FIG. 5 it can be seen, that the push yoke 28 , has been extended, by applying pneumatic air to pressure cylinder 23 , to a predetermined value, and horizontal push/pull bar 30 is received within slots 28 b . As the bow 14 a , is lifted longitudinally upward and forward, by winch 44 , the increased cylinder pressure is released by the pressure regulator 48 . When the frame 24 , has advanced passed TDC by winch belt 46 , connected to winch 44 , the effects of gravity assist will act on the bow 14 a and the frame 24 to complete the controlled rotation (see curved arrow in FIG. 5 ) of the frame 24 to join the apex position with pressurized cylinder 23 , whereby bow 14 a automatically drops into the stowage position on the trailer 10 . Looking at FIG. 1 it can be seen that the taunt winch belt 46 completes the quadrilateral structure for the towing/storage position.
The embodiments shown and described above are only examples. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the detail, including in matters of shape, size and arrangement of the parts within the principles of the present disclosure up to, and including, the full extent established by the broad general meaning of the terms used in the claims.
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A boat trailer is equipped with a powered boat launch and retrieval system that negates the shallow entry of a launch ramp. The system uses a weldment frame, pivotally connected to the trailer frame. The weldment frame works in combination with a powered cylinder, gravity's effect on the weldment frame and the hull of the boat to automatically release the boat into the water or automatically retrieve the boat from the water.
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FIELD AND BACKGROUND OF THE INVENTION
This invention relates in general to sewing machines and, in particular, to a new and useful device for initiating the movement of the thread catcher of a thread cutting device whose actuating linkage comprises a sensing lever adapted to be coupled with a control disc drivable synchronously with the looper shaft of the sewing machine.
A thread cutting device for sewing machines is known from German Pat. No. 1,125,742, wherein the movement of the thread catcher is initiated by means of a hand lever which may be actuated only during standstill of the machine, via a shift linkage. A locking lever cooperating with a cam plate is pivoted in a certain position of the cam plate to release the pawl of an entrainer disc. The pawl is secured on an intermediate shaft connected with the looper drive shift, so that the pawl comes into operative position, in which it comes into engagement with a driver pin secured on a gear loosely mounted on the intermediate shaft and connected with the looper drive shaft via a gear pair. Via the pin and the pawl, as the rotation of the machine continues, the entrainer disc is driven by the intermediate shaft, from which via a crank, a coupling and a disc loosely mounted on the looper drive shaft, the movement required for thread cutting is imparted to the thread catcher. A cam plate provides for the control of the locking lever to bring the pawl into its inoperative position outside the movement path of the pawl at the end of the cutting process.
Since this cutting device can be operated for thread cutting only at standstill of the machine, it has been proposed by German Pat. No. 1,159,247, to provide a shifting shaft parallel to the looper drive shaft, consisting of two sections connected by a compensating clutch, with one section being non-displaceable axially, while the other section is axially movable. The axially non-displaceable section is connected with the thread cutting device, while the other section can be brought into operative connection with a control disc secured on the looper shaft. A compression spring is disposed on this section which takes support at one end against a stop secured on it and at the other end against an axially displaceable bushing disposed on this section for axial displacement and which applies against a hand- or foot-operated shifting fork. An abutment ring is arranged on the axially movable section, the end face of which cooperates with a locking lever in a drive connection with the looper drive shaft via a friction clutch. The locking lever applies against the axially movable section next to the end face of the abutment ring due to the torque acting on it via the friction clutch when the machine is running. If the bushing is axially displaced by the shifting fork and the compression spring is thus tensioned, to initiate the thread cutting process while the machine is running, the locking device will prevent a displacement of the axially movable section. The switch-on pulse, is therefore stored.
After the machine has been stopped, the looper drive shaft rotates back a small amount counter to its operative direction of rotation as a result of the return energy stored in the elastic drive belt of the machine. The locking lever is lifted and releases the abutment ring and hence the switch-on pulse. The axially movable shifting shaft section is suddenly displaced by the slackening compression spring so that a lag pin, fastened to a crank of the section, penetrates into the cam groove of the control disc. As rotation of the machine continues, according to the form of the cam groove, a pivotal movement is transmitted by the crank to the axially movable shifting shaft section and conveyed on via the compensating clutch to the axially non-displaceable section which, via a crank and a coupling, imparts to the thread catcher the movement required for seizing and severing the thread. In this device, the shift fork must be held in its operative position for the duration of the cutting process since, if inadvertently let go, the cutting process would be interrupted prematurely. Thus, some uncertainty exists with respect to the completion of the cutting process.
It can be seen that both devices require considerable cost of engineering for the initiation and control of the thread cutting device. Also unsatisfactory is the fact that the coupling of the gear parts of the thread catcher with the control or entrainer disc causes a percussion noise and the parts are under severe stress by the sudden impact.
The simplification of such devices has been attempted by using an electromagnet as a drive means for the thread catcher (German Pat. No. 1,485,265). Here, the operative movement of the thread catcher proceeds in a sudden stroke of the magnet all the way counter to the action of a return spring, and thus occurs during standstill of the machine in a certain position of the needle in which the threads occupy the correct position for being seized by the thread catcher. However, it is relatively difficult to provide for the exact control of this position, and there is great danger that the position of the threads will vary due to their inherent elasticity after stoppage of the machine, so that the thread catcher does not seize the threads or does not correctly engage the threads.
SUMMARY OF THE INVENTION
The present invention produces a device for initiating the movement of the thread catcher of a thread cutting device to establish a coupling connection between an actuating linkage of the thread catcher and a control disc, both gently and joltlessly and insures that the coupling connection cannot be undone before the thread cutting process is completed.
In accordance with the invention, the control disc is arranged axially displaceable on the looper drive shaft between an inoperative and an operative position and is non-rotationally connected with the shaft. An abutment which is displaceable into the movement path of a cam section of the control disc operative parallel to the longitudinal axis of the looper drive shaft, is provided, which abutment can be returned by a cam of the control disc to its starting position and can be locked there. A retaining member is associated with the control disc for temporary support in its operative position against the restoring action of a spring.
To initiate the cutting process, it is sufficient with this device to undo the locking of the supporting stud. The supporting stud forms an abutment for the control disc in its operative position, which, through its cam section, cooperating with the supporting stud, is axially displaced into the operative position in which its curved faces control the movement of the thread catcher and are in the zone of the sensing lever of the actuating linkage for the thread catcher. The coupling connection with the actuating linkage is thus established in a joltless and quiet manner.
During the displacement of the control disc into its operative position, the supporting stud is pushed out into its starting position by the cam on the control disc and is locked there as soon as the control disc has reached its operative position. The retaining member then holds the control disc in this operative position counter to the action of a return spring. It is thereby assured that the thread cutting process continues to its end and inadvertent premature interruption is ruled out.
In a device according to he embodiment of the invention, having a linkage for the release of the needle thread tension in addition, there results a particularly simple construction due to the fact that the retaining member is arranged on the normally required linkage for the release of the needle thread tension, and the control disc is provided with an axially active butting face for the retaining member which changes over to a slopeless section and terminates in a recess directed parallel to the longitudinal axis of the looper drive shaft and permits the return of the control disc to its starting position.
The use of a control disc with a curved surface at the periphery instead of a control disc with a curved groove on the end face is advantageous because of its simpler and less expensive production cost. When using such a control disc, the contact between the control surface and sensing lever is normally maintained by a relatively strong spring. With the pressurization of the sensing lever, however, the force of the spring must be overcome, causing the machine to run rather heavily. This is remedied in a simple manner in that the sensing lever is forked and its two lever arms come into engagement successively with the cam sections provided on the peripheral surface of the control disc for execution of the operative and return movements of the thread catcher.
With this design, it is possible to arrange the sensing lever and the actuating linkage of the thread catcher for very easy motion. All that is necessary is to see to it that the sensing lever and actuating linkage do not move by themselves due to the vibration of the running machine. This can be effected, for example, by a brake spring.
A simple drive connection for the control disc is obtained by securing a driver on the looper drive shaft carrying the control disc which is connected with the control disc. Also, the driver is provided with a control surface for bringing the sensing lever back to its starting position. It is thereby assured that the sensing lever, which in the cutting process is brought back to its starting position by a cam section of the control disc, will be brought to its starting position by the control surface of the driver with the first revolution of the looper drive shaft, even after repairs or adjustments on the machine, during which it may inadvertently have been moved out of its starting position, which is the only position in which establishment of the coupling connection between the control disc and the sensing lever is possible. In any other position, the control disc and sensing lever would collide when switching on the thread cutting device, and this could lead to damage to these parts and to breakage of the drive members of the machine.
Accordingly, an object of the invention is to provide a device for initiating the movement of a thread catcher of a thread cutting device whose actuating linkage comprises a sensing lever adapted to be coupled with a control disc movable synchronously with a looper shaft and wherein the control disc is arranged axially displaceable on the looper device shaft between an inoperative and an operative position and is non-rotatably connected with the looper drive shaft by a coupling and which further includes an abutment or stud member displaceable into the movement path of the cam section of the control disc which is operative parallel to the longitudinal axis of the looper drive shaft and which can be brought back into its starting position by a cam of the control disc and locked in a position and including a retaining member associated with the control disc for temporarily supporting it in its operative position against the restoring action of an associated spring which biases it to an inoperative position.
A further object of the invention is provide a sewing machine device for initiating the movement of a thread catcher of a thread-cutting apparatus which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference should be had to the accompanying drawing and descriptive matter in this there is illustrated a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is a simplified perspective view of a two-needle sewing machine having a device for initiating a movement of a thread catcher of a thread catching device constructed in accordance with the invention;
FIG. 2 is a perspective view of the control disc and a part of the linkage for release of the thread tension, viewed approximately in the direction of the arrow A of FIG. 1;
FIG. 3 is a front elevational view of the part of the control disc cooperating with the sensing lever, viewed in the direction of arrow B of FIG. 1; and
FIG. 4 is an exploded perspective view of the details of the thread catcher, of a counter-knife, and of a bottom thread clamp on a larger scale from that indicated in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in particular, the invention embodied therein, comprises a device for initiating the movement of a thread catcher of a thread cutting device which is shown on a conventional two-needle flat looper sewing machine, which has a needle holder 2 with two thread guiding needles 3 and 4 attached to its up and down moving needle bar 1. Loopers 5 and 6, driven in a known manner by the looper drive shaft 7, cooperate with the needles 3 and 4 and take up a bottom thread bobbin, for the formation of two independent lock stitch seams (stitch type 301). The sewing machine is driven by a known on-off motor and can be stopped by a needle-positioning device in selected positions, e.g., in needle "down" before initiation of the thread cutting operation and in thread lever "up" position after the thread has been cut.
To seize and cut off the needle and looper threads, two movable thread catchers 8 and 9 cooperate with respective ones of two fixed counter-knives 10 and 11. The knives 10 and 11 are secured on a respective looper bearing block 14 and 15, as are also bottom thread clamps 12 and 13 consisting of two small spring plates. The thread catchers 8 and 9 are forked at their front end and comprise, between the fork legs, a bore 16 and 17 for the respective counter-knife 10 and 11, and spaced therefrom, a cutout 18 and 19 for the bottom thread clamps 12 and 13. The thread catcher 8 is secured on the upper end of a vertical shaft 20 and the thread catcher 9 is secured on the upper end of a vertical shaft 21. The shafts 20 and 21 are mounted in respective looper bearing blocks 14 and 15. A crank 22 is fastened at the lower end of shaft 21, and an angle lever 23 with the lever arms 24 and 25 is fastened at the lower end of shaft 20. The crank 22 and the lever arm 24 of the angle lever 23 are connected by a ball pull rod 26. A ball link 27 engages at the lever arm 25 of the angle lever 23 which is connected with a clamping lever 28 secured on an intermediate shaft 29 mounted in the work-carrying plate of the sewing machine. A forked sensing lever 30 is secured on the shaft 29, and it comprises lever arms 31 and 32. A roll stud 33 with a roll 34 is secured at the free end of the lever arm 31 and a roll stud 35 with a roll 36 * is secured at the free end of the lever arm 32. In addition, lever arm 32 is provided with a butting face 37.
For control of the movements of the sensing lever 30 and hence of the movements of the thread catchers 8 and 9, as well as of the actuating linkage for the thread tension device to be described later, a control member 38 is loosely mounted on the looper shaft 7. The control member 38 includes a curved surface at the periphery of a curved profile disc 39 with cam sections FS, RH, L and M, as shown in FIG. 3. The control member 38 also includes a cam plate 40, whose curved path 41 on the end face ascends in spiral form, and a radially active cam 42, as well as a plate 44, fitted with a segment 43 and having a butting face 45 on the face which, in the initial region, has an axially active slope and then changes over to a slopeless section. The curved profile disc 39 and the segment plate 44 are screwed to cam plate 40. Segment 43 ends with a surface 46 in a recess 47 of plate 44, which extends parallel to shaft 7. The control member 38 is non-rotationally connected with the looper drive shaft 7 by a compensating clutch 50 formed by a driver stud 49 guided in a groove 48 of the control disc 38. The driver stud 49 is secured in a driver 51 secured on the looper driver shaft 7. The outer circular peripheral face of the driver stud 49 serves as a control surface for the return of the sensing lever 30, on whose butting face 37, the driver stud 49 butts. The control disc 38 is axially displaceable counter to the action of a return spring 52 which is disposed on the looper drive shaft 7 between the driver 51 and the control disc 38.
A stud 54 which is displaceably received in a fixed sleeve 55 is associated with cam plate 40 as an abutment. The stud 54 is partially drilled open for the uptake of a compression spring 56 and, in addition, it comprises a peripheral groove 57 for locking in its inoperative position, into which a pawl 59 extending into sleeve 55 through a slit 58 engages by its front end. Pawl 59 is pivotable in a bearing shoulder 60 and is connected with a forked head 63 secured on the pull rod 62 which is connected with the armature of an electromagnet 61. The pull rod 62 is axially displaceable by the magnet 61, counter to the action of a return spring 64. The electromagnet 61 is secured on a holding bracket 65 which is fast to the work carrying plate of the sewing machine.
Before the threads are cut, they must be pulled out to a length sufficient for the next following stitch formation. This is effected expediently with the needle thread tension released. In the drawing, for the sake of clarity, only one thread tension device 66 is shown in FIG. 1, but a tension device is provided for each of the two needle threads. The tension device 66 consists of a sleeve 67 secured in the machine housing having a longitudinally slotted bolt 68 on which are arranged two tension discs 69 and 70 which are compressed by a tension spring 72 adjustable by means of a knurled nut 71 to exert a braking force on the needle thread. A releasing pin 73 is longitudinally displaceable in sleeve 67 by which tension disc 69 can be lifted off tension disc 70, counter to the action of the tension spring 72, to release the thread tension.
To actuate the releasing pin 73 and hence to release the thread tension there serves the butting face 45 of a segment 43 disposed on the segment plate 44 of control disc 38. A shoulder 74 of lozenge-shaped cross-section, which also serves as a retention member for the control disc 38, cooperates with the butting face 45. Shoulder 74 is provided on a lever 75 mounted on the machine housing. The lower end of lever 75 is pivoted by means of a pin 77 passed through a slot 76 with the forked head 79 secured on a sliding rod 78. The sliding rod 78 is received for axial displacement in a bearing shoulder 80 of the machine housing. A return spring 81 is provided between the forked head 79 and the bearing shoulder 80. On the sliding rod 78, to limit the return movement, a setting ring 82 is secured, which cooperates with the bearing shoulder 80. The other end of the sliding rod 78 is connected with an angle lever 83 mounted on the machine housing and connected by a coupling or link 84 with another angle lever 85 mounted on the machine housing. A push rod 86 is articulated to the angle lever 85, which carries a release element 88 at its front end, which is provided with a slant or bevelled surface 87.
Assuming that the sewing machine is running, the control disc 38 non-rotationally connected with the looper drive shaft 7 by the compensating clutch 50 co-rotating in its axial inoperative position, in which the curved surface (L, M, FS, RH) of the profile disc 39 is outside the zone of the sensing rolls 34 and 36, the thread catchers 8 and 9, with their actuating linkage occupying their starting position secured by a brake spring, not shown, the thread tension device 66 being closed and the stud 54 serving as an abutment for the control disc 38 being locked in its inoperative position by the pawl 59, the device operates as follows:
At the end of the seam, the sewing machine is stopped briefly by a known needle positioning device in the needle "down" position as the starting position for thread cutting. The curved profile disc 39 then occupies a position in which the sensing roll 34 of the sensing lever 30 is opposite the starting zone of cam section L. By actuation of a switch, preferably by back-pedaling, the electromagnet 61 is briefly switched on and immediately thereafter, the drive motor of the machine is also switched on. The pawl 59 is pulled back by the pull rod 62 of the electromagnetic 61 and thus releases the stud 54, which is displaced by the relaxing compression spring 56 against the cam plate 40. During the next single rotation of the looper drive shaft 7, in the direction of arrow D, in FIG. 1 and 3, necessary for thread cutting, the control disc 38 takes support by the curved path 41 of the cam plate 40 against the stud 54 serving as an abutment, whereby, the control member 38 is displaced according to the slope of the curved path 41 from its inoperative position axially to the left into its operative position, referred to in FIG. 1. Thus, the curved surface of the profile disc 39 comes into the zone of the sensing rolls 34 and 36 of the sensing lever 30. This coupling occurs noiselessly and joltlessly while the cam section L, corresponding to an arc of circle, runs past the sensing roll 34. The coupling process is completed when the sensing roll 34 has reached point a of the profile disc 39.
As rotation continues, the sensing lever 30 is pivoted over the sensing roll 34 by the ascending cam section FS, and hence, also the intermediate shaft 29. This movement is transmitted via the clamping lever 28 and the ball link 27 to the angle lever 23 firmly connected with the swinging shaft 20 of the thread catcher 8, and via the coupling 26 to the crank 22 firmly connected with the swinging shaft 21 of the thread catcher 9. Here, the thread catchers 8 and 9 undergo a co-directional pivotal movement. The front forked end of each thread catcher 8 and 9 thus begins its rotary movement, which is at first co-directional with the loopers 5 and 6, after the loopers 5 and 6 have seized and widened the respective needle thread loop. Shortly before the dropping of the needle thread loops, the forked ends of the thread catchers seize both the needle thread and the looper thread, so that both come to lie in the intersection of the fork legs in front of the bores 16 and 17, respectively. The looper threads will then lie in front of the cutouts 18 and 19. As soon as the threads are seized in this manner, the needle thread tension device 66 is opened by the slanted butting face 45 of segment 43 via the retention member 74 provided on the lever 75 of the thread tension release linkage and via the actuating linkagen 78 and 79 and 83 to 88, in that, the release pin 73 is axially displaced by the slant 87 of the release element 88 and thereby the tension disc 69 is lifted off the tension disc 70 counter to the action of the tension spring 72.
The portion of the looper threads leading to the thread reserve is supplied during the rotary movement of the thread catchers 8 and 9 to the thread clamps 12 and 13 and is clamped therein. As the forward movement of the thread catchers 8 and 9 continues, the forked ends of the thread catchers 8 and 9 reach the counter-knives 10 and 11, so that both the needle and the looper threads are severed jointly by the counterknives 10 and 11 penetrating into the respective bores 16 and 17. The leg of the needle thread leading to the thread reserve is given a length sufficient to form the first stitch of the next sewing cycle, while the leg of the hopper thread leading to the thread reserve is held by the thread clamps 12 and 13 above the bobbin capsule, so that it will be sure to be seized upon formation of the next stitch. The threads are cut through when the sensing roll 34 is opposite point b of the profile disc 39.
When the control disc 38 has reached its operative position by the cooperation of stud 54 with the curved path 41 of cam plate 40, upon further rotation, the thread catchers 8 and 9 execute their described forward movement for the seizing and cutting of the threads and, via the retaining member 74, the linkage is actuated for the opening of the needle thread tension device 66, that is, when the slopeless section of the butting face 45 of segment 43 runs past the retaining member 74, stud 54 is pushed back by cam 42 into its starting position, in which it is locked by the dropping of pawl 59 into groove 57. The control member 38 is now held in its operative position by the retaining member 74 cooperating with the butting face 45 of segment 43, instead of by stud 54, until the entire cutting process is completed, that is, until the return movement of the thread catchers 8 and 9 is completed.
The bringing back to their starting position, of the thread catchers 8 and 9, is effective by the ascending cam section RH of the profile disc 39 which, via the sensing roll 36, brings back the sensing lever 30 and, hence, also through the actuating linkage, the thread catchers 8 and 9, to the starting position, while sensing roll 34 applies against the descending portion M of the profile disc 39. The starting position of the thread catchers 8 and 9 is reached when sensing roll 36 is in front of the pitch point marked d near the end of the cam section RH. At this time, the recess 47 of the segment plate 44 is opposite the retention member 54. This allows both the return spring 52 and the return spring 81 to relax. Control disc 38 is displaced axially into its inoperative position by spring 52 on the looper drive shaft, and the actuating linkage 74, 75, 78, 79 and 83 to 88 of the needle thread tension device 66 is brought by spring 81 into its starting position determined by the setting ring 82 in connection with the bearing shoulder 80, in which position, the needle thread tension device 66 is closed. The machine is then stopped in thread lever "up" position and is ready for the next sewing operation.
It also should be mentioned that while the machine is running, the outer circular peripheral surface of the driver stud 49 of the compensating clutch 50 is tangential to the curved path 37 of the sensing lever 30 in its inoperative position. This assures that the sensing lever 30 will be brought to the starting position again during the first revolution of the looper drive shaft 7. Thereby, the thread catchers 8 and 9 with their actuating linkage also occupy their starting position, for example, after inadvertent displacement during maintenance work, and are thus ready for the initiation of a thread cutting process.
Lastly, it should be pointed out that the control principle shown is suitable for thread cutting devices also, where the thread catchers are so designed and the counter-knives are so arranged that the threads are only seized during the forward movement of the thread catchers and are cut off upon their being brought back.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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The sewing machine includes a reciprocating needle bar with a thread-engaging needle which cooperates with a rotatable looper carrying the looper thread which is driven by a rotatable looper drive shaft. The construction includes a thread knife and a thread clamp mounted adjacent the looper and a catcher mounted on a catcher shaft for rotation therewith selectively in the same direction of movement as the looper toward engagement with the knife and in an opposite return direction. The construction includes an improved control member for operating the catcher which is freely rotatable on the looper shaft and is axially displaceable therealong between an operative position and an inoperative position spaced axially from the operative position. A coupler is provided between the control member and the looper shaft which includes a driver having a rod portion which extends in a groove of the control member. A biasing spring biases the control member into an operative position. A stud abutment is mounted to move toward and away from a control member between a starting and an operative position and may be locked in the starting position. The stud abutment is engageable with a cam portion of the control member and the cam portion acts to return the stud abutment to a starting position. A retaining member is located adjacent the control member and it is mounted so that it can be biased by a spring associated therewith to hold the control member in an operative position.
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TECHNICAL FIELD
The present invention relates generally to wax compositions for use as expandable media in actuators, and more particularly to such materials including a conductive filler and a viscosity modifier to increase the viscosity of the mixture in the melt.
BACKGROUND
Thermally operated actuators utilizing wax compositions as the expandable medium are known in the art, and used in thermostats, for example. Waxes are particularly suitable for use in actuators because they exhibit a relatively large amount of expansion as they are heated and melt to the liquid phase as the temperature is raised. Long-chain waxes may exhibit a volume change upon melting of more than 10 and even close to 20 volume percent. Another advantage of using waxes is that their melting temperature can be tailored, if so desired, by utilizing a wax of a particular molecular weight. A still further advantage of waxes is that their rate of crystallization from the melt and re-crystallization may be relatively fast as compared to other materials, such as high polymers.
It is desirable to increase thermal conductivity of waxes in thermal actuator applications to facilitate heat transfer and ultimately cycle time of the actuator device. To this end, it is known in the art to add 10, up to 30 and even 50 weight percent of a conductive filler, such as copper spheres and the like. The addition of conductive material does increase the thermal conductivity of the wax-based medium; however, like any heterogeneous system, non-uniformities can arise through particle segregation or stratification and like phenomena. This leads to erratic performance which is likely to become more severe as the amount of filler is increased or the density difference (and consequently the buoyant forces) become more pronounced.
SUMMARY
It has been found in accordance with the present invention, that a better performing wax composition for actuator use is produced through adding a viscosity modifier to increase the viscosity of the wax matrix material in the melt. More specifically, a thermally expandable wax composition for use in actuators is provided including: a wax matrix material in a proportion of about 20 to about 90 per cent by weight of said composition; a polymeric viscosity modifier having a melt index of less than about 30 present in an amount of about 0.5 to about 30 weight percent of the wax composition and being operative in said proportions to increase the melt viscosity of said wax matrix material by a factor of at least 100 and up to a factor of 10 6 as compared to the viscosity of unmodified wax matrix material, the increase being measured at a temperature of about 120° C., with the proviso that the weight ratio of said wax matrix material to said polymeric viscosity modifier is from about 5:1 to about 99:1. There is also present, a conductive filler present in an amount of from about 10 weight percent to about 50 weight percent of said composition and optionally including a thermoxidative stabilizer.
Particularly preferred viscosity modifiers are relatively high molecular weight olefin polymers including poly(ethylene), poly(propylene) and especially poly(ethylene-co-vinyl acetate). Less than 20 mole percent vinyl acetate polymers have been found especially effective. Typically, these modifiers are included in the inventive compositions in amounts from about 1 to about 15 weight percent, with from 2-10 percent being preferred. The modifiers are generally effective to increase the viscosity of melted wax by a factor of 100 or more to a factor of 10 6 or even more, but factors of about 10 3 to 10 5 are more typical. Melt index is a particularly convenient method to characterize the polymeric viscosity modifiers of the present invention. Unless otherwise indicated, all values of melt index appearing in this specification and claims are those measured in accordance with test method ASTM D-1238, Procedure A, Condition E, that is, at a temperature of 190° C. with a weight of 2.16 kilograms. Generally, the polymeric viscosity modifiers exhibit a melt index of less than 30, less than 10 being typical and less than 5 being particularly preferred.
Conductive fillers useful in connection with the present invention include copper flake, aluminum flake and certain forms of carbon such as, for example, graphitic fillers.
Any suitable graphite filler may be used, however, flake, powder and fibers are typical. Spherical powder is especially preferred.
Particularly preferred thermoxidative stabilizers are selected from the group consisting of hydroxycinnamates, phosphites, pentaerythritol diphosphites and hindered phenols.
The present invention has as its basic and novel characteristics the fact that wax, viscosity modifier, and graphitic filler cooperate to provide a highly stable thermally expandable composition which resists segregation over time. Other materials, such as thermoxidative stabilizers may be added to make a more durable material without departing from the spirit and scope of the present invention.
In another aspect of the present invention, the inventive compositions are used in a mechanical actuator and may be heated directly with an electric current.
DESCRIPTION OF DRAWING
The invention is described in detail below, with reference to the single FIG. 1, which is a schematic diagram of a polymer-based mechanical actuator.
DETAILED DESCRIPTION
Wax, as the term is used herein, refers to those materials which are solid materials at ambient temperatures with a relatively low melting point and are capable of softening when heated and hardening when cooled. They are either natural or synthetic and of petroleum, mineral, vegetable or animal origin. Typical of petroleum waxes are paraffin waxes and microcrystalline waxes. The latter consisting primarily of isoparaffinic and naphthenic saturated hydrocarbons, while the former are generally composed of n-alkanes. Beeswax, on the other hand, is primarily made of non-glyceride esters of carboxylic and hydroxy acids with some free carboxylic acids, hydrocarbons and wax alcohols present. The most important commercial mineral wax, montan wax, has as its main components nonglyceride esters of carboxylic acids, alcohols, acids, resins and hydrocarbons. Vegetable-based waxes tend to have relatively large amounts of hydrocarbons. Esters and amides of higher fatty acids are also waxy materials and may be used in connection with the present invention. The foregoing waxes generally have molecular weights less than 1,000; while polyethylene waxes generally have higher molecular weights in the range of 2,000 to less than 10,000.
Hoechst Wax E, commercially available from Hoechst AG, Frankfurt, Germany, is a reprocessed montan wax esterified with higher alcohols and has a melting point of approximately 90° C. Hoechst WAX PED-521 is a polar polyethylene wax also available from Hoechst AG which has a melting point slightly higher, perhaps 100° C. or more.
Conductive fillers useful in connection with the present invention include those which conduct electricity as well as those which conduct heat readily. Particularly suitable fillers are graphitic fillers such as fibers or spherical powders as well as aluminum or copper powders or flakes having a relatively high surface area. Graphite fiber may be obtained from Amoco Corporation, Chicago, Ill., while the other fillers referred to herein are generally available.
Suitable polymeric viscosity modifiers to add to the wax include relatively high molecular weights >10,000 and more typically >50,000. Polyethylenes with molecular weights of 200,000 or more may be suitable, even ultra high density material with molecular weights from 3 to 6 million may be used. Polypropylene of like molecular weights may likewise be employed.
Especially suitable polymeric viscosity modifiers are poly(ethylene-co-vinyl acetate) polymers having melt indices of 30 or less. These materials are available from dupont, Wilmington, Del. and are marketed under the Elvax® trademark. Particularly preferred Elvax® products have a relatively low vinyl acetate content (about 20 mole percent or less) and have a melt index less than 5.
Antioxidants
It is desirable to include antioxidants in the formulation of the actuating material to inhibit oxidation and resultant degradative effects. Such antioxidants are commercially available and include such chemical species as amines, phenols, hindered phenols, phosphites, sulfides, and metal salts of dithioacids. It is further known when carbon black is compounded with organic resins that this can inhibit degradation of the polymer. The presence of two or more antioxidant additives can provide synergistic benefit against degradation of the base resin. Examples of increased stability achieved by the addition of such additives are shown below. Thermogravimetric analysis (TGA) showed significantly reduced loss in weight of samples containing antioxidants when these combinations were heated in air at 200° C. and at 225° C. These materials are available throughout the world from Ciba-Geigy and are generally marketed under the Irganox® trademark.
In a typical embodiment, a thermoxidative stabilizer such as tetrakis (methylene (3,5-di-tert-butyl-4-hydroxycinnamate)) methane and bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite may be included. Preferably, each stabilizer comprises about 0.1-0.5% by weight of the wax composition. Alternatively, the bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite may be replaced by 0.1-0.5% diestearyl pentaerythritol diphosphite.
The present invention may be further appreciated from the following notion of resistance to flow in a fluid: For a suspension of spherical particles in a fluid medium, the terminal sedimentation velocity is given by ##EQU1## where r is the radius of the particle ρ ande ρ 0 are the densities of the particle and the surrounding fluid respectively, g is the acceleration due to gravity, and η is the viscosity of the fluid. In other words, the rate at which suspended particles separate from the suspension can be minimized by reducing the size of the particle, matching the density of the particle to that of the fluid, or increasing the viscosity of the fluid. So also, flaked material has more surface area and tends not to segregate.
The addition of ethylene-vinyl acetate copolymers (e.g., Elvax® from dupont) may be used conveniently to increase the melt viscosity of Hoechst Wax E.
______________________________________Wax Sample Melt Viscosity (poise)______________________________________Wax E 2.54 × 10.sup.-1Wax E with 15% Elvax 7.75 × 10.sup.3______________________________________
Thus the addition of only 15% viscosity enhancer results in an increase of more than four orders of magnitude in the melt viscosity of the base wax. It is desirable to keep the percentage of additives as low as possible so as not to lose the volume expansion which occurs upon melting of the wax.
The following data demonstrating the increased viscosity of Hoechst Montan Wax E and PED-521 polar polyethylene containing Elvax 770 (An ethylene-vinyl acetate copolymer) is likewise illustrative of the effect of the modifier on the matrix wax.
______________________________________VISCOSITY OF WAX E AND PED-521 WITH ELVAX 770 (TESTTEMPERATURE = 120° C.) Average Viscosity Viscosity IncreaseWax Sample (Poise) due to Additive (%)______________________________________Wax E 2.60 × 10.sup.-1 N/AWax E #2 2.48 × 10.sup.-1 N/AWax E w/15% Elvax 770 7.75 × 10.sup.3 3 × 10.sup.4PED-521 2.53 N/APED-521 #2 2.22 N/APED-521 w/15% 1.22 × 10.sup.3 5 × 10.sup.2Elvax 770______________________________________ Note: Elvax ® 770 typically has a melt index of 0.6 to 1.0.
The following process was used to prepare wax samples containing:
(a) Conductive additives such as graphite powder, fiber and flakes
(b) Thermal stabilizers such as Irganox 1010 and Irganox 1425 (Ciba Geigy)
(c) Viscosity modifier such as ELVAX 770 (duPont). The process description given below further illustrates the present invention.
Process Description
In a batch process (1000 ml beaker), 188 g of Hoechst Wax E, 10 g of ELVAX 770, 1 g of Irganox 1010 and 1 g of Irganox 1425 were slowly heated under constant agitation for approximately 3 to 4 hours at 140° C. After making a clear solution (of ELVAX, Irganox and wax), the mixture was cooled to room temperature and removed as brownish wax product referred to as Stabilized Wax. The final composition of this mixture was: 94 wt % Hoechst Wax E, 5 wt % ELVAX 770, 0.5 wt % Irganox 1010 and 0.5 wt % Irganox 1425. After grinding into fine powder, the product was used for subsequent melt blending with conductive additives.
Melt blending of the Stabilized Wax with graphite powder was performed in a Haake System 90 Melt Mixer. The blend mixture was prepared by introducing 70 g of a sample consisting of 35 wt % graphite powder and 65 wt % Stabilized Wax into the mixing bowl which was preheated to 120° C. The blending was completed by continuous mixing of the melt at 200 RPM for approximately 15 minutes. After cooling, the material was ground and evaluated for particle distribution by microscopy.
Graphite fiber such as P-120 (Amoco) and GY-70 graphite fiber produced at Hoechst Celanese was also evaluated as a conductive additive. Using the same blending system, P-120 was evaluated with Stabilized Wax (same formulation as above) at 7 wt % and 20 wt %. GY-70 was tested at 5 weight percent.
Additive Sources
Graphite Powder: High Purity Crystalline Graphite, Series 4900 from Superior Graphite Company, 120 South Riverside Plaza, Chicago, Ill. 60606. The copper and aluminum powders have a grain size less than about 20 μm and may be flaky or spheric. They are commercially available from Schlenk Gmbh, Erlangen, Germany, under the trade names MULTIPRINT or LUMINOR.
Viscosity Modifier: ELVAX 770 Resin from dupont Company, Polymer Products Department, Wilmington, Del. 19898
The invention is further understood by reference to FIG. 1, a schematic of a polymer based mechanical actuator. In general, this type of actuator 10 includes a cavity 20 wherein there is placed a thermally expandable composition 30 which in turn contacts a movable piston 40. In FIG. 1(a), the thermally expandable composition, a wax composition in the case of the present invention, is in solid form in contact with the piston. Heat is applied by any suitable means and as the wax melts, composition 30 expands on the order of twenty volume percent and occupies more of cavity 20, forcing piston 40 upwardly out of the cavity as shown in FIG. 1(b).
Typically, heating is accomplished by external heating means; however since the compositions of the present invention are electrically conductive, heating may be accomplished through direct application of current through the expandable compositions. To this end, the actuator body 50 may be made of an insulative material and produced with electrodes 60 to contact the polymer composition 30. Typically, this may be accomplished with a voltage source (not shown) of 12 volts provided that sufficient current is conducted through composition 30. One may use the above described heating method as the sole heating means; or use this heating means as supplemental to conventional apparatus.
While the present invention has been described in detail, various modifications will be readily apparent to those of skill in the art. Such modifications are within the spirit and scope of the present invention which is defined in the appended claims.
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A thermally expandable wax composition and its use in polymer-based actuators is disclosed and claimed. The compositions are wax-based and include conductive filler as well as a viscosity modifier to stabilize the composition against segregation. Optionally included are thermoxidative stabilizers.
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FIELD OF THE INVENTION
The present invention relates to methods and apparatus for interconnecting a personal safety device in series between a person and a support structure.
BACKGROUND OF THE INVENTION
Various occupations place people in precarious positions at relatively dangerous heights, thereby creating a need for fall-arresting safety apparatus. Such apparatus require a reliable safety line and reliable connections to the support structure and the person working in proximity to the support structure.
Typically, one or more deceleration devices is connected in series with the safety line. For example, U.S. Pat. No. 5,351,906 to Feathers discloses a safety anchorage device which controls pay-out of a safety line. This prior art anchorage device is selectively connected to a support structure, and the safety line is selectively connected to a person (via a body harness, for example). In the event of a fall, the safety line and the other parts of the anchorage device cooperate to safely bring the person to rest.
Another exemplary safety device is disclosed in U.S. Pat. No. 4,877,110 to Wolner. This prior art safety device similarly controls pay-out of a safety line during normal work activity and/or in the event of a fall. In this patent, however, the device is shown anchored to the body harness, and the safety line is shown connected to the support structure.
An object of the present invention is to provide an improved connector for use on and/or together with safety devices like those discussed above.
SUMMARY OF THE INVENTION
The present invention provides methods and apparatus which facilitate connection of a personal safety device in series between a person and a support structure. On a preferred embodiment of the present invention, the distal end of a bolt is inserted though one end of a U-shaped member and through spaced apart tabs on a safety device. The distal end of the bolt is then selectively threaded through an opposite end of the U-shaped member. A stop is rigidly secured to an intermediate portion of the bolt to retain one of the tabs between the stop and the end of the U-shaped member nearer the bolt. A spring is disposed between the stop and the head of the bolt to bias the bolt toward the other tab (and the threaded end of the U-shaped member). The resulting connector is convenient to use and reliable in use, and cooperates with the safety device to provide a novel combination of a safety device with a built-in latching device. Additional features and/or advantages of the present invention may become more apparent from the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWING
With reference to the Figures of the Drawing, wherein like numerals represent like parts and assemblies throughout the several views,
FIG. 1 is a front view of a personal safety apparatus provided with a connector constructed according to the principles of the present invention;
FIG. 2 is a side view of the personal safety apparatus and connector of FIG. 1; and
FIG. 3 is a perspective view of the personal safety apparatus and connector of FIG. 1 interconnected in series between a support structure and a body harness.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment connector constructed according to the principles of the present invention is designated as 100 in FIGS. 1-3. The connector 100 includes a structural member 110 and a bolt 120 which cooperate to releasably connect a personal safety device 90 (with safety line 98) in series between a support structure 80 and a person's harness 70, as shown in FIG. 3. Exemplary prior art safety devices are disclosed in U.S. Pat. No. 5,351,906 to Feathers and U.S. Pat. No. 4,877,110 to Wolner, which are incorporated herein by reference.
The structural member 110 is preferably made of steel and may be described as a U-shaped member having an intermediate base portion, and opposite ends or legs 112 and 114 which extend from opposite ends of the base portion and parallel to one another. The base portion is covered by a protective sleeve 116 which is preferably made of plastic. A slot 118 is provided in the first end 112 of the member 110 (FIG. 2), and a threaded hole is provided in the second end 114 of the member 110.
The bolt 120 is preferably made of steel and has a shaft 121 which extends perpendicular to the ends 112 and 114 of the member 110. A first end 122 of the bolt 120 is provided with a head having a diameter which is greater than the diameter of the shaft 121. A second, opposite end 124 of the bolt 120 is provided with external helical threads which mate with the threaded hole in the second end 114 of the member 110.
The second end 124 of the bolt 120 is inserted through the slot 118, then through a hole in a first flange or tab 92 on the device 90, and then through a helical coil spring 130. A stop 140 is then rigidly secured to an intermediate portion of the shaft 121 on the bolt 120, in such a manner that the spring 130 is compressed between the stop 140 and the flange 92. The stop 140 has a relatively larger diameter than the shaft 121 of the bolt 120 and may be described as a shoulder on the bolt 120. The second end 124 may then be selectively inserted through a hole in a second flange or tab 94 on the device 90, and threaded through the hole in the second end 114 of the member 110.
The threads on the second end 124 of the bolt 120 and inside the hole in the second end 114 of the member 110 provide a means for selectively connecting the second end 124 of the bolt 120 to the second end 114 of the member 110. The spring 130 cooperates with the stop 140 to provide a means for biasing the second end 124 of the bolt 120 to remain connected to the second end 114 of the member 110. The stop 140, the first end 112 of the member 110, and the head of the bolt 120 cooperate to provide a means for securing the connector 100 to the first flange 92. The slot 118 in the first end 112 of the member 110 provides a means for pivoting the connector 100 relative to the first flange 92 when the second end 122 of the bolt is free of the second flange 94.
Those skilled in the art will recognize that alternative arrangements may be used to perform one or more of the aforementioned functions. For example, the first end 112 of the member 110 may be hinged relative to the remainder thereof to facilitate pivoting of the connector 100 relative to the first flange 92. Also, the bias of the spring 130 may operate (in the absence of threads) to facilitate connection of the second end 124 of the bolt 120 to the second end 114 of the member 110. On one alternative embodiment, for example, the second end 124 of the bolt 120 is devoid of threads and has an outside diameter which is less than the inside diameter of the threaded hole. Thus, even when the shaft 121 is not threaded into the threaded hole, the spring 130 biases the second end 124 to remain in the hole. Another option is to use a cotter pin or other latching device to further discourage undesired removal of the bolt end 124 from the member end 114.
Those skilled in the art will also recognize that the connector 100 may be used at various locations in various personal safety systems. For example, FIG. 3 shows the connector 100 attached to the personal safety device 90 and releasably connected to a harness 70 in the same manner as and/or by means of a D-ring, for example. A safety line 98 (or 98') emanates from the device 90 and is releasably connected to a support structure 80. This arrangement is advantageous because it facilitates convenient locking into and out of discrete anchorages (81 and 82, for example) on the support structure. However, the connector 100 may be used in other arrangements according to the needs dictated by a particular situation and/or the preferences of the persons involved.
Another aspect of the present invention is the provision of a built-in connector or latching device on a personal safety device. In other words, a safety device constructed according to the principles of the present invention may be connected directly about a rod or safety line secured to a support structure, thereby eliminating the need for an interconnecting snap hook or other discrete component. In this regard, the connection between the stop 140 and the bolt 120 is intended to be permanent, and thus, the present invention may be seen to provide both the safety device and the connecting means as a unit.
Those skilled in the art will further recognize that the present invention may also be described in terms of a method (with reference to the preferred embodiment 100, for example). In one regard, the present invention may be described in terms of a method of connecting a personal safety device in series between a person and a support structure. A bolt is inserted through a first end of a U-shaped member and through a first flange on the personal safety device. A coil spring is positioned on the bolt and retained in place by rigidly mounting a stop on an intermediate portion of the bolt. A second end of the U-shaped member is disposed about a suitable anchorage and/or inserted through a desired opening (such as a bracket on the support structure or a D-ring on a body harness), and then is aligned with a second flange on the personal safety device. A distal end of the bolt is then inserted through the second flange and threaded into the second end of the U-shaped member.
Although the present invention has been described with reference to a preferred embodiment and a particular application, this disclosure will enable those skilled in the art to recognize additional embodiments and/or applications which fall within the scope of the present invention. Accordingly, the scope of the present invention should be limited only to the extent of the following claims.
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A connector and a personal safety device are secured in series between a person and a support structure. The connector includes a bolt and another structural member which cooperate to form a closed loop. The bolt extends through opposite ends of the other structural member and at least one flange on the personal safety device. A radially extending flange is rigidly secured to an intermediate portion of the bolt and cooperates with an end of the bolt to capture an end of the other structural member therebetween.
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APPLICATION DATA
[0001] This application claims benefit to German application no. DE 102 14 263.7 filed Mar. 28, 2002 and U.S. provisional application No. 60/386,145 filed Jun. 5, 2002.
FIELD OF THE INVENTION
[0002] The invention relates to pressurised gas preparations for metered-dose aerosols with suspension formulations of the crystalline monohydrate of (1α,2β,4β,5α,7β)-7-[(hydroxydi-2-thienylacetyl )oxy]-9,9-dimethyl-3-oxa-9-azoniatricyclo[3.3.1.0 2,4 ]nonane-bromide, processes for the preparation thereof and the use thereof for preparing a pharmaceutical composition, particularly for preparing a pharmaceutical composition with an anticholinergic activity.
BACKGROUND TO THE INVENTION
[0003] The compound (1α,2β,4β,5α,7β)-7-[(hydroxydi-2-thienylacetyl)oxy]-9,9-dimethyl-3-oxa-9-azoniatricyclo[3.3.1.0 2,4 ]nonane-bromide, is known from European Patent Application EP 418 716A1 and has the following chemical structure:
[0004] The compound has valuable pharmacological properties and is known by the name tiotropium bromide (BA679). Tiotropium bromide is a highly effective anticholinergic and can therefore provide therapeutic benefit in the treatment of asthma or COPD (chronic obstructive pulmonary disease).
[0005] Tiotropium bromide is preferably administered by inhalation.
[0006] The aim of the present invention is to prepare HFA-metered-dose aerosols containing tiotropium bromide as the sole active ingredient in suspended form.
DETAILED DESCRIPTION OF THE INVENTION
[0007] It has been found that, depending on the choice of conditions which can be used when purifying the crude product obtained after industrial manufacture, tiotropium bromide occurs in various crystalline modifications.
[0008] It has been found that these different modifications can be deliberately produced by selecting the solvents used for the crystallisation as well as by a suitable choice of the process conditions used in the crystallisation process. For the purposes of preparing the formulations according to the invention, crystalline tiotropium bromide monohydrate has proved particularly suitable.
[0009] Accordingly, the present invention relates to suspensions of crystalline tiotropium bromide monohydrate in the propellant gases HFA 227 and/or HFA 134a, optionally in admixture with one or more other propellant gases, preferably selected from the group consisting of propane, butane, pentane, dimethylether, CHClF 2 , CH 2 F 2 , CF 3 CH 3 , isobutane, isopentane and neopentane.
[0010] Preferred suspensions according to the invention are those which contain as propellant gas HFA 227 on its own, a mixture of HFA 227 and HFA 134a or HFA 134a on its own. If a mixture of propellant gases HFA 227 and HFA 134a is used in the suspension formulations according to the invention, the weight ratios in which these two propellant gas components are used may be freely selected. If in the suspension formulations according to the invention one or more other propellant gases are used in addition to the propellant gases HFA 227 and/or HFA 134a , selected from the group consisting of propane, butane, pentane, dimethylether, CHClF 2 , CH 2 F 2 , CF 3 CH 3 , isobutane, isopentane and neopentane, the proportion of this other propellant gas component is preferably less than 50%, preferably less than 40%, more preferably less than 30%.
[0011] The suspensions according to the invention preferably contain between 0.001 and 0.8% tiotropium. Suspensions which contain 0.08 to 0.5%, more preferably 0.2 to 0.4% tiotropium are preferred according to the invention.
[0012] By tiotropium is meant the free ammonium cation. The propellant gas suspensions according to the invention are characterised in that they contain tiotropium in the form of the crystalline tiotropium bromide monohydrate which is exceptionally suitable for this application. Accordingly, the present invention preferably relates to suspensions which contain between 0.0012 and 1% crystalline tiotropium bromide monohydrate.
[0013] Of particular interest according to the invention are suspensions which contain 0.1 to 0.62%, more preferably 0.25 to 0.5% crystalline tiotropium bromide monohydrate.
[0014] The percentages specified within the scope of the present invention are always percent by mass. If parts by mass of tiotropium are given in percent by mass, the corresponding values for the crystalline tiotropium bromide monohydrate which is preferably used within the scope of the present invention may be obtained by multiplying by a conversion factor of 1.2495.
[0015] In some cases within the scope of the present invention the term suspension formulation may be used instead of the term suspension. The two terms are to be regarded as interchangeable within the scope of the present invention.
[0016] The propellant-containing inhalation aerosols or suspension formulations according to the invention may also contain other ingredients such as surface-active agents (surfactants), adjuvants, antioxidants or flavourings.
[0017] The surface-active agents (surfactants) which may be contained in the suspensions according to the invention are preferably selected from among Polysorbate 20, Polysorbate 80, Myvacet 9-45, Myvacet 9-08, isopropylmyristate, oleic acid, propyleneglycol, polyethyleneglycol, Brij, ethyloleate, glyceryl trioleate, glyceryl monolaurate, glyceryl monooleate, glyceryl monosterate, glyceryl monoricinoleate, cetylalcohol, sterylalcohol, cetylpyridinium chloride, block polymers, natural oil, ethanol and isopropanol. Of the abovementioned suspension adjuvants Polysorbate 20, Polysorbate 80, Myvacet 9-45, Myvacet 9-08 or isopropylmyristate are preferably used. Myvacet 9-45 or isopropylmyristate are particularly preferred. Where the suspensions according to the invention contain surfactants, these are preferably present in an amount of 0.0005-1%, more preferably 0.005-0.5%.
[0018] The adjuvants optionally contained in the suspensions according to the invention are preferably selected from among alanine, albumin, ascorbic acid, aspartame, betaine, cysteine, phosphoric acid, nitric acid, hydrochloric acid, sulphuric acid and citric acid. Of these, ascorbic acid, phosphoric acid, hydrochloric acid or citric acid are preferred, while hydrochloric acid or citric acid is more preferable.
[0019] Where the suspensions according to the invention contain adjuvants, these are preferably present in an amount of 0.0001-1.0%, preferably 0.0005-0.1%, more preferably 0.001-0.01%, while an amount of from 0.001-0.005% is particularly preferred according to the invention.
[0020] The antioxidants optionally contained in the suspensions according to the invention are preferably selected from among ascorbic acid, citric acid, sodium edetate, editic acid, tocopherols, butylhydroxytoluene, butylhydroxyanisol and ascorbyl palmitate, of which tocopherols, butylhydroxytoluene, butylhydroxyanisol and ascorbyl palmitate are preferred.
[0021] The flavourings which may be contained in the suspensions according to the invention are preferably selected from among peppermint, saccharine, Dentomint®, aspartame and ethereal oils (e.g. cinnamon, aniseed, menthol, camphor), of which peppermint or Dentomint® is particularly preferred.
[0022] For administration by inhalation it is necessary to prepare the active substance in finely divided form. The crystalline tiotropium bromide monohydrate which may be obtained as detailed in the experimental section is either ground (micronised or obtained in finely divided form by other technical methods known in principle in the art (such as precipitation and spray drying). Methods of micronising active substances are known in the art. Preferably, after micronisation, the active substance has an average particle size of 0.5 to 10 μm, preferably 1 to 6 μm, more preferably 1.5 to 5 μm. Preferably, at least 50%, more preferably at least 60%, most preferably at least 70% of the particles of active substance have a particle size which is within the ranges specified above. More preferably, at least 80%, most preferably at least 90% of the particles of active substance have a particle size within the ranges specified above.
[0023] Surprisingly, it has been found that it is also possible to prepare suspensions which contain, apart from the abovementioned propellant gases, only the active substance and no other additives. Accordingly, in another aspect, the present invention relates to suspensions which contain only the active substance and no other additives.
[0024] The suspensions according to the invention may be prepared by methods known in the art. For this the ingredients of the formulation are mixed with the propellant gas or gases (optionally at low temperatures) and transferred into suitable containers.
[0025] The propellant gas-containing suspensions according to the invention mentioned above may be administered using inhalers known in the art (pMDIs=pressurised metered dose inhalers). Accordingly, in another aspect, the present invention relates to pharmaceutical compositions in the form of suspensions as hereinbefore described combined with one or more inhalers suitable for administering these suspensions. In addition, the present invention relates to inhalers which are characterised in that they contain the propellant gas-containing suspensions described above according to the invention. The present invention also relates to containers (e.g. cartridges) which are fitted with a suitable valve and can be used in a suitable inhaler and which contain one of the above-mentioned propellant gas-containing suspensions according to the invention. Suitable containers (e.g. cartridges) and methods of filling these cartridges with the propellant gas-containing suspensions according to the invention are known from the prior art.
[0026] In view of the pharmaceutical activity of tiotropium the present invention further relates to the use of the suspensions according to the invention for preparing a drug for administration by inhalation or by nasal route, preferably for preparing a drug for the treatment by inhalation or by nasal route of diseases in which anticholinergics may provide a therapeutic benefit.
[0027] Most preferably, the invention further relates to the use of the suspensions according to the invention for preparing a pharmaceutical composition for the treatment by inhalation of respiratory complaints, preferably asthma or COPD.
[0028] The Examples that follow serve to illustrate the present invention more fully by way of example, without restricting it to their content.
[0000] Starting Materials
[0000] Crystalline Tiotropium Bromide Monohydrate:
[0029] The tiotropium obtained according to EP 418 716 A1 may be used to prepare the crystalline tiotropium bromide monohydrate. This is then reacted as described below. 15.0 kg of tiotropium bromide are added to 25.7 kg of water in a suitable reaction vessel. The mixture is heated to 80-90° C. and stirred at constant temperature until a clear solution is formed. Activated charcoal (0.8 kg), moistened with water, is suspended in 4.4 kg of water, this mixture is added to the solution containing tiotropium bromide and rinsed with 4.3 kg of water. The mixture thus obtained is stirred for at least 15 min. at 80-90° C. and then filtered through a heated filter into an apparatus which has been preheated to an outer temperature of 70° C. The filter is rinsed with 8.6 kg of water. The contents of the apparatus are cooled to a temperature of 20-25° C. at a rate of 3-5° C. every 20 minutes. Using cold water the apparatus is cooled further to 10-15° C. and crystallisation is completed by stirring for at least another hour. The crystals are isolated using a suction filter drier, the crystal slurry isolated is washed with 9 L of cold water (10-15° C.) and cold acetone (10-15° C.). The crystals obtained are dried at 25° C. for 2 hours in a nitrogen current. Yield: 13.4 kg of tiotropium bromide monohydrate (86% of theory). The tiotropium bromide monohydrate obtainable using the method described above was investigated by DSC (Differential Scanning Calorimetry). The DSC diagram shows two characteristic signals. The first, relatively broad, endothermic signal between 50-120° C. can be attributed to the dehydration of the tiotropium bromide monohydrate into the anhydrous form. The second, relatively sharp, endothermic peak at 230±5° C. can be put down to the melting of the substance. This data was obtained using a Mettler DSC 821 and evaluated using the Mettler STAR software package. The data was recorded at a heating rate of 10 K/min.
[0030] The crystalline tiotropium bromide monohydrate was characterised by IR spectroscopy. The data was obtained using a Nicolet FTIR spectrometer and evaluated with the Nicolet OMNIC software package, version 3.1. The measurement was carried out with 2.5 μmol of tiotropium bromide monohydrate in 300 mg of KBr. The following Table shows some of the essential bands of the IR spectrum.
Wave number (cm −1 ) Attribution Type of oscillation 3570, 3410 O—H elongated oscillation 3105 Aryl C—H elongated oscillation 1730 C═O elongated oscillation 1260 Epoxide C—O elongated oscillation 1035 Ester C—OC elongated oscillation 720 Thiophene cyclic oscillation
[0031] The monocrystal X-ray structural analysis carried out showed that the crystalline tiotropium bromide monohydrate obtainable by the above process has a simple monoclinic cell with the following dimensions:
a=18.0774 Å, b=11.9711 Å, c=9.9321 Å, β=102.691°, V=2096.96 Å 3 .
[0033] These data were obtained using an AFC7R 4-circuit diffractometer (Rigaku) using monochromatic copper K α radiation. The structural resolution and refinement of the crystal structure were obtained by direct methods (SHELXS86 Program) and FMLQ-refinement (TeXsan Program).
[0034] To prepare the suspensions according to the invention the crystalline tiotropium bromide monohydrate obtainable by the above process is micronised by methods known per se in the art, to prepare the active substance in the form of the average particle size which corresponds to the specifications according to the invention.
[0035] A method of determining the average particle size of the active substance will now be described.
[0000] Determining the Particle Size of Micronised Tiotropium Bromide Monohydrate:
[0000] Measuring Equipment and Settings:
[0036] The equipment is operated according to the manufacturer's instructions.
Measuring equipment: HELOS Laser diffraction spectrometer, SympaTec Dispersing unit: RODOS dry disperser with suction funnel, SympaTec Sample quantity: 50 mg-400 mg Product feed: Vibri Vibrating channel, Messrs. Sympatec Frequency of vibrating 40 rising to 100% channel: Duration of sample feed: 15 to 25 sec. (in the case of 200 mg) Focal length: 100 mm (measuring range: 0.9-175 μm) Measuring time: about 15 s (in the case of 200 mg) Cycle time: 20 ms Start/stop at: 1% on channel 28 Dispersing gas: compressed air Pressure: 3 bar Vacuum: maximum Evaluation method: HRLD
Sample Preparation Product Feed:
[0037] About 200 mg of the test substance are weighed onto a piece of card. Using another piece of card all the larger lumps are broken up. The powder is then sprinkled finely over the front half of the vibrating channel (starting about 1 cm from the front edge). After the start of the measurement the frequency of the vibrating channel is varied from about 40% up to 100% (towards the end of the measurement). The sample should be fed in as continuously as possible. However, the quantity of product should not be too great, so as to ensure adequate dispersal.
[0038] The time taken to feed in the entire 200 mg sample is about 15 to 25 sec., for example.
EXAMPLES OF FORMULATIONS
[0039] Suspensions containing other ingredients in addition to active substance and propellant gas:
a) 0.02% Tiotropium* 0.20% Polysorbate 20 99.78% HFA 227 b) 0.02% Tiotropium* 1.00% Isopropylmyristate 98.98% HFA 227 c) 0.02% Tiotropium* 0.3% Myvacet 9-45 99.68% HFA 227 d) 0.04% Tiotropium* 1.00% Myvacet 9-08 98.96% HFA 227 e) 0.04% Tiotropium* 0.04% Polysorbate 80 99.92% HFA 227 f) 0.04% Tiotropium* 0.005% Oleic acid 99.955% HFA 227 g) 0.02% Tiotropium* 0.1% Myvacet 9-45 60.00% HFA 227 39.88% HFA 134a h) 0.02% Tiotropium* 0.30% Isopropylmyristate 20.00% HFA 227 79.68% HFA 134a i) 0.02% Tiotropium* 0.01% Oleic acid 60.00% HFA 227 39.97% HFA 134a *used in the form of the tiotropium bromide monohydrate (conversion factor 1.2495)
[0040] Suspensions containing only active substance and propellant gas:
j) 0.02% Tiotropium* 99.98% HFA 227 k) 0.02% Tiotropium* 99.98% HFA 134a l) 0.04% Tiotropium* 99.96% HFA 227 m) 0.04% Tiotropium* 99.96% HFA 134a n) 0.02% Tiotropium* 20.00% HFA 227 79.98% HFA 134a o) 0.02% Tiotropium* 60.00% HFA 227 39.98% HFA 134a p) 0.04% Tiotropium* 40.00% HFA 227 59.96% HFA 134a q) 0.04% Tiotropium* 80.00% HFA 227 19.96% HFA 134a *used in the form of the tiotropium bromide monohydrate (conversion factor 1.2495)
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The invention relates to propellant gas formulations containing suspensions of the crystalline monohydrate of (1α,2β,4β,5α,7β)-7-[(hydroxydi-2-thienylacetyl)oxy]-9,9-dimethyl -3-oxa-9-azoniatricyclo[3.3.1.0 2,4 ]nonane-bromide.
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FIELD OF THE INVENTION
[0001] This invention relates, in general, to equipment utilized in conjunction with operations performed in subterranean wells and, in particular, to remote actuated downhole pressure barriers for use in subterranean wells and methods for use of same.
BACKGROUND OF THE INVENTION
[0002] Without limiting the scope of the present invention, its background is described with reference to using dissolvable members in plugging devices, as an example.
[0003] It is well known in the completion and production arts to install and retrieve plugs in subterranean wells via intervention into the wells. For example, when it is desired to plug a well, a plugging device may be latched in an internal profile of a tubular string using a conveyance such as a slickline, a wireline, a coiled tubing or the like. When it is later desired to produce or otherwise access the well, the plugging device may be retrieved using the appropriate conveyance.
[0004] It has been found, however, that in some well configurations, such as certain deviated or horizontal wells, the use of such conveyances may not be desirable or feasible for installation or retrieval of a plugging device. In such well configurations, the plugging device may be installed at the desired location within the tubular string at the surface then conveyed into the well as part of the tubular string in which it is installed. Once installed, such plugging devices have been remotely actuated using a variety of techniques such as dissolving all or part of the plugging device using a chemical solution, ultraviolet light, a nuclear source or an explosive. For example, certain plugging devices have utilized a dispersible plug member that is dissolvable or otherwise dispersible by contact with fluid, including chemical solutions or water. In such cases, the member may be initially isolated from contact with the fluid and then, when it is desired to permit flow through the plugging device, the fluid is placed in communication with the member, thereby dispersing the member. In one commonly used plugging device, the dispersible plug member has been constructed using a mixture of compacted salt and sand. These and other types of plugging devices have used activation mechanisms including timer-controlled mechanical, hydraulic and electrical devices as well as wireless communication systems.
[0005] It has been found, however, that conventional dispersible plug members are not suitable for service over an extended time period and thus cannot operate as pressure barriers. Accordingly, a need has arisen for a plugging device that is suitable installation and deployment in a tubular string. A need has also arisen for such a plugging device that is operable to be remotely actuated. Further, a need has arisen for such a plugging device that has an extended service life and may therefore operate as a pressure barrier.
SUMMARY OF THE INVENTION
[0006] The present invention disclosed herein is directed to remote actuated downhole pressure barriers for use in subterranean wells and methods for use of same. The downhole pressure barrier of the present invention is suitable for installation and deployment in a tubular string and is operable to be remotely actuated. In addition, the downhole pressure barrier of the present invention has an extended service life.
[0007] In one aspect, the present invention is directed to a downhole pressure barrier that is operatively positionable in a subterranean well. The downhole pressure barrier includes a housing having a flow passage formed therethrough and a plug member positioned within the flow passage that selectively prevents flow through the flow passage and allows flow through the flow passage responsive to contact with an activating agent. At least one retainer assembly supports the plug member within the housing. The retainer assembly selectively prevents communication between the activating agent and the plug member. An activating assembly includes a combustible agent that is positioned between at least a portion of retainer assembly and the plug member. The activating assembly is operable to create a communication path through the retainer assembly upon combustion of the combustible agent to allow communication between the activating agent and the plug member.
[0008] In one embodiment, the plug member may be a mixture of sand and salt. In another embodiment, the activating agent may be at least one of a wellbore fluid and water. In this embodiment, the housing may include a fluid chamber operable to contain the activating agent. In a further embodiment, the combustible agent may be a mixture of a metal powder and a metal oxide.
[0009] In one embodiment, a seal element is positioned between the retainer assembly and the housing to prevent fluid flow therebetween. In another embodiment, the retainer assembly may include a discoidal portion that has a spaced apart relationship with the plug member. In this embodiment, the combustible agent may be positioned in the space between the plug member and the discoidal portion of the retainer assembly. Also in this embodiment, a separator member may be positioned between the combustible agent and the plug member. The discoidal portion of the retainer assembly and the separator member may be metallic. In a further embodiment, the activating assembly may include an ignition agent operably positioned proximate the combustible agent used to ignite the combustible agent. In addition, the activating assembly may include an electronic package operable to receive a wireless signal and to send a signal to the ignition agent.
[0010] In another aspect, the present invention is directed to a downhole pressure barrier that is operatively positionable in a subterranean well. The downhole pressure barrier includes a housing having a flow passage formed therethrough. A plug member, formed from a mixture of sand and salt, is positioned within the flow passage to selectively prevent flow through the flow passage and allow flow through the flow passage responsive to contact with an activating agent. At least one retainer assembly supports the plug member within the housing. The retainer assembly selectively prevents communication between the activating agent and the plug member. An activating assembly includes a combustible agent that is integrally formed in the plug member. The activating assembly is operable to create a communication path through the retainer assembly upon combustion of the combustible agent to allow communication between the activating agent and the plug member.
[0011] In a further aspect, the present invention is directed to a downhole pressure barrier that is operatively positionable in a subterranean well. The downhole pressure barrier includes a housing having a flow passage formed therethrough. A plug member, formed from a thermosetting polymer, is positioned within the flow passage to selectively prevent and allow flow through the flow passage. At least one retainer assembly supports the plug member within the housing. An activating assembly includes a combustible agent that is integrally formed in the plug member. The activating assembly is operable to create a communication path through the downhole pressure barrier upon combustion of the combustible agent.
[0012] In a further aspect, the present invention is directed to a method for remotely actuating a downhole pressure barrier positioned in a subterranean well. The method includes receiving a wireless signal at a receiver positioned within the downhole pressure barrier, generating a activation signal responsive to the received wireless signal, activating an ignition agent responsive to the activation signal, igniting a combustible agent with the ignition agent, creating a communication path between an activating agent and a plug member of the downhole pressure barrier responsive to the combustion and contacting the plug member with the activating agent to disperse the plug member, thereby opening a communication path through the downhole pressure barrier.
[0013] The method may also include one or more of sensing a series of pressure fluctuations via the receiver, activating a magnesium fuse, igniting a mixture of a metal powder and a metal oxide, contacting the plug member with at least one of a wellbore fluid and water, contacting a mixture of sand and salt with the activating agent and containing the activating fluid in a fluid chamber of the downhole pressure barrier.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
[0015] FIG. 1 is a schematic illustration of an offshore oil and gas platform operating a remote actuated downhole pressure barrier according to an embodiment of the present invention;
[0016] FIGS. 2A-2B are cross sectional views of consecutive axial sections of a remote actuated downhole pressure barrier according to an embodiment of the present invention;
[0017] FIGS. 3A-3B are cross sectional views of consecutive axial sections of a remote actuated downhole pressure barrier according to an embodiment of the present invention;
[0018] FIGS. 4A-4B are cross sectional views of consecutive axial sections of a remote actuated downhole pressure barrier according to an embodiment of the present invention;
[0019] FIGS. 5A-5B are cross sectional views of consecutive axial sections of a remote actuated downhole pressure barrier according to an embodiment of the present invention; and
[0020] FIGS. 6A-6B are cross sectional views of consecutive axial sections of a remote actuated downhole pressure barrier according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
[0022] Referring initially to FIG. 1 , a remote actuated downhole pressure barrier being operated from an offshore oil and gas platform is schematically illustrated and generally designated 10 . A semi-submersible platform 12 is centered over an offshore oil and gas formation 14 located below sea floor 16 . A subsea conduit 18 extends from deck 20 of platform 12 to wellhead installation 22 including subsea blow-out preventers 24 . Platform 12 has a hoisting apparatus 26 and a derrick 28 for raising and lowering pipe strings such as work string 30 .
[0023] A wellbore 32 extends through the various earth strata including formation 14 . A casing 34 is cemented within wellbore 32 by cement 36 . The portion of wellbore 32 extending through horizontal portion 38 includes a plurality of perforations 40 that allow fluid communication between formation 14 and wellbore 32 . Work string 30 includes various tools such as a plurality of sand control screens 42 , a remote actuated downhole pressure barrier 44 and a packer 46 . In operation, remote actuated downhole pressure barrier 44 provides a pressure barrier that allows the operator to set production and isolation packers as well as pressure test the production tubing.
[0024] In the illustrated embodiment, even though remote actuated downhole pressure barrier 44 has been disposed in a horizontal portion of wellbore 32 , it should be understood by those skilled in the art that the remote actuated downhole pressure barriers of the present invention are equally well-suited for use in other well configurations including, but not limited to, inclined wells, wells with restrictions, non-deviated wells, multilateral wells and the like. As such, use of directional terms such as “above”, “below”, “upper”, “lower” and the like are used for convenience in referring to the illustrations. In addition, even though an offshore operation has been depicted in FIG. 1 , the remote actuated downhole pressure barriers of the present invention are equally well-suited for use in onshore operations.
[0025] Referring now to FIGS. 2A-2B , therein is representatively illustrated a remote actuated downhole pressure barrier that is generally designated 100 . Barrier 100 includes a generally tubular housing assembly 102 . Housing assembly 102 that includes a top sub 104 that is securably and sealingly connected to a middle sub 106 by a plurality of set screws 108 and seal 110 . At its lower end, middle sub 106 is securably and sealingly connected to a bottom sub 112 at threaded connection 114 and by seal 116 . Disposed within middle sub 106 is an inner mandrel 118 . Seals 120 , 121 provide a sealing relationship between middle sub 106 and inner mandrel 118 . Housing assembly 102 has a flow passage 122 formed axially therethrough. Even though housing assembly 102 is shown as being made up of several interconnected portions 104 , 106 , 112 , 118 , it is to be understood that greater or fewer numbers of housing portions may be utilized in the housing assembly 102 and the portions may be otherwise configured and otherwise attached to each other without departing from the principles of the present invention.
[0026] Fluid flow through passage 122 is initially blocked by a dispersible plug member 124 . Plug member 124 includes a dispersible portion 126 which is initially compacted within a plug sleeve 128 . Plug member 124 is supported within housing assembly 102 by a pair of oppositely disposed retainer assemblies 130 , 132 . Retainer assembly 130 is sealingly coupled to inner mandrel 118 by a seal 134 . Retainer assembly 132 is sealingly coupled to bottom sub 112 by a seal 136 . Retainer assemblies 130 , 132 are axially positioned between lower shoulder 138 of inner mandrel 118 and upper shoulder 140 of bottom sub 112 . Retainer assemblies 130 , 132 respectively include discoidal portions 142 , 144 that are generally impervious and serve to isolate dispersible portion 126 from contact with any fluid in flow passage 122 . Retainer assemblies 130 , 132 including discoidal portions 142 , 144 are preferable formed from a metal such as a stainless steel including, but not limited to, a 625 stainless steel.
[0027] In the illustrated embodiment, dispersible portion 126 is a compacted salt and sand composition which has sufficient compressive strength to resist fluid pressure in flow passage 122 . When an activating agent such a wellbore fluid, water or other fluid, is permitted to contact dispersible portion 126 , however, the salt constituent will dissolve. This dissolving of the salt constituent significantly reduces the compressive strength of dispersible portion 126 , so that it is no longer able to resist fluid pressure in flow passage 122 .
[0028] Plug member 124 may be dispersed by dissolving dispersible portion 126 or a constituent part thereof using wellbore fluid in flow passage 122 . In certain implementations, however, a wellbore fluid capable of dispersing plug member 124 may not available, for example, if the fluid in flow passage 122 is salt-saturated, oil- based or otherwise incapable of dissolving a constituent part of dispersible portion 126 . In the illustrated embodiment, barrier 100 includes a fluid chamber 146 disposed within inner mandrel 118 and an upper portion of middle sub 106 and is protected from contamination with other fluids and debris in the well during conveyance by a debris barrier 148 . Debris barrier 148 extends laterally across flow passage 122 , thus isolating the fluid in fluid chamber 146 from contact with any other fluid or debris in flow passage 122 above debris barrier 148 . As such, the fluid in fluid chamber 146 is available for interaction with dispersible portion 126 when desired.
[0029] As representatively illustrated, debris barrier 148 includes a body portion 150 extending across flow passage 122 and a somewhat enlarged annular-shaped peripheral portion 152 sealingly received between top sub 104 and middle sub 106 of housing assembly 102 . Such sealing engagement of debris barrier 148 acts to completely isolate the fluid in fluid chamber 146 from other fluids in the well. Debris barrier 148 may be formed from an elastomeric material, however, in certain implementations, debris barrier 148 may alternatively be made of a nonelastomeric material. An elastomeric material is preferred, however, since applications of fluid pressure are made to flow passage 122 to initiate activation of plug member 124 as described below.
[0030] In the illustrated embodiment, barrier 100 includes an activating assembly that is operable to create a communication path through retainer assembly 130 to allow communication between the fluid in fluid chamber 146 and dispersible portion 126 . The activating assembly includes an electronic package and a combustion assembly. The electronic package includes a pressure sensor 154 , a logic module 156 , batteries 158 and various signal and current conductors (not pictured). The combustion assembly includes ignition agents 160 , 162 and combustible agents 164 , 166 . As illustrated, separator members 168 , 170 are positioned respectively between combustible agents 164 , 166 and dispersible portion 126 . Separator members 168 , 170 are preferable formed from a metal such as a stainless steel including, but not limited to, a 625 stainless steel. An optional heat shielding sleeve 172 is positioned between plug member 124 and middle sub 106 . Heat shielding sleeve 172 is preferably formed from a ceramic materials or other material capable of shielding middle sub 106 from the heat and temperature generated in the combustion reaction discussed below.
[0031] Pressure sensor 154 is operable to receive and interpret pressure signals sent from the surface. For example, by applying a predetermined number and sequence of fluid pressure fluctuations to flow passage 122 via the tubular string at the surface, pressure sensor 154 receives the signal via the fluid in fluid chamber 146 . The pressure signals are transferred to the fluid in fluid chamber 146 from the fluid in the tubular string through debris barrier 148 . When pressure sensor 154 receives the proper pressure signature, pressure sensor 154 sends a signal to logic module 156 to begin the activation process. Even though the signal for initiating the activation of plug member 124 has been described as a pressure signal received by a pressure sensor, those skilled in the art will understand the other types of signals both wireless and wired could alternatively be used including, but not limited to, acoustic signals, electromagnetic signals, hydraulic signals, electrical signals, optical signals and the like, such signals being received and interpreted by the corresponding type of receiver.
[0032] Logic module 156 receives the activation signal from pressure sensor 154 and causes a current to be sent to ignition agents 160 , 162 . Logic module 156 may include various controllers, processors, memory components, operating systems, instructions, communication protocols and the like. As should be understood by those skilled in the art, any of the functions described with reference to logic module 156 herein can be implemented using software, firmware, hardware, including fixed logic circuitry or a combination of these implementations. As such, the term logic module as used herein generally represents software, hardware or a combination of software and hardware. For example, in the case of a software implementation, the term logic module represents program code and/or declarative content, e.g., markup language content that performs specified tasks when executed on a processing device or devices such as one or more processors or CPUs. The program code can be stored in one or more computer readable memory devices. More generally, the functionality of the illustrated logic module may be implemented as distinct units in separate physical grouping or can correspond to a conceptual allocation of different tasks performed by a single software program and/or hardware unit.
[0033] Batteries 158 are used to power the electronic devices within barrier 100 such as pressure sensor 154 and logic module 156 . In addition, batteries 158 are used to provide suitable current to initiate the combustion of combustible elements 164 , 166 . Batteries 158 may be of any suitable type such as alkaline batteries that provide sufficient power and current and are capable of withstanding the temperature in the well environment.
[0034] In the illustrated embodiment, ignition agents 160 , 162 are metal burning fuses such as magnesium fuses which are activated by the electrical current supplied from batteries 158 in response to the activation signal. Metal fuses are preferred as metals burn without releasing cooling gases and can burn at extremely high temperatures. Magnesium fuses are most preferred as due to the reactive nature of magnesium and temperature at which magnesium burn which is sufficiently high to ignite combustible agents 164 , 166 . Alternatively, a nichrome wire such as a NiCr60 wire, may be used to directly ignite combustible agents 164 , 166 . As another alternative, a nichrome wire may be used in an ignition train to ignite a metal burning fuse which in turn ignites one of the combustible agents 164 , 166 . In this case, both the nichrome wire and the metal burning fuse may be considered to be one of the ignition agents 160 , 162 .
[0035] Combustible agents 164 , 166 are preferable formed from a composition of a metal powder and a metal oxide that produces an exothermic chemical reaction at high temperature such as a thermite reaction. The metal powder used in the composition may include aluminum, magnesium, calcium, titanium, zinc, silicon, boron and the like. The metal oxide used in the composition may include boron (III) oxide, silicon (IV) oxide, chromium (III) oxide, manganese (IV) oxide, iron (III) oxide, iron (II, III) oxide, copper (II) oxide, lead (II, III, IV) oxide and the like. For example, a composition of aluminum and iron (III) oxide may be used which has a reaction according to the following equation:
[0000] Fe 2 O 3 +2Al->2Fe+Al 2 O 3 +Heat
[0036] Use of combustible agents 164 , 166 that produce a thermite reaction is advantageous in the present invention as the reactants are stable at wellbore temperatures but produce an extremely intense exothermic reaction following ignition. The combination of the high temperature and the heat generated by the reaction are sufficient to melt both the metallic separator members 168 , 170 and discoidal portions 142 , 144 of retainer assemblies 130 , 132 . In the illustrated embodiment, this process creates a communication path through retainer assembly 130 to allow communication between the fluid in fluid chamber 146 and dispersible portion 126 . The fluid in fluid chamber 146 dissolves the salt in dispersible portion 126 such that the remaining sand component of dispersible portion 126 lacks sufficient compressive strength to plug flow passage 122 . Accordingly, the sand disintegrates leaving an open bore within plug sleeve 128 .
[0037] Referring next to FIGS. 3A-3B , therein is representatively illustrated a remote actuated downhole pressure barrier that is generally designated 200 . Barrier 200 includes a generally tubular housing assembly 202 that includes a top sub 204 that is securably and sealingly connected to a middle sub 206 by a plurality of set screws 208 and seal 210 . At its lower end, middle sub 206 is securably and sealingly connected to a bottom sub 212 at threaded connection 214 and by seal 216 . Disposed within middle sub 206 is an inner mandrel 218 . Seals 220 , 221 provide a sealing relationship between middle sub 206 and inner mandrel 218 . Housing assembly 202 has a flow passage 222 formed axially therethrough.
[0038] Fluid flow through passage 222 is initially blocked by a dispersible plug member 224 . Plug member 224 includes a dispersible portion 226 which is initially compacted within a plug sleeve 228 . Plug member 224 is supported within housing assembly 202 by a pair of oppositely disposed retainer assemblies 230 , 232 . Retainer assembly 230 is sealingly coupled to inner mandrel 218 by a seal 234 . Retainer assembly 232 is sealingly coupled to bottom sub 212 by a seal 236 . Retainer assemblies 230 , 232 are axially positioned between lower shoulder 238 of inner mandrel 218 and upper shoulder 240 of bottom sub 212 . Retainer assemblies 230 , 232 respectively include discoidal portions 242 , 244 that are generally impervious and serve to isolate dispersible portion 226 from contact with any fluid in flow passage 222 .
[0039] In the illustrated embodiment, dispersible portion 226 is preferably a compacted salt and sand composition, as described above. Barrier 200 includes a fluid chamber 246 disposed within inner mandrel 218 and an upper portion of middle sub 206 and is protected from contamination with other fluids and debris by a debris barrier 248 . Debris barrier 248 includes a body portion 250 extending across flow passage 222 and a somewhat enlarged annular-shaped peripheral portion 252 sealingly received between top sub 204 and middle sub 206 of housing assembly 202 .
[0040] In the illustrated embodiment, barrier 200 includes an activating assembly that is operable to create a communication path, through retainer assembly 230 to allow communication between the fluid in fluid chamber 246 and dispersible portion 226 . The activating assembly includes an electronic package and a combustion assembly. The electronic package includes a pressure sensor 254 , a logic module 256 , batteries 258 and various signal and current conductors (not pictured). The combustion assembly includes ignition agents 260 , 262 and combustible agents 264 , 266 . In the illustrated embodiment, combustible agents 264 , 266 are integrally disposed within dispersible portion 226 such that the greatest concentration of the combustible agents 264 , 266 is located in the two ends of dispersible portion 226 proximate discoidal portions 242 , 244 of retainer assemblies 230 , 232 . Ignition agents 260 , 262 are preferably metal fuses, as described above. Combustible agents 264 , 266 are preferably formed from a composition of a metal powder and a metal oxide, as described above. An optional heat shielding sleeve 272 is positioned between plug member 224 and middle sub 206 .
[0041] In operation, pressure sensor 254 receives and interprets pressure signals sent from the surface. When pressure sensor 254 receives the proper pressure signature, pressure sensor 254 sends a signal to logic module 256 to begin the activation process. Logic module 256 then causes a current to be sent to ignition agents 260 , 262 from batteries 258 . The current is used to ignite ignition agents 260 , 262 which in turn ignite combustible agents 264 , 266 . The combination of the high temperature and the heat generated by the reaction of combustible agents 264 , 266 are sufficient to melt discoidal portions 242 , 244 of retainer assemblies 230 , 232 , which creates a communication path through retainer assembly 230 to allow communication between the fluid in fluid chamber 246 and dispersible portion 226 . The fluid in fluid chamber 246 dissolves the salt in dispersible portion 226 such that the remaining sand component of dispersible portion 226 lacks sufficient compressive strength to plug flow passage 222 . Accordingly, the sand disintegrates leaving an open bore within plug sleeve 228 .
[0042] Referring next to FIGS. 4A-4B , therein is representatively illustrated a remote actuated downhole pressure barrier that is generally designated 300 . Barrier 300 includes a generally tubular housing assembly 302 that includes a top sub 304 that is securably and sealingly connected to a middle sub 306 by a plurality of set screws 308 and seal 310 . At its lower end, middle sub 306 is securably and sealingly connected to a bottom sub 312 at threaded connection 314 and by seal 316 . Disposed within middle sub 306 is an inner mandrel 318 . Seals 320 , 321 provide a sealing relationship between middle sub 306 and inner mandrel 318 . Housing assembly 302 has a flow passage 322 formed axially therethrough.
[0043] Fluid flow through passage 322 is initially blocked by a plug member 324 . Plug member 324 includes a removable portion 326 which is initially compacted within a plug sleeve 328 . Plug member 324 is supported within housing assembly 302 by a pair of oppositely disposed retainer assemblies 330 , 332 . Retainer assembly 330 is sealingly coupled to inner mandrel 318 by a seal 334 . Retainer assembly 332 is sealingly coupled to bottom sub 312 by a seal 336 . Retainer assemblies 330 , 332 are axially positioned between lower shoulder 338 of inner mandrel 318 and upper shoulder 340 of bottom sub 312 . Retainer assemblies 330 , 332 respectively include discoidal portions 342 , 344 that are generally impervious and serve to isolate removable portion 326 from contact with any fluid in flow passage 322 .
[0044] In the illustrated embodiment, removable portion 326 may be a compacted salt and sand composition, as described above, that is generally uniformly mixed with a combustible agent 364 . In this embodiment, barrier 300 includes a fluid chamber 346 disposed within inner mandrel 318 and an upper portion of middle sub 306 and is protected from contamination with other fluids and debris by a debris barrier 348 . Debris barrier 348 includes a body portion 350 extending across flow passage 322 and a somewhat enlarged annular-shaped peripheral portion 352 sealingly received between top sub 304 and middle sub 306 of housing assembly 302 . Alternatively, removable portion 326 may be substantially completely formed from a compaction of the combustible agent 364 . In this embodiment, fluid chamber 346 and debris barrier 348 are optional.
[0045] In the illustrated embodiment, barrier 300 includes an activating assembly that is operable to create a communication path through retainer assembly 330 to allow communication between the fluid in fluid chamber 346 and removable portion 326 . The activating assembly includes an electronic package and a combustion assembly. The electronic package includes a pressure sensor 354 , a logic module 356 , batteries 358 and various signal and current conductors (not pictured). The combustion assembly includes a plurality of ignition agents, only two of which, ignition agents 360 , 362 are shown and combustible agent 364 . The ignition agents are preferably metal fuses, as described above. Combustible agent 364 is preferably formed from a composition of a metal powder and a metal oxide, as described above. An optional heat shielding sleeve 372 is positioned between plug member 324 and middle sub 306 .
[0046] In operation, pressure sensor 354 receives and interprets pressure signals sent from the surface. When pressure sensor 354 receives the proper pressure signature, pressure sensor 354 sends a signal to logic module 356 to begin the activation process. Logic module 356 then causes a current to be sent to the ignition agents from batteries 358 . The current is used to ignite the ignition agents, which in turn ignites combustible agent 364 . The combination of the high temperature and the heat generated by the reaction of combustible agent 364 is sufficient to melt discoidal portions 342 , 344 of retainer assemblies 330 , 332 . In those embodiments including fluid chamber 346 and wherein removable portion 326 includes a salt constituent, a communication path is created through retainer assembly 330 to allow communication between the fluid in fluid chamber 346 and removable portion 326 . The fluid in fluid chamber 346 dissolves the salt in removable portion 326 such that the remaining sand component of removable portion 326 lacks sufficient compressive strength to plug flow passage 322 . Accordingly, the sand disintegrates leaving an open bore within plug sleeve 328 . In those embodiments wherein removable portion 326 is substantially completely formed from a compaction of the combustible agent 364 , combustion of combustible agent 364 not only melts the discoidal portions 342 , 344 of retainer assemblies 330 , 332 but also creates the open bore within plug sleeve 328 .
[0047] Referring next to FIGS. 5A-5B , therein is representatively illustrated a remote actuated downhole pressure barrier that is generally designated 400 . Barrier 400 includes a generally tubular housing assembly 402 that includes a top sub 404 that is securably and sealingly connected to a middle sub 406 by a plurality of set screws 408 and seal 410 . At its lower end, middle sub 406 is securably and sealingly connected to a bottom sub 412 at threaded connection 414 and by seal 416 . Disposed within middle sub 406 is an inner mandrel 418 . Seals 420 , 421 provide a sealing relationship between middle sub 406 and inner mandrel 418 . Housing assembly 402 has a flow passage 422 formed axially therethrough.
[0048] Fluid flow through passage 422 is initially blocked by a plug member 424 . Plug member 424 includes a removable portion 426 which is initially positioned within a plug sleeve 428 . Plug member 424 is supported within housing assembly 402 by a pair of oppositely disposed retainer assemblies 430 , 432 . Retainer assembly 430 is sealingly coupled to inner mandrel 418 by a seal 434 . Retainer assembly 432 is sealingly coupled to bottom sub 412 by a seal 436 . Retainer assemblies 430 , 432 are axially positioned between lower shoulder 438 of inner mandrel 418 and upper shoulder 440 of bottom sub 412 . Retainer assemblies 430 , 432 respectively include discoidal portions 442 , 444 that are generally impervious and serve to isolate removable portion 426 from contact with any fluid in flow passage 422 . In the illustrated embodiment, removable portion 426 is preferably a polymer material such as a thermosetting polymer including, but not limited to, an epoxy.
[0049] Barrier 400 includes an activating assembly that is operable to create a communication path through passage 422 . The activating assembly includes an electronic package and a combustion assembly. The electronic package includes a pressure sensor 454 , a logic module 456 , batteries 458 and various signal and current conductors (not pictured). The combustion assembly includes a plurality of ignition agents, only two of which, ignition agents 460 , 462 are shown and combustible agent 464 . In the illustrated embodiment, combustible agent 464 is integrally disposed within removable portion 426 in a substantially even distribution throughout removable portion 426 . The ignition agents are preferably metal fuses, as described above. Combustible agent 464 is preferably formed from a composition of a metal powder and a metal oxide, as described above. An optional heat shielding sleeve 472 is positioned between plug member 424 and middle sub 406 .
[0050] In operation, pressure sensor 454 receives and interprets pressure signals sent from the surface. When pressure sensor 454 receives the proper pressure signature, pressure sensor 454 sends a signal to logic module 456 to begin the activation process. Logic module 456 then causes a current to be sent to the ignition agents from batteries 458 . The current is used to ignite the ignition agents, which in turn ignites combustible agent 464 . The combination of the high temperature and the heat generated by the reaction of combustible agent 464 is sufficient to melt discoidal portions 442 , 444 of retainer assemblies 430 , 432 as well as the matrix material of removable portion 426 leaving an open bore within plug sleeve 428 .
[0051] Referring next to FIGS. 6A-6B , therein is representatively illustrated a remote actuated downhole pressure barrier that is generally designated 500 . Barrier 500 includes a generally tubular housing assembly 502 that includes a top sub 504 that is securably and sealingly connected to a middle sub 506 by a plurality of set screws 508 and seal 510 . At its lower end, middle sub 506 is securably and sealingly connected to a bottom sub 512 at threaded connection 514 and by seal 516 . Disposed within middle sub 506 is an inner mandrel 518 . Seals 520 , 521 provide a sealing relationship between middle sub 506 and inner mandrel 518 . Housing assembly 502 has a flow passage 522 formed axially therethrough.
[0052] Fluid flow through passage 522 is initially blocked by a plug member 524 . Plug member 524 includes a removable portion 526 which is initially positioned within a plug sleeve 528 . Plug member 524 is supported within housing assembly 502 by a pair of oppositely disposed retainer assemblies 530 , 532 . Retainer assembly 530 is sealingly coupled to inner mandrel 518 by a seal 534 . Retainer assembly 532 is sealingly coupled to bottom sub 512 by a seal 536 . Retainer assemblies 530 , 532 are axially positioned between lower shoulder 538 of inner mandrel 518 and upper shoulder 540 of bottom sub 512 . Retainer assemblies 530 , 532 respectively include discoidal portions 542 , 544 that are generally impervious and serve to isolate removable portion 526 from contact with any fluid in flow passage 522 . In the illustrated embodiment, removable portion 526 is preferably a polymer material such as a thermosetting polymer including, but not limited to, an epoxy.
[0053] Barrier 500 includes an activating assembly that is operable to create a communication path through passage 522 . The activating assembly includes an electronic package and a combustion assembly. The electronic package includes a pressure sensor 554 , a logic module 556 , batteries 558 and various signal and current conductors (not pictured). As illustrated, portions of the electronic package are positioned within removable portion 526 . In other implementations, all of the components of the electronic package could be positioned within removable portion 526 . The combustion assembly includes a plurality of ignition agents, only two of which, ignition agents 560 , 562 are shown and combustible agent 564 . In the illustrated embodiment, combustible agent 564 is integrally disposed within removable portion 526 in a substantially even distribution throughout removable portion 526 . The ignition agents are preferably metal fuses, as described above. Combustible agent 564 is preferably formed from a composition of a metal powder and a metal oxide, as described above. An optional heat shielding sleeve 572 is positioned between plug member 524 and middle sub 506 .
[0054] In operation, pressure sensor 554 receives and interprets pressure signals sent from the surface. When pressure sensor 554 receives the proper pressure signature, pressure sensor 554 sends a signal to logic module 556 to begin the activation process. Logic module 556 then causes a current to be sent to the ignition agents from batteries 558 . The current is used to ignite the ignition agents, which in turn ignites combustible agent 564 . The combination of the high temperature and the heat generated by the reaction of combustible agent 564 is sufficient to melt discoidal portions 542 , 544 of retainer assemblies 530 , 532 as well as the matrix material of removable portion 526 leaving an open bore within plug sleeve 528 .
[0055] While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
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A downhole pressure barrier ( 100 ) operatively positionable in a subterranean well. The downhole pressure barrier ( 100 ) includes a housing ( 102 ) having a flow passage ( 122 ) formed therethrough. A plug member ( 124 ) that is positioned within the flow passage ( 122 ) selectively prevents flow through the flow passage ( 122 ) and allows flow through the flow passage ( 122 ) responsive to contact with an activating agent. At least one retainer assembly ( 130 ) supports the plug member ( 124 ) within the housing ( 102 ). The retainer assembly ( 130 ) selectively prevents communication between the activating agent and the plug member ( 124 ). An activating assembly including a combustible agent ( 164 ) that is positioned between the retainer assembly ( 130 ) and the plug member ( 124 ) is operable to create a communication path through the retainer assembly ( 130 ) upon combustion of the combustible agent ( 164 ) to allow communication between the activating agent and the plug member ( 124 ).
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BACKGROUND OF INVENTION
[0001] Embodiments of the present invention relate generally to electronic messaging tools and, more particularly, to a method, system, and storage medium for validating users of communications services.
[0002] In addition to the exchange of personal communications, email messaging, telephone communications, facsimile transmissions, instant messaging, etc. are increasingly becoming popular tools for marketing purposes as well. As a result, many messaging system users have been inundated with large quantities of unsolicited messages that are often unwelcome and/or of little or no value to the recipient. Further, a large amount of these communications can slow down a user's processor, consume a great deal of memory, carry viruses, and distract the user from the important messages that must be individually filtered. For the providers of communication services, there is a significant cost to carry large quantities of unsolicited traffic, and it does not make economic sense for them to incur this cost if their subscribers do not wish to receive these communications.
[0003] Preventing these unsolicited communications is difficult since the originators often disguise their intentions by frequently changing their identities and message. Accordingly, it would be desirable to be able to validate originators of messages and identify the messages intentions.
SUMMARY OF INVENTION
[0004] The foregoing discussed drawbacks and deficiencies of the prior art are overcome or alleviated by a method, system, and storage medium for validating users of communications services.
[0005] Exemplary embodiments of the invention relate to a method, system, and storage medium for validating users of communications services. The method includes generating records for communications service users by at least one service provider. The records store information relating to the communications service users including legal liability information, an originator type code, and a validation code assigned to selected originator type codes. The validation code facilitates validation of the communications service users. The method also includes storing the records in a subscriber classification database. The originator type code classifies the communications service users according to subject matter such as nature of use, communications type, geography, age, and business type. It will be understood that any additional classifications may be added to, or substituted for, the above classifications in order to realize the advantages of the invention. Other classifiers may include government, politics/voting, solicitations/information, charities/nonprofit, emergencies, etc.
[0006] Embodiments of the system include an originating communications device in communication with a first service provider and a recipient communications device in communication with a second service provider. The first and second service providers are in communication with one another via a communications network. The system also includes a certified communications system executing over the communications network. The certified communications system includes a subscriber classification database storing records of users of the communications services. The records store information relating to the communications service users such as legal liability information, an originator type code, and a validation code assigned to selected originator type codes. The validation code is used to facilitate validation of the communications service users. The originator type code classifies the communications device users according to nature of use, a communications type, business type, geography, and/or age. The certified communications system receives communications from originating communications service users via the first service provider and retrieves associated records. If the associated record contains a validation code, the certified communications system appends the originator type code to the communication and transmits the communication to the recipient communications service user via the second service provider along with the originator type code.
[0007] Other systems, methods, and/or computer program products according to embodiments will be or become apparent to one with skill in the art upon review of the following drawings and detailed description. It is intended that all such additional systems, methods, and/or computer program products be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF DRAWINGS
[0008] Referring to the exemplary drawings wherein like elements are numbered alike in the several FIGURES:
[0009] FIG. 1 is a block diagram of a system upon which the certified communications system is implemented in accordance with exemplary embodiments of the invention;
[0010] FIG. 2 is a flowchart describing a process of registering general users (end users) for the certified communications system services in accordance with embodiments of the invention;
[0011] FIG. 3 is a flowchart describing a process of registering service providers with a central agency for the purpose of becoming ‘validators’ for the certified communications system in accordance with embodiments of the invention;
[0012] FIG. 4 is a flowchart describing a process of implementing the certified communications system in accordance with embodiments of the invention; and
[0013] FIG. 5 illustrates a sample computer screen window as seen by a general user registrant of the certified communications system, in accordance with embodiments of the invention.
DETAILED DESCRIPTION
[0014] Disclosed herein is a method, system, and storage medium for validating users of communications services in order to enable service users to distinguish undesirable messages from relevant messages. Forms of communication that may be serviced by the certified communications system include email messaging, voicemail, facsimile transmissions, multimedia messaging, short message service (SMS), instant messaging, telephony, etc. The certified communications system is device independent in that it validates users of a variety of existing communications devices such as telephones, wireless devices (e.g., laptops, PDAs, cellular telephones), computers, facsimile machines, answering machines, etc. A validation database of communications service users are maintained by one or more communications service validators and examined whenever a communications transmission is initiated. If the service user has a subscription record in the database, a validation flag is associated with the message which is then forwarded on through the network. Validation codes and originator type codes are associated with the subscription records that provide information about the message sender. Subscribing recipients of the certified communications system may also provide validation criteria through their subscription records in order to specify the types of communications they authorize a service provider to forward to them or flag before forwarding to them. The certified communications system may be implemented on any type of existing communications network system such as point-to-point and point-to-multipoint communications networks as well as a public switched telephone network (PSTN), wireless, SMS, MMS, IP, WiFi, LAN, WAN, broadcast, video, radio, VoIP, etc.
[0015] Validation of a communications service user refers to the official or formal sanctioning of a communications service user to the extent that their communications activities are traceable and the service user accountable. Validation, as referred to herein, does not necessarily result in authentication in that the sender's name, as seen by a recipient, may not in all instances be the sender's actual name. However, validation signifies that there is a person or entity that is now accountable for their actions.
[0016] The certified communications system is described in FIG. 1 with respect to a specific type of communications device, namely computer systems. However, it will be understood by those skilled in the art that the certified communications system services are applicable to other types of communications devices as well. Thus, the description provided in FIG. 1 is for illustrative purposes, and should not be interpreted as limiting in scope.
[0017] Referring initially to FIG. 1 , there is shown a block diagram of a network system for implementing the certified communications system in exemplary embodiments of the invention. Network system 100 includes a computer client system 102 in communication with a service provider 104 via a network connection.
[0018] Computer client systems 102 and 110 may be general-purpose desktop computers that subscribe to an Internet service provider and may each include an email application, instant messaging system software, a web browser application, and/or any other suitable programs that reside in memory and execute on computer client systems 102 , 110 . It will be understood by those skilled in the art that the certified communications system of the invention may be executed on systems with variant architectures. Computer client systems 102 , 110 are in communication with other entities of network system 100 via a network connection such as the Internet or other suitable means of networking architecture. Computer client system 102 as the sender of a message is also referred to herein as “originating communications device”, and computer client system 110 as a recipient of the message is referred to herein as “terminating communications device.”
[0019] Computer client systems 102 and 110 each subscribe to a communications plan via service providers 104 and 112 , respectively. In the embodiment depicted in FIG. 1 , service providers 104 and 112 are Internet service providers (ISPs) and provide Internet services to computer clients 102 and 110 under a subscription plan. Generally, service providers receive message transmissions from computer clients and forward them onto other service providers in accordance with the messaging instructions contained in the message address. The other service providers then forward the messages onto the appropriate computer client systems.
[0020] Service providers 104 and 112 each comprise a server 106 and 114 , respectively, for receiving and transmitting communications between subscribing computer client systems 102 and 110 . Servers 106 and 114 , may each comprise a high-powered multiprocessor computer device including web server and applications server software for receiving requests from computer client systems 102 and 110 to access email or other messaging services via the Internet or other network. While only two servers 106 and 114 are shown, it will be understood that any number of servers may be used by service providers 104 and 112 in order to realize the advantages of the invention. In the system of FIG. 1 , service providers 104 and 112 are also referred to herein as communication service validators in that they perform the validation services of the certified communications system as described herein, in addition to providing traditional communication services (e.g., Internet service, telephone service, etc.). It will be understood that third party entities may provide the validation services of the certified communications system under an agreement with the service providers.
[0021] Service providers 104 and 112 further comprise subscription classification databases 108 and 116 , respectively, for storing subscriber account records 115 as described further herein (see generally FIG. 4 ). Subscriber account records 115 include subscriber information, originator type codes, validation codes, and profiles that include business rules adopted by the subscriber. Participating service providers classify their subscribers into categories based on use, communications type, geography, age, etc. Some of these categories may be defined by a centralized body (e.g., standards or industry association). These categories may include consumer, business, telemarketing, and undefined. A consumer classification refers to a subscriber who sends personal communications. A business classification refers to subscribers associated with a business or whose primary use is business related. A telemarketing classification refers to subscribers who plan to use this mode of communications for solicitations. An undefined classification is reserved for subscribers who would prefer not to identify themselves or their intentions. For example, a subscriber may wish to associate with a personal or professional online chat room without revealing his/her identity. Subscribers with undefined classifications will not receive validation and no validation code is associated with the subscriber. By providing this option, a subscriber may selectively toggle between classifications as needed. For example, a subscriber in a consumer classification may wish to be validated with certain recipients and forego validation with other recipients depending upon the subscriber's circumstances. Likewise, a subscriber may toggle between validation and validation suppression with respect to a single recipient. In a telephone environment, for example, a subscriber may set his/her telephone to accept all consumer calls, limit business calls between 9:00 a.m. and 5:00 p.m., and block all telemarketing calls or undefined callers. In the event a friend is calling a subscriber from his/her workplace, the certified communications system provides an option to allow the subscriber to override the classification of received communications via business rules specified in the subscriber's profile. This may also include a caller announcement function whereby the identity of the sender is announced to the subscriber. Exceptions to the business rules may be enabled by a subscriber through the use of an exception report that indicates any exceptions to the prohibited messages defined in the business rules. By having subscribers declare their intentions, receivers of communications may easily screen their messages.
[0022] Also included in FIG. 1 is a central agency entity 118 including a server 120 and certified user database 122 . Central agency entity 118 regulates the service providers 104 and 112 to ensure the integrity of the authorized communications system services. Service providers 104 , 112 register with central agency entity 118 in order to become certified participants in the system. Once registered, service provider records 124 indicating their status are stored in certified user database 122 . Registration activities for service providers and other users are further described in FIG. 2 .
[0023] In one embodiment, central agency 118 executes the certified communications system and allows subscribing clients such as computer client systems 102 , 110 , as well as service providers 104 and 112 to access its features and functions as described further herein. In alternate embodiments, service providers themselves execute the certified communications system. In yet a further embodiment, client systems 102 and 110 share execution of the certified communications system with either of service provider systems 104 , 112 or central agency entity 118 and may store the certified communications software internally. In alternate embodiments, service providers 104 and 112 are Internet service providers that provide email messaging services and maintain a client base of email users. It will be understood that other embodiments, in addition to those specified above, are contemplated by the certified communications system and that the above representations are made for illustrative purposes and should not be construed as limiting in scope.
[0024] The certified communications system further comprises a graphical user interface 117 for enabling users of computer client systems 102 and 110 define criteria for determining relevant or desirable messages as desired. Sample computer screen 400 of FIG. 4 illustrates the features of the certified communications system graphical user interface 117 .
[0025] As indicated above, the certified communications system may be executed as a standalone application that is installed or downloaded on a computer client system or may be incorporated into an existing messaging application or similar commercially-available product as an enhancement feature. Further, as indicated above, the features of the certified communications system may be provided via a third party application service provider (ASP) or e-utilities broker where service is provided for a per-use fee in alternative embodiments.
[0026] FIG. 2 is a flowchart describing the process of registering service providers with a central agency 118 to become validators for the certified communications system. The certified communications system receives a request to register from a service provider at step 202 . A service provider record 124 is created by the certified communications system at step 204 . At step 206 , contact information is collected for the registrant such as provider name, address, contact, and other similar types of information. The certified communications system assigns a validation code to the record 124 at step 208 . This may be accomplished by assigning the validation code to the routing address of the communications service user. At step 210 , the completed service provider record 124 is stored in certified user database 122 and the service provider becomes a certified participant in the system.
[0027] Registration for general users will now be described in FIG. 3 . A request to register is received from a general user (e.g., a user of computer client systems 102 , 110 ) at step 302 . A subscriber account record 115 is created at step 304 . A sample computer screen window 500 of FIG. 5 illustrates a registration web page of user interface 117 as seen by a general user. Contact information 502 , 506 is gathered by the certified communications system at step 306 . The certified communications system assigns an originator type code 504 in accordance with the information provided by the registrant at step 308 . A validation code is assigned at step 310 . A validation code may comprise any indicia desired that facilitates the certification of the subscriber. For example, the subscriber's email address 502 may be used as a validation code. In this manner, validation may be processed by sending an email with a unique transaction number to the subscriber requesting that he/she open the email and activate the subscription by clicking on a URL and entering the transaction number. Thus, the user's email account is confirmed to be a valid and accurate source of contact information for the subscriber. The certified communications system contemplates various other ways to validate a subscriber in addition to the above example. For example, a subscriber who accesses the services of the certified communication system under a fee agreement may be required to provide financial account information such as personal bank account or credit card information. This account information could be used for validation as well. A validation code may be presented in any form that is capable of distinguishing a validated message from a non-validated message. For example, a validation code may comprise a symbol, a letter, a word, a picture, or a sound.
[0028] Business rules as shown in subwindows 510 and 512 may also be specified by the registrant at step 312 . At step 314 , the subscriber account record 115 is stored in applicable subscriber classification database 108 , 116 .
[0029] Once a general user registrant has provided the information above in FIG. 3 , the user may begin to use the certified communications system services as described in FIG. 4 . At step 402 , a communication transmission (message) is received by a service provider 104 from an originating user at computer client system 102 . The certified communications system accesses subscriber classification database 108 and retrieves the subscriber account record 115 associated with the sender of the transmission at step 404 . At step 406 , it is determined whether the message is valid by checking the originator type code associated with the sender and the subject line of the message. If valid, the certified communications system flags the message and forwards it on to the recipient at step 408 . The originating service provider 104 appends the originator type code and validation code to the subject line of the email. The validation code includes an encrypted key that the receiving service provider 112 must decrypt in order to validate the authenticity of the originating service provider 104 and originator type code. This appendage, or flag, may comprise various types of indicia for identifying and distinguishing the validated messages from those that are not validated. If not valid, one of several possible actions may be taken. The message may be discarded entirely at step 412 , placed in a queue of invalid messages 414 , forwarded to the recipient without a flag at step 410 , or returned to the sender at step 416 . If options at steps 412 or 416 are selected, the process ends as the recipient never receives the communication.
[0030] The receiving (also referred to as terminal) service provider 112 (if different from the originating service provider) receives the transmission from any of steps 408 , 410 , or 414 at step 418 . Similar to step 406 , the message is examined for validity at step 420 . The certified communications system checks the profile information (see FIG. 5 , 510 - 514 ) and acts in accordance with the recipient subscriber's profile. One of several actions may be performed based upon the results of step 420 . If the message is valid, the message is forwarded with a flag to the recipient at computer client system 110 at step 422 . If the message is not valid, it may be returned to the sender at step 424 or forwarded to the recipient without a flag at step 426 , thus, distinguishing the message from those identified as valid. Alternatively, the message may be discarded at step 428 , or placed in a message queue at step 430 . Once the message is forwarded, a recipient is able to acquire information about the message and the message sender without engaging in a full communication engagement or establishing a communications session with the originator. For example, the recipient receives a telephone transmission that indicates via the originator type code that the caller is a telemarketer. The recipient has learned of this information without answering the telephone call. Likewise, a recipient of an email, instant message, or other communication may acquire this information before engaging in a communications session with the calling party as well.
[0031] As will be appreciated from the above description, the restrictions and limitations that exist with messaging systems are efficiently overcome. Validation codes and originator type codes are associated with subscription records of communications service users which provide information about the users. Users provide validation criteria through their subscription records in order to specify the types of messages they authorize a service provider to forward to them or flag before forwarding to them. This allows the users to effectively screen communications before opening them.
[0032] As described above, embodiments may be in the form of computer-implemented processes and apparatuses for practicing those processes. In exemplary embodiments, the invention is embodied in computer program code executed by one or more network elements. Embodiments include computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, or any other computer-readable storage medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. Embodiments include computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits.
[0033] 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 embodiments disclosed for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims.
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Exemplary embodiments of the invention relate to a method, system, and storage medium for validating users of communications services. The method includes generating records for communications service users by at least one service provider. The records store information relating to the communications service users including legal liability information, an originator type code, and a validation code assigned to selected originator type codes. The validation code facilitates validation of the communications service users. The method also includes storing the records in a subscriber classification database. The originator type code classifies the communications service users according to nature of use, communications type, business type, geography, and age.
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The present invention relates to powder coating compositions which may be applied to heat sensitive substrates, such as wood, fibreboard or the like. These compositions produce a fine, uniformly distributed textured finish on these heat sensitive substrates.
BACKGROUND OF THE INVENTION
Powder coatings are dry, finely divided, free flowing solid materials at room temperature. They have gained considerable popularity in the surface coatings industry for numerous reasons. For one, since they are virtually free of the harmful fugitive organic solvents which are normally present in liquid coatings, they are considered safer to handle and apply. Further, their use results in less damage to the environment caused by the release of potentially harmful solvents.
Powder coatings are very convenient to use in that they may be easily swept up in the event of a spill. No special containment devices or procedures are needed as would be required for handling liquid coating formulations. Further, powder coatings are essentially 100% recyclable. Over-sprayed powders can be fully reclaimed and recombined with the powder feedstock. This factor provides for a more efficient industrial process and substantially reduces the amount of waste generated. In contrast, oversprayed liquid coatings are not recycled which results in an overall increase in the amount of waste generated. This adds significant costs to the coating process and further burdens the environment in general by increasing the amount of hazardous waste being generated.
The furniture making industry has long desired a coating for heat-sensitive substrates which, when cured, provides a uniformly distributed, fine textured finish. Thermofused vinyl laminates have traditionally provided very fine textured finishes. However, the process of applying vinyl laminates to wood-like substrates is difficult to control and the uniform quality of the surface finish is often inconsistent, especially around the corners and edges of the substrate. Attempts to solve these various problems with powder coatings have, heretofore been unsuccessful.
Historically, powder coatings have been utilized with metallic substrates which can withstand the high temperatures required to cure the coating. Recently, however, coatings have been developed which permit curing at lower temperatures, thus substantially reducing both the chance of charring and the excessive outgassing of moisture from the substrate. A controlled amount of moisture in the wood substrate is essential to the formation of a uniformly bonded coating. U.S. Pat. No. 5,721,052 discloses an epoxy based powder coating system which is able to be cured at lower temperatures. However, in order to give the cured coating a finely textured finish, conventional texturizing agents are employed. Examples of such texturizing agents are PTFE, various PTFE/wax mixtures, organophilic clays and modified rubber particles. These materials, however, produce textures which are too bold when compared to vinyl laminates and often look mottled or blotchy when applied over a large surface such as a cabinet door or counter top. U.S. Pat. No. 5,212,263 discloses a fine texture finish without the use of conventional texturizing agents, but its system employs a mixture of an epoxy resin, methylene disalicylic acid and isopropyl imidazole Bis-A epoxy resin adduct that must be cured at 375° F. Because of the high cure temperature, metal is disclosed as the substrate of choice.
Another problem encountered when searching for a powder coating for wood substrates is the relatively narrow temperature differential between the extrusion process, which is required to uniformly mix the various coating ingredients prior to creating the powder, and the cure temperature. For example, extrusion temperatures may reach 250° F. while the desired cure temperature may only be 250-275° F. Careful control of the extrusion and cure temperatures is essential.
STATEMENT OF INVENTION
It is therefore an object of the present invention to provide a powder coating suitable for application onto heat-sensitive substrates which, when cured, exhibits a uniformly distributed fine textured finish.
It is another object of the present invention to provide a method of coating fine textured finish onto heat sensitive substrates, particularly wood substrates, at cure temperatures of about 300° F. or lower for acceptable curing oven dwell times by use of the inventive powder coating having rapid cure and/or low temperature cure properties without damaging or adversely affecting the physical or physiochemical properties of the substrate.
The present invention provides a powder coating consisting of a glycidyl methacrylic (GMA) resin which is cured with either difunctional or trifunctional carboxylic acids, and 1,3,5-tris (2-carboxyethyl)isocyanurate at low temperatures in the presence of a catalyst. This powder coating may be applied to the surfaces of wood substrates, without damage thereto, to provide a uniform fine textured finish without the need to add a texturizing agent.
DETAILED DESCRIPTION
The powder coating of this invention is intended for use on heat sensitive substrates such as, for example, wood and wood-like materials. For the purposes of this invention, wood may be defined as any lignocellulosic material whether it comes from trees or other plants and whether it be in its natural forms, shaped in a saw mill, separated into sheets and made into plywood, chipped and made into particle board or had its fibers separated, felted and compressed.
The glycidyl methacrylate (GMA) resin is in the form of a copolymer which may be produced by copolymerizing between 20 and 100 wt % gylcidyl acrylate or glycidyl methacrylate and between 0 and 80 wt % other alpha, beta ethylenically unsaturated monomers, such as methyl methacrylate, butyl methacrylate and styrene. Such resin typically has a weight average molecular weight of from about 3,000 to about 20,000, and preferably from about 3,000 to about 20,000, as determined by gel permeation chromatography. The glass transition temperature Tg) of the GMA is preferably between about 40° and 70° C. Its viscosity is referably in the range of between about 10 and 500 poise, and most preferably between about 30 and 300 poise at 150° C., as determined by an ICI Cone and Plate Viscometer.
The GMA can be prepared under traditional reaction conditions known in the art. For instance, the monomers can be added to an organic solvent such as xylene and the reaction conducted at reflux in the presence of an initiator such as azobisisobutyronitrile or benzoyl peroxide. An exemplary reaction may be found in U.S. Pat. No. 5,407,706. In addition, such resins are commercially available under the trademark “ALMATEX” from Anderson Development Company of Adrian, Mich. The GMA resin is present in the powder coating composition in an amount ranging from about 20 to 100 phr (parts per hundred parts resin plus curing agent).
The choice of the curing agents is critical to achieve the desired end product manufactured via the narrow process parameters required by heat sensitive substrates. The 1,3,5-tris-(2-carboxyethyl)isocyanurate (TCI) can be prepared by the reaction of cyanuric acid and acrylonitrile as set forth, for example, in U.S. Pat. No. 3,485,833. In the alternative, TCI may be acquired commercially from Cytec Industries, Inc. of Stamford, Conn. It may be added to the powder coating composition in an amount ranging from 1 to 20 phr, preferably 12 to 18.
A second curing agent selected from the group consisting of difunctional or trifunctional carboxylic acids and polyanhydrides of aliphatic dicarboxylic acids may also be utilized. The functionality number relates to the number of —COOH moieties on the molecule. Preferred are the difunctional carboxylic acids, and sebacic acid and polyanhydrides of aliphatic carboxylic acids are the most preferred. These products are well known curing agents which came readily commercially available, While the second curing agent is a desired component of the inventive formulation, it has been found that the objectives of the invention may be achieved without its presence. However, the preferred embodiment includes this ingredient. Sebacic acid may be present in the formulation in an amount up to 7 phr (i.e., from 0 to 7 phr). The polyanhydride of an aliphatic dicarboxylic acid, such as VXL 1381, available commercially from Vianova, may be used in an amount up to 24 ph, and preferably 5-17 phr. In addition, a mixture of sebacic acid and polyanhydride maybe used.
In order to conduct the reaction at the desired rate, a catalyst is required. Catalysts having utility within the boundaries of this invention are the imidazoles, the phosphines, phosphonium and ammonium. Of these, imidazoles are most preferred. Examples of such imidazoles are 2-phenyl-imidazoline, 2-methylimidazole, a 2-methylimidazole epoxy adduct, a substituted imidazole (50% active on castor oil) and an isopropyl imidazole Bis-A epoxy resin adduct. A preferred catalyst for curing the inventive powder coating onto wood substrates is an isopropyl imidazole Bis-A epoxy resin adduct. The imidazole itself is insoluble in GMA copolymer systems. Therefore, the purpose for adducting it to the epoxy resin is to make it compatible with this system. This catalyst is commercially available from the Ciba-Geigy Corporation under the trade name HT-3261. This catalyst is added in an amount ranging from 1 to 10 phr, and preferably 2 to 5 phr.
The powder coating composition may also contain fillers or extenders. These extenders include, without limitation, calcium carbonate, barium sulfate, wollastonite and mica. They may be added to the powder coating composition in amounts ranging up to 120 phr, preferably between 10 and 80 phr.
Further, the powder coating composition of the present invention may include traditional additives to impart various physical characteristics to the finished coating or to assist in the formulating and application of the composition. Such additives include, without limitation, flow additives, degassing agents, gloss control waxes, such as polyethylene, and slip additives, such as siloxanes.
The powder coating compositions of this invention are prepared by conventional techniques employed in the powder coatings art. Typically, the components of the powder coating are thoroughly blended together and then melt blended in an extruder. Melt blending is typically carried out in the temperature range of between 140° and 180° F. with careful control of the extrudate temperature to minimize any premature curing of the powder coating formulation in the extruder. These extruder temperatures are lower than the typical cure temperatures of the powder coating which may begin initial curing at temperatures as low as 250° F. The extruded composition, usually in sheet form, after cooling, is ground in a mill, such as a Brinkman mill or Bantam hammer mill, to achieve the desired particle size.
The heat sensitive wood substrates which are targeted for coating by the powder coating of the present invention are, without limitation, hardwood, particle board, medium density fiberboard (MDF), electrically conductive particle board(ECP), masonite or any other cellulosic based materials. Wood substrates which are particularly suitable for use in this invention have a moisture content of from about 3% to 10%. After they are cut, milled, shaped and/or formed, these wood materials are generally used to make articles such as computer furniture, business furniture, ready to assemble furniture, kitchen cabinets and the like.
The powder coating compositions of the present invention have very low cure temperature properties. These properties provide a powder coating it composition which can be readily applied, especially by electrostatic spraying, to heat sensitive materials, particularly wood products, while limiting the substrate heat exposure so as to not cause damage to said substrate. Ideally, the substrate is preheated. In a preferred embodiment, MDF is preheated in an oven for 10 to 15 minutes at @350° F. to 375°F. The substrate is then coated when the board surface temperature reaches between 170° F. and 240° F. The coated substrate is then post cured in an oven set at between 250° F. and 375° F. for from 5 to 30 minutes. The board temperature must not exceed 300° F. The rate of cure is time/temperature dependent. An effective cure may be achieved with a cure temperature as low as 250° F. for a period of 30 minutes. An equally effective cure may be achieved with a cure temperature of up to 375° F., but with a resident oven time of only about 5 minutes at this temperature. After the cure has been achieved, the coated substrate is then air cooled.
It is important to minimize the outgassing from the wood substrate. Significant outgassing will degrade the internal structural integrity of the substrate as well as form large, noticeable surface defects in the finished coating. By providing coatings which cure at lower temperatures, the potential for significant outgassing is reduced or eliminated altogether.
The high viscosity and low melt flow of the inventive compositions permits the cured powder coating to uniformly cover and hide not only the flat surface(s) of the wood substrate but the edges as well, which are highly porous and, therefore, most difficult to uniformly coat in the application process.
The preferred method used to apply the low temperature cure powder coating onto heat sensitive substrates is by electrostatic spraying. The method of the present invention accordingly will be discussed hereinafter with reference to electrostatic spraying methods. However, it should be understood that other fusion coating methods can be employed.
Electrostatic spraying of powder coatings is based upon the principle of electrostatic charging. In electrostatic spraying, the powder particles receive charges by one of the two following methods. In the corona method, the powder coating particles are passed in a carrier gas stream through a corona discharge in a corona spray gun and the charge is transferred from the ionized discharged air molecules to the powder particles, whereby the powder particles become electrostatically charged. In the triboelectric method, use is made of the principle of frictional electricity. The powder particles rub against a friction surface of, usually, polytetrafluoroethylene (TEFLON), in the tribo gun and are given an electrostatic charge which is opposite in polarity to the charge of the substrate surface.
After charging, the particles are ejected as a cloud through the spray gun nozzle by virtue of their charge and output carrier gas pressure to the vicinity of the grounded target substrate. The charged spray particles are attracted to the grounded substrate by virtue of the difference in their respective charges. This causes the particles to deposit as a uniform coating onto the desired substrate, covering the entire substrate including faces and edges. The charged powder adheres to the substrate for a period of time sufficient to permit conveying the coated article to an oven. A subsequent bake, or cure, process in the oven transforms the powder into a uniform, continuous coating having the desired fine texture surface finish characteristics.
The present invention will be further clarified by a consideration of specific examples which are intended to be purely exemplary of the invention. All parts and percentages specified herein are by weight unless otherwise stated.
EXAMPLES
A uniform, fine texture coating was achieved with a powder coating consisting of the ingredients listed in Table 1.
TABLE 1
Ingredient
phr
Material
Use
PD 7690 GMA resin
80
glycidyl meth-
resin
(Anderson Development
acrylate polymer
Co)
HT 3261 (Ciba Geigy)
3
imidazole/epoxy
catalyst
resin adduct
TCI (Cytec Industries)
16.5
1,3,5-tris-(2-carboxy-
cure
agent
ethyl) isocyanurate
Sebacic acid
3.5
cure
agent
TiO2
40
titanium dioxide
pigment
(white)
Barite 1075
10
barium sulfate
extender
Resiflow P-67
2
2-propenoic acid
flow
agent
ethyl ester polymer
Troy EX542
1
—
degassing
additive
Various Pigments
0.182
The ingredients were then melt blended in an extruder at a temperature of 150° F. The extruded material was mixed with about 0.2% of the dry flow additive Aluminum Oxide C and then ground into a coarse powder. These particles were next ground into a fine powder by use of a high speed Brinkman grinder having a 12-pin rotor and then sieved through a 200 mesh screen.
The fine powder particles were then electrostatically sprayed with a corona discharge gun onto MDF panels which had been pre-heated for 10-15 minutes at 350-375° F. The coated panels were then post cured in an oven set at 350-375° F. for 5-10 minutes. During the time that the panels were in the oven their surface temperatures did not exceed 300° F.
Gel time and hot plate melt flow were tested on the powder coating. MEK resistance and gloss were then tested on the cured panels. The final coating thickness was about 4-7 mils. The resulting properties are summarized in Table 2.
TABLE 2
Property
Result
Gel Time at 300° F.
131
seconds
Hot Plate Melt Flow at 300° F.
13-14
mm
60° Gloss
9-13
units
Appearance
Fine Texture
MEK (50 double rubs)
Good (4+)
Crosshatch Adhesion
5B
Intercoat Adhesion
5B
KCMA Stain testing
Pass
KCMA QUV Exposure
Pass
Hot/Cold Cycle
Pass
Detergent Resistance
Pass
Taber Abrasion
92
mg loss
A second example was prepared using the ingredients shown in Table 3.
TABLE 3
Ingredient
phr
Material
Use
PD 4219 GMA resin
80
gylcidyl meth-
resin
(Anderson)
acrylate polymer
TCI (Cytec)
8.4
1,3,5-tris-(2-carboxy-
cure
agent
ethyl isocyanurate
VXL 1381 (Vienova)
17.2
polyanhydride
cure
agent
Sebacic acid
4
cure
agent
HT 3261 (Ciba-Geigy)
2
imidazole/epoxy
catalyst
resin adduct
Resiflow P-67
1
2-propenoic acid
flow
agent
ethyl ester polymer
Troy EX 542
1
degassing
additive
Barite 1075
30
barium sulfate
extender
Nyad 325
30
filler
305 Green Chromium Oxide
0.59
pigment
Omega Green DMY
1.5
pigment
Raven Black 22
1
pigment
Yellow 29
0.5
pigment
Titanium Dioxide
30
pigment
The ingredients from Table 3 were prepared and tested as set forth in the protocol shown above under Table 1. The results are shown in Table 4.
TABLE 4
Property
Result
Gel Time at 300° F.
74 seconds
Appearance
Fine Texture
60° Gloss
25-30 units
MEK (50 double rubs)
Good (4+)
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Thermosetting powder coating composition adapted to provide a uniform, fine textured finish onto heat sensitive substrates, without damaging the substrate while curing the coating. The composition comprises a glycidyl methacrylate resin, 1,3,5-tris-(2-carboxyethyl)isocyanurate, a catalyst and, optionally, a second curing agent selected from the group consisting of difunctional and trifunctional carboxylic acids. The composition according to the present invention provides a fine texture finish without the need to add texturizing agents. The composition may be cured at temperatures below 300° F. so as to not damage the heat sensitive substrate.
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TECHNICAL FIELD
The present invention relates generally to a system for sealing of closures and, more particularly, to a sealing apparatus for vehicle closures including a vacuum operated control circuit to deflate multiple weatherstrips so as to provide relatively low closing effort for each closure, but providing an exceptionally firm, tight seal upon reinflation.
BACKGROUND OF THE INVENTION
Closed cell sponge weatherstrips have been the standard for years to seal vehicle closures against the passage of air and moisture. The weatherstrip attaches to the vehicle body or closure around the opening (e.g. door or trunk opening). The weatherstrip preferably includes a bulbular or tubular section that is designed to provide an interference fit between the closure and body, and a mounting section to secure the weatherstrip in place. Generally, the greater the interference, the better the sealing function is obtained.
A tight seal is important in order to isolate passengers from inclement weather conditions and also to reduce wind noise as the vehicle passes through the air. The tighter the degree of interference of the weatherstrip between the closure and closure frame, however, the greater the effort is required to close the closure.
Another consideration of a higher degree of interference is the annoying problem of "compression shock". The rapid closing of a door on an otherwise closed vehicle often results in a trapping of air and a momentary air compression in the passenger compartment. This compression shock not only further increases the closing effort required, but also causes an unpleasant feeling to the passengers.
Until recently, attempts to reduce door closing effort resulted in reduced sealing efficiency. Conversely, early attempts to improve sealing resulted in a need for excessive closing effort. Neither extreme is favored by consumers. Thus, in the past, automotive engineers found it necessary to compromise these apparently conflicting engineering requirements, with the best designs carefully balancing the relationship between sealing and closing effort. Of course, any solution that is the result of compromise fails to provide either the most desired closing effort or the best sealing. Accordingly, a significant need existed for a system that could independently address the requirements and provide better sealing while also maintaining closing effort at a desired level.
One of the best approaches to date and one that effectively addresses the conflicting concerns for improved sealing and reduced closing effort is set forth in U.S. Pat. No. 4,761,917 entitled "Deflatable Weatherstrips", issued Aug. 9, 1988, of which I am a co-inventor. In this patent a system is described that provides both improved sealing and reduced closing effort of vehicular closures by utilizing the concept of deflatable weatherstrips. With this approach, a deflatable sealing member forms a weatherstrip to seal the opening in the vehicle body around the closure. The sealing member is connected to a vacuum source such as a bellows pump mounted in the hinge area of the closure. When the closure is closed, the sealing member is deflated so as not to engage in an interference fit between the door and closure. In this manner, closing effort is reduced and compression shock substantially eliminated. Following closing, the sealing member is vented to ambient pressure. This causes the sealing member to expand by built-in resilient memory to provide firm sealing engagement with increased resilient interference between the closure and the body. Advantageously, better sealing is thereby provided. Accordingly, wind noise is reduced and passenger comfort is enhanced.
Space limitations and design constraints particularly in compact automobile models, however, make it very difficult to mount a bellows pump in position in the hinge area between the closure and the frame. U.S. Pat. No. 4,805,347 issued Feb. 21, 1989, entitled Bellows System for Deflating Weatherstrips of which I also am the inventor, addresses this problem by providing a closure sealing mechanism wherein a bellows pump, actuated by closure movement, is specially adapted for convenient mounting in a space anywhere on the closure or the frame adjacent but spaced from the hinge area. While this improved system may be adapted for utilization in some compact automobiles where insufficient space exists in the hinge area to utilize the original design of U.S. Pat. No. 4,761,917 certain vehicle designs still do not have the necessary space to effectively incorporate this design.
Additionally, since both of these prior art systems include an individual deflation or vacuum unit for each sealing member, there is a duplication of components that adds significantly to system cost, while also potentially increasing maintenance requirements. Also, since the vacuum volume generated by each bellows is necessarily limited, there is a lack of reserve vacuum, which can present a problem in terms of attaining full deflection of the sealing member. This may occur where the closure is opened only partially and then closed.
The present invention addresses these problems by providing a centralized vacuum source that may be selectively connected to a plurality of deflatable sealing members. Thus, advantages in packaging convenience in the vehicle, cost over the prior art and improved operation are provided. The centralized vacuum source incorporating the desired capacity to assure appropriate reserve, may be mounted at any convenient location within the vehicle body including the engine compartment. Hence, it may be adapted for use for any desired number of closures and in substantially any vehicle including compact and subcompact models.
It should also by appreciated that the operational problems resulting from small system leaks that have plagued previous centralized systems are minimized by the present invention. This is done by providing a means to actuate the vacuum source only upon the closing movement of the closure. Thus, negative pressure need only be maintained for a very short period of time (i.e. the pressure is provided for only the one or two seconds during door closing). At all other positions of the closure, the vacuum is blocked and the weatherstrip is opened to the atmosphere to allow expansion to full cross-section by built-in resilient memory. As a result, the desired tight seal is provided.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a more energy and cost efficient apparatus for sealing between a closure and a body that provides improved interference sealing while also maintaining a desired relatively low closing effort.
An additional object of the present invention is to provide a sealing apparatus for swinging closures including integral automatic controls to regulate operation.
Still another object of the present invention is to provide a sealing apparatus for swinging closures that may be especially adapted for smaller compact vehicles. The apparatus utilizes a single central vacuum source, such as the engine vacuum reserve tank or an electrical vacuum pump connected to multiple sealing members, one associated with each vehicular closure. Accordingly, the present invention provides better packaging convenience and lower system cost than prior art systems requiring separate deflation units for each sealing member.
Yet another object of the present invention is to provide a sealing apparatus that utilizes a special ratcheting sensor to detect closing motion of a closure. In response to this detected closing motion, the sealing member associated with that closure is deflated. Accordingly, as the closure latches closing effort is minimized, and air is allowed to pass through the substantially peripheral gap around the seal, and thereby eliminate the annoying problem of compression shock. Once closed, the sealing member is vented to atmosphere and expands under the influence of resilient memory to provide a tight interference fit between the closure and the body for better sealing and improved passenger comfort.
Additional objects, advantages, and other novel features of the invention will be set forth in part in the description that follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned with the practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention as described herein, an improved apparatus and related control circuit is provided for assuring tight sealing of a vehicular closure, such a swinging door, hatchback door or trunk lid of an automobile.
The apparatus includes a plurality of resilient sealing members each having a deflatable bulbular or tubular section. Each sealing member is associated with a cooperating vehicular closure. A mounting section is provided on each sealing member to fix the sealing member either around the inner peripheral margin of a cooperating closure or to the vehicle body around the entire periphery of the opening. When the door is closed and the sealing member inflated, a tight interference seal is provided between the door and the body that prevents the passage of air and moisture.
A single vacuum source as, for example, the engine vacuum reserve tank or a separate electrical vacuum pump, is selectively connected to the sealing members. When the negative pressure of the vacuum source is selectively applied to a sealing member, the tubular section of that sealing member deflates and collapses. Conversely, when air and ambient pressure is readmitted to the sealing member, the tubular section reexpands due to its resilient memory.
The apparatus also includes means for sensing the movement or motion of a particular closure and actuating a valve in a flow control circuit to selectively provide fluid communication between the deflatable sealing members and the vacuum source or ambient atmosphere. According to the invention, alternative flow control valves coupled with the motion sensor/actuator may be used for controlling the deflation and inflation of the individual sealing members. Simple closure or door jamb button actuators are used to operate the valve upon the door reaching the full closed position. Some examples of the valves suitable for use include mechanically actuated push action valves, pneumatically actuated valves, electrical solenoid valves and fluidic devices.
Preferably, the apparatus is designed so that negative pressure is selectively applied to deflate a particular sealing member as the closure associated with that sealing member is closing. With the sealing member deflated and thus collapsed, the degree of interference between the sealing member and the closure or closure frame is reduced or even substantially eliminated at the instant of full closure. Thus, the force required to overcome the interference and latch the door is advantageously reduced proportionally. Consequently, a desirable, relatively low closing effort is all that is required to operate the door. In addition, it should be recognized that because the operative tubular section of the sealing member is collapsed, a space exists between the sealing member and the closure or closure frame. Accordingly, the passage for air from the interior of the vehicle around the sealing member is provided. Consequently, the unpleasant problem of compression shock, characteristic of many prior art closure sealing systems is avoided.
The control circuit utilized in the present invention may include a single mechanical three-way push action valve (with spring return) or a single three-way solenoid valve connected to an electrical power source through a switch. In both instances the unique motion sensor/actuator of the invention serves to operate the valve and/or switch. The sealing member is under vacuum during closing and open to atmosphere when fully closed.
Alternatively, a pair of the push action valves may be provided in each line between the vacuum source and a particular deflatable sealing member. More particularly, the mechanical action valves may comprise in combination a three-way valve actuated by the jamb button actuator and a two-way valve actuated by the motion sensor/actuator. The three-way valve includes ports communicating with the vacuum source, the atmosphere, and the two-way valve. The two-way push action valve includes ports communicating with the three-way push action valve and the deflatable sealing member. In response to detected closing movement of the closure by the sensor/actuator, the two-way valve is actuated to provide communication between the three-way valve and the two-way valve. The two-way valve thus provides direct communication to the deflatable sealing member causing deflation of the sealing member. Vacuum is applied until the jamb button actuator switches the three-way valve to atmosphere when the door is fully closed.
In yet another embodiment a power source is connected to first and second electrical switches in series. The first switch is responsive to the closure motion sensor/actuator for operating a three-way solenoid valve; the ports in the valve communicating with the vacuum source, the atmosphere, and the particular sealing member. The first electrical switch is normally open and only closed upon sensing closing movement of the associated closure. The second electrical switch is normally closed and only opened by direct closure contact with its button actuator when the closure is closed all the way. In this manner, the circuit is also advantageously operative to activate the solenoid valve and provide direct communication between the vacuum source and the sealing member only during actual closing movement of the closure. Hence, the deflatable sealing member is only connected to the vacuum source and deflated for the short period of time during closing, and not after closing. Thus, any small system leaks are well tolerated and similarly any energy drain to the system is minimized.
Thus, at all times except closing, including when the closure is fully closed, the circuit is open and the solenoid valve is de-energized to block the vacuum source and provide a direct communication passage between the sealing member and the atmosphere. This allows expansion of the sealing member by resilient memory to full cross-section and hence, the provision of a tight interference seal for best passenger comfort.
In accordance with yet another aspect of the present invention, the closure motion sensor/actuator comprises a special ratcheting mechanism. More specifically, the sensor/actuator includes a flexible strip of, for example, nylon material, having a plurality of equally spaced apertures. The strip has one end attached to either the closure or the vehicle body. An actuator lever is pivotally mounted to a base plate. The distal end of the lever carries a spring loaded pawl.
A guide track is mounted to the base plate of the sensor/actuator. The guide track receives and maintains the flexible strip in a stiffened condition directly over and in engagement with the pawl. Where the end of the flexible strip is mounted to the closure, the sensor/actuator is mounted to the vehicle body. Where the end of the flexible strip is mounted to the vehicle body, the sensor/actuator is mounted to the closure.
A valve stem of the push action valve or jamb button actuator, depending on whether a push action or solenoid valve is being used, is biased into engagement with the actuator lever. As the closure is opened, the pawl rotates out of the way to provide unimpeded movement. Conversely, as the closure is closed, the spring loaded pawl rotates to its normal upright position and engages serially in apertures in the flexible strip as they move past. At this point, further rotation of the pawl is prevented and the force applied by the strip causes the lever to rotate on its hinge and actuate the valve. The rapid engagement of the pawl with the apertures is effective to keep the actuator lever depressed. Thus, during the closing movement of the closure, with the actuator lever depressed, the valve (push action or solenoid operated) is actuated to provide communication between the vacuum source and the sealing member. Accordingly, the sealing member is deflated to allow closing of the closure with the desired reduced effort, and allow the passage of air so as to substantially eliminate the problem of compression shock.
An enlarged opening may be provided at the proximal end in the flexible strip in the embodiments where a single valve or single switch is being used in the circuit. This enlarged opening is designed to receive the pawl. Accordingly, the valve actuator button and the valve stem are biased back to the original position pushing the lever upwardly and the pawl into the enlarged opening once the closure is closed. This results in the single valve system being effective in blocking the flow line to the vacuum source and returning fluid communication between the sealing member and atmosphere. Where dual valves/switches are utilized, this opening is not required. In either case, the sealing member reexpands to its full cross-section as it is opened to the atmosphere, to provide tight interference sealing between the closure and vehicle body.
Advantageously, the system of the present invention provides the advantages of reduced closing effort, elimination of compression shock and a higher integrity seal for a vehicular closure. Further, using inexpensive off-the-shelf and reliable components, and only a single centralized vacuum source, results in additional advantages. Where space is limited, such as in some compact, and in subcompact vehicles, the concept can be used for the first time.
Still other objects of the present invention will become readily apparent to those skilled in this art from the following description wherein there is shown and described a preferred embodiment of this invention, simply by way of illustration of one of the modes best suited to carry out the invention. Several alternative embodiments are also shown. As will be realized, the invention is capable of still other embodiments and its several details are capable of modifications in various, obvious aspects all without departing from the invention. Accordingly, the drawings and description will be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawings incorporated in and forming a part of the specification, illustrates the several aspects of the present invention, and together with the description serves to explain the principles of the invention. In the drawings:
FIG. 1 is a broken away side view of a vehicle equipped with the apparatus of the present invention for sealing between a closure and a vehicle body;
FIG. 2 is a detailed side elevational view of the closure motion sensor/actuator of the apparatus of the present invention, showing rotation of the pawl in response to opening movement of the closure;
FIG. 3 is a view of the sensor/actuator of FIG. 2 showing operation in response to closing movement of the closure;
FIG. 4 is a view of the sensor/actuator when the closure is in the closed position and the pawl is received in an enlarged opening in the overlying flexible strip;
FIG. 4a is a top plan view of the flexible strip of the sensor shown in FIG. 4;
FIG. 5 is a schematical representation showing one embodiment of the apparatus of the present invention incorporating a single mechanical push action valve to control inflation/deflation of the sealing member;
FIG. 6 is a schematical representation of an alternative embodiment of the apparatus of the present invention utilizing a three-way solenoid valve connected to a power source through a single switch;
FIG. 7 is a schematical representation of an alternative embodiment of the apparatus of the present invention showing dual mechanical push action valves in series;
FIG. 8 is a schematical representation of still another alternative embodiment of the apparatus of the present invention including a three-way solenoid valve connected to a power source through dual electrical switches.
Reference will now be made in more detail to the present preferred and alternative embodiments of the invention, the specific examples of which are illustrated in these accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
A sealing system or apparatus 10 of the present invention is provided for tightly sealing a closure, such as a door or closure D on an automobile. As best shown in FIG. 1, and the schematical representations of various systems in FIGS. 5-8, the apparatus 10 includes a sealing member or weatherstrip 12 having a bulbular or tubular section 14. The sealing member 12 is mounted to the face F of the door jamb or frame or vehicle body B by means of a mounting section 16 (see FIG. 5). A one-way clip (not shown), adhesive or any other appropriate means known in the art may be utilized to secure the sealing member 12 in place. The sealing member 12 is constructed of EPDM or other elastomeric material. In this way, the sealing member 12 is provided with sufficient resiliency to furnish a tight sealing engagement with the door D when in the closed position with the sealing member 12 expanded by venting to the atmosphere. Of course, since the sealing member 12 forms a ring extending around the entire periphery of the door opening, complete sealing of the opening is provided. As a result, the passage of air and moisture between the door D and the door jamb face F is prevented.
As best shown in FIGS. 1 and 5, the sealing member 12 is connected to a vacuum source 18, such as the engine vacuum reserve tank, an electrical vacuum pump, or a vacuum reserve tank backed-up by an electrical vacuum pump, by means of a flow control circuit generally designated by reference numeral 20. In the preferred embodiment shown in FIGS. 1 and 5, the flow control circuit 20 includes a flexible air flow line 22 extending from the sealing member 12 to a mechanical three-way push action valve 24. The valve 24 is actuated by a combined closure motion sensor and valve actuator, generally designated by reference numeral 26, and described in greater detail below. Together, the closure movement sensor/actuator 26 and the three-way valve 24 serve to regulate the operation of the sealing apparatus 10.
More particularly, during closing movement of the door D, the push action valve 24 is actuated to the phantom line position (shown in FIG. 5). This provides direct communication through flow control lines 28 and 22 from the vacuum source 18 to the sealing member 12. Accordingly, during closing motion, and only during closing of the door, the sealing member 12 is deflated and collapsed as shown in the corresponding phantom line outline. This serves to reduce the cross-section of the sealing member 12 thereby reducing the degree of interference between the sealing member and the door D as the door closes and latches. This results in a decrease in the effort required to close and latch the door D. Additionally, it serves to provide a space or gap through which air may pass from the interior of the vehicle as the door closes. Accordingly, any buildup of air pressure inside the passenger compartment is relieved and compression shock is substantially avoided. This serves to significantly increase the consumer satisfaction.
Once closed, and at all other times including opening movement of the door D, valve 24 remains deactivated in its home position, as shown in full line in FIG. 5. Thus, the valve 24 serves to provide fluid communication through the air flow lines 22 and 30 from the atmosphere to the sealing member 12. This venting to ambient pressure serves to reexpand the sealing member 12 through resilient memory of the sealing member itself so as to provide the desired increased interference fit for maximum sealing of the door opening against the passage of air and moisture.
The closure movement sensor/actuator 26 for controlling operation of the valve 24 is best shown in FIGS. 2 and 3. The sensor portion includes a flexible nylon strip 32. As shown in FIG. 1, a proximal end of the strip 32 is fastened to the closure or door D. Advantageously, due to the flexibility of the strip material, the strip 32 bends as necessary to snake around frame components, such as the door pillar P.
As best shown in detail in FIG. 2, the strip 32 is received in the sensor/actuator 26 through a pair of guide blocks 34. The guide blocks form the guide track and together serve to stiffen the strip therebetween (see FIGS. 2 and 4a). Each guide block 34 is mounted to a base plate 36. The base plate 36 may be conveniently mounted to the body of the vehicle, such as to pillar P, in or near the door jamb as shown in FIG. 1.
An actuator portion of the sensor/actuator includes a lever 40 mounted for pivotal movement about a hinge 42. A spring loaded pawl 44 is pivotally mounted about a pin 45 on the free end of the lever 40. As shown, the guide track maintains the stiffened strip 32 in engagement with the pawl 44. In other words, the guide blocks 34 stretch the strip 32 and effectively limit its movement relative to the pawl 44 to a back-and-forth motion.
As the door D is swung open, the strip 32, due to its stiffness, is pushed in the direction of action arrow A (see FIG. 2). The force of movement of the strip 32 is applied to the pawl 44 due to its engagement therewith. The force serves to overcome the spring bias action of the pawl 44 to cause it to rotate downwardly (in the direction of action arrow B) to the release position shown in FIG. 2. The pawl 44 remains in the release position as long as the door is held open, the lever 40 is lifted and the valve 24 not actuated.
As the door D is reversed and swung toward a closed position, the strip 32 reverses and moves in the direction of action arrow C, as shown in FIG. 3. As shown in FIG. 4a, the strip 32 includes a series of closely spaced, aligned apertures 46. As the closure or door D is closed, the spring loading serves to bias the pawl 44 so that the tip 48 substantially immediately engages in one of the apertures 46. The apertures 46 are, however, sufficiently small to prevent the tip 48 of the pawl 44 from extending completely through the strip 32. Consequently, the pawl 44 is simply momentarily caught and rotated to a fully upright position (note FIG. 3 and action arrow B'). As this occurs, the base 50 of the pawl 44 engages a stop (not shown) on the lever 40 short of going over center and further rotation of the pawl is prevented. Accordingly, application of continued closing force in the direction of action arrow C causes the lever 40 to rotate downwardly about the hinge 42. The curved edge of tip 48 of the pawl 44 serially and rapidly engages the apertures providing sufficient friction to keep the pawl in the FIG. 3 position. In this way, the lever 40 is held depressed against the actuating button 52 of the valve stem of the push action valve 24.
The valve 24 is now open to the central vacuum source 18 (see phantom line position shown in FIG. 5). Thus, the sealing member 12 is now subject to the evacuation, and is deflated (see phantom line outline in FIG. 5).
An enlarged opening 54 in the strip 32 is positioned in direct alignment over the tip 48 of the pawl in the fully closed position. The enlarged opening 54 is of sufficient size to fully receive the tip 48 of the pawl 44. The actuator button 52 of the valve 24 is biased with a sufficient force by means of a spring (not shown) to lift the lever 40 and push the pawl 48 into the opening 54 (see FIG. 4). This serves to return the valve 24 to the position shown in full line in FIG. 5 opening the sealing member 12 to the atmosphere. Thus, the sealing member reexpands to provide a tight interference seal between the door D and the jamb face F of the vehicle body B.
Advantageously, the closure motion sensor/actuator 26 effectively provides consistent and reliable operation for each opening and closing cycle of the door D. Further, it should be appreciated that the sensor/actuator 26 and push action valve 24 cooperate to efficiently control the operation of the sealing apparatus 10 so as to effectively limit application of negative pressure to the sealing member 12 only during closing movement of the door D. At all other times, including when fully closed, the sealing member 12 is vented to the atmosphere. Advantageously by limiting vacuum application to the relatively short time (one or two seconds) during closing motion, drain on the vacuum system is minimized. Further, the adverse affects of leaks in the system, including pinhole leaks inherent in the structure of the sealing members themselves especially after several years of service, are effectively eliminated.
Since a vehicle includes multiple closures, such as driver and passenger side doors, and a hatchback lid or truck lid, a second flow control circuit 20' identical to the flow control circuit 20 is illustrated in FIG. 5 to highlight the concept of the centralized vacuum source 18 and multiple sealing members. Of course, operation of the second flow control circuit 20' is identical to the operation of flow control circuit 20 as described above. Together, the flow control circuits 20, 20' allow selective application of negative pressure to the sealing member 12, 12' or others. Each circuit cooperates with a corresponding door when being closed at any particular time.
An alternative embodiment of the present invention is schematically shown in FIG. 6. In this embodiment, the closure motion sensor 26 is operatively connected as described above to a normally open electrical solenoid switch 60. During closing movement of the door D, actuator lever 40 is forced downwardly to depress button actuator 61 of the switch 60. This serves to close the circuit between electrical power source 62 and a solenoid valve 64. When activated, the valve 64 moves to the phantom line position shown in FIG. 6 providing direct communication between the central vacuum source 18 and the sealing member 12. As described above, this serves to deflate the sealing member 12 and allow the door D to close and latch with a smooth action under application of a relatively low closing force.
Following closing, the actuator button 61 is biased so as to raise the lever 40 and the pawl 48 into the opening 54 in the flexible strip 32 (see FIG. 4). This deactivates the valve 64 and returns the connection to the full line open to atmosphere position. Accordingly, the sealing member 12 expands as described above to provide a tight interference fit and seal. The valve 64 remains in this position with the sealing member 12 open to the atmosphere even during the opening of the door (see FIG. 2). As described above, it is only upon closing motion that the switch 60 is closed to connect the vacuum source 18 with the sealing member 12.
Another alternative embodiment is schematically represented in FIG. 7. In this embodiment a pair of mechanical push action valves 66, 68 are utilized to control and regulate the operation of the flow control circuit 20. A three-way push action valve 66 and two-way push action valve 68 are serially connected in the air flow line 70 between the sealing member 12, the vacuum source 18 and atmosphere. The three-way valve 66 includes a valve stem and button actuator,, schematically shown at 71, mounted in the door jamb F in a manner similar to a dome light switch actuator, as is known in the art. More specifically, when the door D is closed, the button actuator 71 is depressed. When the actuator 71 is depressed, the three-way valve is switched to the full line position shown in FIG. 7 providing communication from the atmosphere to one port of the two-way valve 68. At all other times, including opening and closing of the door D, the actuator 71 is biased outwardly and the three-way valve 66 remains in the position (note phantom line) providing communication with the vacuum source 18.
The two way valve 68 is operated by the motion sensor/actuator 26, substantially as described above. The only difference is that the flexible strip 32 need not include the enlarged opening 54. Thus, both during closing and when the door is closed, the sensor/actuator 26 is held in the position shown in FIG. 3, with the lever 40 depressed and the sealing member 12 communicating with the valve 66.
In contrast, when the door D is being opened, the strip 32 is moving to the left, as shown by action arrow A in FIG. 2. Accordingly, the pawl 44 rotates as shown, and the two-way valve 68 raises the actuator lever 40 and returns the valve 68 to its closed position, shown in phantom line in FIG. 7. Accordingly, when the door is being opened, the air line 70 between the three-way valve 66 and the sealing member 12 is blocked by the valve 68.
Thus, reviewing the operation of the two push action valve embodiment disclosed in FIG. 7, as the door is opening, the three-way valve 66 provides communication between the vacuum source 18 and the two-way valve 68. The two way valve 68 is, however, closed to block communication between the vacuum source 18 and the sealing member 12. In contrast, during closing of the door, both the three-way valve 66 and the two-way valve 68 are open to provide direct communication between the vacuum source 18 and the sealing member 12. Accordingly, the sealing member 12 deflates and collapses so as to allow the door D to be latched with the desired minimum effort. Once the door is closed, the three way valve 66 is switched by the button actuator 71 to provide communication through the two-way valve 68 between the sealing member 12 and the atmosphere. This opening to the atmosphere serves to cause the sealing member 12 to reexpand to full cross-section and provide the tight interference seal.
Yet another embodiment of the present invention is schematically represented in FIG. 8. The control circuit 20 of this embodiment incorporates a three-way solenoid valve 72 powered by an electrical power source 74 and includes a pair of switches 78, 80 in series. Switch 78 is a normally open switch that is connected to the door motion sensor/actuator 26, modified as described above with respect to the embodiment shown in FIG. 7. More specifically, the flexible strip 32 does not include the enlarged opening 54 designed to receive the pawl 44 when the door is closed. Switch 80 is normally closed and includes a push button actuator 82 mounted so as to engage the door D only when it is fully closed (in a manner similar to a dome light switch actuator). The two switches connected together in series control the power to the solenoid valve 72.
During door opening, the pawl 44 of sensor 26 rotates away from the flexible strip 32 (note FIG. 2) and the switch 78 remains open. During door closing and when the door is closed, the actuator lever 40 of sensor/actuator 26 operates to cause the switch to close (see FIG. 3). In contrast, switch 80 is closed during both door opening and closing. Only when the door is closed and the button actuator 82 for switch 80 is depressed by the door D is the switch 80 open. Accordingly, it should be appreciated that the circuit 20 is only completed between the power source 74 and the solenoid valve 72 during door closing movement. Thus, at that time, the solenoid valve 72 is energized and provides direct communication between the vacuum source 18 and the sealing member 12. As a result, the sealing member 12 is deflated and collapsed only during door closing movement to provide the advantages described above. At all other times, one or the other of the switches 78 or 80 is open and the circuit is interrupted. When the solenoid valve 72 is deenergized, there is of course direct communication between the sealing member 12 and the atmosphere. Thus, it should be appreciated that when the door is fully closed, the sealing member 12 is assured of being expanded to full cross-section, and the desired tight interference seal is provided.
In summary, numerous benefits have been described which result from employing the concepts of the present invention. Advantageously, the apparatus 10 of the present invention provides the swinging vehicular closure D with the desired reduced closing effort while also providing good interference sealing. Additionally, this is done with the centralized vacuum source 18. Accordingly, duplication of parts which otherwise add to system cost and possible maintenance is avoided. Further, space requirements for the system are reduced and, accordingly, the system 10 of the present invention is adapted for use on compact and sub compact vehicles.
As the closure D is closed, the sealing member 12 is deflated to reduce interference engagement and allow closing and latching of the door with reduced effort. At the instant of closing, air can flow past the sealing member 12 so that the annoying problem of compression shock is substantially eliminated. Immediately upon closing, the sealing member 12 is vented to atmosphere allowing expansion by resilient memory to full cross-section so as to provide a desired tight interference engagement with a door for maximum sealing. In order to achieve this end, the present invention utilizes the closure motion sensor/actuator 26 including the novel ratcheting mechanism described. The flexible strip 32 includes a series of closely spaced apertures that engage the pawl 44 on the actuator lever 40 providing the desired closing motion detection and valve operation. The deflation of the sealing member 12 only upon detection of closing movement of the closure obviates the loss of vacuum inherent in other prior art arrangements.
The foregoing description of a preferred and alternative embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
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A sealing apparatus for a vehicle closure, such as a door, includes a vacuum system for deflating the vehicle weatherstrips or sealing members. A plurality of deflatable sealing members may be connected to a single vacuum source. The system includes a sensor/actuator for detecting motion of the individual vehicle closures and a flow control circuit including valve arrangements for selectively connecting a particular sealing member to the vacuum source. In response to detected closing motion of a particular closure, the sealing member associated with that closure is deflated to allow the closure to close and latch with relatively low effort. Once closed, the sealing member is vented to atmosphere and reexpands by resilient memory to full cross-section thereby providing a relatively tight interference seal. The closure motion sensor/actuator includes a flexible strip having a series of aligned, closely spaced apertures and a cooperating pawl and actuator lever for operating the valves.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This patent application is a continuation-in-part of U.S. patent application Ser. No. 13/526,303, filed on 18 Jun. 2012. The co-pending parent application is hereby incorporated by reference herein in its entirety and is made a part hereof, including but not limited to those portions which specifically appear hereinafter.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to an intravenous apparatus and method, and more particular, to an intelligent intravenous apparatus and method for detecting a problem with a catheter tip placement or withdrawal in and from a vein for infusion of intravenous (IV) fluids.
[0004] 2. Discussion of Related Art
[0005] Certain emergency circumstances demand immediate intravenous therapy for patients facing life threatening loss of bodily fluids due to accidents or other critical care applications found in emergency centers or in critical care facilities of a hospital. IV therapy requires the infusion of liquid substances directly into a vein of the patient. Typically, IV fluids in a bag suspended from an IV pole employing a drip chamber that is connected to a peripheral IV line which consists of a short catheter inserted through the skin into a peripheral vein outside of the chest or abdomen. This is usually in the form of a cannula-over-needle apparatus, in which a flexible plastic or polymer cannula comes mounted on a metal trocar. Once the tip of the needle and cannula are located properly in the vein, the trocar is withdrawn and discarded. Meanwhile, the cannula is advanced inside the vein to a predetermined position where an external hub or valve area of the catheter is secured to the patient's body by medical tape or the like to hold it in place. Blood is often withdrawn at the time of the initial insertion of the cannula into the patient's vein. This is the most common intravenous access method used in both hospitals and in the field by paramedics or emergency medical technicians (EMTs).
[0006] The calibers of cannula generally range from 12 to 26 gauge with 12 being the largest and 26 being the smallest. The part of the catheter remaining outside of the skin is called the IV connecting hub or IV valve that is connected to the IV lines back to the IV hag of fluids. For example, an all-purposes IV cannula for infusions and blood draws might be an 18 and 20 gauge sized cannula manufactured by BD/Becton Dickinson Infusion Therapy AB. This intravenous cannula comes with an inner needle that is removed once the flexible portion of the cannula is fully inserted into the patient's vein.
[0007] Due to the different skill levels of the medical personnel inserting the IV cannula into the peripheral vein of a patient's hand or arm, complications sometimes develop in a number of the patients receiving IV fluid therapy from infiltration. This is a condition where through improper insertion or withdrawal of the cannula either into or from a peripheral vein, respectfully, results in IV fluids leaking into the surrounding tissues around the vein causing a potential serious health condition known as infiltration.
[0008] Before the blood is withdrawn at the time of insertion, this is also the time to detect whether the cannula portion of the catheter is being properly inserted in the patient's vein or not. If the cannula is not sited properly or the vein is missed or even pierced where the cannula goes through the vein and enters into the surrounding subcutaneous tissue rather than remaining in the vein, complications may develop for the patient receiving the IV fluid therapy. Many serious complications can result from improper cannula insertion into the vein. The potential complications include edema causing tissue damage or may even include necrosis depending on the medication or fluid being infused. This extravasation is a leakage of infused fluids into the vasculature of the subcutaneous tissue surrounding the vein. The leakage of high osmotic solutions or chemotherapy fluids can result in significant tissue destruction or other complications. Therefore, in an emergency room of a hospital where interns or nurses are treating a patient by administering fluids intravenously, it becomes a critical factor in the safety of the patient that IV fluids are indeed flowing into the vein of the patient and not into the surrounding tissue. Insertions of a cannula by EMTs in the field at accident scenes who need to administer IV fluid therapy to an injured party are a critical application where the cannula needs to be inserted properly into the vein and to remain within the vein during transportation to the hospital to prevent a loss of life.
[0009] However, due to human error, mistakes are bound to be made while inserting the cannula into a vein or the vein is missed altogether during the initial insertion of the needle/cannula. Other times due to movement of the patient by medical personnel or by the patient themselves, the cannula begins to withdraw from the vein. To avoid this chronic problem or other problems during insertion of the needle through the skin into the vein, the medical staff needs some indication about the successful insertion of the needle and cannula into the patient's peripheral vein. The medical personnel also need a convenient way to monitor and then to be alerted to any withdrawal of the cannula from the vein during IV fluid treatment.
[0010] To solve this problem of cannula tip placement and to reduce the incidents of infiltration of IV fluids into the surrounding tissues instead of the vein, the intern, nurse or EMT tasked with the needle insertion into a patient's vein to start the IV therapy would greatly be helped by knowing that their insertion of the cannula into the peripheral vein is being accomplished successfully by some type of feedback signal indicating that the proper insertion of the cannula tip within the vein of a patient has occurred.
[0011] To solve the problem of infiltration after the initial insertion of the cannula into the patient's vein when the cannula tube backs out of the vein or begins to leak for various reasons, a variety of complex leak detectors have been proposed for detecting a leak or an extravasation of a liquid injected through a needle into a blood vessel of a human body, as described, for example, in U.S. Pat. Nos. 7,546,776, 6,408,204, 5,964,703, 5,947,910, 6,375,624, 5,954,668, 5,334,141, 4,647,281, and 4,877,034. Still other U.S. Pat. Nos. 6,408,204, 5,964,703, 5,947,910 disclose complex leak detectors for detecting a leaking liquid due to a change in impedance on the skin surface of a human body; U.S. Pat. Nos. 6,375,624, 5,954,668, 5,334,141, 4,647,281 disclose leak detectors for detecting a leaking liquid from a change in temperature of a human organ; and U.S. Pat. Nos. 8,078,261 and 4,877,034 disclose a light-guided catheter and leak detector for placement through the skin and for detecting a leaking liquid from a change in optical characteristics of the blood, respectively. There are a number of various prior art solutions to the infiltration problem that center around the monitoring of the pressures of the IV fluids administered to the patient. The pressure information is used to control the flow of the IV fluids. Examples of pressure monitoring systems are shown in U.S. Pat. Nos. 4,277,227; 4,457,751; 4,534,756; 4,648,869 and 7,169,107.
[0012] However, none of these prior art patents teach a highly reliable portable apparatus and method of guiding a catheter into a vein and then detecting the proper insertion of the IV cannula of the catheter during its insertion into the patient's peripheral vein by providing a feedback signal either visual or audible for the intern, nurse or EMT starting the IV therapy. Moreover, this smart IV catheter is highly portable and capable of being used in emergency situations outside of a doctor's office or hospital setting in field emergency situations by EMTs prior to the patient being taken by ambulance to the hospital's emergency room.
[0013] Most of these prior art infusion detection systems referred to above while doing a good job in detecting problems once the TV therapy begins, the prior art systems do not monitor the initial insertion of the IV cannula into the vein to make sure the cannula is properly inserted into the patient's vein. Some of the prior art systems even require a substantial infusion of IV liquids prior to even detecting a leakage such as a leakage that occurs when the cannula pulls out of the patient's vein. In short, all of these systems are rather complicated and therefore require expensive pieces of equipment that are not necessarily readily available to paramedics or EMTs in the field who must start the IV therapy to an injured patient at an accident scene or even immediately available to the nurses, interns or EMTs even in a hospital emergency room setting.
SUMMARY OF THE INVENTION
[0014] A sharp, pointed rod or trocar fits inside a cannula or the soft catheter tube and the sharp point pierces the skin and is directed into a predetermined vein of the patient by the medical technician or doctor. The trocar is then withdrawn. A sensor generally located within the hollow tubing of the flexible or rigid cannula detects a drop in the impedance as blood flows across the surface of the cannula. The sensor is usually embedded within the polymer material of the cannula that protects it from being damaged when it pierces the skin and enters into the patient's vein. The sensors and the wire connections are generally embedded in the polymer material during the manufacturing and extrusion process or later after the extrusion process the sensors and wire are deposited on the cannula surface and properly covered by a thin skin material to prevent damage or dislocation from the cannula along with any wire connections extending back to a module for processing the sensed signal. The sensor(s) then send an electrical signal back to the module for either a visual display or audible sound indication of proper cannula insertion within the patient's vein. The module may take several shapes and have a predetermined thickness and shape in order to house a power source, processing electronics, a soft button switch or similar device for initiating the device when taken out of its package for the first time to be used on a patient. The processing electronics in the module receives the input signal from the sensor(s) and then generates an output signal that fires a light emitting diode (LED) display or in addition, fires a piezo-electric buzzer horn along with the light indication so the medical technician gets both a light and a sound indication of proper insertion of the cannula into a patient's vein.
[0015] In one embodiment, an intravenous catheter for guiding tip placement into a peripheral vein of a body and monitoring any tip removal from the peripheral vein, comprises:
[0016] a flexible plastic, tubular cannula having a tip at the distal end for insertion into a peripheral vein of a body and a hub at the opposite end for attachment to an IV bag;
[0017] a sensor mounted within the cross section of the cannula at a predetermined location thereon, or at the hub, for sensing an impedance of a sensed biological material in the body including the blood and then generating an output signal representative of a sensed biological material;
[0018] processor and modulation circuitry connected to the output signal for receiving and then generating a display or audible sound representing the location of the cannula tip within the biological material being sensed in the body during insertion of the cannula or upon the withdrawal of the cannula from the body; and wherein the display provides a feedback to a physician or medical personnel for correct catheter tip placement in the peripheral vein of the patient and wherein the display provides an alert to shut off the infusate when the tip dislodges from the vein but remains in the body to avoid infiltration into the subcutaneous tissues of the body.
[0019] In brilliant sunlight, the sound indicator that varies in sound according to state of properly inserting the cannula into a vein is often more useful to overcome the washed out LED display under brilliant sunlight conditions. In a portable unit of the apparatus, the circuitry to process the signals from the sensor(s), drive the LED display and piezo buzzer are preferably contained within a single application specific integrated chip (ASIC) or other suitable miniaturized circuitry mounted within the module or mounted to the catheter itself.
[0020] In another preferred embodiment, the module includes an initiation switch activated when peeling back a suitable protective cover over an adhesive backing to the module used to securely attach the module to the skin of a hand or forearm of the patient once the cannula is properly inserted into the peripheral vein of the patient. Also, a soft or dome switch accessible on the non-adhesive topside of the module could provide multiple functions to be described later in greater detail. This dome switch is also a source for the initial activation of the module and the processing and modulation circuitry when pressed for the first time.
[0021] Because of the miniaturization of electronic circuitry today, the module might be integrated or mounted in close proximity to the hub or IV valve on the catheter. The module might also be connected via a wire of predetermined length from the catheter to the module mounted on the hand or forearm of a patient receiving the IV therapy. The signal might even travel either by a wired connection or a wireless connection from the module back to a monitoring station located on either an IV cart, IV pole or other base station located in any predetermined location such as in the patient hospital room, in a hospital emergency room or even in a patient's doctor office. The wireless communication for the device of the present invention includes the use of radio frequencies (RF) like Bluetooth which is a proprietary open wireless technology standard for exchanging data over short distances (using short-wavelength radio transmissions in the ISM band from 2400-2480 MHz) from fixed or mobile devices. This allows a hospital to create personal area networks (PANs) with high levels of security within the hospital where up to seven such devices are capable of being connected to the same base station. Another RF connection available for the device of the present invention is a WiFi connection for a sensing module to receive and then output the processed sensor signal to a potential receiving base station similar to a cellular base station in 3g or 4g communications or Wi-Fi connection. The Wi-Fi technology allows either the sensors or the module to exchange data wirelessly using the radio waves over a computer network, including high-speed Internet connections. Wi-Fi as any wireless local area network (WLAN) product are generally based on the Institute of Electrical and Electronics (IEEE) 802.11 standards. The present invention incorporates both the Bluetooth and WiFi standards in its smart IV Catheter design. These communication networks allow the use of passwords for security purposes.
[0022] So the portable IV Catheter/Cannula manufactured according to the present invention includes a multi-functional module that receives signals from the sensors mounted within or on the surface of the cannula and then sends the sensor signals as an input to the sensing module for processing or the sensor signals are sent back to a base station via a hardwired connection or wireless connections of either a Bluetooth or a WiFi connection for processing and displaying the outcome. The electronic circuitry within the sensing module or within the base station then processes the sensor signals for generating output signals to drive the LED display or piezo buzzer for indicating the successful insertion of the cannula into the patient's peripheral vein.
[0023] The LED is preferably capable of indicating at least several states. When the needle is first being inserted into the skin, the LED would display a flashing red color that progresses to a steady red as the cannula is inserted further under the skin. As the cannula progresses under the skin to the surface of the vein, a flashing yellow would be seen before the flashing yellow changed to a steady yellow. Finally, the steady yellow would change to a flashing green and then a steady green light when the cannula is fully inserted into the vein and all of the sensors detect the flow of blood within the vein. The changes of colors are directly correlated to the drop in impedance as the sensors located within or on the surface of the cannula sense the condition of a blood flow in the vein. If the cannula is not properly inserted within the vein, the EMT will see a red or flashing red indication from the LED and/or a beeping sound from the Piezo Buzzer related to a pattern of sounds to indicate that it is not properly inserted within the vein.
[0024] Once the doctor, intern, nurse or EMT has properly inserted the cannula within the vein, the display of LED or sound from the Piezo Buzzer provides predetermined signals from light or sound that indicate that the cannula is sited properly within the vein. The indication may be on the module unit and/or patch attached to the hand or forearm and/or on a display back at the base station located at the IV pole or other area in proximity to the doctor, intern, nurse or EMT personnel inserting the IV cannula into the patient's peripheral vein. The signal indications are used to properly guide the hand of the caretaker or medical professional to make sure the IV cannula is inserted within the vein of the patient and not into the subcutaneous tissue surrounding the vein. The signals from the sensor(s) spaced a predetermined distance apart from one another which are located within the wall or on surface of the flexible polymer cannula tube along its longitudinal axis from its distal end to generally in close proximity to the end connected to the hub of the cannula show the change of impedance as the cannula is positioned within the vein. The sensors detect the presence or absence of the blood in and around the cannula inserted within the vein at each sensor stage. For example, if the cannula has four sensors A, B, C and D, then we would have at least three sensing stages as follows: A-B, B-C and C-D.
[0025] Circuitry within the sensing module processes and modulates the signal(s) from the cannula tube sensors and provide a drive signal to at least one LED located on the module that enables the LED to change between steady red, yellow and green colors or between flashing red, yellow or green colors related to the positioning of the cannula either in or out of the patient's vein. The drive signal could also go to a control panel display or the like at the IV pole etc. or some other base station that could have separate LEDs for the colors of red, yellow and green. A red color at each LED on a control panel display might indicate the absence of blood in proximity to any one of the sensor(s) while a change in color to yellow and then to a solid green color for the LED indicator would indicate the presence of blood being sensed at each sensor stage on the cannula, which in turn indicates a proper insertion of the cannula within the patient's vein. The single or multiple LEDs are arranged in any logical pattern desired on the main control panel or display back at the base station.
[0026] In a typical embodiment of the invention, a cannula tube includes at least four sensors spaced apart a predetermined distance from each other. Each sensor is embedded within the sidewall of the flexible polymer cannula tubing. Each sensor is spaced around the circumference of the generally tubular shaped cannula by approximately a 90 degrees rotational change between the first sensor at the distal end to the second sensor etc. such until a full 360 degrees change is reached from the distal end toward the hub end in the spacing of the sensors within the tubing. The first LED at the distal end shows a red signal as the blood is beginning to approach the sensor then it would start changing colors from red to finally green indicating a blood flow across all four sensors and three stages of impedance level of the blood. Likewise, as the blood begins to flow between the sensors the resistance and/or impedance keeps dropping until the blood is across all four sensors and the LED has changed to a solid green with the lowest resistance or impedance level in all three stages. The doctor, intern, nurse or EMT would then see the display change from red to yellow to green with the LED display on the module or on a control panel display providing information on whether the cannula tubing of the IV catheter is properly inserted into the patient's vein as all four sensors are now detecting blood and the impedance is at the lowest reading.
[0027] Next, the four sensors are capable of being connected by thin wires or ribbon conductors embedded within the soft plastic wall of the cannula tube leading back to the hub of the catheter and then onto the module located on a forearm or back to a control panel at the base station. The module and the control panel are both capable of housing the electronic circuitry for processing the signals from the sensor(s) and then generating a drive signal for changing the LED color on the module or for selecting the correct colored LED on the control panel located at the IV pole, IV Cart or other medical monitoring panel. The electronic circuitry is also capable of generating a drive signal to an audible alarm. The audible alarm with varying tones provides a means for the healthcare professional inserting the catheter into the patient's vein to be guided during insertion of the cannula within the vein and to further indicate the status of a proper insertion of the cannula within the vein. The electronics required to process the signals and provide the output signal for the LED, LEDs or sound device are capable of being placed within a single ASIC or another miniaturized integrated chip circuitry as shown in U.S. Pat. No. 7,169,107 which is incorporated by reference thereto or other similar miniaturized electronic integrated chip sets which a person having ordinary skill in the medical arts of monitoring patients is capable of assembling.
[0028] A method of inserting and monitoring the placement of a catheter tip within a peripheral vein on a patient body according to a preferred embodiment may include: inserting a cannula-over-needle apparatus into the body, the apparatus including a cannula connected to an IV bag at a hub opposite a cannula tip; sensing various biological material within the body from detection circuitry connected to a sensor mounted on the cannula or at the hub; guiding the tip of the cannula corresponding to the sensed biological material; stopping the insertion of the cannula into the body when the sensed biological material is blood from within the peripheral vein; withdrawing and discarding the needle when the tip of the cannula is located properly within the peripheral vein; monitoring the status of the catheter tip within the peripheral vein from the cannula sensor: and generating an alert signal in the event the catheter tip begins to withdraw from the peripheral vein in order to shut off the infusate.
[0029] The sensors used can be a single type or multiple types that are capable of detecting impedance or resistive changes when the blood is sensed within the vein by an impedance drop. For instance, a suitable sensor type might include bio-impedance, micro electrodes for resonance impedance sensing of human blood as set forth in Sensors and Actuators A: Physical Volumes 146-148, July August 2008, Pages 29-36 and presented at the 14th International Conference on Solid State Sensors by authors Siyang Zheng, Mandheerej S. Nandra, Chi-Yuan Shih, Wei Li and Yu-Chong Tai in the Department of Electrical Engineering, California Institute of Technology, CA. USA, which paper is published by Elsevier and hereby incorporated by reference thereto. Other types of sensors that are capable of providing signals include medical Telesensor ASICs with detection of the blood reported back to the control panel by wireless telemetry. Very small medical Telesensor ASICS have been developed by Oak Ridge National Laboratory. The sensors might use technologies like magneto resistive, or micro-electro-mechanical systems (MEMES) sensors, acoustic sensors and others.
[0030] The above summary of the present invention is not intended to describe each illustrated embodiment or every implementation of the present invention. The figures and the detailed description which follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] This invention is explained in greater detail below in view of exemplary embodiments shown in the drawings, wherein:
[0032] FIG. 1A shows a cannula with DC sensors made in accordance with the present invention completing a first stage insertion into a patient vein;
[0033] FIG. 1B shows a cannula with DC sensors made in accordance with the present invention completing a first stage and second stage insertion into a patient vein;
[0034] FIG. 1C shows a cannula with DC sensors made in accordance with the present invention sensing a first stage, second stage and third stage insertion into a patient vein;
[0035] FIG. 1D shows a cannula with DC sensors made in accordance with the present invention sensing a second stage and third stage insertion into a patient vein with the first stage sensing the piercing of the vein wall and being outside of the vein into the surrounding tissues;
[0036] FIG. 2A shows a cannula with a single AC sensor made in accordance with the present invention sensing proper insertion of the cannula within the vein;
[0037] FIG. 2B shows a cannula with a single AC sensor made in accordance with the present invention sensing improper insertion of the cannula within the tissues surrounding the vein;
[0038] FIG. 3A shows a cannula with a single AC sensor and a conductive trace made in accordance with the present invention sensing a state prior to insertion within any vein;
[0039] FIG. 3B shows a cannula with a single AC sensor and a conductive trace made in accordance with the present invention sensing insertion of the cannula into the tissues surrounding the vein;
[0040] FIG. 3C shows a cannula with a single AC sensor and a conductive trace made in accordance with the present invention sensing proper insertion of the cannula into the vein;
[0041] FIG. 4A shows a flowchart where the cannula and circuitry are initialized;
[0042] FIG. 4B shows a flowchart where the sensors of the cannula are at various stages during insertion into a peripheral vein of a patient in accordance with the invention of FIG. 1A ;
[0043] FIG. 4C shows a flowchart where the sensors of the cannula indicate an over penetrate through the vein in accordance with the invention of FIG. 1A ;
[0044] FIG. 4D shows a flowchart where the sensors of the cannula indicate withdrawal failure detection and shut off flow of infusate in accordance with the invention of FIG. 1A ;
[0045] FIG. 5A shows a cannula with an acoustical sensor made in accordance with the present invention prior to proper insertion within the vein in accordance with the present invention of FIG. 1A ;
[0046] FIG. 5B shows a cannula with an acoustical sensor made in accordance with the present invention with proper vein insertion in accordance with the present invention of FIG. 1A ;
[0047] FIG. 6 shows a cannula with an acoustical sensor made in accordance with the present invention with proper vein insertion including other monitoring devices connected to the processing module which wirelessly transmits signals to a base station display in accordance with the present invention of FIG. 1A ;
[0048] FIG. 7A shows a cannula with an acoustical sensor made in accordance with the present invention with proper vein insertion hardwired to a control panel and/or base station for processing and monitoring the vein insertion in accordance with the present invention of FIG. 1A ;
[0049] FIG. 7B shows a cannula with an acoustical sensor made in accordance with the present invention with proper vein insertion wirelessly sending the sensing signals to a control panel and/or base station for processing and display in accordance with the present invention of FIG. 1A ; and
[0050] FIG. 8 shows a cannula with an acoustical sensor made in accordance with the present invention with proper vein insertion including other monitoring devices connected to the processing module which wirelessly transmits sensor and other device signals to a base station for processing and display in accordance with the present invention of FIG. 1A .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0051] The present invention relates to an intelligent intravenous apparatus and method for guiding and detecting proper insertion of a cannula tip of a catheter into a vein for infusion of intravenous (IV) fluids and further monitoring and sensing when a withdrawal of the cannula tip from the vein occurs. B. Braun Intrusion Safety IV Catheter is an example of a catheter that is capable of being modified to incorporate the features of the present invention. Various embodiments of the invention are contemplated. One embodiment is illustrated in FIGS. 1A-1D . A second embodiment is illustrated in FIGS. 2A and 2B . A third embodiment is illustrated in FIGS. 3A-3C . A fourth embodiment is illustrated in FIGS. 5A , 5 B, 6 , 7 A, 7 B and 8 . In all illustrated embodiments, the cannula includes one or more sensors that provide signals indicating whether or not the cannula tip is properly inserted within a patient's vein or properly withdrawn therefrom to avoid medical complications with infusate. The broad principles of the invention are applicable to DC, AC and acoustical sensors with wires or wireless connections to electronic or electrical sensing module having signal processing and modulation electronics therein attached to the patient or connected by either a hardwired connection or wirelessly back to a control panel and/or base station that typical includes a computer with a monitor and keyboard.
[0052] As mentioned above, the first embodiment is illustrated in FIGS. 1A-1D and includes a catheter 10 constructed in accordance with the present invention. The typical catheter 10 consists of a short polymer tube (a few centimeters long) inserted through the skin into a peripheral vein 14 (any vein generally not inside the chest or abdomen). This is usually in the form of a flexible cannula 12 over-needle device, in which a flexible plastic cannula 12 comes mounted on a metal trocar (needle and trocar not shown as already withdrawn from cannula 12 ). Once the tip of the needle and cannula 12 are located within the vein 14 the trocar is withdrawn and discarded. The cannula 12 is further advanced inside the vein to an appropriate position and then secured with medical tape or the like over a pair of plastic wings 20 secured to the tubing near a port or hub 22 . An IV line 24 connects to the port or hub 22 through a male fluid input 26 that is inserted into the IV line 24 . The IV line 24 extends back to an IV Bag 28 containing the IV fluids 30 . The IV Bag 28 is hung on a hook 32 on an IV Pole 34 held upright by an IV Pole Stand or Platform 36 having several wheel sets 38 attached thereto for portability of the IV Pole Stand 36 .
[0053] Attached to the IV Pole 34 or Stand 36 or located at some other convenient place is a control and display panel 40 . The control and display panel 40 includes a computer or microprocessor circuitry for processing input signals from the sensors and then displaying information related to insertion of the cannula through the skin and into a peripheral vein 14 . Suitable circuitry adaptable to process the input signals is shown in the FIGS. 1 , 4 , 6 and 7 and taught in the specification of the U.S. Pat. No. 5,423,743 or is shown in FIGS. 1 and 2 and taught in the specification of the U.S. Pat. No. 4,959,050 and both are hereby incorporated by reference thereto. All of this circuitry is capable of being incorporated into a single micro integrated silicon chip or an application specific integrated chip (ASIC) in today's technology. Software required to program the ASIC and/or microprocessor circuitry is well known by a programmer of ordinary skill in the art of programming microprocessor and ASICS circuits. In fact, a person of ordinary skill in the art of programming is capable of writing numerous programs to provide the desired results set forth in this application. There are probably thousands of different ways to create a software program that is capable of processing the signals from the sensors and then generating a visual or audible alert to the end user of the apparatus and method in accordance with the present invention. For example, a simplified software programming would follow the logic diagrams and/or flowcharts as shown in FIGS. 4A-D to program the ASIC or microprocessor circuitry located in the monitor module 48 on the patient's forearm or back at the base station control panel 40 . A micro-computer with appropriate inputs and outputs with a software program therein could duplicate some portion of the circuitry shown in '743 and '050 patents for electrical circuits capable of using either direct current (“DC”) or alternating current (“AC”) to power the guidance, monitoring and detection circuitry of the present invention. A Telesensor is capable of being used also. Medical telesensors are self-contained integrated circuits for measuring and transmitting vital signs over a distance of approximately 1-2 meters. The circuits of a Telesensor generally contain a sensor, signal processing and modulation electronics, a spread-spectrum transmitter, an antenna and a thin-film battery.
[0054] Turning now to FIGS. 1A-D , the cannula 12 of catheter 10 includes bio-impedance, micro electrode sensors or even telesensors A, B, C and D (hereinafter “sensors”) embedded within the polymer or rubber during the manufacturing process of extruding the flexible plastic or rubber cannula 12 of the catheter 10 . Thus in the preferred embodiment, the smart IV cannula 12 includes multiple (4-6) conductive spots exposed from the tip to the midpoint of the cannula 12 , and each conductive spot includes conductive traces running back to the hub 22 , and then either back to the control panel 40 or to a sensing monitor module 48 mounted by an adhesive backing on to the forearm 18 of the patient where the DC resistance and/or capacitance measurements are taken between the multiple spots or sensors A, B, C or D to determine whether the spots, and therefore the cannula 12 , are in the vein 14 and bloodstream. This embodiment directly measures the conductivity within the bloodstream to determine cannula 12 position within it. The sensors or conductive spots A, B, C or D could also be mounted on the inner or outer surface of the cannula tubing 12 and then covered with a material bonded to the surface of the tubing 12 . Also, as shown in FIGS. 1A-D , each sensor is connected by a hardwired line or conductive trace 44 indicated by an arrow 42 of any suitable conductor material to carry the extremely low level current and voltage of the micro-electronic circuitry used to process the signals back to the control and display panel 40 at the base station or back to a monitor module 48 on the forearm 18 for processing of the input signals from the sensors.
[0055] As mentioned in the background of the invention, there are numerous scientific articles that discuss the ability to sense the conductivity of blood and thus its impedance. When the sensors or conductive spots A, B, C and D of the cannula 12 are in the top layers of skin 16 or within the subcutaneous tissues 17 surrounding the vein 14 , the sensors would each generate a high impedance signal output back to the control panel 40 or module 48 . In FIG. 1A , when the pairing of the sensors A and B (“first stage”) are within the vein 14 , the impedance would be indicated as being low on the control panel 40 at the base station. Meanwhile, when the pairings of the sensors B-C (“second stage”) and C-D (“third stage”) are still outside of the vein 14 and therefore not sensing the presence of the blood then a high impedance would be indicated back on the control panel 40 at the base station. Next, FIG. 1B shows the first and second stages sensing the presence of blood within the vein 14 and so the pairings of A-B and B-C would both show a low impedance detection.
[0056] In FIG. 1C , all three stages or pairings of A-B, B-C and C-D are sensing the presence of blood so all three stages would show a low impedance on the control panel 40 indicating a proper insertion of the cannula 12 within the vein 14 . If the medical technician pushed the cannula 12 through the vein 14 as shown in FIG. 1D then the first stage or pairing of sensors A-B would show a high impedance indicating that the distal end 46 of the cannula 12 had passed through the vein 14 and had gone back out into the subcutaneous surrounding tissue 17 .
[0057] Turning now to FIG. 2A , an IV cannula with a single conductive spot or sensor 56 near the tip or distal end 46 , with a conductive trace 44 running back to the hub 22 , and thus to the sensing module 48 which is attached to the patient much like a conductive EEG pad. In this second embodiment, a 50 kHz signal (or other suitable AC freq) is transmitted and received through the cannula at a very low current of 500 μA and voltage by the sensing module 48 . The signal impedance will vary significantly when the cannula 12 is in the vein/bloodstream vs insertion just under the skin 18 but not within the vein 14 . The sensing module 48 further includes a soft switch or dome switch 50 to initiate the smart IV catheter when it is first taken from its package. Or the sensing module 48 is initiated when the adhesive cover is removed when the catheter is taken out of its packaging and placed onto the forearm 18 . There is also an LED 52 and audible piezo horn 54 mounted within the sensing module 48 for providing guidance signals for the proper insertion of the cannula 12 within the vein 14 . This makes the apparatus 10 of the present invention totally portable for EMT usage in the field. The sensing module 48 mounted on the forearm 18 of the patient further includes a battery power source to run the circuitry. Because the sensor 56 is within the vein 14 , a low impedance visual signal from the LED 52 and/or an audible sound corresponding to low impedance visual alert would be given by the piezo horn 54 .
[0058] FIG. 2B shows the cannula 12 inserted below the top surface of the skin 16 but not within the vein 14 so the impedance reading would be high as indicated on the monitor panel 40 and a corresponding color on the single LED 52 would blink or provide a steady red or flashing yellow color along with the audible signal from the horn 54 corresponding to the LED pattern of colors.
[0059] FIGS. 3A-C shows a third embodiment which is another version of the second embodiment but further includes wireless transmission by either Bluetooth or WiFi 59 to a computer base station 60 in which the conductive spot or sensor 56 at the tip of the cannula 12 is followed by an exposed, partially conductive trace 58 extending toward the hub 22 for about a centimeter or more on the cannula 12 . This will increase the resolution of the signal measurement when the cannula tip 46 is either pushed through the vein, or has begun to withdraw from the vein. This embodiment is a wireless version of either the AC or DC circuitry previously described. The computer base station 60 would allow for a more sophisticated programming of the overall systems incorporating the smart IV catheter for guiding the medical professional when inserting the cannula within a vein 14 of the patient. For example, partially conductive trace would allow a variation of colors to be used with the LED visual indication of the progress being made by the medical professional. The colors of red 52 a , yellow 52 b and green 52 c are shown on the sensing module 48 but other colors might be used too when using the computer 60 with a monitor 62 allowing the use of many different colors to match the stage of progress during the insertion of the cannula tubing 12 within the forearm and guiding inside of the vein 14 .
[0060] For example, in FIG. 3A the cannula tubing 12 is above the skin 16 so a red LED 52 a is visually displayed on the sensing module 48 and then on the computer monitor or screen 62 . FIG. 3B shows a partial insertion and the colors of red 52 a and yellow 52 b may be visible by the LEDs on the sensing module 48 and on the computer monitor 62 . Finally, in FIG. 3C , the cannula 12 is properly inserted within the vein 14 and the steady color of a green LED 52 c is visible on the sensing module 48 and then likewise on the computer monitor 62 .
[0061] For the second and third embodiments, the smart IV catheter of the present invention uses bioelectric impedance to monitor infiltration using a 50 KHz signal at 500 μA. This high frequency signal at low amperages is similar to handheld AC devices made by Tanita and Omron Corporation in U.S. Pat. No. 7,039,458 and U.S. RE 37954 that operate somewhat similar but are totally different in functioning and method.
[0062] FIGS. 4A-D shows simple flowcharts for the operation of the smart IV catheter. Turning now to 4 A, when a portable catheter 10 made in accordance with the invention is taken out of its packaging with the attached sensing module 48 , the user removes the adhesive backing cover, which turns on the power and initializes the circuitry of the module 48 . Alternatively, the soft button 50 is pushed to power on/initialize the device. First, the DC version of embodiment of the device first checks the three stages and the sensors thereof to make sure the impedance is high for all three pairings of sensors. The LEDs preferably flash in a sequence of green, yellow and red to indicate a good device. Optionally, the piezo horn provides three short tones to indicate that the catheter is not functioning properly. In the AC version, a check of the impedance cannula emitter (TX) to base (RX) is done which should show a high impedance when initialized.
[0063] FIG. 4B show the steps when insertion is being done by the medical professional. There is a monitoring resistance/capacitance/impedance at tip or tip plus trailer A-B, B-C and C-D. A-B flashes green/yellow LED colors and a tone of two long tones is emitted. If there is A-B plus B-C then the LEDs flash green, green and yellow. And finally, if there is A-B, plus B-C, plus C-D flash solid green with a continuous tone for a predetermined count and then stop to preserve the battery.
[0064] FIG. 4C shows an overpenetration through the vein. In the DC version of the device, the A-B resistance increases as it passes through the vein and the B-C and C-D stages continue indicating a low impedance. The device then creates an alert to the medical professional with the LED flashing red-red and an audible tone indicating failure occurs so that IV fluids may be stopped. In the AC version, the spot or sensor at the tip increases in impedance while the trailer conductive strip is still decreasing or is steady.
[0065] In the final flowchart, FIG. 4D deals with the situation when there is a withdrawal failure detected and a shut off of the infusate needs to be initiated. Here as the cannula pulls out of the vein, in the DC version the last stage C-D opens briefly and remains different from B-C and A-B. An LED display of green, yellow occurs. Then as B-C opens briefly, it will differ from A-B and flashes similar to C-D with a flash of green, yellow and yellow. And then when A-B opens briefly, it matches B-C and C-D. Then the alert on the display becomes a solid red color on the LED while three short audible tones are repeated indicating a failure has occurred with the withdrawal of the cannula tip from the vein.
[0066] In FIGS. 5A-B , a fourth embodiment shows the use of an acoustical signature for the apparatus and method to continuously monitor that the cannula 12 is remaining properly inserted within the vein 14 in accordance with the present invention. The cannula 12 includes an acoustical transducer 64 of a broadband 25 to 50 MHz type well known in the art such as the medical transducers manufactured and sold by General Electric Company of Schenectady, N.Y. The transducer 64 is placed at a position along the cannula 12 , such as near the tip 46 of the cannula 12 , within or on a hub 22 at an end opposite the tip 46 , or in or on the cannula in between the tip 46 and the hub 22 , such that a large amplitude echo signal from the transducer 64 , 64 ′ is continuously monitored to indicate the correct tip placement of the cannula tubing 12 within the vein 14 . In one embodiment of this invention, the transducer 64 , 64 ′ is angled with respect to the cannula 12 in an insertion direction, such as having an emitting and/or receiving sensor component or surface disposed at 45-90° relative to the longitudinal axis of the cannula 12 .
[0067] As shown and described, transducer 64 , 64 ′ may be positioned within the cannula 12 as shown in transducer 64 or, alternatively, upstream of and external to the cannula 12 such as shown in transducer 64 ′. In one embodiment, the transducer 64 , 64 ′ is positioned upstream from the tip 46 so that the transducer 64 , 64 ′ is not beneath the skin 16 upon insertion of the tip 46 , and can be placed in the upper 75%, desirably the upper 50%, and preferably the upper 25% of the cannula 12 . In one preferred embodiment, the transducer 64 , 64 ′ is placed at, either on or within, the connecting hub 22 . As such, transducers 64 , 64 ′ shown in FIG. 5A are intended to show two alternative feasible placements for use in the subject system. If suddenly a smaller amplitude echo signal from the transducer 64 , 64 ′ is detected then this provides an indication that the tip of the cannula 12 of the catheter 10 is withdrawing from the vein 14 into the subcutaneous tissue surrounding the vein.
[0068] Most high frequency transducers for medical applications are made from a thin piezo-electric polymer film. The transducing element 64 , 64 ′ is mounted within the cross section near the cannula tip 46 or upstream of the cannula tip 46 , respectively. A coaxial cable 66 within the cross section of polymer cannula 12 connects the transducer to an external signal source. Electrical signals are transmitted to and received from the ultrasonic transducer 64 , 64 ′ via the coaxial cable running the length of the cannula and out the hub area 22 back to either the signal processor in the sensing module 48 or the base station control panel 40 . The external signal source for the ultrasonic transducer is well known in the art. The control panel screen or the LED(s) on the sensing module 48 provides a display for the received transducer signals to monitor the placement of the tip 46 of the cannula within the vein 14 .
[0069] FIG. 5A further shows that the cannula is through the outer surface of the skin 16 but not yet within the vein 14 so the acoustical signature echo generated is small in amplitude due to the dense nature of the normal tissues rather than a greater amplitude echo signature when the transducer 64 , 64 is within a bloodstream of the vein 14 . On the other hand, FIG. 5B shows the cannula 12 and within the vein 14 and the echo signature picked up from the distal end 46 of the cannula tubing 12 is generating a larger amplitude echo signal for indicating that the tip of the cannula tubing 12 is properly secured within the bloodstream of the vein 14 . The magnitude of the echo signature is then either displayed on the screen of the control panel 40 or indicated by visual and/or audible sounds on the sensing module 48 . In summary, when the cannula 12 is outside of the vein 14 , the amplitude echo signal generated by the transducer is small and when the cannula 12 is within the vein and sensing the bloodstream, the echo signal is large.
[0070] In FIG. 6 , the cannula 12 is properly inserted within the vein 14 with the acoustical signature being used with a sensing module 48 . Also, a pulse oximeter 68 which is a non-invasive method allowing the monitoring of the oxygenation of a patient's hemoglobin is connected to the index finger 69 and its output signal is connected via a conductor 70 to an input terminal 72 to the sensing module 48 . Moreover, the sensing module 48 might have other inputs such a blood pressure monitoring input. The unique feature also shows that the sensing module 48 is sending back its signal of the smart IV catheter 10 insertion plus information from the pulse oximeter 68 wirelessly to the base station control and display panel 40 .
[0071] FIG. 7A shows an acoustical signature device that includes a hardwire connection back to the control and display panel 40 . FIG. 7B shows an acoustical signature device that includes a wireless transmission back to the control and display panel 40 . Both devices as shown in FIGS. 7A-B function as previously described for the devices shown in FIGS. 5A-B above for the apparatus and method in accordance with the present invention.
[0072] According to the embodiments shown in FIGS. 5-7 , IV infiltration occurs when the cannula 12 pulls out of the vein yet remains under the skin. The embodiments shown in FIGS. 5-7 may further detect and identify occlusions as described below. Occlusion occurs when the cannula 12 remains in the vein, properly placed, but starts to accrete blood platelets at the orifice of the tip. This blood clot accretion at the orifice of the tip slowly closes off the tip to any fluid flow. When this occurs, the medical professional often has to pull The IV and run a new one, an expensive and often painful inconvenience. Medical professionals have to watch for occlusion indications and keep the cannula 12 open by pushing saline through the cannula or Heparin, an anticoagulant.
[0073] According to a preferred embodiment, the sensing module 48 and/or the display module 40 may be tuned in such a way as to detect a reduction in return echo strength from the acoustical transducer 64 , 64 , so as to detect occlusion in process before it fully closes the tip of the cannula 12 . With a desired acoustical transducer 64 , 64 ′ and software analysis capability, movement of the cannula 12 within the vein (termed a “trombone effect”) and occlusion of the tip of the cannula 12 may be sensed and detected.
[0074] FIG. 8 shows the wireless connection back to control panel 40 in which the pulse oximeter 68 is connected from the index finger 69 back to the sensing module 48 and further may include a blood pressure input to the sensing module 48 (not shown). In addition, the sensing module further includes a reflective pulse oximeter 74 mounted within the sensing module 48 that shines down into the hand from the backside of the sensing module 48 for its measurements, includes bright red, yellow and green LED lights to show the various stages of operation of the device covered by the apparatus and method claims.
[0075] As noted above, the present invention is directed generally to a medical device and more particularly to an electrical signal-guided catheter with sensors embedded in the polymer skin of a flexible plastic cannula to sense the presence of the bloodstream for proper insertion of the cannula tubing within a peripheral vein to administer IV fluids. The electrical signals corresponding to the sensing of subcutaneous tissue and the bloodstream within a vein provide an electronic signal visualization of the placement through the skin and subcutaneous tissues into the vein and further including a method to locate the flexible cannula within the vein for correct catheterization. Secondly, this catheter detects any improper withdrawal of the catheter from the vein and thus a leakage into the subcutaneous tissues indicating an infiltration condition.
[0076] According to one preferred embodiment of this invention, the smart IV cannula 12 as shown and described may further include a superhydrophobic coating and/or construction. Accordingly, the cannula 12 may include at least one of: a micro- or nano-coating over and/or within the cannula 12 ; the cannula 12 may be constructed or Teflon® or silicone; and/or a hybrid construction, such as silicone oil impregnated urethane.
[0077] A suitable micro- or nano-coating may comprise a coating such as described in U.S. Pat. Nos. 8,574,704 and 8,535,779 to Smith et al., which are hereby incorporated by reference. The Smith et al. patents describe non-wetting surfaces that include a liquid impregnated within a matrix of micro/nano-engineered features on the surface, or a liquid filling pores or other tiny wells on the surface. Such a product, called Liquiglide™, may be used to coat the cannula 12 described herein. As described, a micro/nano-engineered surface coating enables a durable liquid-impregnated surface coating to be placed over the full exterior and interior surfaces of an IV cannula 12 .
[0078] Alternatively, the cannula 12 may be constructed of a non-stick material such as Teflon® or silicone. The cannula 12 may be wholly constructed of such material or partially constructed, coated and/or reinforced with such material.
[0079] According to another alternative of the subject invention, the cannula 12 may comprise a hybrid construction that includes a hydrophobic coating impregnated within or coated over and around a non-stick construction. Such, hybrid construction may include a silicone oil impregnated urethane construction.
[0080] A benefit of such liquid-impregnated surface coating or alternatively described constructions is to inhibit the initial “seed” adhesion of blood protein fibrin to the cannula surface, thus preventing further fibrin accretion at the orifice of the tip of the cannula, thus preventing IV cannula occlusion.
[0081] The present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the present specification. The claims are intended to cover such modifications and devices.
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A method and apparatus for inserting and monitoring the placement of a cannula tip within a peripheral vein of a human body where the cannula includes a sensor located at predetermined location and mounted on the cannula for sensing the biological material of the body to guide the insertion of the cannula tip into the vein and alerts to the withdrawal of the cannula tip from the vein in the body.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a chip package structure and a fabricating method thereof. More particularly, the present invention relates to a fabrication method of a multi-layered substrate and the multi-layered substrate thereof.
[0003] 2. Description of Related Art
[0004] The board on chip (BOC) packaging concept, which uses a board substrate mounted above the silicon chip(s) as the lead-on-chip (LOC) technology, has been developed for high frequency applications. The BOC substrates or certain window ball grid array (BGA) substrates are essentially single-sided substrates i.e. circuit patterns and fiducials are only located on one side of the substrates. At present, rather wasteful approaches are employed to fabricate these single-sided substrates, as the dummy side of the substrates went through the similar processing steps and then removed. Therefore, not only the raw materials and processing chemicals are wasted but also the efforts spent on the dummy side become futile.
[0005] It is desirable to develop suitable manufacturing procedure for such substrate using the present manufacturing line.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention is directed to a fabrication method of a multi-layered substrate, which is capable of doubling the productivity or yield and is compatible with the present manufacturing processes.
[0007] The present invention is also directed to a fabrication method of fabricating a multi-layered substrate structure, which can provide single-sided or double-sided substrate structure.
[0008] As embodied and broadly described herein, the present invention directs to a method of fabricating a multi-layered substrate by providing a double-sided lamination structure having at least a core structure and first and second laminate structures stacked over both surfaces of the core structure. The core structure functions as the temporary carrier for carrying the first and second laminate structures through the double-sided processing procedures.
[0009] The laminate structure can be either a single-clad laminate having a metal layer at one side or a double-clad laminate having two metal layers respectively at both sides.
[0010] As embodied and broadly described herein, when the first and second laminate structures are single-clad laminates, after the two outermost metal layers of the double-sided lamination structure are patterned and protected with mask layers, single-sided substrates are obtained by separating the first and second laminate structures from the core structure.
[0011] As embodied and broadly described herein, when the first and second laminate structures are double-clad laminates, after the two outermost metal layers of the double-sided lamination structure are patterned and protected with mask layers, the first and second laminate structures are separated from the core structure, turned inversely and re-laminated to a carrier for further processing. The metal layer at the other side of the first/second laminate structure can be either removed or further patterned to provide single-sided substrates or double-sided substrates.
[0012] In an embodiment of the present invention, the fabrication method may further comprise forming a plurality of plated-through holes in the double-sided lamination structure by drilling and plating.
[0013] In an embodiment of the present invention, the fabrication method may further comprise performing a surface plating process to form a Ni/Au layer located on the metal layer that is not covered by the mask layer.
[0014] The present invention further provides a multi-layered substrate structure. The substrate structure includes a base having a top surface, a bottom surface, and at least a through-hole passing through the base, patterned first and second metal layers formed respectively on the bottom surface and the top surface of the base, a first plating layer covering a sidewall of the through-hole and the bottom surface surrounding a bottom opening of the through hole, and a second plating layer covering the first plating layer and the top surface surrounding the top opening of the through hole.
[0015] In the present invention, the multi-layered substrate structure has the plated-through holes with double plating layers, which reinforces the plated-through holes for better electrical performances
[0016] In order to make the aforementioned and other objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below.
[0017] It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0019] FIG. 1 is flow chart of process steps for fabricating a substrate according to an embodiment of the present invention.
[0020] FIGS. 2A-2G are cross-sectional views showing the substrate according to the fabricating process steps of an embodiment in the present invention.
[0021] FIG. 3 is flow chart of process steps for fabricating a multi-layered substrate according to another embodiment of the present invention.
[0022] FIGS. 4A-4G are cross-sectional views showing the multi-layered substrate according to the fabricating process steps of another embodiment in the present invention.
[0023] FIG. 5 shows a cross-sectional view of an example of the double-sided substrate structure of the present invention.
DESCRIPTION OF EMBODIMENTS
[0024] The present invention is described below in detail with reference to the accompanying drawings, and the embodiments of the present invention are shown in the accompanying drawings. However, the present invention can also be implemented in a plurality of different forms, so it should not be interpreted as being limited in the following embodiments. Actually, the following embodiments are intended to demonstrate and illustrate the present invention in a more detailed and completed way, and to fully convey the scope of the present invention to those of ordinary skill in the art. In the accompanying drawings, in order to be specific, the size and relative size of each layer and each region may be exaggeratedly depicted.
[0025] It should be known that although “first”, “second” and the like are used in the present invention to describe each element, region, layer, and/or part, such words are not intended to restrict the element, the region, the layer, and/or the part, but shall be considered to distinguish one element, region, layer, or part from another. Therefore, under the circumstance of without departing from the teaching of the present invention, the first element, region, layer, or part can also be called the second element, region, layer, or part.
[0026] In addition, “under”, “on”, and similar words for indicating the relative space position are used in the present invention to illustrate the relationship between a certain element or feature and another element or feature in the drawings. It should be known that, beside those relative space words for indicating the directions depicted in the drawings, if the element in the drawing is inverted, the element described as “under” another element or feature becomes “on” another element or feature.
[0027] FIG. 1 is flow chart of process steps for fabricating a substrate according to an embodiment of the present invention. FIGS. 2A-2G are cross-sectional views showing the substrate according to the fabricating process steps of an embodiment in the present invention.
[0028] Firstly, in Step 10 & FIG. 2A , a double-sided lamination structure 100 is provided, which has a first metal layer 106 a and a first passivation or dielectric layer 104 a disposed on a top surface 102 a of the core structure 102 and a second metal layer 106 b and a second passivation layer 104 b disposed on a bottom surface 102 b of the core structure 102 . The material of the first and the second metal layers 106 a, 106 b may be copper formed by electroplating or copper foil lamination, for example. The first and second passivation layers may be formed from the same or different resin materials, for example. The core structure 102 may be a release film or a peelable mask film, for example. The release film may be made of a Teflon-based material (such as Tedlar® film), and has very limited adhesion toward the passivation layer. If the release film is used, adhesive resin may be applied on the corners or the borders of the release film for enhancing the adhesion. If the peelable mask film is employed, the peelable mask film should achieve sufficient adhesion with the passivation layer during processing and remain peelable at the end of processing. For example, the peelable mask film can be applied on the borders (shaped as the picture frame) of the passivation layers.
[0029] In Step 12 & FIG. 2B , a drilling process is performed by, for example, mechanical drilling or laser drilling to form through holes passing through the double-sided lamination structure 100 . Then, an optional plating process is performed to electroplate the sidewalls of the through holes so as to form plated-through holes 108 . The plating step may also be used to reinforce the Cu foil only.
[0030] In Step 14 & FIG. 2C , after first and second patterned photoresist layers 110 a, 110 b are respectively formed on the first and second metal layers 106 a, 106 b, the first and second metal layers 106 a, 106 b are patterned, using the first and second patterned photoresist layers 110 a, 110 b as the etching masks.
[0031] In Step 16 & FIG. 2D , after removing the remained first and second patterned photoresist layers 110 a, 110 b, first and second mask layers 112 a, 112 b are respectively formed on the first and second passivation layers 104 a, 104 b and partially covering the first and second metal layers 106 a, 106 b. The first and second mask layers may be solder mask layers, for example.
[0032] In Step 18 & FIG. 2E , a surface plating process is performed to form a nickel/gold layer 114 a/b on the exposed surfaces of the first and second metal layers 106 a, 106 b respectively.
[0033] In Step 20 & FIG. 2F , a punching/routing process may be performed to cut bond channels into the substrates to form a BOC type substrate. In the same pass or in a separate punching/routing pass, the strips may be cut from the panel or the border frame of the double-sided lamination structure 100 may be cut off.
[0034] In Step 22 & FIG. 2G , a separating process is performed to the double-sided lamination structure 100 , so that two single-sided substrate structures 120 a, 120 b are obtained. The first single-sided substrate structure 120 a, including the first passivation layer 104 a, the patterned first metal layer 106 a, the first mask layer 112 a and the first nickel/gold layer 114 a, is detached from the top surface 102 a and separated from the core structure 102 . Similarly, the second single-sided substrate structure 120 b, including the second passivation layer 104 b, the patterned second metal layer 106 b, the second mask layer 112 b and the second nickel/gold layer 114 b, is detached from the bottom surface 102 b and separated from the core structure 102 . If strips were punched/routed out of the panel, then the separating process forms individual strips. If only the border was cut off, then individual panels are formed which need to be cut into strips in a later process step.
[0035] According to the fabrication process of the present invention, metal layers and passivation layers can be stacked on both surfaces of the temporary carrier as the double-sided lamination structure, and both sides of the lamination structure can be processed and then separated to provide single-sided substrates. As the single-sided substrates are detached from the temporary carrier, the bottom surface or the blank backside of the single-sided substrates is protected by the temporary carrier and turns out to be a pretty smooth surface, having a roughness R z ≦5 μm, for example. That is, the bottom surface or the blank backside of the single-sided substrates is significantly smoother than the conventional backside where copper has been etched or polished.
[0036] FIG. 3 is flow chart of process steps for fabricating a multi-layered substrate according to another embodiment of the present invention. FIGS. 4A-4G are cross-sectional views showing the multi-layered substrate according to the fabricating process steps of another embodiment in the present invention.
[0037] Firstly, in Step 30 & FIG. 4A , a double-sided lamination structure 300 is provided, which has a first laminate structure 310 a disposed on a top surface 302 a of the core structure 302 and a second laminate structure 310 b disposed on a bottom surface 302 b of the core 302 structure. The first laminate structure 310 a includes a first metal layer 306 a, a second metal layer 308 a and a first passivation layer 304 a sandwiched there-between, while the second laminate structure 310 b includes a third metal layer 306 b, a fourth metal layer 308 b and a second passivation layer 304 b sandwiched there-between. The first and second laminate structures 310 a, 310 b may be copper clad laminates (CCL), and the material of the metal layers may be copper formed by electroplating or copper foil lamination, for example. The first and second passivation layers 304 a, 304 b may be formed from the same or different resin materials, for example. The core structure 302 may be a release film or a peelable mask film, for example.
[0038] The double-sided lamination structure 300 can be formed by joining the core structure 302 with two laminate structures 310 a, 310 b in sequence or simultaneously, for example. The release film may be made of a Teflon-based material (such as Tedlar® film), and has very limited adhesion toward the passivation layer or the metal layer. If the release film is employed as the core structure 302 , adhesive resin may be applied on the corners or the borders of the release film for enhancing the adhesion. If the peelabel mask film is employed as the core structure 302 , it is preferred to choose the size or the shape of the peelable mask film for achieving sufficient adhesion and remaining peelable at the end of processing. For example, the peelable mask film can be applied on the borders (shaped as the picture frame) of one or both of the laminate structures 310 a, 310 b.
[0039] Alternatively, as shown in FIG. 4 A′, the core structure 302 ′ of the lamination structure 300 ′ is an aluminum layer and the lamination structure 300 ′ can be formed by laminating and pressing the metal layers and the passivation layers to both surfaces of the aluminum layer sequentially or simultaneously, for example. Such lamination structure 300 ′ can be obtained through direct lamination or be commercially available. For the commercially available lamination structure 300 ′, adhesive resin is usually applied on the borders (shaped as the picture frame) of one or both of the laminate structures 310 a, 310 b.
[0040] In Step 32 & FIG. 4B , a drilling process and a plating process are performed to form plated-through holes 310 passing through the double-sided lamination structure 300 ( 300 ′).
[0041] In Step 34 & FIG. 4C , after first and second patterned photoresist layers 312 a, 312 b are respectively formed on the second and fourth metal layers 308 a, 308 b, the second and fourth metal layers 308 a, 308 b are patterned, using the first and second patterned photoresist layers 312 a, 312 b as the etching masks.
[0042] In Step 36 & FIG. 4D , after removing the remained first and second patterned photoresist layers 312 a, 312 b, first and second mask layers 314 a, 314 b are respectively formed on the first and second passivation layers 304 a, 304 b and partially covering the second and fourth metal layers 308 a, 308 b. The first and second mask layers may be solder mask layers, for example.
[0043] In Step 38 & FIG. 4E , a surface plating process is performed to form a nickel/gold layer 316 a/b on the exposed surfaces of the second and fourth metal layers 308 a, 308 b respectively. Optionally, a protective layer (not shown) may be further formed over both surfaces of the double-sided lamination structure 300 ( 300 ′).
[0044] In Step 40 , a punching/routing process may be optionally performed to cut off the border frame of the double-sided lamination structure 300 ( 300 ′).
[0045] In Step 42 & FIG. 4F , the first and second laminate structures 310 a, 310 b are detached from the top and bottom surfaces 302 a, 302 b of the core structure 302 ( 302 ′). For the lamination structure 300 , as the border frame is punched off, it is easy to separate the first and second laminate structures 310 a, 310 b from the core structure 302 by peeling with or without using an exatco knife blade, for example. For the commercially available lamination structure 300 ′, as the border frame is removed along with the adhesive resin frame, the laminate structures 310 a, 310 b can be straightforwardly peeled apart. However, for the directly-laminated lamination structure 300 ′, the separating process may require more force by using radius drums to peel the laminate structures 310 a, 310 b from the aluminum layer. Alternatively, for easier split, it is preferred to arrange small pieces of release films at corners before the direct lamination.
[0046] In Step 44 & FIG. 4G , the first and second laminate structures 310 a, 310 b are re-laminated together. As the first and second laminate structures 310 a, 310 b are laminated to a carrier film 320 , the first and third metal layers 306 a, 306 b of the first and second laminate structures 310 a, 310 b become the external layers (i.e. face the outside). The carrier film 320 can be a peelable film, for example.
[0047] If the single-sided substrate structure is desired, the obtained first and second laminate structures 310 a, 310 b can be further processed to remove the first and third metal layers 306 a, 306 b. For single sided substrates, PTH plating may be optional.
[0048] If the double-sided substrate structure is desired, the first and third metal layers 306 a, 306 b of the obtained first and second laminate structures 310 a, 310 b can be further processed following the above described Steps 32 - 42 .
[0049] FIG. 5 shows a cross-sectional view of an example of the double-sided substrate structure of the present invention. The double-sided substrate structure 500 includes two patterned metal layers 506 , 508 respectively disposed on both surfaces of the base 504 and mask layers 505 , 507 over the patterned metal layers 506 , 508 .
[0050] If considering following the above steps to process both metal layers of the structure 500 , it is optional to perform the drilling and plating process twice or just once. If the plated-through holes 510 are drilled twice and plated twice during processing, the resultant plated-through hole 510 has a first plating layer 512 a covering the sidewall of the through hole and the surface surrounding the bottom opening of the through hole and a second plating layer 512 b covering the first plating layer and the surface surrounding the top opening of the through hole. It can reinforce the corners of the plated-through holes and increase the total thickness of the plating layers. The material of the first and second plating layer can be copper or copper alloys, for example.
[0051] According to the fabrication process of the present invention, copper clad laminates can be stacked on both surfaces of the aluminum carrier, the release film, or the peelable mask film as the lamination structure, and the lamination structure can be processed and separated to provide pseudo single-sided substrates. In addition, the pseudo single-sided substrates can be re-laminated and processed (the other side) to provide single-sided or double-sided substrates.
[0052] To sum up, the fabrication process of the present invention can efficiently provide single-sided substrates or double-sided substrates based on the currently standard two-layer manufacturing technology. Furthermore, the productivity can be practically doubled without wasting the processing materials or the production line.
[0053] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
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The present invention directs to fabrication methods of single-sided or double-sided multi-layered substrate by providing a lamination structure having at least a core structure and first and second laminate structures stacked over both surfaces of the core structure. The core structure functions as the temporary carrier for carrying the first and second laminate structures through the double-sided processing procedures. By way of the fabrication methods, the production yield can be greatly improved without increasing the production costs.
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FIELD OF THE INVENTION
[0001] This invention relates to the field of characterizing the existence of a disease state; particularly to the utilization of mass spectroscopy to elucidate particular biopolymer markers indicative of disease state, and most particularly to specific biopolymer sequences having a unique relationship to at least one particular disease state.
BACKGROUND OF THE INVENTION
[0002] Methods utilizing mass spectrometry for the analysis of a target polypeptide have been taught wherein the polypeptide is first solubilized in an appropriate solution or reagent system. The type of solution or reagent system, e.g., comprising an organic or inorganic solvent, will depend on the properties of the polypeptide and the type of mass spectrometry performed and are well known in the art (see, e.g., Vorm et al. (1994) Anal. Chem. 66:3281 (for MALDI) and Valaskovic et al. (1995) Anal. Chem. 67:3802 (for ESI). Mass spectrometry of peptides is further disclosed, e.g., in WO 93/24834 by Chait et al.
[0003] In one prior art embodiment, the solvent is chosen so that risk that the molecules may be decomposed by the energy introduced for the vaporization process is considerably reduced, or even fully excluded. This can be achieved by embedding the sample in a matrix, which can be an organic compound, e.g., sugar, in particular pentose or hexose, but also polysaccharides such as cellulose. These compounds are decomposed thermolytically into CO 2 and H 2 O so that no residues are formed which might lead to chemical reactions. The matrix can also be an inorganic compound, e.g., nitrate of ammonium which is decomposed practically without leaving any residues. Use of these and other solvents are further disclosed in U.S. Pat. No. 5,062,935 by Schlag et al.
[0004] Prior art mass spectrometer formats for use in analyzing the translation products include ionization (I) techniques, including but not limited to matrix assisted laser desorption (MALDI), continuous or pulsed electrospray (ESI) and related methods (e.g., IONSPRAY or THERMOSPRAY), or massive cluster impact (MCI); these ion sources can be matched with detection formats including linear or non-linear reflection time-off-light (TOF), single or multiple quadropole, single or multiple magnetic sector, Fourier Transform ion cyclotron resonance (FTICR), ion trap, and combinations thereof (e.g., ion-trap/time-of-flight). For ionization, numerous matrix/wavelength combinations (MALDI) or solvent combinations (ESI) can be employed. Subattomole levels of protein have been detected, for example, using ESI (Valaskovic, G. A. et al., (1996) Science 273:1199-1202 ) or MALDI (Li, L. et al., (1996) J. Am. Chem. Soc. 118:1662-1663) mass spectrometry.
[0005] ES mass spectrometry has been introduced by Fenn et al. (J. Phys. Chem. 88, 4451-59 (1984); PCT Application No. WO 90/14148) and current applications are summarized in recent review articles (R. D. Smith et al., Anal. Chem. 62, 882-89 (1990) and B. Ardrey, Electrospray Mass Spectrometry, Spectroscopy Europe, 4, 10-18 (1992)). MALDI-TOF mass spectrometry has been introduced by Hillenkamp et al. (“Matrix Assisted UV-Laser Desorption/Ionization: A New Approach to Mass Spectrometry of Large Biomolecules,” Biological Mass Spectrometry (Burlingame and McCloskey, editors), Elsevier Science Publishers, Amsterdam, pp. 49-60, 1990). With ESI, the determination of molecular weights in femtomole amounts of sample is very accurate due to the presence of multiple ion peaks which all could be used for the mass calculation.
[0006] The mass of the target polypeptide determined by mass spectrometry is then compared to the mass of a reference polypeptide of known identity. In one embodiment, the target polypeptide is a polypeptide containing a number of repeated amino acids directly correlated to the number of trinucleotide repeats transcribed/translated from DNA; from its mass alone the number of repeated trinucleotide repeats in the original DNA which coded it, may be deduced.
[0007] U.S. Pat. No. 6,020,208 utilizes a general category of probe elements (i.e., sample presenting means) with Surfaces Enhanced for Laser Desorption/Ionization (SELDI), within which there are three (3) separate subcategories. The SELDI process is directed toward a sample presenting means (i.e., probe element surface) with surface-associated (or surface-bound) molecules to promote the attachment (tethering or anchoring) and subsequent detachment of tethered analyte molecules in a light-dependent manner, wherein the said surface molecule(s) are selected from the group consisting of photoactive (photolabile) molecules that participate in the binding (docking, tethering, or crosslinking) of the analyte molecules to the sample presenting means (by covalent attachment mechanisms or otherwise).
[0008] PCT/EP/04396 teaches a process for determining the status of an organism by peptide measurement. The reference teaches the measurement of peptides in a sample of the organism which contains both high and low molecular weight peptides and acts as an indicator of the organism's status. The reference concentrates on the measurement of low molecular weight peptides, i.e. below 30,000 Daltons, whose distribution serves as a representative cross-section of defined controls. Contrary to the methodology of the instant invention, the '396 patent strives to determine the status of a healthy organism, i.e. a “normal” and then use this as a reference to differentiate disease states. The present inventors do not attempt to develop a reference “normal”, but rather strive to specify particular markers which are evidentiary of at least one specific disease state, whereby the presence of said marker serves as a positive indicator of disease. This leads to a simple method of analysis which can easily be performed by an untrained individual, since there is a positive correlation of data. On the contrary, the '396 patent requires a complicated analysis by a highly trained individual to determine disease state versus the perception of non-disease or normal physiology.
[0009] Richter et al, Journal of Chromatography B, 726(1999) 25-35, refer to a database established from human hemofiltrate comprised of a mass database and a sequence database. The goal of Richter et al was to analyze the composition of the peptide fraction in human blood. Using MALDI-TOF, over 20,000 molecular masses were detected representing an estimated 5,000 different peptides. The conclusion of the study was that the hemofiltrate (HF) represented the peptide composition of plasma. No correlation of peptides with relation to normal and/or disease states is made.
[0010] As used herein, “analyte” refers to any atom and/or molecule; including their complexes and fragment ions. In the case of biological molecules/macromolecules or “biopolymers”, such analytes include but are not limited to: proteins, peptides, DNA, RNA, carbohydrates, steroids, and lipids. Note that most important biomolecules under investigation for their involvement in the structure or regulation of life processes are quite large (typically several thousand times larger than H 2 O.
[0011] As used herein, the term “molecular ions” refers to molecules in the charged or ionized state, typically by the addition or loss of one or more protons (H + ).
[0012] As used herein, the term “molecular fragmentation” or “fragment ions” refers to breakdown products of analyte molecules caused, for example, during laser-induced desorption (especially in the absence of added matrix).
[0013] As used herein, the term “solid phase” refers to the condition of being in the solid state, for example, on the probe element surface.
[0014] As used herein, “gas” or “vapor phase” refers to molecules in the gaseous state (i.e., in vacuo for mass spectrometry).
[0015] As used herein, the term “analyte desorption/ionization” refers to the transition of analytes from the solid phase to the gas phase as ions. Note that the successful desorption/ionization of large, intact molecular ions by laser desorption is relatively recent (circa 1988)—the big breakthrough was the chance discovery of an appropriate matrix (nicotinic acid).
[0016] As used herein, the term “gas phase molecular ions” refers to those ions that enter into the gas phase. Note that large molecular mass ions such as proteins (typical mass=60,000 to 70,000 times the mass of a single proton) are typically not volatile (i.e., they do not normally enter into the gas or vapor phase). However, in the procedure of the present invention, large molecular mass ions such as proteins do enter the gas or vapor phase.
[0017] As used herein in the case of MALDI, the term “matrix” refers to any one of several small, acidic, light absorbing chemicals (e.g., nicotinic or sinapinic acid) that is mixed in solution with the analyte in such a manner so that, upon drying on the probe element, the crystalline matrix-embedded analyte molecules are successfully desorbed (by laser irradiation) and ionized from the solid phase (crystals) into the gaseous or vapor phase and accelerated as intact molecular ions. For the MALDI process to be successful, analyte is mixed with a freshly prepared solution of the chemical matrix (e.g., 10,000:1 matrix:analyte) and placed on the inert probe element surface to air dry just before the mass spectrometric analysis. The large fold molar excess of matrix, present at concentrations near saturation, facilitates crystal formation and entrapment of analyte.
[0018] As used herein, “energy absorbing molecules (EAM)” refers to any one of several small, light absorbing chemicals that, when presented on the surface of a probe, facilitate the neat desorption of molecules from the solid phase (i.e., surface) into the gaseous or vapor phase for subsequent acceleration as intact molecular ions. The term EAM is preferred, especially in reference to SELDI. Note that analyte desorption by the SELDI process is defined as a surface-dependent process (i.e., neat analyte is placed on a surface composed of bound EAM). In contrast, MALDI is presently thought to facilitate analyte desorption by a volcanic eruption-type process that “throws” the entire surface into the gas phase. Furthermore, note that some EAM when used as free chemicals to embed analyte molecules as described for the MALDI process will not work (i.e., they do not promote molecular desorption, thus they are not suitable matrix molecules).
[0019] As used herein, “probe element” or “sample presenting device” refers to an element having the following properties: it is inert (for example, typically stainless steel) and active (probe elements with surfaces enhanced to contain EAM and/or molecular capture devices).
[0020] As used herein, “MALDI” refers to Matrix-Assisted Laser Desorption/Ionization.
[0021] As used herein, “TOF” stands for Time-of-Flight.
[0022] As used herein, “MS” refers to Mass Spectrometry.
[0023] As used herein “MALDI-TOF MS” refers to Matrix-assisted laser desorption/ionization time-of-flight mass spectrometry.
[0024] As used herein, “ESI” is an abbreviation for Electrospray ionization.
[0025] As used herein, “chemical bonds” is used simply as an attempt to distinguish a rational, deliberate, and knowledgeable manipulation of known classes of chemical interactions from the poorly defined kind of general adherence observed when one chemical substance (e.g., matrix) is placed on another substance (e.g., an inert probe element surface). Types of defined chemical bonds include electrostatic or ionic (+/−) bonds (e.g., between a positively and negatively charged groups on a protein surface), covalent bonds (very strong or “permanent” bonds resulting from true electron sharing), coordinate covalent bonds (e.g., between electron donor groups in proteins and transition metal ions such as copper or iron), and hydrophobic interactions (such as between two noncharged groups).
[0026] As used herein, “electron donor groups” refers to the case of biochemistry, where atoms in biomolecules (e.g, N, S, O) “donate” or share electrons with electron poor groups (e.g., Cu ions and other transition metal ions).
[0027] With the advent of mass spectroscopic methods such as MALDI and SELDI, researchers have begun to utilize a tool that holds the promise of uncovering countless biopolymers which result from translation, transcription and post-translational transcription of proteins from the entire genome.
[0028] Operating upon the principles of retentate chromatography, SELDI MS involves the adsorption of proteins, based upon their physico-chemical properties at a given pH and salt concentration, followed by selectively desorbing proteins from the surface by varying pH, salt, or organic solvent concentration. After selective desorption, the proteins retained on the SELDI surface, the “chip”, can be analyzed using the CIPHERGEN protein detection system, or an equivalent thereof. Retentate chromatography is limited, however, by the fact that if unfractionated body fluids, e.g. blood, blood products, urine, saliva, and the like, along with tissue samples, are applied to the adsorbent surfaces, the biopolymers present in the greatest abundance will compete for all the available binding sites and thereby prevent or preclude less abundant biopolymers from interacting with them, thereby reducing or eliminating the diversity of biopolymers which are readily ascertainable.
[0029] If a process could be devised for maximizing the diversity of biopolymers discernable from a sample, the ability of researchers to accurately determine the relevance of such biopolymers with relation to one or more disease states would be immeasurably enhanced.
SUMMARY OF THE INVENTION
[0030] The instant invention is characterized by the use of a combination of preparatory steps in conjunction with SELDI mass spectroscopy and time-of-flight detection procedures to maximize the diversity of biopolymers which are verifiable within a particular sample. The cohort of biopolymers verified within a sample is then viewed with reference to their ability to evidence at least one particular disease state; thereby enabling a diagnostician to gain the ability to characterize either the presence or absence of said at least one disease state relative to recognition of the presence and/or the absence of said biopolymer.
[0031] Although all manner of biomarkers related to all disease conditions are deemed to be within the purview of the instant invention and methodology, particular significance was given to those markers and diseases associated with the complement system and Syndrome X and diseases related thereto.
[0032] The complement system is an important part of non-clonal or innate immunity that collaborates with acquired immunity to destroy invading pathogens and to facilitate the clearance of immune complexes from the system. This system is the major effector of the humoral branch of the immune system, consisting of nearly 30 serum and membrane proteins. The proteins and glycoproteins composing the complement system are synthesized largely by liver hepatocytes. Activation of the complement system involves a sequential enzyme cascade in which the proenzyme product of one step becomes the enzyme catalyst of the next step. Complement activation can occur via two pathways: the classical and the alternative. The classical pathway is commonly initiated by the formation of soluble antigen-antibody complexes or by the binding of antibody to antigen on a suitable target, such as a bacterial cell. The alternative pathway is generally initiated by various cell-surface constituents that are foreign to the host. Each complement component is designated by numerals (C 1 -C 9 ), by letter symbols, or by trivial names. After a component is activated, the peptide fragments are denoted by small letters. The complement fragments interact with one another to form functional complexes. Ultimately, foreign cells are destroyed through the process of a membrane-attack complex mediated lysis.
[0033] The C 4 component of the complement system is involved in the classical activation pathway. It is a glycoprotein containing three polypeptide chains (α, β, and γ). C 4 is a substrate of component C 1 s and is activated when C 1 s hydrolyzes a small fragment (C 4 a ) from the amino terminus of the a chain, exposing a binding site on the larger fragment (C 4 b ).
[0034] The native C 3 component consists of two polypeptide chains, α and β. As a serum protein, C 3 is involved in the alternative pathway. Serum C 3 , which contains an unstable thioester bond, is subject to slow spontaneous hydrolysis into C 3 a and C 3 b . The C 3 f component is involved in the regulation required of the complement system which confines the reaction to designated targets. During the regulation process, C 3 b is cleaved into two parts: C 3 bi and C 3 f . C 3 bi is a membrane-bound intermediate wherein C 3 f is a free diffusible (soluble) component.
[0035] Complement components have been implicated in the pathogenesis of several disease conditions. C 3 deficiencies have the most severe clinical manifestations, such as recurrent bacterial infections and immune-complex diseases, reflecting the central role of C 3 . The rapid profusion of C 3 f moieties and resultant “accidental” lysis of normal cells mediated thereby gives rise to a host of auto-immune reactions. The ability to understand and control these mechanisms, along with their attendant consequences, will enable practitioners to develop both diagnostic and therapeutic avenues by which to thwart these maladies.
[0036] In the course of defining a plurality of disease specific marker sequences, special significance was given to markers which were evidentiary of a particular disease state or with conditions associated with Syndrome-X. Syndrome-X is a multifaceted syndrome, which occurs frequently in the general population. A large segment of the adult population of industrialized countries develops this metabolic syndrome, produced by genetic, hormonal and lifestyle factors such as obesity, physical inactivity and certain nutrient excesses. This disease is characterized by the clustering of insulin resistance and hyperinsulinemia, and is often associated with dyslipidemia (atherogenic plasma lipid profile), essential hypertension, abdominal (visceral) obesity, glucose intolerance or noninsulin-dependent diabetes mellitus and an increased risk of cardiovascular events. Abnormalities of blood coagulation (higher plasminogen activator inhibitor type I and fibrinogen levels), hyperuricemia and microalbuminuria have also been found in metabolic syndrome-X.
[0037] The instant inventors view the Syndrome X continuum in its cardiovascular light, while acknowledging its important metabolic component. The first stage of Syndrome X consists of insulin resistance, abnormal blood lipids (cholesterol and triglycerides), obesity, and high blood pressure (hypertension). Any one of these four first stage conditions signals the start of Syndrome X.
[0038] Each first stage Syndrome X condition risks leading to another. For example, increased insulin production is associated with high blood fat levels, high blood pressure, and obesity. Furthermore, the effects of the first stage conditions are additive; an increase in the number of conditions causes an increase in the risk of developing more serious diseases on the Syndrome X continuum.
[0039] A patient who begins the Syndrome X continuum risks spiraling into a maze of increasingly deadly diseases. The next stages of the Syndrome X continuum lead to overt diabetes, kidney failure, and heart failure, with the possibility of stroke and heart attack at any time. Syndrome X is a dangerous continuum, and preventative medicine is the best defense. Diseases are currently most easily diagnosed in their later stages, but controlling them at a late stage is extremely difficult. Disease prevention is much more effective at an earlier stage.
[0040] Subsequent to the isolation of particular disease state marker sequences as taught by the instant invention, the promulgation of various forms of risk-assessment tests are contemplated which will allow physicians to identify asymptomatic patients before they suffer an irreversible event such as diabetes, kidney failure, and heart failure, and enable effective disease management and preventative medicine. Additionally, the specific diagnostic tests which evolve from this methodology provide a tool for rapidly and accurately diagnosing acute Syndrome X events such as heart attack and stroke, and facilitate treatment.
[0041] Accordingly, it is an objective of the instant invention to define a disease specific marker sequence which is useful in evidencing and categorizing at least one particular disease state.
[0042] It is another objective of the instant invention to evaluate samples containing a plurality of biopolymers for the presence of disease specific marker sequences which evidence a link to at least one specific disease state.
[0043] It is a further objective of the instant invention to elucidate essentially all biopolymeric moieties contained therein, whereby particularly significant moieties may be identified.
[0044] It is a further objective of the instant invention provide at least one purified antibody which is specific to said disease specific marker sequence.
[0045] It is yet another objective of the instant invention to teach a monoclonal antibody which is specific to said disease specific marker sequence.
[0046] It is a still further objective of the invention to teach polyclonal antibodies raised against said disease specific marker.
[0047] It is yet an additional objective of the instant invention to teach a diagnostic kit for determining the presence of said disease specific marker.
[0048] It is a still further objective of the instant invention to teach methods for characterizing disease state based upon the identification of said disease specific marker.
[0049] Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0050] [0050]FIG. 1 is a representation of derived data which characterizes a disease specific marker having a particular sequence useful in evidencing and categorizing at least one particular state;
[0051] [0051]FIG. 2 is the characteristic profile derived via SELDI/TOF MS of the disease specific marker of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0052] Serum samples from individuals were analyzed using Surface Enhanced Laser Desorption Ionization (SELDI) using the Ciphergen PROTEINCHIP system. The chip surfaces included, but were not limited to IMAC-3-Ni, SAX2 surface chemistries, gold chips, and the like.
[0053] Preparatory to the conduction of the SELDI MS procedure, various preparatory steps were carried out in order to maximize the diversity of discernible moities educable from the sample. Utilizing a type of micro-chromatographic column called a C18-ZIPTIP available from the Millipore company, the following preparatory steps were conducted.
[0054] 1. Dilute sera in sample buffer;
[0055] 2. Aspirate and dispense ZIP TIP in 50% Acetonitrile;
[0056] 3. Aspirate and dispense ZIP TIP in Equilibration; solution;
[0057] 4. Aspirate and Dispense in serum sample;
[0058] 5. Aspirate and Dispense ZIP TIP in Wash solution;
[0059] 6. Aspirate and Dispense ZIP TIP in Elution Solution.
[0060] Illustrative of the various buffering compositions useful in the present invention are:
[0061] Sample Buffers (various low pH's): Hydrochloric acid (HCl), Formic acid, Trifluoroacetic acid (TFA),
[0062] Equilibration Buffers (various low pH's): HCl, Formic acid, TFA;
[0063] Wash Buffers (various low pH's): HCl, Formic acid, TFA;
[0064] Elution Solutions (various low pH's and % Solvents): HCl, Formic acid, TFA;
[0065] Solvents: Ethanol,Methanol, Acetonitrile. Spotting was then performed, for example upon a Gold Chip in the following manner:
[0066] 1. spot 2 ul of sample onto each spot
[0067] 2. let sample partially dry
[0068] 3. spot I ul of matrx, and let air dry.
HiQ Anion Exchange Mini Column Protocol
[0069] 1. Dilute sera in sample/running buffer;
[0070] 2. Add HiQ resin to column and remove any air bubbles;
[0071] 3. Add Uf water to aid in column packing;
[0072] 4. Add sample/running buffer to equilibrate column;
[0073] 5. Add diluted sera;
[0074] 6. Collect all the flow through fraction in Eppendorf tubes until level is at resin;
[0075] 7. Add sample/running buffer to wash column;
[0076] 8. Add elusion buffer and collect elusion in Eppendorf tubes.
[0077] Illustrative of the various buffering compositions useful in this technique are:
[0078] Sample/Running buffers: including but not limited to Bicine buffers of various molarities, pH's, NaCl content, Bis-Tris buffers of various molarities, pH's, NaCl content, Diethanolamine of various molarities, pH's, NaCl content, Diethylamine of various molarities, pH's, NaCl content, Imidazole of various molarities, pH's, NaCl content, Tricine of various molarities, pH's, NaCl content, Triethanolamine of various molarities, pH's, NaCl content, Tris of various molarities, pH's, NaCl content.
[0079] Elution Buffer: Acetic acid of various molarities, pH's, NaCl content, Citric acid of various molarities, pH's, NaCl content, HEPES of various molarities, pH's, NaCl content, MES of various molarities, pH's, NaCl content, MOPS of various molarities, pH's, NaCl content, PIPES of various molarities, pH's, NaCl content, Lactic acid of various molarities, pH's, NaCl content, Phosphate of various molarities, pH's, NaCl content, Tricine of various molarities, pH's, NaCl content.
Chelating Sepharose Mini Column
[0080] 1. Dilute Sera in Sample/Running buffer;
[0081] 2. Add Chelating Sepharose slurry to column and allow column to pack;
[0082] 3. Add UF water to the column to aid in packing;
[0083] 4. Add Charging Buffer once water is at the level of the resin surface;
[0084] 5. Add UF water to wash through non bound metal ions once charge buffer washes through;
[0085] 6. Add running buffer to equilibrate column for sample loading;
[0086] 7. Add diluted serum sample;
[0087] 8. Add running buffer to wash unbound protein;
[0088] 9. Add elution buffer and collect elution fractions for analysis;
[0089] 10. Acidify each elution fraction.
[0090] Illustrative of the various buffering compositions useful in this technique are: Sample/Running buffers including but not limited to Sodium Phosphate buffers at various molarities and pH's;
[0091] Charging buffers including but not limited to Nickel Chloride, Nickel Sulphate, Copper II Chloride, Zinc Chloride or any suitable metal ion solution;
[0092] Elution Buffers including but not limited to Sodium phosphate buffers at various molarities and pH's containing various molarities of EDTA and/or Imidazole.
HiS Cation Exchange Mini Column Protocol
[0093] 1. Dilute sera in sample/running buffer;
[0094] 2. Add HiS resin to column and remove any air bubbles;
[0095] 3. Add Uf water to aid in column packing;
[0096] 4. Add sample/running buffer to equilibrate column for sample loading;
[0097] 5. Add diluted sera to column;
[0098] 6. Collect all flow through fractions in Eppendorf tubes until level is at resin.
[0099] 7. Add sample/running buffer to wash column.
[0100] 8. Add elusion buffer and collect elusion in Eppendorf tubes.
[0101] Illustrative of the various buffering compositions useful in this technique are:
[0102] Sample/Running buffers: including but not limited to Bicine buffers of various molarities, pH's, NaCl content, Bis-Tris buffers of various molarities, pH's, NaCl content, Diethanolamine of various molarities, pH's, NaCl content, Diethylamine of various molarities, pH's, NaCl content, Imidazole of various molarities, pH's, NaCl content, Tricine of various molarities, pH's, NaCl content, Triethanolamine of various molarities, pH's, NaCl content, Tris of various molarities, pH's, NaCl content.
[0103] Elution Buffer: Acetic acid of various molarities, pH's, NaCl content, Citric acid of various molarities, pH's, NaCl content, HEPES of various molarities, pH's, NaCl content, MES of various molarities, pH's, NaCl content, MOPS of various molarities, pH's, NaCl content, PIPES of various molarities, pH's, NaCl content, Lactic acid of various molarities, pH's, NaCl content, Phosphate of various molarities, pH's, NaCl content, Tricine of various molarities, pH's, NaCl content.
[0104] The procedure for profiling serum samples is described below:
[0105] Following the preparatory steps illustrated above, various methods for use of the PROTEINCHIP arrays, available for purchase from Ciphergen Biosystems (Palo Alto, Calif.), may be practiced. Illustrative of one such method is as follows.
[0106] The first step involved treatment of each spot with 20 ml of a solution of 0.5 M EDTA for 5 minutes at room temperature in order to remove any contaminating divalent metal ions from the surface. This was followed by rinsing under a stream of ultra-filtered, deionized water to remove the EDTA. The rinsed surfaces were treated with 20 ml of 100 mM Nickel sulfate solution for 5 minutes at room temperature after which the surface was rinsed under a stream of ultra-filtered, deionized water and allowed to air dry.
[0107] Serum samples (2 ml) were applied to each spot (now “charged” with the metal-Nickel) and the PROTEINCHIP was returned to the plastic container in which it was supplied. A piece of moist KIMWIPE was placed at the bottom of the container to generate a humid atmosphere. The cap on the plastic tube was replaced and the chip allowed to incubate at room temperature for one hour. At the end of the incubation period, the chip was removed from the humid container and washed under a stream of ultra-filtered, deionized water and allowed to air dry. The chip surfaces (spots) were now treated with an energy-absorbing molecule that helps in the ionization of the proteins adhering to the spots for analysis by Mass Spectrometry. The energy-absorbing molecule in this case was sinapinic acid and a saturated solution prepared in 50% acetonitrile and 0.05% TFA was applied (1 ml) to each spot. The solution was allowed to air dry and the chip analyzed immediately using MS (SELDI).
[0108] Serum samples from patients suffering from a variety of disease states were analyzed using one or more protein chip surfaces, e.g. a gold chip or an IMAC nickel chip surface as described above and the profiles were analyzed to discern notable sequences which were deemed in some way evidentiary of at least one disease state.
[0109] In order to purify the disease specific marker and further characterize the sequence thereof, additional processing was performed.
[0110] For example, Serum (20 ml) was (diluted 5-fold with phosphate buffered saline) concentrated by centrifugation through a YM3 MICROCON spin filter (Amicon) for 20 min at 10,000 RPM at 4° C. in a Beckman MICROCENTRIFuge R model bench top centrifuge. The filtrate was discarded and the retained solution, which contained the two peptides of interest, was analyzed further by tandem mass spectrometry to deduce their amino acid sequences. Tandem mass spectrometry was performed at the University of Manitoba's (Winnipeg, Manitoba, Canada) mass spectrometry laboratory using the procedures that are well known to practitioners of the art.
[0111] As a result of these procedures, the disease specific marker DAHKSEVAHRFKD was found. This marker is characterized as a Serum Albumin having a molecular weight of about 1521 daltons. The characteristic profile of the marker is set forth in FIG. 2. As easily deduced from the data set forth in FIG. 1, this marker is indicative of renal failure.
[0112] In accordance with various stated objectives of the invention, the skilled artisan, in possession of the specific disease specific marker as instantly disclosed, would readily carry out known techniques in order to raise purified biochemical materials, e.g. monoclonal and/or polyclonal antibodies, which are useful in the production of methods and devices useful as point-of-care rapid assay diagnostic or risk assessment devices as are known in the art.
[0113] The specific disease markers which are analyzed according to the method of the invention are released into the circulation and may be present in the blood or in any blood product, for example plasma, serum, cytolyzed blood, e.g. by treatment with hypotonic buffer or detergents and dilutions and preparations thereof, and other body fluids, e.g. CSF, saliva, urine, lymph, and the like. The presence of each marker is determined using antibodies specific for each of the markers and detecting specific binding of each antibody to its respective marker. Any suitable direct or indirect assay method may be used to determine the level of each of the specific markers measured according to the invention. The assays may be competitive assays, sandwich assays, and the label may be selected from the group of well-known labels such as radioimmunoassay, fluorescent or chemiluminescence immunoassay, or immunoPCR technology. Extensive discussion of the known immunoassay techniques is not required here since these are known to those of skilled in the art. See Takahashi et al. (Clin Chem 1999;45(8):1307) for S100B assay.
[0114] A monoclonal antibody specific against the disease marker sequence isolated by the present invention may be produced, for example, by the polyethylene glycol (PEG) mediated cell fusion method, in a manner well-known in the art.
[0115] Traditionally, monoclonal antibodies have been made according to fundamental principles laid down by Kohler and Milstein. Mice are immunized with antigens, with or without, adjuvants. The splenocytes are harvested from the spleen for fusion with immortalized hybridoma partners. These are seeded into microtitre plates where they can secrete antibodies into the supernatant that is used for cell culture. To select from the hybridomas that have been plated for the ones that produce antibodies of interest the hybridoma supernatants are usually tested for antibody binding to antigens in an ELISA (enzyme linked immunosorbent assay) assay. The idea is that the wells that contain the hybridoma of interest will contain antibodies that will bind most avidly to the test antigen, usually the immunizing antigen. These wells are then subcloned in limiting dilution fashion to produce monoclonal hybridomas. The selection for the clones of interest is repeated using an ELISA assay to test for antibody binding. Therefore, the principle that has been propagated is that in the production of monoclonal antibodies the hybridomas that produce the most avidly binding antibodies are the ones that are selected from among all the hybridomas that were initially produced. That is to say, the preferred antibody is the one with highest affinity for the antigen of interest.
[0116] There have been many modifications of this procedure such as using whole cells for immunization. In this method, instead of using purified antigens, entire cells are used for immunization. Another modification is the use of cellular ELISA for screening. In this method instead of using purified antigens as the target in the ELISA, fixed cells are used. In addition to ELISA tests, complement mediated cytotoxicity assays have also been used in the screening process. However, antibody-binding assays were used in conjunction with cytotoxicity tests. Thus, despite many modifications, the process of producing monoclonal antibodies relies on antibody binding to the test antigen as an endpoint.
[0117] The purified monoclonal antibody is utilized for immunochemical studies.
[0118] Polyclonal antibody production and purification utilizing one or more animal hosts in a manner well-known in the art can be performed by a skilled artisan.
[0119] Another objective of the present invention is to provide reagents for use in diagnostic assays for the detection of the particularly isolated disease specific marker sequences of the present invention.
[0120] In one mode of this embodiment, the marker sequences of the present invention may be used as antigens in immunoassays for the detection of those individuals suffering from the disease known to be evidenced by said marker sequence. Such assays may include but are not limited to: radioimmunoassay, enzyme-linked immunosorbent assay (ELISA), “sandwich” assays, precipitin reactions, gel diffusion immunodiffusion assay, agglutination assay, fluorescent immunoassays, protein A or G immunoassays and immunoelectrophoresis assays.
[0121] According to the present invention, monoclonal or polyclonal antibodies produced against the disease specific marker sequence of the instant invention are useful in an immunoassay on samples of blood or blood products such as serum, plasma or the like, spinal fluid or other body fluid, e.g. saliva, urine, lymph, and the like, to diagnose patients with the characteristic disease state linked to said marker sequence. The antibodies can be used in any type of immunoassay. This includes both the two-site sandwich assay and the single site immunoassay of the non-competitive type, as well as in traditional competitive binding assays.
[0122] Particularly preferred, for ease and simplicity of detection, and its quantitative nature, is the sandwich or double antibody assay of which a number of variations exist, all of which are contemplated by the present invention. For example, in a typical sandwich assay, unlabeled antibody is immobilized on a solid phase, e.g. microtiter plate, and the sample to be tested is added. After a certain period of incubation to allow formation of an antibody-antigen complex, a second antibody, labeled with a reporter molecule capable of inducing a detectable signal, is added and incubation is continued to allow sufficient time for binding with the antigen at a different site, resulting with a formation of a complex of antibody-antigen-labeled antibody. The presence of the antigen is determined by observation of a signal which may be quantitated by comparison with control samples containing known amounts of antigen.
[0123] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0124] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings/figures.
[0125] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The oligonucleotides, peptides, polypeptides, biologically related compounds, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
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The instant invention involves the use of a combination of preparatory steps in conjunction with mass spectroscopy and time-of-flight detection procedures to maximize the diversity of biopolymers which are verifiable within a particular sample. The cohort of biopolymers verified within such a sample is then viewed with reference to their ability to evidence at least one particular disease state; thereby enabling a diagnostician to gain the ability to characterize either the presence or absence of said at least one disease state relative to recognition of the presence and/or the absence of said biopolymer.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of International Application No. PCT/AU2008/000726 filed May 23, 2008, which claims priority to Australian Patent Application No. 2007902747, filed May 23, 2007, the entire contents of all of which are incorporated by reference as if fully set forth.
FIELD OF INVENTION
[0002] This invention relates to a system of injection for a high vapor pressure fuel, such as LPG or injecting a mix of fuels and a changeover from one fuel to another.
BACKGROUND
[0003] It is most advantageous if liquid petroleum gas (LPG) can be fed to an engine in liquid form so gaining the advantage of the better combustion provided by the volumetric effect, the phase change from liquid to gas.
[0004] Prior art (Granted Australian Patents 647561, 647857) has disclosed energy efficient low pressure methods of delivering liquid LPG into the inlet manifold of a spark ignition (SI) engine.
SUMMARY
[0005] The present disclosure is directed to a liquid fuel injection system for a combustion engine. The system includes a high pressure electric pumping system arranged to receive high vapor pressure fuel in liquid form from a pressure tank. The electric pumping system is arranged to pump the liquid high vapor pressure fuel from the pressure tank at a controlled pressure high enough to ensure it is pumped in liquid form to a variable volume accumulator which is arranged to direct the liquid fuel to fuel injectors for the combustion engine. The system also includes a regulating system for maintaining the fuel pumped to the fuel injectors at the controlled pressure in liquid form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The invention is to be subsequently explained in more detail based on exemplary embodiments in conjunction with the drawings. In the drawings:
[0007] FIG. 1 is a schematic representation of a first embodiment of the system of the present invention;
[0008] FIG. 2 is a schematic representation of a second embodiment of the system of the present invention;
[0009] FIG. 3 depicts a system of integral measuring by the use of two pumps mounted on a common shaft.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] This invention provides a liquid fuel injection system employing a high pressure pumping system and accumulator, to provide a constant and adequate high pressure fuel supply of high vapor pressure fuel such as LPG alone, or in a fuel mixture, such as a lower vapor pressure fuel such as petrol or diesel, maintained in a liquid stage to fuel injectors. The fuel injector may be axial or bottom feed liquid fuel injectors injecting into the inlet manifold or cylinders of a spark ignition internal combustion engine, or directly into the cylinders of a diesel or compression engine, to keep said engine running at its critical usable power output levels.
[0011] In a spark ignition engine the invention may provide a seamless changeover from a high vapor pressure fuel to another fuel of lower vapor pressure of which a change from LPG to petrol is an example.
[0012] The system, as configured, may be controlled electronically, such as by an engine management system.
[0013] According to the invention, an advantageous alternative is to overcome the high vapor pressure of the LPG so enabling the delivery of the LPG to the inlet manifold or direct into the cylinder in the highly desirable liquid stage. A way of doing so is shown in FIG. 1 .
[0014] It is highly advantageous to be able to simplify the installation by deleting the return of fuel to the tank. An additional benefit is not raising the tank temperature of the LPG.
[0015] Whereas this description concentrates upon the use of LPG as the fuel it is possible to utilize mixed fuels of which LPG may be a constituent, utilizing a mixer prior to the inlet of the high pressure pump. Alternatively, the pump and fuel measuring device may be one unit with a mixer prior to or integral with the accumulator, as in FIG. 2 .
[0016] The invention provides in one aspect a liquid fuel injection system for a combustion engine comprising,
a liquid fuel injection system for a combustion engine comprising, a high pressure electric pumping system arranged to receive high vapor pressure fuel in liquid form from a pressure tank holding a high vapor pressure fuel the electric pumping system being arranged to pump the liquid high vapor pressure fuel from the pressure tank at a controlled pressure high enough to ensure it is pumped in liquid form to a variable volume accumulator which is arranged to direct the liquid fuel to fuel injectors for the combustion engine, and a regulating system for maintaining the fuel pumped to the fuel injectors at the controlled pressure in liquid form.
[0020] An economical high pressure liquid LPG fuel supply system for an internal combustion engine is described. The LPG can be fed from an LPG tank, either vapor pressure fed, or with the aid of a low pressure submerged pump in the tank, providing a LPG feed at tank vapor pressure, plus up to 250 kPa from the submerged pump, to a high pressure pump capable of delivering at least 2.5 MPa pressure. The purpose behind the use of the low pressure pump is the avoidance of cavitations on the inlet side of the high pressure pump.
[0021] The pumping of the LPG in liquid form from the tank to the inlet side of the high pressure pump may include a return line to the LPG tank and a pressure regulation device in the form of a one way valve, such valve having a fixed spring of a certain cracking pressure and located at the return inlet to the tank, as disclosed in the prior art quoted, Granted Australian Patents 647561, 647857. A similar system of a return line for diesel can be utilized.
[0022] The high pressure pump in the preferred embodiment delivers liquid LPG at 2.5 MPa pressure to the fuel line and to an accumulator having a suggested capacity capable of fuelling the engine in question for one minute at peak revolutions. As shown in FIGS. 1 and 2 the accumulator is a variable volume accumulator by virtue of a spring loaded diaphragm which is movable to vary the capacity of the accumulator.
[0023] This period of one minute is ample time in which to achieve a changeover from one fuel type to another. The engine management system can calculate the time required for the first fuel to be almost exhausted from the fuel lines and accumulator, gauging the fuel pressure and temperature in the lines, before changing to the second fuel at the optimum pressure for that fuel to be injected through the same injectors delivering the liquid fuel.
[0024] The high pressure pump and accumulator can be set at any pressure which will guarantee that the LPG remains in a liquid state for injection, directly into the engine or into the engine intake manifold.
[0025] Upon demand, the liquid LPG can be fed to injectors, axial or bottom feed injectors on the engine, via a distribution manifold and flexible high pressure fuel lines, providing the LPG to each injector. An alternative is to utilize a common rail system as found in modern diesel engines which method is suitable for direct into the cylinder fuel injection.
[0026] A pressure switch, acting in accordance with the pressure in the accumulator turns the high pressure pump off, either directly or through the engine management system (EMS) when the set pressure (here 2.5 MPa) is reached. Upon the pressure in the accumulator falling by one hundred kPa, or other preferred pressure difference, a switch will turn on the high pressure pump to restore the set pressure.
[0027] Alternatively the speed of the high pressure pump can be modulated by the EMS to match the delivery rate to engine requirement thereby maintaining a constant pressure.
[0028] The accumulator may be used to ensure constant delivery of LPG in liquid form to the injectors at all operating times and to assist starting of the engine following a period of shut down of the engine or, by choice, the accumulator may be dispensed with, which would reduce the time needed to exhaust the old fuel in the accumulator when changing from one fuel to another and reliance can rest upon the high pressure pump to provide sufficient high pressure fuel at all operating moments to ensure smooth operation of the engine. The absence of a conventional accumulator may be aided by elasticity in the tubing used to conduct the liquid LPG from the pump to the injectors as the elasticity allows the tubing to be an accumulator.
[0029] Hot starts may not be instantaneous due to vaporization of the LPG in the fuel lines whilst the engine is stopped.
[0030] In this invention the high pressure accumulator can be used to keep LPG in the liquid state ready for an instant start, or re-start of the engine.
[0031] The injectors may be designed to deliver LPG at pressures up to and over 20 MPa with a preference to operating around 2.5 MPa so limiting the energy needed to drive the system, but still allowing for direct into the cylinder injection or injection into the engine manifold.
[0032] The pressure of injection is such as to keep liquid fuel at the tip of the injector for injection into the inlet manifold of the engine or directly into the cylinders of the engine.
[0033] The system can be aided by heat shielding of components and cooling, via the air conditioning system of the vehicle or other means, of the high vapor pressure fuel.
[0034] Experience with the prior art has encountered the heating up of the LPG by its continuous recirculation through the injectors and fuel lines of the engine.
[0035] It is preferable that the LPG can be supplied from the high pressure pump to the engine without a return line to the LPG tank so as to avoid raising the temperature of the LPG in the tank, which heat can raise the vapor pressure and affect the time taken for filling the LPG tank, plus incurring the added cost and complexity of return tubing.
[0036] The invention will be generally discussed in relation to the operation of a liquefied petroleum gas fuelled vehicle, as an example of a high vapor pressure fuel system, but the invention is not restricted to this fuel.
[0037] This present invention can provide an arrangement whereby such an engine can be supplied to advantage with high pressure bottom feed or axial feed injectors of a size equal to or smaller than commonly used petrol injectors. The bottom feed injectors discussed by this invention do not require to be placed in a housing or pod, the outer shell of the injector serving that function. They do not sit in a series of pods, constituting a fuel rail, but are connected, in the preferred embodiment, by flexible high pressure fuel lines from pump or accumulator to injector. A common rail system or plastic coated steel fuel lines may be used to feed the injectors.
[0038] It is of assistance and is specified as the desired option in this invention that to deliver liquid LPG to the injecting orifice of the injector, adequate pressure is exerted by the high pressure pump to keep the LPG liquid in all normal circumstances of motoring and the desired pressure is 2.5 MPa.
[0039] Utilizing an axial injector the fuel is fed through the top of the injector in the common embodiment. With a bottom feed injector, the fuel is fed to the bottom of the injector and removed therefrom if so required via arms which are rigid and to which the flexible tubing used is connected or a common rail is used.
[0040] The nozzle of the injector can be relatively small at 8 or 9 mm in diameter and can be fitted with a collar to ensure that the injector is a snug fit in the holes provided in the inlet manifold by the engine manufacturer. This aids rapidity and economy of assembly.
[0041] The pressure and temperature of the LPG is taken at closely located points to determine, via the EMS, from look up charts the composition of the LPG. This knowledge is then used to set the base injection pulse width and ignition timing specific to the fuel composition, is the readings for which are then modified by the oxygen sensor and other inputs required for the effective running of the engine by the EMS in the normal manner, as disclosed in Australian Patent 647857.
Dual Fuel System
[0042] With dual fuel systems that inject the fuel in the liquid state via bottom feed injectors as in Australian Patents 647561 “A Method of Fuel Injection” and 647857 “Dual Fuel Injection System” there exists a problem in sizing the required injectors, relatively low flow injectors for high pressure LPG, and relatively high flow injectors for low pressure petrol injection.
[0043] Using one high pressure pump and one set of high pressure injectors eliminates the need for a second set of low pressure injectors when running solely on petrol or other low vapor pressure fuel.
[0044] According to one aspect of the invention this problem can be ameliorated by injecting both fuels at the relatively high pressure of 2.5 MPa. The fuel to be used can be selected by use of lock off solenoids on the fuel lines with care being taken to ensure that there is no flowing of one fuel to the tank of the alternative.
[0045] A mixed charge of differing fuels can be used employing the aid of a mixer which can mix the fuels in set proportions and such proportions can be varied.
[0046] In the preferred embodiment, shown in FIG. 2 , the pressurizing of the fuels or fuel is shown with integral measuring of the relative volume of the fuels.
[0047] A system of integral measuring by the use of two pumps mounted on a common shaft is shown in FIG. 3 .
[0048] Adequate mixing of the fuels may also be achieved with a mixer prior to or being an integral part of the accumulator.
[0049] Economy is served if the pump in the LPG tank can be dispensed with and this will depend on the ability to avoid cavitations at the inlet of the high pressure pump and therefore depend on operating conditions encountered.
[0050] Prior to this invention a common method of switching from the high vapor pressure fuel to the low vapor pressure fuel is to allow the pressure in the fuel rail to subside after switching off the high vapor pressure fuel, mainly LPG in Australia or Europe and propane in the United States of America. For the pressure in the fuel rail to subside to a level of less than 250 kPa or such level as the fuel pump will normally pump the low vapor pressure fuel such as petrol may take 2 minutes of time during which the engine will not run in an effective manner.
[0051] If the engine is in a motor vehicle, the vehicle is normally stationary during the fuel changeover and this can be a source or irritation and inconvenience, even danger. This problem is avoided as all fuels are injected at similar pressures thereby requiring no time for pressure adjustment.
[0052] In the current invention the high pressure pump can be used for the injection of a mixture of both fuels, or other suitable alternative fuels, through the one set of injectors, otherwise petrol or LPG as a single fuel, with solenoid control over the fuel selected.
[0053] In such a system the alteration to the power output will be a minimum in any changeover of fuels and both fuels can successfully be injected at high pressure. For LPG or petrol, or a petrol LPG mix, the engine may be a spark ignition engine and for diesel, or a diesel LPG mix, the engine may be a compression ignition engine. However a variable compression engine fitted with spark ignition such as that disclosed in UK Patent cover Family 4, EP Number 03792495.8, PCT No. PCT/GB2003/003643 can utilize all of the above fuels.
[0054] Using the computing facilities of the engine management system into which the temperature and pressure of the fuel are fed the appropriate pulse width for the injectors can be calculated for which verification of the fuel mix being used by the engine can come from exhaust sensors which also read back to the engine management system and compensate for fuel metering errors.
[0055] Accordingly, the present invention can be directed to a high pressure single fuel injection, or a dual fuel system employing high and low vapor pressure fuels which will be capable of being switched from one fuel to the other, or operating with mixed fuels, without interrupting the effective functioning of the engine.
[0056] Whereas the mixed fuels may commonly be LPG and petrol, or ethanol, it is possible to use a mix of LPG and diesel, including biodiesel where the engine is a compression ignition engine and in which case the injection of the fuel mix for maximum efficiency, could be direct into the cylinder.
[0057] Although various forms of the invention have been described it is to be noted the invention is not limited thereto but can include variations and modifications falling within the spirit and scope of the invention.
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A high vapor pressure liquid fuel (e.g. LPG) injection system is provided that keeps the fuel liquid at all expected operating temperatures by use of a high pressures pump capable of at least 2.5 MPa pressures. The fuel can be injected directly into the cylinder or into the inlet manifold of an engine via axial or bottom feed injectors and also could be mixed with a low vapor pressure fuel (e.g. diesel) to be injected similarly. The fuel, mixed or unmixed, can be stored in an accumulator under high pressure assisting in keeping the engine running during fuel changeovers and injection after a period of time as in re-starting the engine. The same injectors can be used to inject any of the fuels or mixtures of them.
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FIELD OF THE INVENTION
This invention relates to an improved railcar truck and more particularly to a lighter weight three-piece truck. These types of trucks are well known in the railroad industry and the term "three-piece" refers to a truck which consists of two sideframes that are positioned parallel to the wheels and rails, and to a bolster that transverses between each of the sideframes. Railcar trucks operate in a severe operating environment where they must be strong enough to support both the car structure and its contents, particularly the sideframes on which the car body is either directly or indirectly supported. Most usually this means that the sideframes and bolsters will be manufactured from cast steel, making the sideframe a large contributor to the total weight placed upon the rails. Thus, the maximum quantity of product a shipper may place within a railcar will be directly affected by the weight of the car body, the trucks, and its contents. Any weight reduction that is made to the truck will be directly available as increased carrying capacity of the car. But weight reduction in the sideframe castings has heretofore been approached very conservatively in order to eliminate field failures. Recent developments in improved laboratory simulation testing and computer analysis techniques, combined with the increased experience in sideframe manufacturing testing, has now made it possible to design and produce lighter weight sideframes without sacrificing operational safety and performance. Greater use of improved testing techniques and advanced computer analysis has led sideframe designers to reexamine existing sideframe designs in order to determine if there are areas of "dead weight" which can be eliminated. Moreover, these techniques have also helped to more precisely identify the primary loadcarrying areas on the existing models of sideframes and more readily identify whether these areas should be structurally enhanced.
SUMMARY OF THE INVENTION
Accordingly, it is the primary object of the present invention to more precisely identify the areas of the sideframe which contain non-critical load-bearing areas and to reduce the weight of the railcar truck sideframe by removing metallic mass from those noncritical areas.
It is another object of the present invention to more precisely identify the areas of the sideframe which are considered critical load-bearing areas and to structurally reinforce those areas with additional metallic mass, as necessary.
It is a final object of the present invention to improve the casting quality of the sideframe by simplifying the internal core assembly of the casting mold, made possible by the removal of metallic mass from non-critical areas and the redistribution of mass to critical areas.
Briefly stated, the present invention primarily involves the reduction of metal in the following sideframe components: 1) the top compression member; 2) the sideframe columns behind the wear plate area; 3) the outer pedestal jaw member wall; 4) the upper surface of the diagonal tension member; 5) the bottom half of sideframe of the column member; 6) the top surface of the spring seat plate. Removing metallic mass in the above-mentioned areas substantially involves adding additional lightener holes to the sideframe as indicated. In addition to removing the unnecessary dead weight, the extra lightener holes will actually affect and improve the quality of the casting by stabilizing the internal casting mold cores, since only one core is required to cast the entire sideframe end of the present invention. Casting an entire sideframe end from only one core is made possible because the casting mold is partially supported by the above-mentioned lightener holes. Providing one core to cast the sideframe midsection, and a respective core, with the appropriate appendages, to cast each sideframe end, is a significant departure from the current casting practices which typically require multiple cores within each sideframe end and midsection. The reduced-core sideframe of the present invention offers several distinct advantages over the current multiple-core casting. A primary advantage of using only one core per section (3 cores total per sideframe), is that dimensional consistency is markedly improved, permitting reductions in the cross-sectional thickness of several areas on the sideframe, and doing so without the possibility of the cross-sectional thicknesses becoming too thin, as might occur with present casting techniques. By this, it is meant that with present casting techniques using multiple cores, chaplets are used to hold each core within the mold at a determined, spaced distance from the adjacent core, thereby setting the relevant cross-sectional thickness of the casting. However, during handling of the mold, it is not unusual for the chaplets to shift somewhat, resulting with some of the sideframe cross-sectional thicknesses being cast with either thicker or thinner dimensional tolerances than desired. Due to the ever-present possibility of chaplets and cores shifting, certain sideframe structural areas are intentionally cast with thicker-than-necessary cross-sectional thicknesses in anticipation of a core shifting and leaving a particular member too thin. If a core does not shift, the sideframe cross-sectional thickness will be produced with a thicker-than-necessary dimensions. It follows then that the sideframe will be carrying extra metallic mass, thereby adding to the total weight of the truck. Thus, it can be appreciated that casting a sideframe with either a heavier sideframe than needed or with a sideframe having multiple cores results with inconsistent cross-sectional geometries. Furthermore, the inconsistencies provide stress accumulation areas between non-uniform cross-sectional areas.
It should also be appreciated that fewer cores and fewer chaplets automatically enhances dimensional consistency and stabilizes the structural geometry of the sideframe such that the sideframe cross-sectional thicknesses can be reduced, resulting with a lighter and structurally stronger truck member.
Another major advantage of the present invention is that it substantially stabilizes the mold during handling, thereby eliminating much of the possibility for sand particles to loosen during handling or core shifting and becoming inclusions in the cast metal. Still another advantage is that it eliminates the seam lines which normally form between cores due to the inconsistent cross sections. Eliminating the seam lines will significantly reduce the finishing requirements of the casting and greatly improve the finished appearance. But more importantly, eliminating the seam lines will eliminate the potential for stress risers to occur, because seam lines represent areas where stress accumulations can occur. Moreover, the reducted-core casting mold is considerably cheaper to produce than the current multiple core casting mold because it requires substantially less equipment and manpower to make fewer cores.
BRIEF DESCRIPTIONS OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent from the following detailed descriptions taken in conjunction with the drawings wherein:
FIG. 1 is a top plan view of a railcar truck sideframe according to the present invention;
FIG. 2 is a side elevation view of the sideframe as shown in FIG. 1;
FIG. 2A is a cross-sectional side view taken along line 2A--2A of FIG. 2;
FIG. 2B is a cross-sectional side view taken along line 2B--2B of FIG. 2;
FIG. 2C is a cross-sectional top view taken along line 2C--2C of FIG. 2;
FIG. 3 is a bottom plan view of the sideframe as shown in FIG. 1;
FIG. 4A is a cross-sectional view representing the positioning arrangement of the cores within a casting mold of a prior art sideframe;
FIG. 4B is a cross-sectional view representing the positioning arrangement of a single core arrangement within a casting mold of the present invention;
FIG. 5 is a perspective view of one end of a prior art sideframe showing the multiplicity of cores required to produce that sideframe end;
FIG. 6 is a perspective view of the single core required to produce one end of the sideframe of the present invention.
FIG. 7 is a top view of a prior art sideframe;
FIG. 8 is an elevation view of a prior art sideframe;
FIG. 9 is a bottom view of a prior art sideframe;
FIG. 10 is a cross-sectional sideview taken along line C--C of FIG. 8;
FIG. 11A is a perspective view of a prior art bolster midsection showing the multiplicity of cores required to produce this section of the sideframe;
FIG. 11B is a perspective view of the single core required to produce the midsection of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-3 illustrate the preferred embodiment of a cast steel railcar truck sideframe according to the present invention wherein the sideframe 20 has a longitudinal axis "L" and will generally include an upper or top compression member 30 extending lengthwise of the truck, and a lower tension member 40, generally parallel to upper member 30. Lower member 40 also has upwardly extending diagonal arms 46,48, connecting the upper and lower members together. Vertical column members 53,55 also connect the upper and lower members together, while forming the structural framework necessary for defining bolster opening 25. Each sideframe end, designated at 22 and 24, has a downwardly depending jaw portion 26,28, for retaining the truck axle bearing within the bearing retainer thrust lugs 21 on each jaw. Upwardly extending diagonal arms 46,48 respectively depend from a first end 41 and a second end 42 of lower member 40 such that the respective connection points form respective first and second bend points, 43,45. The base of each vertical column is herein designated as 54,56, and each base is tied into bottom member 40 at the respective bend points 43,45, while a top portion of each column is tied into the bottom wall 32 of upper compression member 30. As previously mentioned, a truck bolster (not shown) will be mounted transversely between the sideframes to form the three-piece truck that is located beneath one end of a railcar body. The bolster ends extend through windows 25 in each respective sideframe 20, and are supported by spring groups (not shown) that rest on a horizontally disposed spring base plate 16 which extends between columns 53,55 and is integrally formed as part of lower tension member 40. The spring group is held in place by a plurality of spring seat bosses 15 integrally cast as part of base plate 16, and the base plate is of a substantial cross-sectional thickness in order to resist the bending moments acting on the plate when the springs are compressed during vertical loading. A pair of damping devices (not shown) are retained on opposite sides of each end of bolster for frictionally engaging a wear plate area 57,58 on each vertical column 53,55 of each sideframe in order to harmonically dampen the energy stored within the springs.
As seen from FIG. 2B, upper member 30 is actually comprised of a top wall 31, bottom wall 32, and arcuate interconnecting sidewalls 33 which define an upper compression member core opening 35 that extends the longitudinal length of sideframe 20, except for the midsection area between the vertical columns. In that area, there is a substantial portion of the bottom wall removed for weight saving purposes, effectively leaving the bottom midsection area "open"; this will become clearer later in the discussion. Each of the upper member walls has a cross-sectional thickness that varies according to the rated truck tonnage. Similarly, bottom tension member 40 is also comprised of a top wall 47, a bottom wall 49, and arcuate interconnecting sidewalls 51 which form a lower tension member core 52. Core opening 52 extends the entire length of member 40, including within the upwardly extending diagonal arms 46,48. Although not shown, it is to be understood that each vertical column 53,55 is defined by cores which vertically extend the entire extent of each column.
Attention is now directed to FIGS. 7-10 where a prior art sideframe is shown. A comparison of that sideframe to the one of the present invention will now be provided so that a clear understanding of the structural differences is gained. The prior art sideframe is also comprised of a top compression member, a bottom tension member, and vertical columns, and like the present invention, prior art sideframes were designed to eliminate as much unneeded metallic mass as possible. Some of the same weight saving features have been retained in the sideframe of the present invention. For example, the figures show that the prior art sideframes were typically constructed with large lightener openings 60,70 in the area of the sideframe generally bounded by the upper and lower members and the column members. These openings represent the greatest amount of weight saved on a sideframe and they have been retained in the present sideframe, referenced by the same numerals.
Other less significant openings on prior art sideframes were provided on specific areas of each sideframe component. For example, FIGS. 7-9 show the upper compression member top wall 31 with lightener openings 80,90 at each pedestal jaw and the bottom wall has with the large openings 100 and 110 in the midsection. Openings 100,110 extend the width of bottom wall 32 such that brace 36 is the only remaining section of bottom wall 32 spanning the midsection area. As mentioned earlier, the midsection of the sideframe is the only area of the upper compression member which does not form an enclosed core opening 35, and this is due to openings 100 and 110. On the lower tension member, the bottom wall has been provided with lightener openings at two locations, illustrated at 120,130 and at 140,150. Openings 120 and 130 are no longer provided on the lower tension member of the present sideframe, and this structural difference will be explained in greater detail below. Openings 140,150 have been retained at the bend points 43,45 on the present invention, and they remain substantially the same dimensional size as before. The present sideframe has also retained a lightener hole at each of the jaw areas, but the holes have been substantially increased in size compared to former openings 80,90. FIG. 10 shows that each of the vertical columns on the prior art sideframe include a core support hole opening 160, which was not specifically intended for weight reducing purposes, but nevertheless, lessened the overall weight of the sideframe. These core support hole openings 160 serve to facilitate positioning of sand cores within molding flasks prior to pouring molten metal into the mold and for assisting in the subsequent removal of the mold after the cast metal cools. The present invention retains this core support hole in the same area, but present core support hole 175 is substantially larger. It should be realized that even though some of the prior art weight savings features have been retained in the present invention, the present invention involves adding additional weight saving holes in unique combinations, actually making the present sideframe lighter, yet stronger than prior art sideframes. The additional weight savings features of the present invention will now be discussed.
It has been identified that the principle area of the sideframe which handles the greatest majority of stress is in the midsection of the sideframe, namely within lower member 40 between the vertical columns 53,55, and within each diagonal arm 46,48. The present invention has investigated this area thoroughly for potential non-stress locations, knowing that the flexure and static forces acting on a sideframe are decreasing as the distance away from the center of the sideframe increases and that the forces acting at the sideframe ends are the lowest in magnitude. The newer lab techniques and the computer analysis programs were collectively used as a means to match the stress concentrations at a given area with the amount of mass in that stress location; this was not done with prior art sideframes. In short, the present invention is concerned with removing mass from areas which have been determined as being non-critical, and adding mass to areas designated as critical, or primary load carrying areas. Taking metallic mass from a non-critical area and then reposturing it to a critical area produces greater structural integrity.
Turning attention now to the sideframe of the present invention shown in FIGS. 1-3, it was determined that the outer pedestal jaws 26,28 experienced the least critical loading stresses and in relation to the mass comprising each jaw, removal of some of that mass was in order. In that respect, if FIGS. 1-3 are comparted with FIGS. 7-10, it is seen that top wall 31 of upper compression member 30 has a much larger lightener hole at the jaw area. The hole generally starts from the bearing thrust lug level 21, and upwardly extends along the curved perimeter of the jaw to a point "P" . FIGS. 2A and 3 show this enlarged area as new lightener holes 185,195, wherein the new holes are about 25% larger in cross-sectional area than a similarly located hole of a prior art sideframe.
Two additional non-critical stress areas on the top compression member top wall were identified and each area was provided with a lightener hole set 205,215 and 225,235. The hole sets are generally disposed between a respective vertical columns 53 or 55 and a respective pedestal jaw 26 or 28. Their location is critical to prevent failure under AAR (American Association of Railroads) specification static tests, which can buckle even solid members in some designs. Each set is identical in shape and dimensional size to each other, however, the holes 205,225, are smaller in dimensional size than their respective partner hole 215 or 235, although the shape of the hole is similar. The holes comprising each of the hole sets are only located in the top wall of the upper member since this keeps all holes under continuous compression during loading, and minimizes the possibility of cracks to propagate.
The present invention also identified non-critical stress areas on the lower tension member 40 as additional areas for reducing mass. The cross sectional thickness of bottom wall 49 was reduced from 0.75 inches to 0.6125 inches, and this thickness was maintained along the entire length of lower member 40. The amount of cross sectional reduction might be different for other sideframe designs, but the relative variations would be roughly the same when applied to different capacity sideframes of the type applicable to this invention. The spring seat plate 16 attached to lower member 40 was reduced in cross sectional thickness from 0.8125 inches to 0.75 inches and additional weight savings was gained when the pair of spaced lightener holes 245,255 was added to the center of plate 16. The holes are laterally displaced from each other and the holes may be varied in size, shape and number, depending upon the specific sideframe design. The holes allow the midsection area to be cast from a single core, ensuring consistent wall cross sectional thicknesses, while decreasing the occurrences of walls being cast too thin, as happens when using past molding practices.
Regarding the diagonal tension members 46 and 48, close scrutiny of the lightener openings 120 and 130 shown on prior art sideframe of FIGS. 7-10, revealed them to be the cause of high stresses. Casting the area solid in the present invention eliminated the high stress condition and the need for special attention to finishing of the former hole edge.
It was also found that filling in the holes in the bottom wall increased the overall the strength of the tension member. This increase was so significant that reinforcing ribs 76,77, which extended beyond the apex of each respective triangular opening 60,70 were removed because they were no longer needed to resist twisting. In addition, the increased strength of the lower tension member allowed removal of additional mass from top wall 47 in the form of a lightener hole, and that mass was roughly equivalent to the mass added through the filling of former openings 120,130. However, instead of providing one large hole in top wall 47, and creating a source of weakness, FIGS. 2 and 2C illustrate that the mass being removed was to be split between a respective pair of lightener holes 265,275 and 285,295. Although FIG. 2C only shows holes 265,275, it should be understood that holes 285,295 on diagonal arm 48 are exactly the same in size and location. Each pair of holes is disposed in a spaced relationship along a respective web lightener hole 60,70. As best seen from the FIG. 2 illustration, each respective lightener hole 60,70 has a generally triangular shape as well as respective leg 71,72, which defines one side of the respective triangular openings. This leg also corresponds to a portion of the top wall 47 of the lower tension member 40. As FIG. 2C illustrates, each respective hole 265,285 is generally centered along its respective leg 71,72 and substantially extends across the width of top wall 47. The other respective holes 275,295 are equal in size and shape to each other and to holes 265,285 and they are an equal distance from its respective partner hole 265 or 285. Holes 275,295 are adjacent to a respective lower comer of the triangularly shaped holes 60 or 70, and extend downwardly along each respective diagonal arm 46 or 48, terminating before reaching either bend point 43 or 45.
FIG. 2B is a cross-sectional view taken along line B--B of FIG. 2 and it shows that additional lightener holes have also been added to each of the vertical column wear plate areas 57,58, in the form of an identical pair of twin lightener hole sets 230 and 240. As seen from the illustration, column 55 contains the rectangularly configured twin holes 240A and 240B. Likewise, column 53 will contain an identical set of twin holes 230A and 230B, even though they are not specifically shown in the illustrations. Each of the twin hole sets on each column are in an opposed, confronting relationship to each other, and each set is disposed between a respective wear plate attachment bore 65 and 67 on each respective column. For the sake of this discussion, only the details of twin holes 240A and 240B will be provided, although the description equally applies to hole set 230.
As FIG. 2B illustrates, holes 240A and 240B are in a laterally spaced relationship from each other, wherein the vertical extent of each hole is about three times greater than the longitudinal extent, with the distance between each hole being designated as "X" . Each hole 240A and 240B is also a laterally spaced distance from a respective column edge 55A or 55B; these distances are respectively designated as "Y" and "Z" . Collectively, the distances "X" , "Y" , and "Z" , approximately equals the width or lateral extent of an individual hole 240A or 240B. Therefore, it necessarily follows that the combined width or lateral extent of both holes 240A and 240B, is about two-thirds of the total width or lateral extent of the sideframe column 55. As mentioned, the other hole set 230 will have similar attributes to hole set 240. In field operation, each of the twin hole sets will be covered by a wear plate (not shown) which is attached to each vertical column by bolting it into bores 65 and 67.
When considering all of the additionally added sideframe holes and the reduced cross sections of the top and bottom walls of the lower tension member and of the spring plate 16, a total sideframe weight savings of approximately between four and ten percent can be realized over a prior art sideframe like that of FIGS. 7-10. The range of weight savings is attributable to the particular type of truck being employed. For example, if a pro-rated 100 ton truck were considered, the final weight savings would amount to about 4% of the original base weight of a 100 ton capacity side frame, or the two trucks would be reduced in weight by about 160 pounds per car. Collectively, significant weight savings are realized when all the cars in a train unit are considered.
The foregoing structural changes have also gone hand-in-hand in making very dramatic changes upon the core making practices in relation to casting the sideframe. For instance, FIG. 5 shows a typical prior art core arrangement when casting one end of a sideframe. In this figure, it is seen that seven cores are required to form each sideframe end, or fourteen cores total per mold, just to make the sideframe ends; the core required to make the midsection will be discussed shortly. However, when casting a sideframe of the present invention, one can see from FIG. 6 that each end of the sideframe can be cast with a single core 500,600 (core 600 is not shown but represents the single core for the other end). Thus, the total requirement of 14 cores in this part of the sideframe can be reduced to only two cores. This substantial reduction in cores is accomplishable due to the fact that several of the added lightener holes, namely holes 185,205, 215, 265,275, and 230 seen in FIGS. 1 and 2 have actually improved the coring arrangement on each sideframe end because the casting mold can now be partially supported through these lightener holes instead of by chaplets, as will be explained below.
In addition to reducing the number of cores in the end section of the sideframe, further core consolidation is accomplished in the midsection area of the sideframe too. This is best understood by comparing FIGS. 11A and 11B, and it should be understood that this comparison generally applies to the sideframe end core reductions also. FIG. 1 1B illustrates that the midsection can be reduced from a total of cores (See FIG. 11A) to only one core. Part of this consolidation is made possible by the inclusion of holes 245 and 255 which are shown in FIGS. 2B and 3. These holes allow the attachment of the bottom center cores 325,335 (#2 BOX COPE and DRAG of FIG. 11) to the spring seat core 365. The attachment means is illustrated and best understood by viewing FIGS. 4A and 4B. FIG. 4A shows how prior molds required separate cores for the spring seat plate 325 and the far bottom center of the sideframe 325,335. It is also seen that the prior system required numerous chaplets 450 to hold the various cores apart from each other. FIG. 4B shows that with the sideframe of the present invention, the additional lightener holes 245,255 in the spring seat plate eliminate the need for the chaplets 450. This is only possible since the cores 325, 335 and 375 are tied together as a single core section 390, which is now part of the single midsection core 400. From a quality control aspect, removal of the chaplets by having only a single core for the sideframe midsection, virtually eliminates the problem of core shifting during mold handling. Although some chaplets are still used between each sideframe end section core and the midsection core, the core shifting problem is virtually eliminated throughout the sideframe mold, thereby virtually eliminating the possibility of a finished sideframe being thicker in cross section on one end compared to the other. As shown, the six midsection area currently uses seven cores, and the lightener holes help reduce the number to just one, large core 400. Thus, the total core consolidation in both sideframe ends and in the midsection of a sideframe of the present invention is reduced from 21 cores to only three cores, 400,500 and 600.
It should be understood that several additional cores are required for adding various appendages to the sideframe although those other cores will not be addressed by this invention; they represent an additional six cores in the manufacturing process. Thus, even with the six additional cores, the present invention significantly reduces the total number of cores in a complete sideframe from 27, to a new total of only nine. The large, single cores used for the sideframe ends and midsection, provide several substantial advantages over a similar casting made from the traditional number of cores. As mentioned earlier, the greatest advantage is related to multiple coring sometimes having a tendency to shift during the handling of the mold. The result is that internal metallic mismatches can be caused in the final casting, and sometimes they are extreme enough to require the casting to be scrapped. Secondly, the single core eliminates the multitude of seam lines which normally result between the faces of multiple cores. Elimination of these seam lines improves the appearance of the final casting, and it reduces the amount of preparatory or finishing work necessary to remove the unsightly lines. Moreover, the elimination of seam lines improves the internal casting quality of the workpiece by either eliminating or greatly reducing the potential for stress risers which tend to form along the entire seam line. Furthermore, a casting made from only nine cores, instead of 27, is considerably cheaper to produce due to substantially lower manpower requirements, equipment costs, and material costs. Those in the casting field know that the tooling costs in creating a single mold, as well as the replacement maintenance necessary for retaining quality standards for each mold is substantial. In addition, far less waste of mold-sand occurs when only one mold has to be formed, and less waste also reduces other interrelated costs such as clean-up labor. Finally, the relative motion between cores in a multiple core casting can actually dislodge some of the sand particles in the core, with these particles ultimately becoming inclusions in the finally-cast metal. As mentioned earlier, inclusions can either potentially become stress concentration areas or simply result in an area on the casting which requires surface clean-up.
The foregoing details have been provided to describe the best motive invention and further variations in modifications may be made without departing from the spirit and scope of the invention which is defined in the following claims.
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A lightweight, cast steel railcar truck sideframe is the result of matching stress levels within each of the sideframe components with an amount of metallic mass necessary to maintain structural integrity during railcar loading. Areas on each component which were found to be low stress accumulation areas have removed mass from them, reducing sideframe weight. The removal of mass is accomplished by adding lightener holes to and/or reducing thickness of the particular component. Areas on each component found to be high stress areas have added mass in order to strengthen the sideframe. Areas with reduced mass far exceed those increased. The lightener holes are uniquely used in the casting mold such that only nine cores are needed when casting the entire sideframe. By using only a total of nine cores instead of twenty-eight, substantial manhour and production costs savings are realized. The nine core mold also improves internal and external casting quality through the stabilization of core geometry, elimination of seam lines and stress riser locations, which means that there will be far less of a chance for defects to occur.
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BACKGROUND OF THE INVENTION
[0001] This non-provisional application claims priority under 35 U.S.C. § 119(a) on Korean Patent Application No. 2006-30969 filed on Apr. 5, 2006 which is herein incorporated by reference.
[0002] 1. Field of the Invention
[0003] The present invention relates to a method for preparing a porous material using nanostructures and a porous material prepared by the method. More specifically, the present invention relates to a method for preparing a porous material using nanostructures by producing nanostructures using a porous template, dispersing the nanostructures in a source or precursor material for the porous material, aligning the nanostructures in a particular direction and removing the nanostructures by etching, and a porous material prepared by the method.
[0004] 2. Description of the Related Art
[0005] Porous materials, through which fluids are allowed to flow, are classified into microporous materials having a pore size of less than 2 nm, mesoporous materials having a pore size ranging from 2 to 50 nm, and macroporous materials having a pore size of more than 50 nm according to the pore size of the porous materials. Of these porous materials, mesoporous materials have a sufficiently large pore size to permit fluids to freely pass therethrough and a relatively large surface area where they are in contact with fluids. Based on these advantages, mesoporous materials have drawn attention as materials for catalysts, catalyst supports, adsorbents, separators and electric double-layer capacitors. Particularly, since nanoporous materials having a mesopore size, which can be synthesized using numerous precursors, can be used in the production of highly functional catalysts, catalyst supports, separators, hydrogen storage materials, adsorbents, photonic crystal bandgap materials, etc., they are currently in the spotlight. Examples of porous materials include inorganic materials, metals, polymers and carbon materials. Of these, carbon materials have superior chemical, mechanical and thermal stability, and are useful in a variety of applications.
[0006] However, it is not easy to prepare porous materials having a structure in which pores are connected to each other. It is particularly difficult to control the pore morphology of porous materials. Under these circumstances, methods for controlling the internal structures (e.g., pore size and porosity) of porous materials using templates have been proposed. For example, a proposal has been made on a method for producing porous carbon structures by filling a carbon precursor into a solid porous silica template, carbonizing the carbon precursor under non-oxidizing conditions, and dissolving the silica template in a HF or NaOH solution to remove the template.
[0007] In addition, a method for producing porous metal oxide spheres using porous polymer beads as templates has been proposed (Template Synthesis and Photocatalytic Properties of Porous Metal Oxide Spheres Formed by Nanoparticle Infiltration, Chem. Mater. 2004, 16, 2281-2292). This method comprises the step of dipping the porous polymer beads in a metal oxide sol. Since the method has an advantage in that porous materials having a uniform size and a regular lattice arrangement can be prepared, it is widely employed for the preparation of porous materials. According to the method, however, the controllable size of the beads is as large as 100 nm to several micrometers. The method has a limitation in preparing porous material having a pore size of a few to a few tens of nanometers. Moreover, the method has a problem in that the shape of pores cannot be controlled because the polymer beads have a spherical shape.
SUMMARY OF THE INVENTION
[0008] Therefore, the present invention has been made in view of the prior art problems, and it is one object of the present invention to provide a method for preparing a porous material using nanostructures by which the size and shape of pores of the porous material are easily controlled and the preparation of the porous material is simplified, leading to a reduction in preparation costs.
[0009] It is another object of the present invention to provide a porous material prepared by the method.
[0010] In accordance with one aspect of the present invention for achieving the above objects, there is provided a method for preparing a porous material using nanostructures, the method comprising the steps of:
[0011] (a) producing nanostructures using a porous template;
[0012] (b) dispersing the nanostructures in a source or precursor material for the porous material;
[0013] (c) aligning the nanostructures in a particular direction; and
[0014] (d) removing the nanostructures by etching.
[0015] The nanostructures used in the preparation of the porous material may be nanorods, nanowires, or nanotubes.
[0016] The step of producing nanostructures may include the sub-steps of:
[0017] i) providing a porous template having a plurality of holes;
[0018] ii) producing nanostructures using the template by a solid-liquid-solid (SLS) or vapor-liquid-solid (VLS) method; and
[0019] iii) removing the template.
[0020] In accordance with another aspect of the present invention, there is provided a porous material prepared by the method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0022] FIG. 1 shows schematic diagrams illustrating the procedure of a method for preparing a porous material using nanostructures according to one embodiment of the present invention;
[0023] FIG. 2 shows schematic diagrams illustrating the procedure of a method for producing nanostructures according to one embodiment of the present invention;
[0024] FIG. 3 is a schematic diagram illustrating the procedure of a method for producing nanostructures by a solid-liquid-solid (SLS) method; and
[0025] FIG. 4 is a schematic diagram illustrating the procedure of a method for producing nanostructures by a vapor-liquid-solid (VLS) method.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The present invention will now be described in greater detail with reference to the accompanying drawings.
[0027] A method for preparing a porous material according to the present invention is characterized by the use of nanostructures produced using a porous template. Specifically, the nanostructures are produced using a porous template having a plurality of holes. Examples of the nanostructures include, but are not limited to, nanowires, nanorods, and nanotubes.
[0028] FIG. 1 shows schematic diagrams illustrating the procedure of a method for preparing a porous material using nanostructures according to one embodiment of the present invention. With reference to FIG. 1 , a porous material is prepared by the following procedure. First, nanostructures are produced using a porous template (step (a)). Then, the nanostructures are dispersed in a source or precursor material for the porous material (step (b)). An electric field is applied to the dispersion to align the nanostructures in a particular direction (step (c)). Finally, the nanostructures are removed by etching, leaving the final porous material (step (d)).
[0029] A more detailed explanation of the respective steps of the method according to the present invention will be provided below.
[0030] Step (a): Production of Nanostructures
[0031] When it is intended to produce nanostructures using a porous template, as shown in FIG. 2 , a porous template having a plurality of long holes in the form of channels is provided, and then nanostructures are produced using the porous template by a solid-liquid-solid (SLS) or vapor-liquid-solid (VLS) method. Finally, the template is removed.
[0032] i) Provision of Porous Template
[0033] Since the size and length of the porous template and the spacing between holes of the template can be appropriately varied during the manufacture of the template, nanostructures suitable for the desired applications can be produced. Accordingly, the pore size, shape and regularity of the final porous material can be easily controlled.
[0034] The template used in the method of the present invention can be made of a material selected from the group consisting of glass, silica, and metal oxides, such as TiO 2 , ZnO, SnO 2 and WO 3 . The porous template may be embedded within a matrix formed of a metal oxide or an insulating polymer.
[0035] The template is basically manufactured by preparing a template preform and extracting a template form from the template preform. The formation of holes is determined depending on the extraction speed and cooling conditions. Particularly, by previously processing the desired hole shape of the preform, a structure in which the initial shape is reduced to a nanometer scale can be attained by extraction.
[0036] Since the diameter and height of the porous template have a high degree of freedom, they can be selected according to the size of a substrate on which nanostructures are grown. It is preferred that the template have a diameter of 1 nm to 1 mm and a height of 100 nm to 1 mm. Depending on the size of the substrate, two or more templates may be used. The diameter of the holes formed within the porous template and spacing between the holes vary depending upon the specification of nanostructures to be produced. It is preferred that the holes have a diameter of 1 to 100 nm and a spacing of 2 nm to 1 μm.
[0037] ii) Production of Nanostructures
[0038] Nanostructures used in the present invention can be made of a metal oxide, a metal nitride, a semiconductor, a metal, a polymer, or carbon nanotubes. Examples of suitable semiconductors include Group II-VI, Group III-V, Group IV-VI, and Group IV compound semiconductors.
[0039] The porous template is placed on a metal catalyst layer overlying a substrate. The metal catalyst layer is formed by coating a substrate with a metal catalyst, e.g., gold (Au). At this time, the substrate may be previously washed by known techniques to remove impurities present thereon.
[0040] As the substrate, there can be exemplified a silicon substrate or a silicon-on-glass substrate.
[0041] The metal catalyst coated on the silicon substrate is not particularly restricted so long as nanostructures can be grown thereon. Non-limiting examples of metal catalysts that can be used in the present invention include Au, Ni, Fe, Ag, Pd, and Pd/Ni. The metal catalyst used in the present invention can be coated in the form of nanoparticles or can be formed into a thin film on the substrate. The metal catalyst layer formed on the substrate preferably has a thickness of 50 nm or less.
[0042] The metal catalyst can be deposited on the substrate by common coating processes, including chemical vapor deposition (CVD), sputtering, e-beam evaporation, vacuum evaporation, spin coating, and dipping.
[0043] After formation of the catalyst layer on the substrate, nanostructures are grown by a solid-liquid-solid (SLS) or vapor-liquid-solid (VLS) method.
[0044] According to the solid-liquid-solid (SLS) method shown in FIG. 3 , nanostructures are produced by condensing silicon diffused from a solid substrate (e.g., silicon substrate) on the surface of the molten catalyst without supply of vapor phase silicon to form a crystal, and growing the crystal.
[0045] On the other hand, according to the vapor-liquid-solid (VLS) method shown in FIG. 4 , silicon nanostructures are produced by condensing a vapor phase silicon-containing species supplied from a high-temperature reaction furnace on the surface of a molten catalyst, such as molten gold, cobalt or nickel, to form a crystal, and growing the crystal.
[0046] Specifically, the solid-liquid-solid (SLS) method employed in the present invention can be carried out by introducing the substrate on which the template is placed into a reaction furnace and heating the substrate while feeding a gas into the furnace to diffuse a source for nanostructures from the substrate, thus completing the production of the nanostructures. At this time, a force can be applied so that the metal present on the substrate is included in the nanostructures upon growth of the nanostructures.
[0047] On the other hand, the vapor-liquid-solid (VLS) method employed in the present invention can be carried out by introducing the substrate on which the template is placed into a reaction furnace and heating the substrate while feeding a gas and a source for nanostructures to produce the nanostructures.
[0048] Specifically, the gas used in the solid-liquid-solid (SLS) and vapor-liquid-solid (VLS) methods can be selected from the group consisting of Ar, N 2 , He, and H 2 , but is not limited thereto.
[0049] Both solid-liquid-solid (SLS) and vapor-liquid-solid (VLS) methods can be carried out under a pressure of 760 torr or less. The solid-liquid-solid (SLS) method can be carried out at a temperature of 800-1,200° C., and the vapor-liquid-solid (VLS) method can be carried out at a temperature of 370-600° C. On the other hand, when it is intended to produce silicon nanowires as the nanostructures by the vapor-liquid-solid (VLS) method, SiH 4 , SiCl 4 or SiH 2 Cl 2 can be used as a source for the silicon nanowires.
[0050] iii) Removal of Template
[0051] After the nanostructures are formed within the holes of the porous template, as shown in FIG. 1 , the template is removed using an etchant, e.g., hydrofluoric acid, to obtain pure nanostructures. Specifically, the removal of the template can be achieved by etching using a solvent selective for the template and the nanostructures.
[0052] Step (b): Dispersion of Nanostructures
[0053] The nanostructures produced using the porous template are dispersed in a source or precursor material for the final porous material. As the source or precursor material for the porous material, there can be used a liquid precursor of a metal, a metal oxide, a polymer or carbon nanotubes, which is similar to the material for the nanostructures. However, the source or precursor material for the porous material must be different from the material for the nanostructures so that the template can be selectively removed during etching.
[0054] The precursor material is dissolved in a dispersion solvent, such as an organic solvent or water, before use. If required, a dispersant may be further added so that the nanostructures are readily dispersed in the precursor solution. The dispersant used herein consists essentially of a head containing a polar group capable of being adsorbed on the surface of quantum dots and an apolar tail capable of being adsorbed to a binder. Examples of preferred dispersants include, but are not limited to, those consisting essentially of a head containing a polar group, e.g., an amine group or its salt, a carboxylic group or its salt, a phosphoric acid group or its salt, a sulfonic acid group or its salt or a hydroxyl group, and a tail selected from polyethylene glycol, polypropylene glycol and C 5 -C 30 alkyl groups. It is preferred that the dispersant be highly compatible with the binder used.
[0055] Step (c): Alignment of Nanostructures
[0056] After the nanostructures are dispersed in the source or precursor material for the porous material, the orientation of the nanostructures is controlled in such a manner that the nanostructures are aligned in a particular direction. The control over the orientation of the nanostructures enables utilization of optical properties, such as mobility of electrons or polarization in a particular direction.
[0057] The alignment of the nanostructures can be achieved by applying an electrical or magnetic field to the dispersion or by mechanically controlling the flow direction of the dispersion medium. For example, the alignment of the nanostructures using the flow direction of the dispersion medium is achieved by the method described in Charles Lieber et al., Science 291 (2001) p 630˜633. This method uses a polymer (PDMS) mold in which channels having a width of from about tens to about hundreds of micrometers and a length of from about hundreds of micrometers to several millimeters are formed. A dispersion of nanostructures in an appropriate dispersion medium (e.g., an organic solvent or water) is sprayed at a high velocity on the channels of the PDMS mold placed on a substrate, and as a result, the nanostructures are aligned in a flow direction of a fluid along the PDMS channels on the substrate. The density per unit area and orientation of the aligned nanostructures can be controlled by varying various factors, e.g., the flow rate of the fluid flowing along the PDMS channels, the retention time of the fluid in the channels, and the chemical properties and composition of the substrate.
[0058] Step (d): Removal of Nanostructures
[0059] Finally, the nanostructures are removed by etching, leaving the final porous material. The etching of the nanostructures can be performed by various processes according to the kind of the material for the nanostructures and the kind of the source or precursor material for dispersing the nanostructures. The selective removal of the nanostructures from the source material can be achieved by etching using a solution selective for the nanostructures and the source material, or calcining.
[0060] For example, nanostructures made of a metal can be etched using nitric or sulfuric acid. Nanostructures made of a metal oxide can be etched using a hydrofluoric acid solution. Nanostructures made of an organic polymeric material can be removed by pyrolysis at a high temperature of 500° C. or higher. For example, when the nanostructures are made of polystyrene, they are thermally decomposed by calcining at 500-550° C. for 6-7 hours, leaving the final porous material.
[0061] In another aspect, the present invention is directed to a porous material prepared by the method. The porous material of the present invention has regularly aligned, highly oriented pores of uniform size. Since the size, shape, orientation, anisotropy and regularity of the pores can be readily controlled, the porous material of the present invention can find a variety of applications, including catalysts, separation systems, low-dielectric constant materials, hydrogen storage materials, photonic crystal bandgap materials, and the like.
[0062] Although the present invention has been described herein with reference to the foregoing embodiments, these embodiments do not serve to limit the scope of the present invention. Accordingly, those skilled in the art to which the present invention pertains will appreciate that various modifications are possible, without departing from the technical spirit of the present invention.
[0063] As apparent from the above description, according to the method of the present invention, a porous material can be easily prepared by the use of nanostructures produced using a porous template. The porous material prepared by the method of the present invention has regularly aligned pores of uniform size. In addition, since the size, shape, regularity, anisotropy and orientation of the pores can be readily controlled, the porous material of the present invention can be utilized in a variety of applications.
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Disclosed herein is a method for preparing a porous material using nanostructures. The method comprises the steps of producing nanostructures using a porous template, dispersing the nanostructures in a source or precursor material for the porous material, aligning the nanostructures in a particular direction, and removing the nanostructures by etching. According to the method, the size, shape, orientation and regularity of pores of the porous material can be easily controlled, and the preparation of the porous material is simplified, leading to a reduction in preparation costs.
Further disclosed is a porous material prepared by the method.
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This application claims the benefit of U.S. Provisional Application No. 60/876,571, filed 21 Dec. 2006, which is incorporated in its entirety as a part hereof for all purposes.
TECHNICAL FIELD
This invention relates to the manufacture of ethers of hydroxy aromatic acids, which are valuable for a variety of purposes such as use as intermediates or as monomers to make polymers.
BACKGROUND
Ethers of aromatic acids are useful as intermediates and additives in the manufacture of many valuable materials including pharmaceuticals and compounds active in crop protection, and are also useful as monomers in the production of high-performance rigid rod polymers, for example, linear rigid oligoanthranilamides for electronic applications [Wu et al, Organic Letters (2004), 6(2), 229-232] and polypyridobisimidazoles and the like [see e.g. Beers et al, High - Performance Fibres (2000), 93-155].
Existing processes to produce 2,5-dialkoxy- and 2,5-diarenoxyterephthalic acid involve stepwise alkylation of 2,5-dihydroxyterephthalic acid to form the corresponding 2,5-alkoxy- and 2,5-diarenoxyterephthalic esters followed by dealkylation of the ester to the acid. An n-hydroxy aromatic acid may be converted to an n-alkoxy aromatic acid by contacting the hydroxy aromatic acid under basic conditions with an n-alkyl sulfate. One suitable method of running such a conversion reaction is as described in Austrian Patent No. 265,244. Yields are moderate to low, productivity is low and a two-step process is necessary.
A need therefore remains for a process by which ethers of aromatic acids can be produced economically and with high yields and high productivity in small- and large-scale operation, and in batch and continuous operation.
SUMMARY
The inventions disclosed herein include processes for the preparation of an ether of an aromatic acid, processes for the preparation of products into which such an ether can be converted, the use of such processes, and the products obtained and obtainable by such processes.
One embodiment of the processes hereof provides a process for preparing an ether of an aromatic acid, the ether being described by the structure of Formula I
wherein Ar is a C 6 ˜C 20 monocyclic or polycyclic aromatic nucleus, R is a univalent organic radical, n and m are each independently a nonzero value, and n+m is less than or equal to 8; comprising
(a) contacting a halogenated aromatic acid such as is described by the structure of Formula II
wherein each X is independently Cl, Br or I, and Ar, n and m are as set forth above, with
(i) a polar protic solvent, a polar aprotic solvent or an alcoholic solvent containing the alcoholate RO − M + (wherein M is Na or K), wherein the polar protic solvent, polar aprotic solvent or alcoholic solvent is either ROH or is a solvent that is less acidic than ROH; (ii) a copper (I) or copper (II) source; and (iii) a ligand that coordinates to copper,
wherein the ligand comprises a Schiff base; to form a reaction mixture;
(b) heating the reaction mixture to form the m-basic salt of the product of step (a), as described by the structure of Formula III;
(c) optionally, separating the Formula III m-basic salt from the reaction mixture in which it is formed; and
(d) contacting the Formula III m-basic salt with acid to form therefrom an ether of an aromatic acid.
Another embodiment of this invention provides a process for preparing a compound, monomer, oligomer or polymer by preparing an ether of an aromatic acid that is described generally by the structure of Formula I, and then subjecting the ether so produced to a reaction (including a multi-step reaction) to prepare therefrom a compound, monomer, oligomer or polymer.
DETAILED DESCRIPTION
This invention provides a process having improved yield and productivity for preparing an ether of an aromatic acid, the ether being described by the structure of Formula I
wherein Ar is a C 6 ˜C 20 monocyclic or polycyclic aromatic nucleus, R is a univalent organic radical, n and m are each independently a nonzero value, and n+m is less than or equal to 8.
On embodiment of the processes hereof proceeds by (a) contacting a halogenated aromatic acid such as is described by the structure of Formula II
wherein each X is independently Cl, Br or I, and Ar, n and m are as set forth above, with
(i) a polar protic solvent, a polar aprotic solvent or an alcoholic solvent containing the alcoholate RO − M + (wherein M is Na or K), wherein the polar protic solvent, polar aprotic solvent or alcoholic solvent is either ROH or is a solvent that is less acidic than ROH; (ii) a copper (I) or copper (II) source; and (iii) a ligand that coordinates to copper,
wherein the ligand comprises a Schiff base; to form a reaction mixture;
(b) heating the reaction mixture to form the m-basic salt of the product of step (a), as described by the structure of Formula III;
(c) optionally, separating the Formula III m-basic salt from the reaction mixture in which it is formed; and
(d) contacting the Formula III m-basic salt with acid to form therefrom an ether of an aromatic acid.
In Formulae I, II and III, Ar is a C 6 ˜C 20 monocyclic or polycyclic aromatic nucleus; n and m are each independently a nonzero value and n+m is less than or equal to 8; R is a univalent organic radical; and in Formula II, each X is independently Cl, Br or I.
The radical denoted by
is an n+m valent C 6 ˜C 20 monocyclic or polycyclic aromatic nucleus formed by the removal of n+m hydrogens from different carbon atoms on the aromatic ring, or on the aromatic rings when the structure is polycyclic. The radical “Ar” may be substituted or unsubstituted; when unsubstituted, it contains only carbon and hydrogen.
One example of a suitable Ar group is phenylene, as shown below, wherein n=m=1.
A preferred Ar group is shown below, wherein n=m=2.
The univalent radical R is a univalent organic radical. Preferably, R is a C 1 ˜C 12 alkyl group or an aryl group. More preferably, R is a C 1 ˜C 4 alkyl group or phenyl. Examples of particularly suitable R groups include without limitation methyl, ethyl, i-propyl, i-butyl, and phenyl. Several other nonlimiting examples of R are shown below:
An “m-basic salt”, as the term is used herein, is the salt formed from an acid that contains in each molecule m acid groups having a replaceable hydrogen atom.
Various halogenated aromatic acids, to be used as a starting material in the process of this invention, are commercially available. For example, 2-bromobenzoic acid is available from Aldrich Chemical Company (Milwaukee, Wis.). It can be synthesized, however, by oxidation of bromomethylbenzene as described in Sasson et al, Journal of Organic Chemistry (1986), 51(15), 2880-2883. Other halogenated aromatic acids that can be used include without limitation 2,5-dibromobenzoic acid, 2-bromo-5-nitrobenzoic acid, 2-bromo-5-methylbenzoic acid, 2-chlorobenzoic acid, 2,5-dichlorobenzoic acid, 2-chloro-3,5-dinitrobenzoic acid, 2-chloro-5-methylbenzoic acid, 2-bromo-5-methoxybenzoic acid, 5-bromo-2-chlorobenzoic acid, 2,3-dichlorobenzoic acid, 2-chloro-4-nitrobenzoic acid, 2,5-dichloroterephthalic acid, 2-chloro-5-nitrobenzoic acid, 2,5-dibromoterephthalic acid, and 2,5-dichloroterephthalic acid, all of which are commercially available. Preferably, the halogenated aromatic acid is 2,5-dibromoterephthalic acid or 2,5-dichloroterephthalic acid.
Other halogenated aromatic acids useful as a starting material in the process of this invention include those shown in the left column of the table below, wherein X═Cl, Br or I, and wherein the corresponding ether of an aromatic acid produced therefrom by the process of this invention is shown in the right column:
(COOH) m —Ar—(X) n I
(COOH) m —Ar—(OR) n II
In step (a), a halogenated aromatic acid is contacted with a polar protic or polar aprotic solvent or alcoholic solvent containing the alcoholate RO − M + , wherein R is as defined above and M is Na or K; a copper (I) or copper (II) source; and a diamine ligand that coordinates to copper.
The alcohol may be ROH, which is preferred, or it may be an alcohol that is not more acidic than ROH. For example, if R is phenyl, such that ROH is phenol, then one nonlimiting example of a less acidic alcohol that can be used in step (a) is isopropanol. Examples of suitable alcohols include without limitation methanol, ethanol,i-propanol, i-butanol, and phenol, with the proviso that the alcohol is either ROH or an alcohol that is not more acidic than ROH.
The solvent may also be a polar protic or polar aprotic solvent or a mixture of protic or polar aprotic solvent. A polar solvent, as used herein, is a solvent whose constituent molecules exhibit a nonzero dipole moment. A polar protic solvent, as used herein, is a polar solvent whose constituent molecules contain an O—H or N—H bond. A polar aprotic solvent, as used herein, is a polar solvent whose constituent molecules do not contain an O—H or N—H bond. Examples of polar solvents other than an alcohol suitable for use herein include tetrahydrofuran, N-methylpyrrolidone, dimethylformamide, and dimethylacetamide.
In step (a), a halogenated aromatic acid is preferably contacted with a total of from about n+m to n+m+1 equivalents of the alcoholate RO − M + per equivalent of halogenated aromatic acid. Between m and m+1 equivalents is needed for forming the m-basic salt and between n and n+1 equivalents is needed for the displacement reaction. It is preferred that the total amount of alcoholate not exceed m+n+1. It is also preferred that the total amount of alcoholate not be less than m+n in order to avoid reduction reactions. One “equivalent” as used in this context is the number of moles of alcoholate RO − M + that will react with one mole of hydrogen ions; for an acid, one equivalent is the number of moles of acid that will supply one mole of hydrogen ions.
As mentioned above, in step (a), the halogenated aromatic acid is also contacted with a copper (I) or (II) source in the presence of a Schiff base ligand that coordinates to copper. The copper source and the ligand may be added sequentially to the reaction mixture, or may be combined separately (for example, in a solution of water or acetonitrile) and added together.
The copper source is a Cu(I) salt, a Cu(II) salt, or mixtures thereof. Examples include without limitation CuCl, CuBr, CuI, Cu 2 SO 4 , CuNO 3 , CuCl 2 , CuBr 2 , CuI 2 , CuSO 4 , and Cu(NO 3 ) 2 . The selection of the copper source may be made in relation to the identity of the halogenated aromatic acid used. For example, if the starting halogenated aromatic acid is a bromobenzoic acid, CuCl, CuBr, CuI, Cu 2 SO 4 , CuNO 3 , CuCl 2 , CuBr 2 , CuI 2 , CuSO 4 , and Cu(NO 3 ) 2 will be included among the useful choices. If the starting halogenated aromatic acid is a chlorobenzoic acid, CuBr, CuI, CuBr 2 and CuI 2 will be included among the useful choices. CuBr and CuBr 2 are in general preferred choices for most systems. The amount of copper used is typically about 0.1 to about 5 mol % based on moles of halogenated aromatic acid.
The ligand may be a Schiff base. The term “Schiff base” as used herein denotes a functional group or type of chemical compound containing a carbon-nitrogen double bond with the nitrogen atom connected to an aryl group or an alkyl group but not to hydrogen, such as shown by the structure of Formula IV. It is typically the condensation product of a primary amine and a ketone or aldehyde, produced by a reaction scheme such as the following:
wherein R 1 , R 2 and R 3 are each independently selected from substituted and unsubstituted C 1 -C 16 n-alkyl, iso-alkyl and tertiary alkyl groups; and substituted and unsubstituted C 6 -C 30 aryl and heteroaryl groups.
In one embodiment, a Schiff base suitable for use herein as the ligand includes a diimine such as described generally by Formula V
wherein A is selected from the group consisting of
R 1 , R 2 , R 3 and R 4 are each independently selected from substituted and unsubstituted C 1 -C 16 n-alkyl, iso-alkyl and tertiary alkyl groups; and substituted and unsubstituted C 6 -C 30 aryl and heteroaryl groups;
R 5 is selected from H, substituted and unsubstituted C 1 -C 16 n-alkyl, iso-alkyl and tertiary alkyl groups; and substituted and unsubstituted C 6 -C 30 aryl and heteroaryl groups; and halogen;
R 6 , R 7 , R 8 and R 9 are each independently selected from H or a substituted or unsubstituted C 1 -C 16 n-alkyl, iso-alkyl or tertiary alkyl group; and
n=0 or 1.
The term “unsubstituted”, as used with reference to an alkyl or aryl group in a Schiff base as described above, means that the alkyl or aryl group contains no atoms other than carbon and hydrogen. In a substituted alkyl or aryl group, however, one or more O or S atoms may optionally be substituted for any one or more of the in-chain or in-ring carbon atoms, provided that the resulting structure contains no —O—O— or —S—S— moieties, and provided that no carbon atom is bonded to more than one heteroatom.
In another embodiment, a suitable diimine for use herein as the ligand includes N,N′-dimesityl-2,3-diiminobutane (such as described generally by Formula VI)
In this instance, n=0, R 1 =R 2 =mesityl, and R 3 and R 4 are taken together to form the CH 3 —C—C—CH 3 moiety bonded to the two nitrogen atoms.
In a further embodiment, a diimine suitable for use herein as the ligand includes N,N′-di(trifluoromethylbenzene)-2,3-diiminoethane (such as described generally by Formula VII)
In this instance, n=0, R 1 =R 2 =(trifluoromethyl)benzyl, and R 3 and R 4 are taken together to form the CH 3 —C—C—CH 3 moiety bonded to the two nitrogen atoms.
A ligand suitable for use herein may be selected as any one or more or all of the members of the whole population of ligands described by name or structure above.
Various copper sources and ligands suitable for use herein may be made by processes known in the art, or are available commercially from suppliers such as Alfa Aesar (Ward Hill, Mass.), City Chemical (West Haven, Conn.), Fisher Scientific (Fairlawn, N.J.), Sigma-Aldrich (St. Louis, Mo.) or Stanford Materials (Aliso Viejo, Calif.).
In various embodiments, the ligand may be provided in an amount of about 1 to about 8, preferably about 1 to about 2, molar equivalents of ligand per mole of copper. In those and other embodiments, the ratio of molar equivalents of ligand to molar equivalents of halogenated aromatic acid may be less than or equal to about 0.1. As used herein, the term “molar equivalent” indicates the number of moles of ligand that will interact with one mole of copper.
In step (b), the reaction mixture is heated to form the m-basic salt of the product of step (a), as described by the structure of Formula III:
The reaction temperature for steps (a) and (b) is preferably between about 40 and about 120° C., more preferably between about 75 and about 95° C. Typically, the time required for step (a) is from about 0.1 to about 1 hour. The time required for step (b) is typically from about 0.1 to about 1 hour. Oxygen may desirably be excluded during the reaction. The solution is typically allowed to cool before optional step (c) and before the acidification in step (d) is carried out.
The m-basic salt of the ether of the aromatic acid is then contacted in step (d) with acid to convert it to the hydroxy aromatic acid product. Any acid of sufficient strength to protonate the m-basic salt is suitable. Examples include without limitation hydrochloric acid, sulfuric acid and phosphoric acid.
In one embodiment, the copper (I) or copper (II) source is selected from the group consisting of CuBr, CuBr 2 and mixtures thereof; the ligand is selected from the group consisting of N,N′-dimesityl-2,3-diiminobutane and N,N′-di(trifluoromethylbenzene)-2,3-diiminoethane; and the copper (I) or copper (II) source is combined with two molar equivalents of the ligand.
The process described above also allows for effective and efficient synthesis of products made from the resulting ethers of aromatic acids such as a compound, a monomer, or an oligomer or polymer thereof. These produced materials may have one or more of ester functionality, ether functionality, amide functionality, imide functionality, imidazole functionality, thiazole functionality, oxazole functionality, carbonate functionality, acrylate functionality, epoxide functionality, urethane functionality, acetal functionality, and anhydride functionality.
Representative reactions involving a material made by the process of this invention, or a derivative of such material, include, for example, making a polyester from the ether of an aromatic acid and either diethylene glycol or triethylene glycol in the presence of 0.1% of ZN 3 (BO 3 ) 2 in 1-methylnaphthalene under nitrogen, according to the method taught in U.S. Pat. No. 3,047,536 (which is incorporated in its entirety as a part hereof for all purposes). Similarly, the ether of an aromatic acid is suitable for copolymerization with a dibasic acid and a glycol to prepare a heat-stabilized polyester according to the method taught in U.S. Pat. No. 3,227,680 (which is incorporated in its entirety as a part hereof for all purposes), wherein representative conditions involve forming a prepolymer in the presence of titanium tetraisopropoxide in butanol at 200˜250° C., followed by solid-phase polymerization at 280° C. at a pressure of 0.08 mm Hg.
The ether of an aromatic acid can also be polymerized with the trihydrochloride-monohydrate of tetraaminopyridine in a condensation polymerization in strong polyphosphoric acid under slow heating above 100° C. up to about 180° C. under reduced pressure, followed by precipitation in water, as disclosed in U.S. Pat. No. 5,674,969 (which is incorporated in its entirety as a part hereof for all purposes); or by mixing the monomers at a temperature from about 50° C. to about 110° C., and then 145° C. to form an oligomer, and then reacting the oligomer at a temperature of about 160° C. to about 250° C. as disclosed in U.S. Provisional Application No. 60/665,737, filed Mar. 28, 2005 (which is incorporated in its entirety as a part hereof for all purposes), published as WO 2006/104974. The polymer that may be so produced may be a pyridobisimidazole-2,6-diyl(2,5-dialkoxy-p-phenylene) polymer or a pyridobisimidazole-2,6-diyl(2,5-diareneoxy-p-phenylene) polymer such as a poly(1,4-(2,5-diareneoxy) phenylene-2,6-pyrido[2,3-d: 5,6-d′]bisimidazole) polymer. The pyridobisimidazole portion thereof may, however, be replaced by any one or more of a benzobisimidazole, benzobisthiazole, benzobisoxazole, pyridobisthiazole and a pyridobisoxazole; and the 2,5-dialkoxy-p-phenylene portion thereof may be replaced by an alkyl or aryl ether of one or more of isophthalic acid, terephthalic acid, 2,5-pyridine dicarboxylic acid, 2,6-naphthalene dicarboxylic acid, 4,4′-diphenyl dicarboxylic acid, 2,6-quinoline dicarboxylic acid, and 2,6-bis(4-carboxyphenyl)pyridobisimidazole, wherein such an ether is produced according to the methods disclosed herein.
The polymer prepared in such manner may, for example, contain one or more of the following units:
pyridobisimidazole-2,6-diyl(2,5-dialkoxy-p-phenylene) and/or pyridobisimidazole-2,6-diyl(2,5-diphenoxy-p-phenylene) units;
units selected from the group consisting of pyridobisimidazole-2,6-diyl(2,5-dimethoxy-p-phenylene), pyridobisimidazole-2,6-diyl(2,5-diethoxy-p-phenylene), pyridobisimidazole-2,6-diyl(2,5-dipropoxy-p-phenylene), pyridobisimidazole-2,6-diyl(2,5-dibutoxy-p-phenylene) and pyridobisimidazole-2,6-diyl(2,5-diphenoxy-p-phenylene);
pyridobisthiazole-2,6-diyl(2,5-dialkoxy-p-phenylene) and/or pyridobisthiazole-2,6-diyl(2,5-diphenoxy-p-phenylene) units;
units selected from the group consisting of pyridobisthiazole-2,6-diyl(2,5-dimethoxy-p-phenylene), pyridobisthiazole-2,6-diyl(2,5-diethoxy-p-phenylene), pyridobisthiazole-2,6-diyl(2,5-dipropoxy-p-phenylene), pyridobisthiazole-2,6-diyl(2,5-dibutoxy-p-phenylene) and pyridobisthiazole-2,6-diyl(2,5-diphenoxy-p-phenylene);
pyridobisoxazole-2,6-diyl(2,5-dialkoxy-p-phenylene) and/or pyridobisoxazole-2,6-diyl(2,5-diphenoxy-p-phenylene) units;
units selected from the group consisting of pyridobisoxazole-2,6-diyl(2,5-dimethoxy-p-phenylene), pyridobisoxazole-2,6-diyl(2,5-diethoxy-p-phenylene), pyridobisoxazole-2,6-diyl(2,5-dipropoxy-p-phenylene), pyridobisoxazole-2,6-diyl(2,5-dibutoxy-p-phenylene) and pyridobisoxazole-2,6-diyl(2,5-diphenoxy-p-phenylene);
benzobisimidazole-2,6-diyl(2,5-dialkoxy-p-phenylene) and/or benzobisimidazole-2,6-diyl(2,5-diphenoxy-p-phenylene) units;
units selected from the group consisting of benzobisimidazole-2,6-diyl(2,5-dimethoxy-p-phenylene), benzobisimidazole-2,6-diyl(2,5-diethoxy-p-phenylene), benzobisimidazole-2,6-diyl(2,5-dipropoxy-p-phenylene), benzobisimidazole-2,6-diyl(2,5-dibutoxy-p-phenylene) and benzobisimidazole-2,6-diyl(2,5-diphenoxy-p-phenylene);
benzobisthiazole-2,6-diyl(2,5-dialkoxy-p-phenylene) and/or benzobisthiazole-2,6-diyl(2,5-diphenoxy-p-phenylene) units;
units selected from the group consisting of benzobisthiazole-2,6-diyl(2,5-dimethoxy-p-phenylene), benzobisthiazole-2,6-diyl(2,5-diethoxy-p-phenylene), benzobisthiazole-2,6-diyl(2,5-dipropoxy-p-phenylene), benzobisthiazole-2,6-diyl(2,5-dibutoxy-p-phenylene) and benzobisthiazole-2,6-diyl(2,5-diphenoxy-p-phenylene);
benzobisoxazole-2,6-diyl(2,5-dialkoxy-p-phenylene) and/or benzobisoxazole-2,6-diyl(2,5-diphenoxy-p-phenylene) units; and/or
units selected from the group consisting of benzobisoxazole-2,6-diyl(2,5-dimethoxy-p-phenylene), benzobisoxazole-2,6-diyl(2,5-diethoxy-p-phenylene), benzobisoxazole-2,6-diyl(2,5-dipropoxy-p-phenylene), benzobisoxazole-2,6-diyl(2,5-dibutoxy-p-phenylene) and benzobisoxazole-2,6-diyl(2,5-diphenoxy-p-phenylene).
EXAMPLES
The advantageous attributes and effects of the processes hereof may be seen in a laboratory example, as described below. The embodiments of these processes on which the example is based are representative only, and the selection of those embodiments to illustrate the invention does not indicate that conditions, arrangements, approaches, steps, techniques, configurations or reactants not described in the example are not suitable for practicing these processes, or that subject matter not described in the example is excluded from the scope of the appended claims and equivalents thereof.
As used herein, the term “conversion” refers to how much reactant was used up as a fraction or percentage of the theoretical amount. The term “selectivity” for a product P refers to the molar fraction or molar percentage of P in the final product mix. The conversion multiplied by the selectivity thus equals the maximum “yield” of P; the actual or “net” yield will normally be somewhat less than this because of sample losses incurred in the course of activities such as isolating, handling, drying, and the like. The term “purity” denotes what percentage of the in-hand, isolated sample is actually the specified substance.
The meaning of abbreviations is as follows “h” means hour(s), “mL” means milliliter(s), “g” means gram(s), “MeOH” means methanol, “mg” means milligram(s), “mmol” means millimole(s), and “mol equiv” means molar equivalent.
Example 1
In an air and moisture free environment, 4.2 g (77 mmol) of sodium methoxide is combined with 125 g of anhydrous methanol, followed by the addition of 5 g (15 mmol) of 2,5-dibromoterephthalic acid. Separately, 103 mg (0.03 mol equiv) of CuBr 2 and 0.06 mol equiv of N,N′-dimesityl-2,3-diiminobutane
are combined under nitrogen, followed by addition of anhydrous methanol to dissolve. This solution is then added to form the reaction mixture. The reaction mixture is heated to reflux with stirring for 8 h, remaining under a nitrogen atmosphere. After cooling, the product is filtered, washed with hot MeOH and dried to yield a white solid as the bis-sodium salt. The isolated salt is then acidified with hydrochloric acid. The purity is over 95% and the net isolated yield is over 90%.
Each of the formulae shown herein describes each and all of the separate, individual compounds that can be formed in that formula by (1) selection from within the prescribed range for one of the variable radicals, substituents or numerical coefficents while all of the other variable radicals, substituents or numerical coefficents are held constant, and (2) performing in turn the same selection from within the prescribed range for each of the other variable radicals, substituents or numerical coefficents with the others being held constant. In addition to a selection made within the prescribed range for any of the variable radicals, substituents or numerical coefficents of only one of the members of the group described by the range, a plurality of compounds may be described by selecting more than one but less than all of the members of the whole group of radicals, substituents or numerical coefficents. When the selection made within the prescribed range for any of the variable radicals, substituents or numerical coefficents is a subgroup containing (i) only one of the members of the whole group described by the range, or (ii) more than one but less than all of the members of the whole group, the selected member(s) are selected by omitting those member(s) of the whole group that are not selected to form the subgroup. The compound, or plurality of compounds, may in such event be characterized by a definition of one or more of the variable radicals, substituents or numerical coefficents that refers to the whole group of the prescribed range for that variable but where the member(s) omitted to form the subgroup are absent from the whole group.
Where a range of numerical values is recited herein, the range includes the endpoints thereof and all the individual integers and fractions within the range, and also includes each of the narrower ranges therein formed by all the various possible combinations of those endpoints and internal integers and fractions to form subgroups of the larger group of values within the stated range to the same extent as if each of those narrower ranges was explicitly recited. Where a range of numerical values is stated herein as being greater than a stated value, the range is nevertheless finite and is bounded on its upper end by a value that is operable within the context of the invention as described herein. Where a range of numerical values is stated herein as being less than a stated value, the range is nevertheless bounded on its lower end by a non-zero value.
In this specification, unless explicitly stated otherwise or indicated to the contrary by the context of usage, amounts, sizes, ranges and other quantities and characteristics recited herein, particularly when modified by the term “about”, may but need not be exact, and may also be approximate and/or larger or smaller (as desired) than stated, reflecting tolerances, conversion factors, rounding off, measurement error and the like, as well as the inclusion within a stated value of those values outside it that have, within the context of this invention, functional and/or operable equivalence to the stated value.
Where an embodiment of this invention is stated or described as comprising, including, containing, having, being composed of or being constituted by certain features, it is to be understood, unless the statement or description explicitly provides to the contrary, that one or more features in addition to those explicitly stated or described may be present in the embodiment. An alternative embodiment of this invention, however, may be stated or described as consisting essentially of certain features, in which embodiment features that would materially alter the principle of operation or the distinguishing characteristics of the embodiment are not present therein. A further alternative embodiment of this invention may be stated or described as consisting of certain features, in which embodiment, or in insubstantial variations thereof, only the features specifically stated or described are present.
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The inventions disclosed herein include processes for the preparation of an ether of an aromatic acid, processes for the preparation of products into which such an ether can be converted, the use of such processes, and the products obtained and obtainable by such processes. A key feature of the processes described is the use of a solvent comprising an alcohol ROH and an alcoholate RO − M + .
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is related to U.S. Patent Application Publication No. US 2010/0074623 A1, the disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to optical network signals and more particularly to signaling protocols for multi-domain optical networks.
BACKGROUND OF THE INVENTION
[0003] There are numerous difficulties in setting up optical connections in a multi-domain Wavelength Division Multiplex (WDM) optical network. Multi-Domain means that there are interconnected optical network domains. Each optical network domain is operated by a different administrative entity; typically each administrative entity is a telecommunications carrier. A multi-domain optical network requires setting up point-to-point optical connections that have their end-points in different domains. One important goal is to be able to set up end-end multi-domain connections very quickly (e.g., ranging from 100 ms to a few seconds). Another important goal is that within each domain it is desired to have the connectivity be as much all-optical as possible. However, the optical channel interconnection between domains must go through Optical-Electrical-Optical (OEO) processing on each end of a link connecting two domains. This is because the OEO functionality optically isolates the two domains from one another. Within a domain, OEO is used to do wavelength conversion or regeneration as described below. The OEO functionality at one end of a link is provided by two back-to-back transponders. The optical connection between domains is called an External Network Node Interface (E-NNI) and has been standardized by the Optical Internetworking Forum (OIF).
[0004] Within a domain, the optical network consists of optical switches, fiber connecting the optical switches, and WDM technology used to carry multiple wavelengths (optical channels) in a fiber. The optical switches are either Reconfigurable Optical Add-Drop Multiplexers (ROADMs) or Optical Cross Connects (OXCs). ROADMs can be viewed as small OXCs (i.e., they connect to a small number of fibers). ROADMs and OXCs have add/drop ports that connect to client ports, and optical connections between client add/drop ports are set up through the ROADM and OXC optical switching fabrics. An optical connection is set up through multiple fibers. A basic connection within a domain consists of a single wavelength channel, and the frequency of the wavelength channel is the same frequency in each fiber the connection goes through. The ROADMs and OXCs cross-connect the wavelength used by the connection from one fiber to the other. In order for a single wavelength to be used from domain border node to domain border node for a connection, there must be a fiber path between the domain border nodes that has that wavelength available on each fiber in the path (i.e., it is not being used for another connection on any of the fibers along the fiber path). This is known as the “Wavelength Continuity Constraint” (WCC).
[0005] If within a domain a single wavelength is not available in each fiber along a fiber path, the connection can be established using wavelength conversion (OEO) within the ROADMs or OXCs connecting two fibers that require different wavelengths. However, not every node will support dynamic provisioning of transponders, so wavelength conversion can only be done at nodes equipped with transponder pools. It is desirable to minimize the amount of wavelength conversion required, since the transponders used to do the wavelength conversion are expensive. A wavelength conversion requires two back-to-back transponders. Thus, an important part of setting up optical connections within a domain is having information available to be able to determine what wavelengths are available in the different fibers and what OXCs/ROADMs have available transponders to do the OEO wavelength conversion. This information is needed to efficiently set up optical connections within a domain.
[0006] Another aspect of setting up optical connections is that some services provide restoration or 1+1 protection after a failure (e.g., fiber cut) causes the working channel to fail. One type of restoration is known as end-to-end “Shared Mesh Restoration.” In this method of restoration an end-to-end restoration path that is diverse from the working path is determined as part of the connection provisioning process. The restoration paths are only set up after a failure occurs, so if two working connections do not share any failure modes, they can both “share” the same restoration resources. Thus, for provisioning connections using shared mesh restoration, it is important to be able to identify what wavelengths on different fibers can be shared for restoration.
[0007] In 1+1 protection a working path and a diverse, dedicated protection path are set up. When a failure occurs on the working path, both ends of the connection switch to the diverse protection path. Thus, when a 1+1 connection is set up, both a working path and a diverse protection path must be determined and set up.
[0008] Another important aspect of the problem of setting up optical connections is that routing must be done to determine what route a connection will take (if a shared mesh restoration path or 1+1 protection path is to be provided, then that diverse restoration/protection path must also be determined). It must be determined what domains will be used to provide the connection (and restoration/protection) path, what border nodes will be used to go in and out of each domain, and what route will be used in each domain to connect the chosen border nodes (or a connection end node and a border node). An important constraint is that network operators want to keep their network topology and capacity usage information private, so detailed routing information (network topology and network state) cannot be shared across domains, and detailed routing information within a domain must be generated and kept within that domain.
[0009] There have been previous approaches to routing and setting up connections in a multi-domain optical network. There are two basic approaches that have been used to determine the routing of the working and restoration/protection paths. One is called the Per-Domain Approach and the other is called the Backward Recursive Path Computation (BRPC) approach. In either approach the methods assume that for a particular source-destination node-pair there is a pre-determined sequence of domains (Domain 1 , 2 , . . . N) and candidate domain border nodes that will be used for determining the working paths.
[0010] Paths are computed using link cost metrics, and minimum cost paths are computed. For working paths the metric is typically based on the latest recorded spare capacity on the link and link weighting factors the carrier assigns to the link. The link routing information is sometimes distributed by a domain routing protocol such as OSPF-TE (IETF RFC 4203). Route computation can either be done by the domain border nodes or by a Path Computation Element (PCE). In multi-domain networks a PCE is usually used since it can more easily communicate with other domain PCEs. For the previous methods described here, all routing is done by PCEs.
[0011] In the per-domain approach the path computation is done one domain at a time, starting at the source node. First a minimum cost working path from the source node to each of the candidate domain border nodes is determined, and the border node having the least cost path is chosen. This determines the egress border node from the source domain and the candidate ingress border nodes in the next domain that will be used. In the next domain, an optimal path from each candidate ingress border node to each candidate egress border node is determined. The minimum cost ingress node to egress node path is chosen for traversing that domain. This process is continued from domain to domain until the destination domain is reached. At the destination domain, a minimum cost path is determined from the ingress border node to the destination node. Note that this methodology does not necessarily find the minimum cost end-to-end path.
[0012] In the BRPC approach, the process begins at the destination node in Domain N. Minimum cost paths are computed from each potential ingress border node to destination D. This gives a Virtual Shortest Path Tree (VSPT) between the border nodes of Domain N and Destination D. This VSPT is attached to the candidate egress border nodes of the previous domain, Domain (N−1). Minimum cost paths from each ingress border node of Domain (N−1) to destination D are then computed. This gives a VSPT from Domain (N−1) ingress nodes to destination D. This is done recursively until a minimum cost path from the source to destination is determined.
[0013] RSVP-TE signaling, extended for GMPLS (RFC 3473), is used to establish the connections, which includes determining what wavelengths will be used and where wavelength conversion needs to be done. This is done after the routing has been done, so the routing decisions described above do not consider wavelength conversion requirements.
[0014] The prior solutions, however, has failed to completely solve the problem of setting up optical connections in a multi-domain network. In previous solutions, for each connection request a multi-domain routing function must be performed to determine the working path and, when restoration or 1+1 protection is provided, a restoration/protection path. After that routing work is done, signaling must be done to set up the working path. In the previous methods, this routing function takes significant time (e.g., hundreds of ms) and would not be able to meet setup times on the order of 100 ms.
[0015] Most of the previous solutions do not include providing shared restoration or 1+1 protection capability. One prior approach attempts to enhance the BRPC approach to include computation of a 1+1 protection path. Also, the 1+1 method used in previous work requires the protection path to go through the same domains as the working path.
[0016] Another prior approach uses solutions that provide shared restoration within the domains, but this methodology does not protect against failure of border nodes or failure of links connecting border nodes (i.e., links connecting two domains). Thus, additional capabilities are needed to provide full protection of working connections.
[0017] None of the previous solutions address the optimization of the use of wavelength conversion within a domain when the Wavelength Continuity Constraint (WCC) cannot be satisfied end-to-end within a domain. For example, one prior solution blocks connection requests when the WCC cannot be met. It is widely recognized that wavelength conversion capability is essential in optical networks in order to get efficient use of the optical resources. However, wavelength conversion requires expensive transponders, and so it is highly desirable to have provisioning methods that can minimize the amount of wavelength conversion required.
[0018] A multi-domain optical network provisioning methodology that keeps resource information private in each domain, but optimizes connection setup equivalent to full information sharing across domains is disclosed.
SUMMARY OF THE INVENTION
[0019] A multi-domain optical network provisioning methodology that keeps resource information private in each domain, but optimizes connection setup equivalent to full information sharing across domains is disclosed. The present invention considers both shared mesh restoration and dedicated 1+1 protection. Shared mesh restoration is much more efficient than dedicated 1+1 protection, but 1+1 protection has a faster recovery time than shared mesh restoration. The present invention provides the capability to minimize the amount of wavelength conversion required. In optical networks providing shared mesh restoration or 1+1 protection, it is desirable to consider many possible paths for the working and restoration/protection paths, and optimize the choice of what paths to use for working and restoration/protection so as to minimize the total resources consumed for the connection. For working path choices it is desirable to minimize the path length and the amount of wavelength conversion required. For the shared restoration path it is desirable to use as much shared capacity as possible, so the amount of additional wavelength capacity reserved for restoration is minimized. For the 1+1 working and protection path choices it is desirable to minimize the combined working and protection path length and the combined working and protection path use of wavelength conversion. The present invention collects information that allows these resource usage considerations to be made. In addition, the present invention collects information in each domain and passes on summary information for each domain so that an optimal choice of end-to-end working and restoration/protection paths can be made that is equivalent to what can be achieved with a centralized entity (e.g., a PCE) having a global view of the multi-domain network state. This is highly significant, because the constraint that detailed topology and network state information cannot be shared across domains precludes such a centralized capability. Thus, the present solution achieves a centralized global optimality without violating the sharing of information across domains.
[0020] The present invention, in one exemplary embodiment, is directed to a method for optical signaling message processing in a multi-domain optical network, each domain having one or more border nodes, one or more intermediate nodes and a plurality of links connecting the nodes to form a plurality of paths through the domain. The method comprising the steps of sending first pass signaling messages from a source node in a source domain to a destination node in a destination domain through one or more intermediate domains, the first pass signaling messages being sent on a plurality of candidate diverse domain border node paths, each border node path having a unique path topology. The first pass signaling messages comprises collecting first pass information identifying available working and restoration resources for each candidate border node path. For a particular domain and pair of border nodes there can be multiple paths connecting the two border nodes. A Pass 1 signaling message is sent on each of the paths to collect working and restoration resource information. The exit border node computes a working and restoration metric for each path. It then determines the best working and restoration path metric. It then composes a Pass 1 signaling message to the next domain border node in the border node path being probed. The Pass 1 signaling message contains a Path Key for the best working path and its working path metric. The Pass 1 message also contains a Path Key for the best restoration path and its restoration path metric. The Path Keys provide the means to identify a path and it's metric outside the domain without providing any detailed network topology information. The Pass 1 signaling message continues to gather Path Key and working and restoration metrics along the border node path, and at the destination domain the destination node receives all of the Pass 1 working and restoration metric information (including information for the destination domain between the border node and the destination node). With this collected information from all probed border node paths, the destination node can determine the best working and restoration border node paths to use for a shared mesh restoration connection, and it can determine the best pair of border node paths to use for a 1+1 protected connection.
[0021] The method further comprises sending a second pass signaling message from the destination node to the source node along the selected domain working paths and selected border nodes using the path keys to identify the chosen paths for each domain, the second pass signaling message reserving the identified routing resources within the selected domain working paths and selected border nodes, determining at the source node which of the identified signaling message routing resources were successfully reserved, and selecting at the source node which successful identified routing resources to use.
[0022] The method also comprises sending a third pass signaling message from the source node to the destination node along the selected domain working paths and selected border nodes identifying the selected routing resources, and establishing an optical path between the source node and the destination node along the selected domain working path and selected border nodes using the selected routing resources.
[0023] In another embodiment, the method includes, for shared mesh restoration, a second pass signaling message reserving restoration resources for the identified working resources, determining at the source node which restoration routing resources were successfully reserved, and selecting at the source node which successful restoration routing resources to use, identifying the selected resources during the third pass signaling message, and using the selected restoration resources for restoring the working connection in the event of a failure.
[0024] In a further embodiment, the method includes for a 1+1 protected connection during the first pass signaling message, for each candidate domain working path for each domain, collecting information relating to 1+1 protection capacity, calculating a domain 1+1 protection metric representing the collected 1+1 protection capacity information and storing each of the domain 1+1 protection metrics at the respective border node within each candidate working path in each domain, determining at the destination node a selected 1+1 protection path from one of the candidate 1+1 protection paths to use in each domain based on the 1+1 protection path metrics from each domain, sending a 1+1 protection pass signaling message from the destination node to the source node along the selected 1+1 protection path, and reserving 1+1 protection resources within each domain using the domain path key for the selected 1+1 protection path.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] These and other features, benefits, and advantages of the present invention will become apparent by reference to the following figures, with like reference numbers referring to like structures across the views, wherein:
[0026] The FIGURE is a schematic illustration which illustrates the method according to the present invention.
DETAILED DESCRIPTION
[0027] The FIGURE shows an illustration of a multi-domain network. There are five domains (A, B, C, D, and E) each illustrated as a network within a cloud. Domain border nodes 2 are represented as black circles, and domain interior nodes (non-border nodes) 4 are represented as shaded circles. Border nodes are used to connect from one domain to another. Connections between border nodes in different domains are represented by links 6 . As indicated above, these links are known as E-NNI links, and OEO processing is done on each end of the E-NNI link. Therefore there is no need to consider maintaining wavelength continuity between these links and links they connect to within a domain. The present invention is concerned with how to quickly set up wavelength connections between two nodes in different domains. A wavelength connection can consist of one or more wavelength channels. For purposes of simplicity only, the specification will restrict description to setting up a single wavelength channel.
[0028] In one embodiment, the methodology assumes that there are pre-computed domain-to-domain paths. The domain-to-domain paths are identified by the sequence of border nodes they go through. For example, there may be four domain-to-domain paths connecting Domain A and Domain E. This embodiment also assumes at there are pre-computed paths from each interior node to each domain border node and there are pre-computed paths between all border node pairs in a domain. When a connection request arrives for a wavelength connection, between a source node, Node A in Domain A, and a destination node, Node Z in Domain E, it must be determined what A-to-Z working path will be used and what A-to-Z diverse restoration path or 1+1 protection path will be used for the connection.
[0029] Consider first the working path. It must be determined what border node path will be used, what path from Node A to the chosen border node in Domain A to use, what path to use between border nodes in each intermediate domain and what path to use from the border node in Domain E to Node Z. Similarly, an end-end (A to Z) restoration path or 1+1 protection path must be determined that is diverse from the working path.
[0030] The multi-domain signaling procedure of the present invention is a 3-way handshake (3WHS) process that involves three passes of signaling messages. In Pass 1 , signaling messages (called Pass 1 messages) are sent from Node A to Node Z on each candidate border node path to collect information on the available resources in each domain. When all of the Pass 1 messages arrive at Node Z, it determines, based on the collected resource information, which border node path to use for the working path and which to use for the restoration path. Node Z also determines the specific intra-domain working path and restoration or 1+1 protection path to use from Node Z to the selected working and restoration/protection border nodes in its domain. Node Z then sends Pass 2 signaling messages back to Node A on the selected working and restoration/protection paths to reserve resources and initiate switch cross-connects on the working path. Extra resources are reserved on the working and 1+1 protection path in Pass 2 to protect against blocking due to a selected resource from being occupied by another connection before the Pass 2 message can reserve them. When the working path Pass 2 messages reach Node A, it will know which connection reservations were successful, and it will choose which successful connections to use. If 1+1 protection is being used, Node A will know which 1+1 protection reservations were successful, and it will choose which successful connections to use. Node A then sends a working path Pass 3 message to Node Z indicating the selected resources. In addition the working path Pass 3 message signals the release of any extra reserved resources that are not needed. Node A also sends a Pass 3 restoration/protection path message indicating the success or failure of reserving resources on the restoration path or the 1+1 protection path. The detailed 3WHS procedures are described below.
[0031] The FIGURE illustrates the 3WHS procedure of the present invention with respect to a connection setup between Node A in Domain A and Node Z in Domain E. In this exemplary embodiment, two border paths are used. Node A sends a Pass 1 signaling message to each of the two border nodes 8 , 10 . To simplify the discussion, we assume in this example that, for each of the border nodes, Node A uses a single path from itself to the border node. In the general case there can be multiple paths from Node A to each border node, each is probed with a Pass 1 message, and an optimal choice of which path to use is made at the border node based on the collected Pass 1 information. The Pass 1 signaling messages will follow paths 12 , 14 to the border nodes 8 , 10 respectively. Each Pass 1 message collects for each link on its path to the border nodes the available wavelengths on each link and the available transponders at each node. Also for each link it collects the amount of capacity currently reserved for restoration and the identification of the failure modes that would require all of the reserved capacity on the link to be used for restoration. The failure mode identification labels are called Shared Risk Link Groups, or SRLGs. If a new working path being set up is using a particular link, in its restoration path and that working path does not have any of the SRLGs that require all of the link reserved capacity to be used, then no additional reserve capacity is needed on the link to protect the new working path. If the new working path does have an SRLG that currently requires all of the link's reserve capacity, then an additional channel will need to be reserved for restoration on the link to protect the new working path connection. Thus, the SRLG information collected by the Pass 1 message will allow restoration metrics to be computed as described below.
[0032] When each of the Pass 1 messages reach their border node, the border node computes a working path metric and a restoration path metric for the path traversed. The working path metrics are the lightpath km from Node A to the border node along the path and the minimum number of wavelength converters required (based on the available wavelengths on each link) to establish a lightpath from Node A to the border node. For 1+1 protection, the 1+1 protection metric is the same as the working path metric. The restoration metric is a list of the SRLGs that require all the reserved capacity on one or more links, and associated with each of the SRLGs on the list is the total link km of those links for which that SRLG requires all their reserved capacity if that SRLG fails. This working and restoration metric information is stored at the border nodes. In addition, each of the Node A to border node paths 12 , 14 has a Path Key to be used for path identification outside the domain. One example of a Path Key mechanism to preserve topology confidentiality is defined in IETF RFC 5520. Thus, by using path keys, the path metric information can be disseminated outside the domain without identifying any specific network topology information. It is noted that the border nodes do not put specific wavelength information in the Pass 1 messages it sends to the next domain. The border node stores the wavelength choices it has made for its domain working paths and 1+1 protection paths.
[0033] The next step is that a Pass 1 message is composed at each of the border nodes 8 , 10 to be sent to the border nodes 16 , 18 in the next domain (Domain C). Each Pass 1 message contains the path key for the path from the border node in Domain A to Node A and the working and restoration metrics for that Domain A path. From node 16 there are two paths 20 , 22 to the next border node 24 . The Pass 1 message is replicated and one copy is sent along Path 20 and the other along Path 22 . These Path 1 messages pick up, as before, the available wavelengths on each link, the number of transponders available at each node, the reserved restoration capacity on each link and the SRLGs that require all of the reserved capacity if they fail. When the Pass 1 messages reach the border node 24 , the working and restoration metrics are computed for paths 20 and 22 in the same manner as described above for Domain A. The wavelength choices on each link and where wavelength conversion is done is stored at node 24 . Then a Pass 1 message is composed to be sent to the next border node in Domain E. The Path 1 message contains the Path 20 working and restoration metrics and an associated Path Key representing Path 20 . The Path 1 message also contains the Path 22 working and restoration metrics and an associated Path Key representing Path 22 .
[0034] There is also a Pass 1 message sent from Node 18 to Node 26 in Domain C, and this message picks up the working and restoration metric information along that Domain C path. Analogous to the Path 20 and Path 22 cases, the wavelength choices on each link and where wavelength conversion is done is stored at Node 26 . Also, the Node 18 to Node 26 path working and restoration metric information is stored at Node 26 and placed in a Pass 1 message to be sent to the next border node in Domain E. Again, path keys are used to identify the paths within Domain C, so no specific topology information is sent outside a domain.
[0035] The process continues in Domain E, where the two border nodes 28 , 30 receive the Pass 1 signaling messages and send them on the indicated paths to Node Z. Node Z then has a Pass 1 message for each of the three probed A-to-Z paths. For each path it has working and restoration metric information. Note that working metric information is used for determining the path metric for working paths and 1+1 protection paths. From this collected metric information, Node Z can determine a diverse working and restoration path pair (or a diverse working and 1+1 protection path pair) that minimizes a total path pair metric. For example, for working path metrics and 1+1 protection path metrics, the total wavelength-km of the path plus an equivalent wavelength-km for each wavelength converter or regenerator can be used to determine an overall working/protection wavelength-km metric for the path. For a restoration path metric, the total additional wavelength-km of reserved capacity required can be used. Node Z can then consider each possible diverse path pair and compute a combined working plus restoration/protection metric, and choose the path pair that has the lowest metric. This process also identifies which path is the working path and which is the restoration path. It should be noted that there are many other possibilities for defining working and restoration metrics, and many possible algorithms Node Z can use to choose an optimal working/restoration path pair.
[0036] At node Z there is information stored that identifies for each Path Key what SRLGs are associated with that path. With this information at hand, when Node Z receives the Pass 1 information it can compute the restoration metric for a path when a candidate working path is provided in the form of Path Keys. The Path Keys of the candidate working path are translated into a set of SRLGs for that candidate working path. Those SRLGs are matched against the SRLGs that trigger additional reservations on the proposed restoration path to get an overall metric of lambda-km of additional reserved wavelength required on the proposed restoration path.
[0037] After receiving and processing the Pass 1 messages, Node Z then sends a Pass 2 signaling message along the selected working path to reserve the selected resources. In order to protect against blocking (called Backward Blocking) caused by resources that were selected in Pass 1 and are taken by another connection before the Pass 2 message can reserve them, additional lightpaths (resources) are reserved in Pass 2 . For a single wavelength connection, this would generally be just one additional lightpath. For multiple wavelength connections it will be more. The number of additional lightpaths that are reserved is chosen to meet a desired Backward Blocking probability. For example, a backward blocking probability of 10 −4 is used when the call blocking requirement is 10 −3 .
[0038] In this example, for the working path, Node Z chooses the path using nodes 28 , 24 , 16 , 8 with sub-path 20 to be used in Domain C. The path using nodes 30 , 26 , 18 , 10 would be used for the restoration path. Node Z then sends a working Pass 2 message along the working path and a restoration/protection Pass 2 message along the restoration/protection path. On the selected working path, and on selected 1+1 protection paths, the Pass 2 message initiates cross-connects at each switch for the selected wavelengths. If wavelength conversion or regeneration is required at a node, the Pass 2 message initiates that connection as well. The Pass 2 message does not wait for the connections to be completed; it continues on to establish the rest of the path.
[0039] When the working Pass 2 message enters a new domain, such as border node Node 24 , the path information in the Pass 2 message needs to be expanded. Node Z used the received Path Keys to identify in the Pass 2 message what paths were to be used for the connection. Therefore, when the Pass 2 message arrives at Node 24 , it must translate the Path Key into the actual path. In this case the actual path is Path 20 . In addition, Node 24 needs to provide what wavelengths are to be used on each link and where wavelength conversion must be done. All this information was stored in Node 24 when the Pass 1 message was processed. The expanded Pass 2 message is then sent along the working path to the next border node, Node 16 . At Node 16 the expanded Pass 2 information is removed and replaced with the Path Key, and the Pass 2 message is sent to the next border node 8 in Domain A. That border node 8 expands the Path Key information for that domain into the actual path, wavelengths to use on each link and where wavelength conversion is required. Again, this information was stored when the Pass 1 message was processed.
[0040] The expanded working path Pass 2 message is then sent along the working path to Node A, and the Pass 2 message initiates the cross-connects and wavelength conversions specified in the expanded routing information. Node A then determines which successful lightpath will be used and sends a Pass 3 message back toward Node Z to release the resources it did not select. Node A also initiates the cross-connect to the client ports.
[0041] When the Pass 3 message arrives at the border Node 8 it is passed to Node 16 in the next domain. Border node 16 will have selected the successful lightpath it will use in Domain C, and it sends a Pass 3 message along the working path to release the extra resources it will not use. Note that the Pass 3 message is also informing all of the switches along the working path that the connection has been successful. This process of sending Pass 3 messages continues all the way back to Node Z. When the Pass 3 message reaches Node Z it will know that the connection is successful, and it will also know which lightpath was selected for the connection. It will then initiate the connectivity to the client ports.
[0042] It should be noted that if on Pass 2 a connection setup fails, a connection teardown message will be sent to kill the call.
[0043] For the restoration path a Pass 2 message is sent, but it just reserves wavelength resources for restoration and does not setup any cross-connects. Extra resources are not reserved since there is a negligible probability of blockage. As indicated above, for 1+1 protection, the protection path is set up with Pass 2 and Pass 3 signaling messages the same way the working path is set up.
[0044] In the present invention, the routing and connection setup are done in one process, and therefore the invention is capable of significantly shorter setup time. For example, the present invention can achieve setup times on the order of 50 ms plus the round-trip fiber delay. The present invention bases the routing decisions on detailed information in each domain concerning wavelengths available on each link, transponders available at each node, etc. Furthermore, the present invention optimizes the choice of end-to-end working and restoration/protection diverse path-pairs based on this detailed domain information without violating the requirement of not sharing topology or resource information between domains. The present invention can establish multi-domain connections on the order of 50 ms+round-trip fiber delay. Other solutions have setup times on the order of seconds.
[0045] The present invention can optimize the choice of working and restoration path pair based on detailed resource information collected in each domain, no detailed information is shared between domains, but the optimized choices are equivalent to what would be obtained with full sharing of information between domains. Moreover, the invention minimizes the use of transponders for wavelength conversion and regeneration on the working and 1+1 protection paths, and it minimizes the amount of reserved wavelength capacity on the restoration paths.
[0046] The present invention considers multiple domain sequence paths, and the restoration path can use a different domain path than that used by the working path. The present invention collects current network state information on multiple diverse paths, and makes an optimal decision on working and restoration/protection path choices that is equivalent to making that decision with global network state information. In doing this, the present invention maintains the privacy of each domain's state information, and the global method does not.
[0047] Various aspects of the present disclosure may be embodied as a program, software, or computer instructions embodied in a computer or machine usable or readable medium, which causes the computer or machine to perform the steps of the method when executed on the computer, processor, and/or machine. A program storage device readable by a machine, tangibly embodying a program of instructions executable by the machine to perform various functionalities and methods described in the present disclosure is also provided.
[0048] The system and method of the present disclosure may be implemented and run on a general-purpose computer or special-purpose computer system. The computer system may be any type of known or will be known systems and may typically include a processor, memory device, a storage device, input/output devices, internal buses, and/or a communications interface for communicating with other computer systems in conjunction with communication hardware and software, etc.
[0049] The terms “computer system” and “computer network” as may be used in the present application may include a variety of combinations of fixed and/or portable computer hardware, software, peripherals, and storage devices. The computer system may include a plurality of individual components that are networked or otherwise linked to perform collaboratively, or may include one or more stand-alone components. The hardware and software components of the computer system of the present application may include and may be included within fixed and portable devices such as desktop, laptop, and server. A module may be a component of a device, software, program, or system that implements some “functionality”, which can be embodied as software, hardware, firmware, electronic circuitry, or etc.
[0050] The embodiments described above are illustrative examples and it should not be construed that the present invention is limited to these particular embodiments. Thus, various changes and modifications may be effected by one skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims.
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A three-way handshake method for optical messaging in a multi-domain optical network that includes a first pass from a source domain to a destination domain through intermediate domains on candidate working paths, collecting information identifying available routing resources for each working path, calculating a working path metric and storing each of the metrics at the respective border node, determining a path key of the topology of each domain working path and using the path key to identify the path outside its domain and determining the best working paths and border nodes to use. A second pass using the path keys for identifying the working path in each domain and reserving the identified routing resources and selecting which routing resources to use. A third pass identifying the selected routing resources and establishing an optical signaling message path between the source node and the destination node.
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