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This application is a divisional application of application Ser. No. 389,622 filed June 18, 1982 now U.S. Pat. No. 4,477,526.
This invention relates to slivers of stretch broken high tenacity high modulus aramid fibers, a process for making the slivers and high strength, high modulus spun yarns prepared from the slivers.
BACKGROUND OF THE INVENTION
The term "aramid" is used to designate wholly aromatic polyamides. Not all aramid fibers are useful in the present invention but only those derived from aromatic polyamides whose chain extending bonds are either coaxial or parallel and oppositely directed. High strength, high modulus aramid fibers useful in the present invention may be prepared by the processes described in U.S. Pat. Nos. 3,767,756 and 3,869,430. The fibers are characterized by filament tenacities of at least 18 gpd (15.9 dN/tex) and moduli of at least 400 gpd (354 dN/tex). These fibers will be referred to hereinafter as p-aramid fibers. Particularly preferred are p-aramid fibers based on poly(p-phenylene terephthalamide) as produced by Du Pont under the trademark Kevlar®.
P-aramid fibers are characterized by their excellent high-temperature durability. Not only do such fibers fail to soften at temperatures which would melt and destroy ordinary fibers, but in general, they have no melting point. Thus, such fibers cannot be shaped from a polymer melt as in the case of the nylons and the polyesters but rather they are shaped from polymer solutions. In general, it is more economical to wet spin or dry spin polymer solutions to produce a single large bundle of filaments than it is to spin the same number of filaments into several smaller bundles. However, a need exists for the smaller yarns.
An alternative to the spinning of smaller bundles of continuous filaments is to cut filaments of a heavy denier tow into staple fibers and process the staple fibers into spun yarns of the desired fineness. A sacrifice in yarn strength is an expected drawback in this alternative, which becomes more important as the size of the staple yarn decreases. As a general rule of thumb, an average of at least 60 synthetic or 80 cotton fibers per yarn cross section is needed for yarns of minimum acceptable strength at reasonable levels of twist. Lower than this number of fibers per cross section provides less than the minimum amount of fiber-to-fiber interaction required for good yarn strength. It is well known that synthetic filaments can be cut or stretch-broken to produce staple or sliver, respectively, and that either can be converted to useful staple-spun yarns [via e.g., the cotton or worsted systems].
It has now been found that p-aramid continuous-filament yarn or tow stretch broken on a Turbo Stapler or equivalent yields unexpectedly strong spun yarns when processed to spun yarns in a conventional manner.
BRIEF DESCRIPTION OF THE INVENTION
This invention provides a sliver of stretch broken, high strength, high modulus p-aramid fibers of which at least 50% of the fiber ends are fibrillated into at least 5 fibrils along a terminal length which is at least 50 times as long as the diameter of the unfibrillated portion of the fiber, preferably at least 100 times the diameter of the unfibrillated portion of the fiber. This sliver can be processed to a high strength spun yarn by conventional textile processing. Preferably 70-80% of the fibers in the sliver have fibrillated ends. Preferably, at least 50% of the fibrillated stretch broken fibers have 5-20 fibrils per end. Most preferably the fibrillated terminal lengths are 100 to 350 times the fiber diameter.
This invention also provides a process for preparing the sliver of stretch broken, high strength, high modulus p-aramid fibers by feeding a yarn or tow of continuous p-aramid filaments having a yarn tenacity of at least 18 gpd and a yarn modulus of at least 400 gpd under low tension into a tensioning zone, tensioning the filaments almost to their breaking tension, randomly breaking the tensioned filaments by sharply deflecting them laterally with interdigitating deflectors, removing the resulting sliver from the tensioning zone and optionally crimping the filaments. Preferably the high tension in the stretching zone is provided between two sets of restraining rolls wherein the second set of restraining rolls is operated at a speed of 2.8 to 4.0 times faster than the speed of the first set of restraining rolls. Preferably the filaments are deflected sharply in a lateral direction by two rotating, interdigitating, convoluted bars rotating at a surface speed intermediate between the speeds of the first and second sets of restraining rolls. The resulting slivers are preferably processed to spun yarns on the worsted system. Cotton system processing is possible if the length of the broken fibers is sufficiently short.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of apparatus suitable for use in the present invention.
FIGS. 2 and 3 are planar views of the ends of fibers stretch broken according to the present invention.
FIGS. 4 and 5 are planar views of the ends of fibers processed in a Pacific Converter.
FIGS. 6 and 7 are planar views of the ends of fibers processed on a Seydel machine.
DETAILED DESCRIPTION OF THE INVENTION
The Turbo Stapler, manufactured by the Turbo Machine Co., Lansdale, PA, was originally developed as a route to high-bulk yarns from acrylic tow. It is equipped with a stretch section which serves to stretch-orient the tow by heating and drawing between feed and draw rolls, thereby developing high shrinkability. In its original utility, the stretched tow is then cooled and passed through a stretch-break zone in which it is broken randomly as a result of extension beyond its break elongation. "Breaker bars", radially mounted on rotating shafts oriented to each side of the tow path, interdigitate, creating devious paths for the tow in rapid sequence as it passes between them. Thus, in an operation suitably adjusted to the product being processed, the breaker bars impose the final increment of breaking elongation, causing random breaks among the filaments in the tow to concentrate at this location. A sliver results because of this random breaking of the filaments. The longest fibers in the resulting sliver are near the length of the "ratch" (the distance between breaker bars and front rolls). In this original use, the sliver with high shrinkability is, in part, treated in alternating atmospheres of steam and vacuum until it has essentially zero residual shrinkage. When this "fiberset" sliver is blended with other, high-shrinkability fiber, which has not been fiberset, in the worsted processing system, a yarn is produced which develops high bulkiness during dyeing or other high-temperature, wet treatment.
In the present use of a Turbo Stapler or equivalent, neither high fiber shrinkability nor high yarn (or fabric) bulk is an objective; therefore, the stretch-orientation feature of a Turbo Stapler is not required. In fact, it cannot be used in processing p-aramid yarns and tows because they are essentially unstretchable. This section of the machine, accordingly, is bypassed, the filaments being fed directly to the stretch-break zone for applying high tension to the yarn or tow. At least some crimping of the filaments is desirable to facilitate subsequent handling.
P-aramid filaments broken according to the present invention provide a sliver of staple fibers having a unique morphology. Over most of the typical fiber's length, it is apparently unchanged from the original filament. At the ends, however, it is extensively fibrillated to provide a brush-like appearance. The fibrillated terminal lengths of the fibers are quite long with respect to fiber diameter, generally being at least 50, and preferably at least 100, times the fiber diameter. By terminal length is meant the distance at the end of each fiber along which fibrillation into at least 5 fibrils is continuous from a point of initiation to the tip of the longest fibril. The fibrils often join and separate from other fibrils along their length. Because of this, an exact count of the number of fibrils emanating from a given fiber is not possible. Some sporadic discontinuous fibrillation may occur farther away from the tip.
It is probable, although not yet established, that the long fibrillated ends of the fibers are responsibie for more intense fiber-to-fiber interactions and a higher yarn strength. Spun p-aramid yarns made from sliver prepared according to the present invention have up to twice the strength of p-aramid yarns made from yarns or tow cut or broken by other means which provide little or no fibrillation of the fiber ends.
Unexpectedly, p-aramid sliver prepared by breaking p-aramid filaments on a Turbo Stapler can be spun in the worsted system to provide yarns having up to 70% of the tenacity of a continuous filament yarn of the same denier and in which the number of fibers in the average yarn cross section is as low as 30-50.
FIG. 1 schematically represents apparatus of the type useful in carrying out the process of the present invention, e.g., a Turbo Stapler such as manufactured by the Turbo Machine Co., Lansdale, PA. In the figure, 1 is a carton of continuous-filament tow; 2, 3, and 4 comprise a system of guides for tow 10 which serves to adjust the tow width and the uniformity of its thickness; 5 are infeed rolls, 6 denotes the feed rolls, heater, and draw rolls which stretch-orient the filaments in normal use but are bypassed in the practice of the present invention. Intermediate rolls 7 firmly grip the tow and feed it at a constant rate to front roll 8 which also firmly grips the tow and withdraws it at a somewhat higher speed from the breaker bars 9. Broken tow 20 is condensed laterally by guide tray 11 and fed into crimper box 12 by crimper stuffing rolls 13. Crimped sliver 14 is piddled into box 15, where it accumulates for transfer to and use in subsequent processing steps.
FIGS. 2 and 3 depict planar views of the ends of typical fibers provided by the present invention.
FIGS. 4 and 5 depict planar views of typical fibers produced using a Pacific Converter.
FIGS. 6 and 7 depict planar views of fibers taken from a commercial p-aramid spun yarn reputedly prepared by stretch breaking on a Seydel machine.
All of FIGS. 2-7 were drawn from photographs so as to provide equal magnification for all fibers.
TENSILE TESTS
Filament Yarns
Before tensile testing, filament yarns are twisted to a twist multiplier (TM) of 1.1 where ##EQU1## wherein cc is cotton count
D is denier
tpi is turns per inch
The twisted yarns are preconditioned at 50° C. for 3 hours and then conditioned at 24° C. and 55% relative humidity for 24 hours before testing. The tensile properties are determined on a laboratory tensile tester with suitable clamps for yarn using a gauge length of 25.4 cm and a rate of elongation of 12.7 cm/min (50%/min).
Spun Yarns
Spun yarns are conditioned at 21° C. and 65% relative humidity for 16 hours before testing. The tensile properties are determined on a laboratory tensile tester using a gauge length of 25.4 cm and a rate of elongation of 2.54 cm/min (10%/min).
The starting fibers used in the following examples are poly(p-phenylene terephthalamide) yarns having a filament-yarn tenacity of about 18.7 gpd, 3% elongation at break, and a filament-yarn modulus of about 618 gpd. Other high tenacity, high modulus p-aramid yarns, e.g., those having a tenacity of up to 30 gpd and an initial modulus of 1000 gpd or more are also suitable for use in the invention.
EXAMPLE 1
Three ends of yarn of 1500 denier/1000 filament Kevlar® aramid yarn were combined into a thin uniform ribbon and fed to the infeed rolls of a Turbo Stapler as described above. The feed rolls/heater/draw rolls section was bypassed, the ribbon of yarns passing directly to the intermediate rolls which were adjusted in pressure to prevent slippage and rotated at a surface speed 107% faster than that of the infeed rolls. This indicated stretch served only to exert tension on the filaments in this span. The ribbon of filaments was then led between the breaker bars rotating at a surface speed 200% faster than that of the intermediate rolls and into the nip of the front rolls which rotated at a surface speed 3.11 times faster than that of the intermediate rolls while being firmly gripped in the nip to avoid slippage. The breaker bars were operated on a No. 3 setting, which results in about a 1/4" (0.64 mm) overlap of the developed cylinders of rotation. The ratch (the distance between the centerlines of the breaker bars and the front rolls) was set to 6" (about 15 cm.). The sliver was produced at an output rate of 110 ypm. (101 m/min), passed through the crimper and piddled into a can. Fiber length in the sliver ranged from about 4" (10.2 cm.) to 6" (15.2 cm.).
The sliver was directly fed to a Roberts worsted spinning frame set for approximately 16.8X draft. The product was a 62.5 cotton count (cc) singles yarn (85 denier) having 12 tpi (twists per inch) (4.7 tpcm) and a Lea Product of 11,780. Tenacity was 12.2 gpd., elongation at break 2.8% and modulus 380 gpd. This yarn had an average of 57 filaments in the cross section.
EXAMPLE 2
The process of Example 1 was repeated on a larger scale at an output speed of 55 ypm. (50 m/min) to produce a sliver having an average fiber length of 6.4" (16.3 cm.) the longest fiber being 8.1" (20.5 cm.) and the shortest 3.2" (8 cm.).
Two ends of the resulting sliver were pin drafted with 4X draft to yield a 3-grain sliver (1915 denier), then processed on a worsted spinning frame as in Example 1 to yield a 70 cc. yarn (76 denier) having tenacity/elongation/modulus of 9.7 gpd./2.5%/299 gpd. The average number of filaments per cross section is 51. The pin drafting provided a more uniform yarn. There were fewer process breaks, leading to improved process continuity.
EXAMPLE 3
20 Ends of 1500 denier yarn were processed into sliver following the procedure of Example 1 except that sliver was produced at 102 ypm. (93 m/min.) and maximum overlap of the breaker bars in the yarn/sliver path was reduced to 1/8" (0.32 cm.). The yarn had tenacity/elongation/modulus of 12.4 gpd/2.2%/437 gpd. The yarn had an average of 35 fibers per cross section. The yarn had a cotton count of 102 (52 denier).
Twelve fibers were extracted from a sliver prepared in the same manner as above and examined microscopically. The results are summarized in the following table.
______________________________________ Terminal Terminal Length No. ofFiber Length (mm) in Fiber Diameters Fibers______________________________________1 4.0 328 15-202 1.1 90 5-103 4.0 328 10-154 4.0 328 10-155 negligible 0 --6 negligible 0 --7 0.25 20 58 0.7 57 109 2.2 180 15-2010 4.0 328 10-1511 0 0 --12 0 0 --______________________________________ Average all fibers = 138 Average fibrillated fibers = 207
Further processing tended to increase the percentage of fiber ends which were fibrillated.
EXAMPLE 4
(Comparative)
This example demonstrates an alternative stretch-breaking starting with the same p-aramid continuous-filament yarns which does not provide the sliver of the present invention.
Two lots of tow having a denier of 110,000 comprising 1.5-denier filaments were processed on a Pacific Converter, Lot A with a 6" (15.2 cm) square-cut blade and Lot B with a 41/2" (11.4 cm) square-cut blade. Photomicrographs of the ends of fibers appear substantially as illustrated in FIGS. 4 and 5.
The slivers were processed in the worsted system through pin drafting, roving, and spinning to yield yarns having properties as described in the following table.
______________________________________Avg. Tenac-Fiber Cotton Modulus ityLength Count Denier gpd. % E gpd.______________________________________Lot A 5.5 74 72 239 2.1 6.0Lot B 4.5 73 73 177 2.7 7.2______________________________________
It is readily seen from these data that yarns produced from Pacific Converter sliver are not the equivalent to those made according to the present invention.
EXAMPLE 5
(Comparative)
This example demonstrates that commercial spun yarns made from equivalent p-aramid continuous-filament yarns via sliver obtained using a modified Seydel stretch breaker does not provide spun yarn having properties equivalent to those provided by the present invention.
______________________________________ Sample 1 Sample 2______________________________________Cotton count 83 (64 denier) 74 (71 denier)Tenacity (gpd.) 6.1 5.4Elongation (%) 2.5 2.4Modulus (gpd.) 176 178Fiber length, avg. 3.5 3.5low 2.2 1.2high 4.7 5.3Fibers/cross 43 48section______________________________________
The reasons for higher strength in yarns produced in the process of this invention are believed to be due to the highly fibrillated fiber ends. Differences in average fiber length also probably contribute. Such differences could not be avoided because (1) the Turbo Stapler ordinarily provides at least 6 in (15 cm) staple lengths, (2) the Pacific Converter provides lengths of at most 6 in (15 cm), (3) the staple lengths of comparative Example 5 were not under applicant's control. The contribution of different staple lengths to the different tenacities achieved may be estimated from known relationships shown in the published literature.
SAWTRI (South African Wool & Technical Research Institute of the CSIR) Technical Report. No. 223 by L. Hunter, June 1974, investigated the relationships between yarn and fiber properties for 306 singles wool worsted yarns. On page 40 the author's findings are summarized by the following mathematical expression ##EQU2## where BS is breaking strength (not normalized)
BT denotes "bundle tenacity" (strength measured using a very short gage length)
L is average fiber length
While only wool fibers were involved in the study, it is expected that this relationship should be applicable to other fibers.
In the examples of this specification, fiber diameter and bundle tenacity, as defined, were constant throughout. Twist was not available in all tests. Twist levels employed were, however, quite comparable. Because the above mentioned publication indicates that large changes in twist are required to significantly affect BS, twist was ignored in the subsequent comparisons. Also, denier (D) rather than tex was employed since the two are directly proportional and tenacity (T) was utilized rather than BS [i.e., T=BS/(tex)].
Taking the above into consideration, the above equation can be rewritten as follows: ##EQU3## If T 1 , L 1 , and D 1 are as measured for a comparison yarn (Examples 4 and 5) this equation can be used to compute what its tenacity (T 2 ) should have been if it had had the denier (D 2 ) and average fiber length (L 2 ) of a given yarn of the invention (Examples 1 through 3). Comparison of these computed tenacities (T 2 ) with tenacities (T m ) measured for examples of the invention should be a good indicator of any unexplained improvement. Comparisons for Examples 1 through 3 are shown in the following Table where 4a and 4b, and 5a and 5b refer to the two sets of data in each comparison Example.
______________________________________ComparisonExamples D.sub.2 D.sub.1 L.sub.2 L.sub.1 T.sub.1 T.sub.2 T.sub.m______________________________________4a to 1 85 72 5.0 5.5 6.0 6.2 12.24b to 1 ↓ 73 ↓ 4.5 7.2 7.7 ↓5a to 1 ↓ 64 ↓ 3.5 6.1 7.1 ↓5b to 1 ↓ 71 ↓ 3.5 5.4 6.1 ↓4a to 2 76 72 6.4 5.5 6.0 6.3 9.74b to 2 ↓ 73 ↓ 4.5 7.2 7.8 ↓5a to 2 ↓ 64 ↓ 3.5 6.1 7.2 ↓5b to 2 ↓ 71 ↓ 3.5 5.4 6.2 ↓4a to 3 52.1 72 6.4 5.5 6.0 5.6 12.44b to 3 ↓ 73 ↓ 4.5 7.2 7.0 ↓5a to 3 ↓ 64 ↓ 3.5 6.1 6.5 ↓5b to 3 ↓ 71 ↓ 3.5 5.4 5.6 ↓______________________________________
It is clear from examination of the last two columns of the table that, even when tenacity (T 1 ) of each comparison example is normalized to the same denier and fiber length as in a yarn according to the invention, the normalized tenacity (T 2 ) is still significantly below the measured tenacity (T m ) of the yarn according to the invention. Although it is not completely understood why yarns obtained using the Turbo Stapler should be unexpectedly stronger, applicant believes that the long subdenier fibrils on each end of fiber stretch broken on the Turbo Stapler account for the improvement.
FIGS. 2 and 3 are planar views of fiber ends typical of those seen in the slivers produced on the Turbo Stapler. Those produced on the Pacific Converter and Seydel from fibers of the same composition are portrayed in FIGS. 4 and 5 and in FIGS. 6 and 7, respectively. The striking differences in morphology are both readily apparent. It is believed that the highly fibrillated ends of fibers from Turbo Stapler sliver lead to better fiber cohesion. It is clear that high-tenacity, high-modulus p-aramid filaments processed according to the present invention are convertible to spun yarns which retain a substantially higher proportion of their filament tensile properties than when processed by other available means.
It will be apparent to one skilled in the textile-processing arts that the Turbo Stapler, per se, is not essential to the practice of this invention. A simpler machine will suffice if it provides the controlled-speed input means, means for sharp deflection of the filaments in a lateral direction while under high tension means for providing high tension in a stretching zone and optionally a crimper to superficially consolidate the product sliver.
While in its simplest form this process does not require each element of worsted-system processing, it may be found desirable to use other elements than those used in experiments described in the examples. The fiber setter, normally associated with the Turbo Stapler, hasn't been required, since no draw-orientation was employed; and bulkiness through differential shrinkage of fibers in a sliver was not an objective. Not unexpectedly, use of pin drafting and roving operations produced an improvement in spun yarn uniformity. It is expected that still further improvement in uniformity may be realized with more thorough drafting, and thereby blending, of input slivers. There is a probability that double breaking will also produce an improvement in yarn uniformity by elimination of the occasional long fiber. This should permit closer setting of subsequent drafting elements and, as a result, better control of fibers in these operations.
The use of a suitable textile finish is an essential element in optimum textile processing of any fiber. Sliver crimp is also beneficial in subsequent processing, and the amount of crimp is a quality-controlling as well as a processibility variable. Those skilled in textile processing arts will recognize the need for good control of crimper variables and the desirability of optimizing the type and amount of textile finish in this and other processing steps. Supplemental finish may be applied by spray (for example) before or after the crimper. | High strength, high modulus, continuous filament aromatic polyamide yarns are stretch broken under high tension while being sharply deflected in a lateral direction by mechanical means to provide a sliver which is processed by conventional means to a high strength, high modulus spun yarn. The broken ends of the fibers are highly fibrillated to fibrils having lengths of 50-350 times the diameter of the unfibrillated portion of each fiber. | 3 |
BACKGROUND
As buildings age across the United States, a great number of horizontal roof deck assemblies having poured concrete over a corrugated steel deck are in need of repair or replacement. In fact, under current building codes, namely as set forth in the International Building Code, many older flat roofs may be dangerous or classified as in a state of possible collapse. Many of these flat roofs are “composite roofs” or “composite strength roofs” which rely on the combined strength characteristics of their components, as installed, to meet load requirements and where the components considered individually are insufficient to meet those requirements. These roofs have aged and been damaged resulting in the bonding between the concrete and deck to fail. In other words, the concrete “pops off” the deck, cracking sometimes into numerous pieces of concrete rubble. Consequently, these roofs are in need of repair and methods are needed to economically effect these repairs.
BRIEF DESCRIPTION OF THE DRAWING
A drawing of exemplary embodiments of the disclosure are annexed hereto so that the disclosure may be better and more fully understood, in which:
FIG. 1 is an illustration of an exemplary prior art horizontal, composite-strength roof deck assembly, generally designated, having a symmetrically corrugated steel deck secured to horizontal supports and overlaid with roofing concrete;
FIG. 2 is an exemplary flow chart of an exemplary composite roof replacement method according to an aspect of the disclosure;
FIG. 3 is an illustration of an exemplary dry-installed, composite strength roof deck assembly, installed according to aspects of the disclosure;
FIG. 4 is a cross-sectional, orthogonal, partial view of two corrugated deck panels positioned adjacent one another according to an aspect of the disclosure.
FIG. 5 is a cross-sectional elevational illustration of an alternate exemplary dry-installed, composite strength roof deck assembly installed according to aspects of the disclosure. Numeral references are employed to designate like parts throughout the various figures of the drawing.
DESCRIPTION OF PREFERRED EMBODIMENTS
As explained above, repair or replacement is increasingly needed for horizontal composite strength roofs having poured concrete bonded to a corrugated steel deck below. The composite strength roofs employ a corrugated steel deck, supported by and attached to horizontal supports below, covered with roofing concrete. The roofing concrete is sometimes called, and herein includes, lightweight roofing concrete, lightweight insulating concrete, non-structural concrete, foam concrete, and the like. The composite strength of these roofs depends on sufficient bonding between the concrete and the corrugated deck such that the combined components, considered together as-installed, meet load requirements, such as gravitational load, wind uplift resistance, and diaphragm shear load. The concrete is bonded to the steel deck, typically by chemical reaction, and effectively stiffens the steel deck sections. Depth requirements for the concrete varied but were typically about two inches minimum above the upper rib portions of the corrugated deck.
Steel roof deck referenced herein is a corrugated, steel, roof deck, formed in generally flat sheets or panels and having parallel stiffening ribs extending across the sheet. The flat surfaces of the upper ribs provide a supporting surface for one or more layers of rigid sheet material. The corrugations define upper and lower ribs and, in a symmetrical deck, have an equal distribution of steel above and below a neutral axis lying in a plane passing through the center of the sheet and disposed parallel with upper and lower surfaces of the sheet. Symmetrically corrugated deck has been historically used for composite and non-composite cement roof assemblies, however non-symmetric deck is also known in the art.
More recently, symmetrically corrugated configuration has been used in flat roof, dry-installed, composite strength roof deck construction. For further disclosure to such, see U.S. Pat. Nos. 4,736,561, to Lehr, et al., and 5,584,153, to Nunley, et al., which are incorporated herein by reference for all purposes. Dry-installed composite strength roofing relies on the composite strength of the connected components of the roof deck assembly rather than the strength characteristics of the components individually. The roof components identified in the Lehr patent are a corrugated steel roof deck, attached to a rigid, high-density sheet above, by a plurality of fasteners (preferably threaded), and wherein these components are fastened together to create horizontal and vertical trusses.
As used herein, dry-installed composite strength roof assemblies (and similar) are those which rely on their composite strength characteristics, as installed, to meet load and resistance requirements. That is, the corrugated steel deck, rigid sheet, and fasteners, considered in composite together, as installed, provide sufficient strength characteristics, whereas the deck alone or rigid sheet alone fail to provide sufficient strength. As used herein, composite strength concrete roof assemblies (and similar) are those which rely on their composite strength characteristics, as installed, to meet load and resistance requirements. That is, the corrugated steel deck, and the overlaid and dried concrete, considered in composite, as installed, provides sufficient strength characteristics, whereas the deck or concrete alone fail to provide sufficient strength.
FIG. 1 is an illustration of an exemplary prior art horizontal, composite-strength roof deck assembly, generally designated 10 , having a symmetrically corrugated steel deck 12 secured to horizontal supports 14 and overlaid with roofing concrete 16 .
As explained above, the composite strength roof assembly is defined by the strength of the installed roof assembly; that is, the composite strength of the roof is the strength of the roofing components acting together to meet load requirements. The steel deck alone is not sufficient to meet load-bearing requirements. Similarly, the concrete alone fails to provide adequate strength. The concrete, once in place, dried, and bonded to the deck, stiffens the steel section and prevents the corrugations from “folding over” under shear load. Such roof assemblies have been widely used and many are now aged, damaged, or otherwise unfit for use and need repair or replacement. Horizontal supports as used herein includes various types of horizontal roof deck supports, such as purlins, rafters, beams, joists, etc.
Composite concrete roofs are horizontal, typically between zero and three degrees from horizontal or have a slope ranging from about 0.25/12 to 2/12. Low slope allows the poured concrete to set, or dry, without creating substantial uneven areas.
The steel roof deck 12 has symmetrical corrugations creating upper ribs 18 and lower ribs 20 or ridges extending longitudinally across the deck. Corrugated deck 12 has flat, substantially horizontal, upper and lower rib portions 22 and 24 , respectively, typically of substantially equal width, and pitched connector portions 26 extending therebetween. The symmetrical corrugation provides straight, parallel, regular, and equally dimensioned upper and lower ribs. Similarly, the deck defines symmetrical upper and lower hollows 28 and 30 , respectively. This deck configuration has a substantially equal distribution of surface area and weight of the corrugated deck above and below the neutral axis 32 . The dimensions of the corrugated deck vary depending on anticipated loads, span, etc. Typical steel decks are made of 28 to 20 gauge steel, sometimes higher. The most common deck shape is symmetrical, as explained above, however other shapes are known in the art.
In some prior art concrete roof assemblies, insulation board 34 was positioned between upper and lower layers of concrete 16 . Often referred to as “holey board,” such insulation boards have perforations 36 such that the concrete fills the holes, creating columns extending between upper and lower concrete layers.
A further feature of prior art composite concrete roofs is ventilation systems to assist in drying the wet-poured concrete. Ventilation systems employed in prior art composite concrete roofs include vented corrugations (e.g., having holes in the rib portions), vent passageways defined in the steel deck (e.g., lateral indentations extending across the deck ribs), and vent “clips” positioned between adjacent deck panels. It is not unusual to find concrete which has penetrated between adjacent deck panels during setting.
As composite concrete roofs age and experience significant loads and resulting deflections, it is common for the concrete to crack, break into pieces, or “pop loose” of the steel deck thereby breaking the concrete-to-steel bonding necessary to achieve composite strength. For example, significant roof deflection can be induced by severe or repetitive wind uplift or diaphragm shear loading. Concrete can also crack due to weather effects and common loading. Repairing or replacing aged or damaged composite concrete roofs is an expensive proposition. Repairing the roof typically includes removing the concrete and re-laying new concrete. If the roof deck is compromised, it must be removed and replaced as well.
The disclosed methods herein provide an alternative replacement process wherein a composite-strength concrete roof assembly is replaced with a composite-strength dry-installed roof assembly. Such dry-installed assemblies are typically less expensive and easier to perform.
FIG. 2 is an exemplary flow chart of an exemplary composite roof replacement method according to an aspect of the disclosure. In the method, the existing composite-strength concrete roof assembly is evaluated 100 , such as for concrete and deck damage, state of disrepair, type of concrete, gauge and configuration of steel deck, attachment of deck to horizontal supports, concrete-to-deck bonding, etc.
If it is determined that the existing roof is a viable candidate for the disclosed replacement method, then some or all of the existing roof assembly components, or portions thereof, are removed from the building. Removal can include the following, in no particular order: removing some or all of one or more concrete layers; breaking up, scraping off, prying off, or otherwise removing the concrete; removing some or all of the steel deck or panels thereof; removing holey board or insulation materials; removing pipes encased in the concrete; removing ventilation systems such as vent “clips;” and/or removing concrete from seams at adjacent deck panels. Breaking up, scraping off, or otherwise removing the concrete can be performed manually, such as by repeatedly striking the deck with a hammer, sledge-hammer, crowbar, or other blunt object. Alternately, such actions can be performed using suitable machinery, such as jack-hammers, breakers, demolition hammers, rotary hammers, mechanical scrapers, mechanical strippers, and small loading or dozing machinery.
Removal of the concrete at step 102 , according to exemplary and alternative method, can comprise various steps or actions, singly or in combination. For example, removal of the concrete can comprise removing concrete to expose the upper surfaces 25 of the upper rib portions 24 . Such removal allows for positioning of rigid sheets across the upper ribs. Further, concrete removal can include removing some or all of the concrete positioned in the lower hollows 28 . Concrete removal in some embodiments includes removing concrete to expose only portions of the upper surfaces 27 of the lower rib portions 22 . For example, removal of concrete to expose only some areas of the upper surfaces 27 of the lower rib portions can be performed to allow selective attachment of the steel deck 12 and horizontal supports 14 . Stated another way, removal of concrete can include intentionally leaving some concrete in place, namely, in the lower hollows 28 or on the upper surfaces 27 of the lower rib portions 22 . This can be time and labor saving, especially since the concrete may tend to crack through or break off at the top of the deck corrugations. Note that in some methods it is not necessary to remove ventilation systems, vent clips, encased pipes, etc., if such does not interfere with the replacement of concrete with dry-installed composite components.
Where the steel roof deck is also damaged, the method can optionally include repair or replacement of the deck, deck panels, or portions thereof, at 104 . Repair of the deck or panels can be performed by, for example, sanding, blasting, patching, welding, or coating all or part of a deck or panel. Where necessary, the replacement method can include removal and replacement of one or more deck panels or the entire deck.
Once the roof is prepared by removal of concrete, the method includes installation of dry-installed roofing components to form a composite-strength, steel deck and dry board deck assembly.
FIG. 3 is an illustration of an exemplary dry-installed, composite strength roof deck assembly, installed according to aspects of the disclosure.
The dry-installed composite roof deck assembly 48 includes a corrugated steel deck 50 attached to, and supported from below by, horizontal supports 14 . The deck is attached to the support by connectors 57 , which can be welds, fasteners, threaded screws, etc. Opposing edges of the corrugated deck, or panels thereof, are supported by generally parallel, horizontal supports, such that the deck creates a span between supports. A flat, rigid sheet 54 is secured from above by mechanical fasteners 56 to the corrugated deck. The aged or damaged composite concrete roof assembly is replaced with such a dry-installed composite roof assembly according to the disclosure. In some instances, it may be possible to use components, such as the steel deck, from the pre-existing composite concrete roof assembly in the replacement dry-installed composite roof assembly.
Depending on the construction procedures and materials used during initial installation of the composite concrete roof assembly, the corrugated deck may be attached to the horizontal supports by pre-existing connections such as a series of welds, screws, or other fasteners. The disclosed method in some embodiments includes identifying such pre-existing connections (including their number, pattern, state of repair, etc.), evaluating their sufficiency for use with the to-be-installed roof assembly, calculating the load bearing capacity of the pre-existing connections, etc., before step 106 of FIG. 2 .
According to an aspect of the disclosure, at 106 of FIG. 2 , fasteners 57 are applied to secure the corrugated deck 50 to the horizontal supports 14 in sufficient number and appropriate locations to meet load and code requirements.
In most instances, the pre-existing connections are a series of welds performed at or near the perimeters of the corrugated deck, or deck panels, attaching the deck to the horizontal deck supports. Additional welds may be located attaching the deck to intermediate horizontal supports, where present. Where welds are present and functional, they typically do not meet current load or code requirements. Consequently, according to an aspect of the disclosed methods, the corrugated deck is secured to the horizontal supports using a plurality of fasteners 57 , preferably threaded fasteners.
It may be possible to calculate the load bearing capacity of existing connections, calculate a required number and location of fasteners to supplement the pre-existing connections such that the combination of fasteners, pre-existing deck-to-support connections, and other dry-installed roof components, in composite, meet load requirements. It is unlikely that pre-existing welds are sufficient to meet load requirements, but if so, they are left in place. These methods are indicated, if applicable, at the decision node before step 106 of FIG. 2 .
A typical composite concrete roof assembly uses multiple corrugated steel deck panels 68 a - b positioned adjacent one another, defining panel seams 72 , to create the roof deck 50 as a whole. FIG. 3 is a cross-sectional view of two corrugated deck panels 68 a - b positioned adjacent one another according to an aspect of the disclosure. Adjacent deck panels 68 a - b from the pre-existing composite concrete roof assembly typically have overlapping lower rib portions along the seams of adjacent deck panels. The adjacent panels, however, tend to not be mechanically fastened together by welds, threaded fasteners, and the like, in composite concrete roofs. Further, the concrete tends to flow into and between the seams 70 defined between adjacent panels 68 a - b prior to hardening. Consequently, in some methods of the disclosure it is necessary to remove concrete from the panel seams 70 , at 106 . Further, at 106 , the method includes connecting adjacent deck panels 68 a - b together proximate seams 72 to limit or eliminate relative movement between the panels 68 a - b , thereby creating a functionally monolithic roof deck. Preferably, the adjacent panels are fastened together using threaded fasteners. Welds may be acceptable in some circumstances.
The disclosed methods include, at 108 , positioning a rigid sheet 54 , or one or more panels thereof, horizontally above the corrugated deck 50 and spanning adjacent upper ribs 18 . Where panels are installed, they are positioned adjacent one another and can be interlocked with cooperating tongue and groove or similar features. The rigid sheet, or panels thereof, is positioned to create a structural bridge over upper hollows 28 .
At 110 , the method comprises securing the rigid sheet 54 , or panels thereof, by threaded fasteners 56 to upper rib portions 24 of the corrugated sheet 50 . Fasteners 56 preferably have enlarged heads 60 on the end thereof which engage the rigid sheet 54 . Fastener holes formed in the rigid sheet 54 are preferably countersunk to receive the enlarged heads 60 , resulting in a uniform upper surface.
Threaded fasteners 56 are installed from above the rigid sheet 54 extending downwardly through the rigid sheet and through the upper rib portions 24 . Securing the rigid sheet 54 can further include securing a plurality of panels thereof adjacent to one another to cover the corrugated deck 50 or panels thereof. Spaced apart threaded fasteners 56 are secured from above the rigid sheet, through the rigid sheet and through the upper rib portions 24 of the deck 50 . The method can include securing the rigid sheet, or panels thereof, to create a structural bridge over upper hollows 28 .
The method includes, at 110 , securing the fasteners 56 , oriented in a selected pattern, and forming a series of generally triangular-shaped, horizontally-disposed, trusses T h and a series of vertically-disposed trusses T v throughout the length and width of deck spans between spaced horizontal supports 14 to increase resistance to horizontal and vertical planar deflection of the roof deck as seen in FIG. 4 . The method includes providing flexural strength and diaphragm stiffness to the roof deck by securing the rigid sheet to the upper rib portions of the deck and restraining relative horizontal movement of the deck ribs using the rigid sheet and fasteners. The method includes forming a horizontal, triangular-shaped truss T h in the horizontal plane of the rigid sheet, having a triangular segment of the rigid sheet 54 restrained by adjacent mechanical fasteners 56 to upper ribs 24 of corrugated sheet 50 in a span between horizontal supports 14 .
The upper deck ribs are in compression when a downwardly directed force is applied above the deck. The fasteners 56 are positioned such that buckling of the unsupported length of the upper rib portions is minimized. The rigid sheet 54 , or panels thereof, are relatively high density, relatively planar, fire and water resistant board selected to provide resistance to high impacts and concentrated loads without rupturing, and to contribute to the composite roof load capacity. The rigid sheet 54 may comprise a plurality of panels, which may have cooperating tongues and grooves formed thereon to provide continuous interlocking of panels. The method may include interlocking adjacent rigid sheet panels, and more specifically, interlocking adjacent panels using cooperating tongue and groove features 62 .
Fasteners 56 are secured through the rigid sheet and upper rib portions 24 and oriented in a pattern to form a vertical truss T v comprising: a section of the rigid sheet spanning upper hollow 28 between adjacent upper ribs and between adjacent fasteners 56 , the adjacent fasteners 56 , and connector portions 26 of the corrugated deck between the ribs.
The method can include determining a functional fastener pattern for use in securing the rigid sheet to the corrugated deck, calculating necessary spacing between fasteners, using deck span measurements in such calculations, using length, width, and height measurements of the deck in such calculations, using roof shape in such calculations, and using horizontal support spacing measurements in such calculations.
The method can include, at 110 , spacing the trusses T v and T h from the horizontal supports 14 and preventing lateral and vertical distortion of the corrugated deck 50 as a result of force applied in the plane of the rigid sheet 54 . The method can further include maintaining the joint stability of adjacent rigid sheet panels using a selected fastener pattern or installed fasteners in such a pattern.
The composite roof deck functions as a structural diaphragm, providing rigidity. Fasteners 56 , oriented in a pattern at horizontally spaced locations transversely of the span, and at spaced locations longitudinally of the span, form a series of essentially triangular shaped trusses T h and T v in the horizontal and vertical planes throughout and across the span, between the horizontal supports, and stabilize and prevent lateral and vertical deformation of the individual ribs of the corrugated deck, increasing resistance to horizontal and vertical planar deflection of the deck.
The methods herein disclosed are typically required to be completed in a single day's work since the building is usually occupied or operational and must be kept in the dry.
The methods herein disclosed may further include, at 114 , application of a roof covering 78 to the upper surface of the rigid sheet or panels thereof. The roof covering is preferably a smooth, flat, single-ply synthetic material. Typical coverings are made of EPDM, TPO, or PVC, for example. The covering is preferably adhered to the rigid sheet. For example, a layer of asphalt can be applied to the upper surface of the roof and a covering of modified bitumen laid atop the asphalt or other adhesive. Alternately, some roof coverings can be applied to the upper surface of the roof and then heated in place to self-adhere to the below roof component.
The methods herein may further include, at 112 , application of insulation material 80 . The insulation material can be positioned in a sandwiched position between the corrugated deck 50 and the rigid sheet 54 , as seen in FIG. 5 , or in a position above the rigid sheet 54 , as seen in FIG. 3 . Where an insulation layer is applied, the above-described methods are modified accordingly such that securing of roofing components includes extending fasteners through the insulation layer. For further disclosure in this regard see the incorporated references.
The methods disclosed herein may further include, at 116 , installation of ventilating apparatus to control temperature and air pressure below the roof deck. Provision of ventilation apparatus to relieve pressure includes communicating air flow such that change in air pressure above the rigid sheet is accompanied by simultaneous change in air pressure in lower hollows below the rigid sheet. This minimizes the likelihood that sufficient pressure differential will exist to separate rigid sheets 54 from the stronger corrugated deck 50 . For further disclosure in this regard see the incorporated references.
The methods disclosed herein may further include, at 116 , installation of a heat exchanger or the like to eliminate condensation on the corrugated deck and form a vapor barrier between the interior of the building and the roofing. For further disclosure in this regard see the incorporated references.
From the foregoing it should be readily apparent that while the symmetrically corrugated deck, rigid sheet, and optional insulation layer are insufficient in strength characteristics to form a roof assembly when separately considered, the components installed and considered working together or in composite have superior strength. In view of the unorthodox characteristics and functions of the individual components when assembled in a dry-installed composite roof, mathematical calculation of composite strength is infeasible. However, strength characteristics and comparisons with existing structures have been observed by actual construction and testing. Empirical data has been analyzed and formulated into a predictable pattern by applying engineering principles.
The invention is defined by the claims appended hereto and the specification is not limiting to the claim interpretation. It is understood that other and further embodiments of the disclosed methods can be devised without departing from the basic concepts explained herein. Terms take their normal and ordinary meanings unless otherwise addressed herein. The various steps, actions, procedures, etc., described herein are limited in their respective order only when so indicated by the claims. Further, such actions can be omitted, repeated, changed in order, etc., as a person of skill in the art will recognize. Application of common sense by someone of skill in the art should educate use of the disclosed methods and any modifications thereof. | Retrofitting a horizontal building roof having a pre-existing, composite-strength concrete roof having a corrugated steel deck with concrete poured over the deck top. Replacing the pre-existing roof with a dry-installed composite-strength roof having a rigid sheet installed over a corrugated steel deck, the rigid sheet attached to the deck by mechanical fasteners extending through the rigid sheet and the upper ribs of the corrugated deck. The newly installed roof restrains the upper ribs against lateral distortion under loading, thus forcing the corrugated deck to maintain shape and operate to composite capacities in excess of predictable flexural load capabilities of its components considered alone. | 4 |
RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/029,702, filed Feb. 17, 2011, entitled “INHIBITING DENIAL-OF-SERVICE ATTACKS USING GROUP CONTROLS,” which is incorporated herein by reference.
FIELD
This invention relates generally to computer security.
DESCRIPTION OF THE RELATED ART
In today's distributed computing environments, security is of the utmost importance. Due to the rise of wide-area public networks, users have unlimited access to content, e.g., data, files, applications, programs, etc., from a variety of sources. Often, the users are unaware of the origin of the content available in the public networks. Malicious entities utilize this ease of accessibility and anonymity to attack the users. For example, the malicious entities can plant viruses, Trojans, or other malicious agents in publicly available content in order to attack the users' computing systems and steal sensitive information from the users. As such, the users must treat content from unknown sources as untrusted and possibly dangerous.
Typically, to prevent attacks, the users utilize filtering programs, anti-virus programs, etc. in order to identify and block known dangerous content. These programs, however, suffer from several weaknesses. In order to properly identify and block the dangerous content, the filtering and anti-virus programs must typically be configured with the identity of the source of known dangerous content. As such, the filtering and anti-virus programs lack the ability to stop previously unknown and emerging threats. Likewise, the filtering and anti-virus programs are themselves subject to attack. Many types of dangerous content utilize weaknesses in the filtering and anti-virus programs to attack the users' computing systems using the filtering and anti-virus programs as a vehicle for attacking the users' computing systems. As such, the users lack methods to guarantee that untrusted content does not pose a threat.
Currently, operating systems allow a user to place access controls on a process, such as an application program, running on the operating system. When an action by the application program exceeds it level of access, the operating system blocks the action, and the application program immediate shuts down. This prevents possible damage to the user's computing system, but it also prevents the user from using the application program. To utilize the application program, the user is required to increase the level of access granted to the application program.
Additionally, while the operating system can limit an application program's level of access, the application program still may harm the user's computing system. One suck attack is a denial-of-service (DOS) attack. In a DOS attack, a dangerous application program or a harmless application program running dangerous content attempts to render a user's computing system unusable. For example, the dangerous application program or dangerous content can utilize bugs in the computing system in order to consume all the processing power and/or memory of the computing system (e.g., buffer overflow attack, fork bomb, etc.), thereby rendering the computing system unusable or crashing the computing system. In such an attack, the dangerous application or dangerous content can still perform the attack even though it may have limited access because the attack targets the basic functions of the computing system (e.g. processing and memory). Thus, the user has no method to run the application program and also protect the computing system from potential DOS attacks.
BRIEF DESCRIPTION OF THE DRAWINGS
Various features of the embodiments can be more fully appreciated, as the same become better understood with reference to the following detailed description of the embodiments when considered in connection with the accompanying figures, in which:
FIG. 1 illustrates a network of computing systems in which various embodiments of the present teachings can be practiced;
FIG. 2 illustrates an exemplary software environment for utilizing an isolated execution environment, according to various embodiments of the present teachings;
FIG. 3 illustrates components of an exemplary secure operating system including a sandbox tool, according to various embodiments;
FIG. 4 illustrates an exemplary process for accessing untrusted content in the isolated execution environment with cgroup controls, according to various embodiments;
FIGS. 5A and 5B illustrate exemplary interfaces for the isolated execution environment with cgroup controls, according to various embodiments; and
FIG. 6 illustrates an exemplary computing system which can implement the secure operating system and the sandbox tool, according to various embodiments.
DETAILED DESCRIPTION OF EMBODIMENTS
For simplicity and illustrative purposes, the principles of the present teachings are described by referring mainly to exemplary embodiments thereof. However, one of ordinary skill in the art would readily recognize that the same principles are equally applicable to, and can be implemented in, all types of information and systems, and that any such variations do not depart from the true spirit and scope of the present teachings. Moreover, in the following detailed description, references are made to the accompanying figures, which illustrate specific embodiments. Electrical, mechanical, logical and structural changes may be made to the embodiments without departing from the spirit and scope of the present teachings. The following detailed description is, therefore, not to be taken in a limiting sense and the scope of the present teachings is defined by the appended claims and their equivalents.
Embodiments of the present teachings relate to systems and methods for accessing, viewing, and running content, such as data, files, programs, and applications, without exposing a computing system to untrusted content and possibly malicious content and protecting the computing system from DOS attacks. More particularly, a “sandbox tool” can create an isolated execution environment that is isolated from other processes executing on the computing system for accessing content. The sandbox tool can cooperate with components of a secure operating system (OS), such as security enhanced LINUX (SELinux), to create an isolated execution environment for accessing content without exposing other processes and resources of the computing system to the content. As such, the user can access the content without exposing the overall computing system to any possible malicious or dangerous content.
According to embodiments, the sandbox tool can be configured to utilize task control groups (cgroups) of the secure OS with the isolated execution environment. A cgroup defines the hardware resources that can be accessed and utilized by the isolated execution environment. The cgroups can define accessible hardware resources by particular hardware resources, amount of hardware resources, and/or components of the hardware resources. Once a cgroup is applied to the isolated execution environment, any processes running in the isolated execution environment will be confined to the hardware resources defined by the applied cgroup. If a process running in the isolated execution environment attempts to utilize hardware resources outside the definition of the cgroup, the secure OS can block the usage.
By utilizing the sandbox tool, content can be accessed on a computing system without exposing the computing system to any malicious agents that may be contained in the content. Because the sandbox tool utilizes cgroup controls that limit hardware resource usage, application programs can be allowed to execute in the isolated execution environment, but are prevented from highjacking all the hardware resources of the computing system. As such, the content can be accessed without the worry of potential DOS attacks on the computing system.
FIG. 1 illustrates an exemplary network 100 of computing systems, according to various embodiments. It should be readily apparent to those of ordinary skill in the art that the network 100 depicted in FIG. 1 represents a generalized schematic illustration and that other components may be added or existing components may be removed or modified. Moreover, the network 100 may be implemented using software components, hardware components, or combinations thereof.
As illustrated in FIG. 1 , the network 100 can represent the systems of private entities, such as individuals, businesses, partnerships, companies, corporations, etc., and public entities, such as universities, governmental agencies, etc. The network 100 can include a number of computing systems, such as a user computing system 102 and remote computing systems 104 . The computing systems, such as the user computing system 102 and remote computing systems 104 , can be any-type of computing systems such as desktops, laptops, servers, thin-clients, etc. The computing systems, such as the user computing system 102 and remote computing systems 104 , can include hardware resources, such as processors, memory, network hardware, storage devices, and the like, and software resources, such as operating systems (OS), application programs, and the like.
The user computer system 102 can include a secure OS 106 , such as security enhanced Linux (“SELinux”), available from Red Hat™, Inc. In this example, SELinux implements a monolithic kernel which is configured to provide an X-Window computing environment to the user computing system 102 . SELinux is a version of Linux that integrates FLASK architectural components to provide general support for the enforcement of many kinds of mandatory security policies, including those based on the concepts of type enforcement, role-based access control (“RBAC”), and multi-level security (“MLS”).
Additionally, the secure OS 106 can implement cgroups. Cgroups define processes' access to and utilization of the hardware resources of the user computing system 102 . Once a process is assigned to a cgroup, that process is limited to the hardware resources defined by the cgroup. A cgroup can define particular hardware resources that processes, which are assigned to that cgroup, are allowed to access and utilize. For example, a cgroup can define one or more processors in a multi-processor system, one or more threads in a multi-thread processor, a particular memory range, and/or other hardware (disk drives, network devices, etc.) that the processes are allowed to access and utilize. A cgroup can also define amounts of the hardware resources that the processes, which are assigned to that cgroup, are allowed to access and utilize. For example, a cgroup can define a percentage of processing power, a percentage of memory, and/or a percentage of storage that the processes are allowed to access and utilize. A cgroup can also define components of the hardware resources that the processes, which are assigned to that cgroup, are allowed to access and utilize. For example, a cgroup can define particular ports of a network device that processes are allowed to access. If a process attempts to utilize the hardware resources outside the definition of the cgroup, the secure OS 106 can block the process's access or scale back its usage of the hardware resources.
The computing systems in environment 100 can be located at any location, whether located at single geographic location or remotely located from each other. In order to communicate and share data, the user computing system 102 and the remote computing systems 104 can be coupled to one or more networks 108 . The one or more networks 108 can be any type of communications networks, whether wired or wireless, to allow the computing system to communicate, such as wide-area networks (e.g. Internet) or local-area networks.
A user of the user computing system 102 can utilize the computing environment of the secure OS 106 to operate the computing system 102 and access content on the user computing system 102 . The content can include any number and type of data, applications programs such as word processing applications, web browser applications, file sharing applications, electronic mail (e-mail) applications, multimedia applications, chat applications, etc. Likewise, the content can include files and data utilized by the application programs or accessed utilizing the application programs. The content accessed on the user computing system 102 can be acquired from a variety of sources. For example, the content can be installed and copied to the user computing system 102 from media such as compact discs (CDs) and digital versatile discs (DVDs). Likewise, the content can be downloaded from one or more of the remote computing systems 104 via the network 108 .
The content accessed on the user computing system 102 may not be secure. For example, the user computing system 102 can acquire the content from one or more of the remote computing systems 104 . In this example, the user computing system 102 may not know the source of the content and cannot guarantee that the content is secure. Likewise, content installed and copied from media can be untrusted and possibly insecure. As such, the content can be deemed to be untrusted and can possibly be insecure.
In embodiments, regardless of whether the content is trusted or untrusted, the user of the user computing system 102 can desire to access the content without exposing the user computing system 102 to actions performed by the content or malicious agents (e.g. viruses, Trojans, etc.) possibly contained in the content. In order to allow access of the content without exposing the user computing system 102 , the user computing system 102 can include a sandbox tool 110 . The sandbox tool 110 can be configured to cooperate with components of the secure OS 106 to create an isolated execution environment for accessing content (trusted or untrusted) without exposing other processes and resources of the user computing system 102 to the content. In particular, the sandbox tool 110 can be configured to allocate resources (storage space, memory, etc) of the user computing system 102 , which are necessary to create the isolated execution environment, and apply security polices of the secure OS 106 to the isolated execution environment such that content running in the isolated execution environment can only access the resources allocated to the isolated execution environment. As such, the user can access the content without exposing the user computing system 102 to any possible malicious, dangerous, or damaging content.
According to embodiments, the sandbox tool 110 can be configured to utilize cgroups when creating the isolated execution environment. In particular, the sandbox tool 110 can determine a cgroup to apply the the isolated execution environment, apply the cgroup to the isolated execution environment, and cooperate with the secure OS 106 to confine the isolated execution environment's use of the hardware resources to the hardware resources defined by the applied cgroup. Accordingly, any content, accessed or executed in the isolated execution environment, can be prevented from highjacking all the hardware resources of the user computing system 102 .
For example, the sandbox tool 110 can apply a cgroup to the isolated execution environment that defines the maximum processor usage to 20% and the maximum memory usage to 30%. If dangerous content within the isolated execution environment attempts to perform a DOS attack on the user computing system 102 by consuming 100% processor usage and/or 100% memory usage, the secure OS can limit the isolated execution environment's hardware resource usage to the amounts specified in the cgroup (processor usage—20%, the maximum memory usage—30%). As such, the dangerous content can be prevented from rendering the user computing system 102 unusable.
The content (trusted or untrusted) can be applications, programs, files, and/or data. The sandbox tool 110 can be configured to create the isolated execution environment to allow the applications, programs, files, and/or data to be accessed, executed, or viewed without exposing the user computing system 102 to any possible malicious, dangerous, or damaging actions of the content. For example, the applications, programs, files, and/or data can only access the resources allocated to the isolated execution environment.
In embodiments, as illustrated, the sandbox tool 110 can be implemented as part of the secure OS 106 . Likewise, the sandbox tool 110 can be implemented as a standalone application program that communicates with the components of the secure OS 106 . In either case, the sandbox tool 110 can be written in any type of known open-source or proprietary programming language, such as C, C++, JAVA, etc.
In embodiments, the user computing system 102 can store and execute the secure OS 106 and sandbox tool 110 . Additionally, one or more of the remote computing systems 104 can store and execute the secure operating system 106 and the sandbox tool 110 . As such, the user computing system 102 can access the secure OS 106 and the sandbox 110 stored on the one or more remote computing system 104 via the network 108 in order to access content using a client-server model.
FIG. 2 illustrates an exemplary software environment in accordance with various embodiments. It should be readily apparent to those of ordinary skill in the art that software environment depicted in FIG. 2 represents a generalized schematic illustration and that other components may be added or existing components may be removed or modified.
As shown in FIG. 2 , the software environment can include the secure OS 106 , such as SELinux or similar secure multi-tasking, multi-user operating system. A run-time environment (not shown) can be configured to execute on the secure OS 106 . The run-time environment can provide a set of software that supports the access of content (e.g. applications, files, data, etc.). The run-time environment can also comprise an application program interface (“API”) 205 and a complementary API (not shown) within an application space 210 . The API 205 can be configured to provide a set of routines that the application space 210 uses to request lower-level services performed by the secure OS 106 . The secure OS 106 can include a kernel (not shown) and device drivers 215 . The kernel can be configured to provide secure access to the underlying hardware of the user computing system 102 (e.g. processor, memory, storage, input/output devices, network devices, etc.) through the device drivers 215 .
During operation, the secure OS 106 can be configured to create a user execution environment 220 in the application space 210 . The user execution environment 220 allows users to interact with the the user computing system 102 to access content such as run application and programs, view files, etc. The secure OS 106 can be configured to perform the necessary processes to establish the user execution environment 220 such as creating a virtual process server (e.g. X-server) to support user interaction with the user execution environment 220 , providing access to the devices drivers 215 , allocating resources (e.g. user namespace such as home directory and temporary directory) to support the user execution environment 220 , and the like. Likewise, the secure OS 120 can enforce security policies in the user execution environment 220 to allow/prevent access to underlying resources (network ports, file directories, memory, etc.) of the user computing system 102 . The secure OS 106 can also be configured to generate and display, to the user, a user interface, typically a “desktop” graphical user interface (GUI), that allows the user to interact with the user computing system 102 . The desktop GUI communicates with the virtual process server to receive input from the user and display output to the user.
In embodiments, in order to provide access to content 225 without endangering the user computing system 102 , the sandbox tool 110 can be configured to cooperate with components of a secure OS 106 , to create an isolated execution environment 230 for accessing content 225 (trusted or untrusted) without exposing other processes such as the user execution environment 220 and resources of the user computing system 102 to the content 225 . In particular, the sandbox tool 110 can be configured to allocate resources (storage space, memory, etc) of the user computing system 102 , which are necessary to create the isolated execution environment 230 . The sandbox tool 110 can be configured to apply security polices of the secure OS 106 to the isolated execution environment 230 such that the content 225 running in the isolated execution environment 230 can only access the resources allocated to the isolated execution environment 230 . The isolated execution environment 230 can provide the same functionality as the user execution environment 220 , but be isolated from the user execution environment 220 and limited in its access to the resources of the user computing system 102 . A description of the sandbox tool 110 and secure OS 106 and a description of creating an isolated execution environment can be found in U.S. patent application Ser. No. 12/545,500 (U.S. Patent Application Publication No. 2011/0047613), entitled “SYSTEMS AND METHODS FOR PROVIDING AN ISOLATED EXECUTION ENVIRONMENT FOR ACCESSING UNTRUSTED CONTENT” to Daniel J. Walsh et al.; U.S. patent application Ser. No. 12/640,657 (U.S. Patent Application Publication No. 2011/0154431), entitled “SYSTEMS AND METHODS FOR PROVIDING MULTIPLE ISOLATED EXECUTION ENVIRONMENTS FOR SECURELY ACCESSING UNTRUSTED CONTENT” to Daniel J. Walsh; and U.S. patent application Ser. No. 12/789,554 (U.S. Patent Application Publication No. 2011/0296487), entitled “SYSTEMS AND METHODS FOR PROVIDING AN FULLY FUNCTIONAL ISOLATED EXECUTION ENVIRONMENT FOR ACCESSING CONTENT” to Daniel J. Walsh, all of which are assigned to Red Hat Corporation, the disclosures of which are incorporated herein, in their entirety, by reference.
In embodiments, the sandbox tool 110 can be configured to utilize cgroups with the isolated execution environment 230 in order to control the hardware resources available to the isolated execution environment 230 . As such, any processes running in the isolated execution environment 230 , such as potentially harmful content, will be limited to the hardware resources defined by the applied cgroup. As a result, the sandbox tool 110 can prevent any content accessed or executed in the isolated execution environment from highjacking the user computing system 102 .
The sandbox tool 110 can be configured to apply cgroups that define accessible hardware resources by particular hardware resources, amount of hardware resources, and/or components of the hardware resources. For example, a cgroup can define one or more specific processors in a multi-processor system that are accessible, one or more threads in a multi-thread processor that are accessible, a particular memory range that is accessible, and/or other hardware that is accessible (disk drives, network devices, etc.). Likewise, for example, a cgroup can define a percentage of processing power that is accessible, a percentage of memory that is accessible, and/or a percentage of storage that is accessible. Additionally, for example, a cgroup can define particular ports of a network device that are accessible. If a process attempts to utilize the hardware resources outside the definition of the cgroup, the secure OS 106 can block the process's access or scale back its usage of the hardware resources.
During the creation of the isolated execution environment 230 , the sandbox tool 110 can be configured to determine a cgroup to apply to the isolated execution environment 230 . The sandbox tool 110 can be configured to allow a user to create a cgroup during the creation of the isolated execution environment 230 . To achieve this, the sandbox tool 110 can be configured to generate and provide to the user command line interfaces and/or graphical user interfaces (GUIs) that enable the user to specify the hardware resources that are accessible to the isolated execution environment 230 . For example, the user can utilize the command line interfaces or GUIs to specify particular hardware resources to be included in the cgroup, amount of hardware resources to be included in the cgroup, and/or components of the hardware resources to be included in the cgroup.
Likewise, the sandbox tool 110 and/or the secure OS 106 can be configured to maintain predefined cgroups that can be applied to the isolated execution environment 230 . The predefined cgroups can specify various levels of access to the hardware resources of the user computing system 102 . The predefined cgroups can define any combination of particular hardware resources, amount of hardware resources, and/or components of the hardware resources that are accessible. During creation of the isolated execution environment 230 , the sandbox tool 110 can be configured to display the predefined cgroups in the command line and/or GUIs and receive a selection of one of the predefined cgroups from the user. Additionally, the sandbox tool 110 can automatically apply one of the predefined cgroups to the isolated execution environment 230 as a default.
Once determined, the sandbox tool 110 can be configured to apply the cgroup to the isolated execution environment 230 . The sandbox tool 110 can be configured to cooperate with the secure OS 106 to mount the cgroup with the isolated execution environment 230 . As such, any processes running in the isolated execution environment 230 will be limited to the hardware resources specified by the applied cgroup.
In embodiments, the sandbox tool 110 can be configured to create and/or maintain one or more isolated execution environments 230 , simultaneously. The sandbox tool 110 can create one or more isolated execution environments 230 which co-exist and have the same or different level of access, but remain isolated from each other. Likewise, in embodiments, the sandbox tool 110 can be configured to apply the same cgroup to the multiple isolated execution environments. As such, the multiple isolated execution environments would share the defined hardware resources of the cgroup. For example, if the cgroup defined a limit of 20% processor usage, the combined processor usage of the multiple isolated execution environments could not exceed 20%. Additionally, the sandbox tool 110 can be configured to apply different cgroups to one or more of the multiple isolated execution environments. As such, each isolated execution environment would be limited to the hardware resources defined by the applied cgroup.
Additionally, when assigning cgroups to the multiple isolated execution environments, the sandbox tool 110 can be configured to apply cgroups in a hierarchical structure. The sandbox tool 110 can be configured to apply any overall cgroup to all of the multiple isolated execution environments and apply a separate cgroup to each of the multiple isolated execution environments. If the combined hardware resource usage of multiple isolated execution environments exceed the hardware resources defined by the overall cgroup, the sandbox tool 110 and/or secure OS 106 can be configured to limit access to hardware resources of one or more of the multiple isolated execution environments in order that the combined hardware resource usage meets the overall cgroup. For example, the sandbox tool 110 can apply an overall cgroup of a maximum of 50% processor usage and a separate cgroup to each of three multiple isolated execution environments of a maximum of 30% processor usage. In this example, each of the three multiple isolated execution environments would be individually limited to 30% processor usage, and the combined processor usage of all three would be limited to 50% processor usage. If two of the three multiple isolated execution environments were utilizing 20% each, the third of the three multiple isolated execution environments would be limited to 10% processor usage, or the sandbox tool 110 and/or the secure OS 106 can scale back the processor usage of the two of the three multiple isolated execution environments. While the above describes one example of a hierarchical cgroup control, one skilled in the art will realize that the sandbox tool 110 and/or the secure OS 106 can utilize any type of hierarchical cgroups with any number of levels in the hierarchy.
Additionally, in embodiments, the sandbox tool 110 and/or the secure OS 106 can utilize dynamic cgroups. The dynamic cgroups can specify conditions by which the hardware resources defined by the cgroups can change. The conditions can be any conditions that exits in the user computing system 102 . For example, the sandbox tool 110 and/or the secure OS 106 can apply a dynamic cgroup to an isolated execution environment that defines a limit of processor usage to 50% on the condition that total processor usage of the user computing system 102 does not exceed 90%. In this example, if the processor usage of the user computing system exceeds 90% due to other processes running outside the isolated execution environment, the sandbox tool 110 and/or the secure OS 106 can reduce the processor usage of the isolated execution environment to maintain less than a 90% processor usage for the entire system. While the above describes one example of dynamic cgroups with reference to processor usage one skilled in the art will realize that dynamic cgroups can be applied to any type of hardware resource, whether particular hardware usage or particular amounts of hardware usage. Likewise, while the above describes one example in which hardware usage can change based on a single condition, one skilled in the art will realize that hardware usage can change based on any number and types of condition that exist in the user computing system 102 .
FIG. 3 shows an exemplary block diagram of the secure OS 106 including the sandbox tool 110 according to various embodiments. It should be readily apparent to those of ordinary skill in the art that the secure OS 106 depicted in FIG. 3 represents a generalized schematic illustration and that other components may be added or existing components can be removed or modified. Likewise, while FIG. 3 illustrates the sandbox tool 110 as part of the secure OS 106 , those of ordinary skill in the art will realize that the sandbox tool 110 can be implemented as a separate and standalone program or application that can communicate and cooperate with the secure OS 106 , and the sandbox tool 110 can incorporate one or more of the components of the secure OS 106 .
As shown in FIG. 3 , the secure OS 106 can include a namespace module 305 , a security module 310 , a process server module 315 . These components can be incorporated into the secure OS 106 and/or the sandbox tool 110 to implement the functionality of the isolated execution environment 230 as previously described and described in greater detail below.
The namespace module 305 can be configured generate and maintain the namespaces that support the user execution environment 220 and the isolated execution environment 230 . More particularly, the namespace module 305 can create directories including a home directory (Homedir), file directory (/tmp) and /var/tmp for the user execution environment 220 and, when necessary, create a home directory and tmp directory for the isolated execution environment 230 . Likewise, the namespace module 305 can be configured to remove the namespace of the isolated execution environment 230 , if requested.
The security module 310 can be configured to maintain and enforce the security policies of the secure OS 106 according to the security contexts supported by the secure OS 106 . The security policies associated with the security contexts can define the various access levels of the processes running on the user computing system 102 . For example, the security policies can define the various resources that are accessible at different security contexts such as full or limited network access, full or limited memory access, full or limited storage access, and the like. To enforce the security policies, the security module 310 can be configured to associate a security context with the user execution environment 220 and the isolated execution environment 230 . Likewise, the security module 310 can be configured to apply security labels, corresponding to the associated security context, to different processes running on the user computing system 102 by assigning a security label, for example MCS label in SELinux, to different processes. The security label is associated with the secure OS 106 and can identify what security context the security module 310 should apply to the processes running on the user computer system 102 . When the processes, which are assigned a particular security label, request access to resources of the user computing system 102 , the secure OS 106 can read the security label and apply the associated security policy of the associated security context to the processes, thereby restricting access of the processes to the security context. For example, the security module 310 can allow processes associated with a particular security context and with a particular security label to only access the resources, for example, limit and control access to the device drivers 215 , defined by the security policies associated with the particular security context.
In embodiments, the process server module 315 can be configured to implement virtual processes servers for the processes running on the user computing system 102 such as the user execution environment 220 and the isolated execution environment 230 . For example, if secure OS 106 is SELinux, the process server module 310 can be configured to implement one or more X Servers which provide X Windows interfaces that allow the user of the user computing system 102 to interact with the processes running on the user computing system 102 .
In embodiments, the sandbox tool 110 can be configured to include the necessary logic, instructions, and commands to implement the methods and processes of creating the isolated execution environment 230 as described above and below. The sandbox tool 110 can be configured to cooperate with the secure OS 106 to create the isolated execution environment 230 (e.g. creating/removing namespaces, isolating namespaces, copying content, applying security contexts, accessing the untrusted content 225 , and the like). Likewise, the sandbox tool 110 can be configured to cooperate with the secure OS 106 to create and apply cgroups to the isolated execution environment 230 .
In embodiments, the sandbox tool 110 can be configured to apply various cgroups to limit the usage of hardware resources by the isolated execution environment 230 . The sandbox tool 110 can be configured to apply cgroups that define accessible hardware resources by particular hardware resources, amount of hardware resources, and/or components of the hardware resources. Likewise, the sandbox tool 110 can be configured to create and/or maintain one or more isolated execution environments 230 , simultaneously. The sandbox tool 110 can be configured to apply the same or different cgroups to each of the multiple execution environments. The secure OS 106 can limit any processes running in an isolated execution environment 230 to the hardware resources specified by the applied cgroup.
In embodiments, in order to initiate creation of the isolated execution environment 230 , the sandbox tool 110 can be configured to allow a user to request creation of the isolated execution environment 230 , request creation of a cgroup for isolated execution environment 230 , and/or view and select a predefined cgroup to apply to the isolated execution environment 230 . As such, the sandbox tool 110 can be configured to include the necessary logic, instructions, and commands to generate command line interfaces and/or GUIs that allow a user to start the sandbox tool 110 , request creation of the isolated execution environment 230 , provide the specifications of the isolated execution environment 230 , and specify the cgroup to apply to the isolated execution environment 230 . The user can specify particular hardware resources to be included in the cgroup, amount of hardware resources to be included in the cgroup, and/or components of the hardware resources to be included in the cgroup.
In embodiments, the sandbox tool 110 can be directly accessed in order to initiate creation of the isolated execution environment 230 . Additionally, the sandbox tool 110 can be linked to other applications and programs (e.g. web browsers) to allow creation of the isolated execution environment 230 .
In embodiments, additionally, in order to initiate creation of the isolated execution environment, the sandbox tool 110 can be configured to automatically initiate access of the content in the isolated execution environment 230 . For example, upon the access of certain content, such as particular files or applications, the sandbox tool 110 can automatically initiate creation of the isolated execution environment 230 and access of the content in the isolated execution environment 230 . As such, the sandbox tool 110 can be configured to include the necessary logic, instructions, and commands to command line interfaces and/or GUIs that allow selection of types of content 225 which will automatically be accessed in the isolated execution environment 230 and the cgroup to be applied to the isolated execution environment 230 .
FIG. 4 depicts an exemplary flow diagram 400 for creating an isolated execution environment with cgroup controls in accordance with various embodiments. It should be readily apparent to those of ordinary skill in the art that the flow diagram 400 depicted in FIG. 4 represents a generalized schematic illustration and that other stages can be added or existing stages can be removed or modified.
In 405 , the processing can begin. In 410 , the sandbox tool 110 can receive a request to create an isolated execution environment 230 . To receive the request, the sandbox tool 110 can provide to the user an interface (command line interface and/or GUI) to receive the request and specifications for the isolated execution environment 230 .
In 415 , the sandbox tool 110 can determine a cgroup to apply to the isolated execution environment 230 . For example, the sandbox tool 110 can receive via the interface (command line interface and/or GUI) an request to create a cgroup and the hardware resources to be defined by the cgroup. The user can specify particular hardware resources to be included in the cgroup, amount of hardware resources to be included in the cgroup, and/or components of the hardware resources to be included in the cgroup. Likewise, the sandbox tool 110 can provide, via the interface, a list of predefined cgroups and the hardware resources defined by the predefined cgroups and can receive a selection of one of the predefined cgroups.
In 420 , the sandbox tool 110 can create the isolated execution environment 230 . For example, the sandbox tool 110 can create the namespace for the isolated execution environment 230 . Then, the sandbox tool 110 can copy necessary content and content 225 to the namespace for the isolated execution environment 230 . Next, the sandbox tool 110 can optionally create an execution file in the namespace of the isolated execution environment 230 . Then, the sandbox tool 110 can isolate the namespace of the isolated execution environment 230 for other namespaces such as the namespace of the user execution environment 220 . Additionally, the sandbox tool 110 can create a new virtual process server for the isolated execution environment 230 and can apply the security context to the isolated execution environment 230 . The sandbox tool 110 can apply or can instruct the security module 310 to apply security labels within the security context to the processes running the isolated execution environment 230 . After creation, the sandbox tool 110 can remove any data used to create the isolated execution environment 230 .
In 425 , the sandbox tool 110 can apply the cgroup to the isolated execution environment 230 . The sandbox tool 110 can cooperate with the secure OS 106 to mount the cgroup with the isolated execution environment 230 . As such, any processes running in the isolated execution environment 230 will be limited to the hardware resources specified by the applied cgroup.
In 430 , the sandbox tool 110 can generate and display a user interface for the isolated execution environment 230 . For example, if the new virtual process server is an X Windows server, the sandbox tool 110 can instruct, directly or via the process server module 315 , to generate and maximize the X windows, generated by the new X Server, in the user interface of the user execution environment 220 (e.g. desktop GUI).
In 435 , the sandbox tool 110 can optionally track malicious activity of the content 225 . The sandbox tool 110 can track or instruct the security module 310 to track malicious activity from the content 225 . For example, the sandbox tool 110 and/or security module 310 can monitor if the isolated execution environment 230 accesses or exceeds the limited hardware resources specified by the cgroup and can notify the user via the interface.
In 440 , the processing can end, repeat or return to any point.
FIGS. 5A and 5B are exemplary screen shots of various methods and processes of initiating creation of an isolated execution environment with cgroup controls. As illustrated in FIG. 5A , the secure OS 106 , running on the user computing system 102 , can provide the user execution environment 220 with a user interface or desktop GUI 505 , such as an X Windows interfaces, that allows a user to run applications programs, view files and data, and communicate with the remote computing systems 104 . The desktop GUI 505 can include various menus and widgets for accessing application programs, such as a tool bar 510 and application icon 515 for accessing a web browser application program.
The user desktop 505 can include a sandbox icon 520 for initiating the sandbox tool 110 . Once the sandbox icon 520 is selected, the sandbox tool 110 can generate and display a sandbox interface 522 . The sandbox interface 522 can include fields to allow the user to request that a cgroup be applied to the isolated execution environment 230 . As illustrated, for example, the sandbox interface 522 can include a text box 525 for entering hardware resources to be defined by a cgroup and a widget 530 for creating and applying a cgroup as specified in the text box 525 . Additionally, the sandbox interface 522 can include a menu 535 for displaying and selecting predefined cgroups and a widget 540 for applying one of the predefined cgroups.
Once a new cgroup is created or a predefined cgroup is selected, the sandbox tool 110 can create the isolated execution environment 230 , as described above. As illustrated in FIG. 5B , the sandbox tool 110 can display a user interface 545 for the isolated execution environment 230 in the desktop GUI 505 . The user interface 545 can include various menus and widgets for accessing application programs, such as a tool bar 548 and application icon 550 for accessing a web browser application program. The isolated execution environment 230 will be limited to the hardware resources defined in the cgroup that was applied to the isolated execution environment 230 .
FIG. 6 illustrates an exemplary block diagram of a computing system 600 which can be implemented as user computing system 102 and/or the remote computing systems 104 according to various embodiments. The functions of the secure OS 106 and the sandbox tool 110 can be implemented in program code and executed by the computing system 600 .
As shown in FIG. 6 , the computing system 600 includes one or more processors, such as processor 602 that provide an execution platform for embodiments of the secure OS 106 and the sandbox tool 110 . Commands and data from the processor 602 are communicated over a communication bus 604 . The computing system 600 also includes a main memory 606 , for example, one or more computer readable storage media such as a Random Access Memory (RAM), where the secure OS 106 and the sandbox module 110 can be executed during runtime, and a secondary memory 608 . The secondary memory 608 includes, for example, one or more computer readable storage media such as a hard disk drive 610 and/or a removable storage drive 612 , representing a floppy diskette drive, a magnetic tape drive, a compact disk drive, etc., where a copy of a software version of the secure OS 106 and the sandbox tool 110 can be stored. The removable storage drive 612 reads from and/or writes to a removable storage unit 614 in a well-known manner. A user can interfaces with the secure OS 106 and the sandbox tool 110 with a keyboard 616 , a mouse 618 , and a display 620 . A display adapter 622 interfaces with the communication bus 604 and the display 620 . The display adapter 622 also receives display data from the processor 602 and converts the display data into display commands for the display 620 .
Certain embodiments may be performed as a computer application program. The application program may exist in a variety of forms both active and inactive. For example, the application program can exist as software program(s) comprised of program instructions in source code, object code, executable code or other formats; firmware program(s); or hardware description language (HDL) files. Any of the above can be embodied on a computer readable medium, which include computer readable storage devices and media, and signals, in compressed or uncompressed form. Exemplary computer readable storage devices and media include conventional computer system RAM (random access memory), ROM (read-only memory), EPROM (erasable, programmable ROM), EEPROM (electrically erasable, programmable ROM), and magnetic or optical disks or tapes. Exemplary computer readable signals, whether modulated using a carrier or not, are signals that a computer system hosting or running the present teachings can be configured to access, including signals downloaded through the Internet or other networks. Concrete examples of the foregoing include distribution of executable software of the application program on a CD-ROM or via Internet download. In a sense, the Internet itself, as an abstract entity, is a computer readable medium. The same is true of computer networks in general.
While the teachings has been described with reference to the exemplary embodiments thereof, those skilled in the art will be able to make various modifications to the described embodiments without departing from the true spirit and scope. The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. In particular, although the method has been described by examples, the steps of the method may be performed in a different order than illustrated or simultaneously. Furthermore, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” As used herein, the term “one or more of” with respect to a listing of items such as, for example, A and B, means A alone, B alone, or A and B. Those skilled in the art will recognize that these and other variations are possible within the spirit and scope as defined in the following claims and their equivalents. | A processor receives within a user interface of a process server on a first computer system a first signal that includes a request to create an isolated execution environment within a host environment controlled by an operating system executing on a second computer system, receives a second signal that specifies a control group, which specifies an amount of hardware resources on the second computer system that are accessible to the isolated execution environment, for the isolated execution environment. The processor generates a third signal that requests creation by a processor of the second computer system of the isolated execution environment and application of the control group to the isolated execution environment. The processor then repeatedly monitors for signals, from the second computer system, that report on one of an activity and a status of the isolated execution, and displays in the user interface information reflective of such signals. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to electrical supply line protection apparatus. It has application in the protection of three terminal lines (Teed circuits).
Three terminal lines, or Teed circuits, often offer considerable economic, technical and environmental advantage over 2-terminal lines. However, it is well known that, for a number of reasons such lines are often considerably more difficult to protect than plain feeders using conventional unit or non-unit protection techniques. Of the alternatives, differential protection is generally regarded as the method which is fundamentally best suited to Teed feeders, but it is only recently that communication channels have become available that are capable of transmitting both phase and amplitude information with a sufficiently large dynamic range and over a distance compatible with requirements of the transmission line protection.
SUMMARY OF THE INVENTION
According to the invention electrical supply line protection apparatus for Teed circuit lines having three terminals comprises a master unit at one terminal, slave units at each of the other terminals, broad band communication links between the master unit and the slave units separate from the supply lines, a line current transformer and a circuit breaker at each unit, logical decision-making means at the master unit, means for feeding measurement signals derived from the current transformers at the slave units along the links to the decision-making means, and means for transmitting operating signals along the links from the decision-making means to open the circuit breakers.
Preferably the links comprise fibre-optic waveguides. Filtering and signal processing arrangements, together with a novel decision process, are described below which specifically deal with the presence of a significant amount of high frequency (hf) components (due to the wide bandwidth inevitably associated with high speed HS applications) in the spill output under external fault conditions, without affecting the HS capability of the relay for internal faults.
Current signals proportional to the aerial mode currents (as opposed to the more conventional phase currents) at the line ends are preferably employed. This approach is adopted firstly because it requires the processing and transmission of two rather than three signal components and secondly because it increases the stability of the protection on a healthy circuit during the time when a fault occurs on an adjacent circuit.
BRIEF DESCRIPTION OF THE DRAWING
In order that the invention may be more fully understood reference will now be made to the accompanying drawings in which:
FIG. 1 is a block schematic diagram of an embodiment of the invention,
FIG. 2 is a simplified version of the diagram of FIG. 1,
FIG. 3 shows a superimposed extraction filter (SEF) of FIG. 1 in more detail,
FIG. 4(a) is a decision logic algorithm,
FIG. 4 (b) shows waveforms applied to the algorithm of FIG. 4(a),
FIG. 5 is a polar diagram of the steady-state current characteristics,
FIG. 6(a) and 6(b) show a single circuit line and a double circuit line respectively to which the invention is applied,
FIG. 7 shows mode-2-supermimposed relay signals for external faults,
FIG. 8 gives relay performance for internal faults,
FIG. 9 shows relay fault resistance coverage, and
FIG. 10 shows relay performance in double circuit lines.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A block schematic of the complete protection scheme is shown in FIG. 1. A simplified single line representation of the basic system is shown in FIG. 2. At each end there is a current transformer CT and a circuit breaker CB. The equipments at the slave ends transmit local current data and receive any direct intertripping signal for their circuit breakers CB, which signals are generated by the master end where the tripping decision is made. At each end, the output of the current transformer CT is passed through a current interface module (CI) designed to have a constant current/voltage gain over a wide range of frequencies, the constant of proportionality being controlled by the gain constant K i . The signal processing is performed at a rate of 4 kHz and the second-order low pass Butterworth pre-filter (PF) thus has a cut-off frequency of 2 kHz. The phase to modal transformation to form two aerial mode signals is performed using simple analogue signal differencing (P/M).
The transmission of the two signals at the 4 kHz sampling rate and with an 11 bit word plus sign conversion would require two channels of a standard modem, each with a capability of transmitting 64 kbits/sec. The very high security direct intertripping signal from the master to the slave ends can be transmitted with minimal delay over the two separate 64 kbit/sec channels exclusively devoted to this function.
The functional processes performed in the equipment at the master end are implemented in a 16 bit microcomputer. The delays T m , T S1 , T S2 are necessary to compensate for any sampled data mismatch. The differential and bias signals are formed for each mode separately and the final decision process is applied to either the total time variation of the signals or their superimposed components, the latter being chosen because of their certain advantages (as evident later) over the former. It can be seen from FIG. 1 that the final trip decision (T r ) is asserted and transmitted when either of the modal current measurands indicates an internal fault.
The basic relay operating principle hinges upon deriving a differential quantity, D(t), and a bias quantity, B(t), using the instantaneous values of the modal currents at the three ends of the Teed circuit. Thus in FIG. 1 if i p (t), i Q (t), i R (t) are the instantaneous values of the CT secondary currents at terminals P, Q and R respectively, then the two quantities D(t) and B(t) at the master end are given in continuous form by:
D(t)=i.sub.p (t)+i.sub.Q (t)+i.sub.R (t)
B(t)=i.sub.p (t)-i.sub.Q (t)-i.sub.R (t) (1)
In the phase to modal transformation, the first modal component used is formed as the difference of the a and c phase currents and the second modal component as the difference of the a and b phase currents. These signal combinations, which though only correspond exactly to aerial modes of excitation in ideally transposed lines are nonetheless satisfactory for practical purposes. Thus, the differential and bias signals for each mode signal pair are given by:
D.sub.1 (t)=[i.sub.aP (t)-i.sub.cP (t)]+[i.sub.aQ (t)-i.sub.cQ(t) ]+[i.sub.AR (t)-i.sub.cR (t)]
B.sub.1 (t)=[i.sub.aP (t)-i.sub.cP (t)]-[i.sub.aQ (t)-i.sub.cQ(t) ]-[i.sub.aR (t)-i.sub.cR (t)] (2)
D.sub.2 (t)=[i.sub.aP (t)-i.sub.bP (t)]+[i.sub.aQ (t)-i.sub.bQ(t) ]+[i.sub.aR (t)-i.sub.bR (t)]
B.sub.2 (t)=[i.sub.aP (t)-i.sub.bP (t)]-[i.sub.aQ (t)-i.sub.bQ(t) ]-[i.sub.aR (t)-i.sub.bR (t)] (3)
In its simplest form, the relay would operate for faults when the magnitude of the differential quantity exceeds that of the bias quantity by a certain pre-defined threshold value Khd S shown in:
|D(t)|-K.sub.B |B(t)|≧K.sub.S(4)
However, in order to achieve a HS response and at the same time ensure dynamic stability for external faults, it is necessary to apply a special trip decision process in which the differential and bias signals are checked over a number of samples using a specially developed decision logic algorithm. This process also has the effect of producing a near ideal complex current plane stability characteristic.
For purposes of later explanation, it is more convenient to define a time variant threshold signal S(t) as described by:
|D(t)|≧S(t) where S(t)=K.sub.S +K.sub.B |B(t)| (5)
FIG. 3 shows the digital filter used for extracting the superimposed components from the total variations of the signals. It is desirable to use a cascaded filter comprising a half cycle and a full cycle of nominal power frequency delay. The first sub-filter simply delays the incoming digital signal by one half cycle, thus providing exactly the superimposed component at point A in FIG. 3 for one half cycle, this being more than sufficient for practical purposes as the decision process completes the measurement and asserts tripping in approximately one quarter cycle. The second sub-filter, together with the first, gives an impulse response time of 1.5 cycles which causes both the superimposed bias and differential signals to be nominally zero (unlike the case where total variations of the signals are employed), under healthy conditions. This results in a scheme that is much more sensitive in particular to high resistance earth faults. FIG. 4(a) shows a flow process diagram of the decision process algorithm. The process can best be understood by considering the sketched differential current waveforms as shown in FIG. 4(b), which are typical for an external and an internal fault, as evident later. In the Figure, the pick-up levels have been chosen as fixed, i.e ±K S , to simplify the explanation.
Firstly, considering the external fault waveform, it can be seen that the magnitudes of the four samples 2-5 for example, are above the pick-up level. Thus after the completion of the first operation of the logic, the decision counter K D is set for an up count. It can be seen, however, that the polarities of the four samples considered are such that they alternate between positive and negative, thus resulting in the second operation of the logic giving a down count. It is apparent that K D stays close to zero at all times. For an internal fault, it can be seen that once the differential current has very rapidly exceeded the pick-up, it stays above this level for an appreciable time. This means that when the process compares the magnitude and polarities of four successive samples at a time, samples 2-8 succesively indicate an up count, thus allowing K D to attain a value of 4 very quickly. It should be mentioned that the criteria that have been adopted are of the four sample check and a trip signal initiation at a decision counter output of 4. This decision process is a near optimum that maximises stability under external fault conditions and at the same time maximises the sensitivity to internal faults. It also permits HS tripping for internal faults.
The complex current plane method of presenting the steady-state characteristics of differential protection for 2-ended feeders can be extended to Teed circuits. Such characteristics are useful from an application point of view, in that they enable the complex current ratio for any system conditions to be determined for a particular Tee configuration. FIG. 5 shows the stability characteristics for the new relay at current transformer (CT) levels of mode 1 (or 2) current at the P end of 0.15A and 10A r.m.s. Under healthy conditions and for the reference directions defined in FIG. 1 the relay clearly has a near ideal stability characteristic in that the point -1/0° is closely encompassed. The relatively higher sensitivity of the superimposed component is clearly evident.
An application of the invention to a 400 kV Teed circuit is shown in FIG. 6(a), and a double-circuit application is shown in FIG. 6(b). The earth resistivity and the system frequency are 100 Ωm and 50 Hz respectively and each terminating source has an X/R ratio at power frequency of 30. The source sequence ratio Z So /Z s1 =0.5 and the nominal CT ratios are 2000/1 at each end.
The current interface module gain K i is the only application dependent setting that the scheme posssess. It is set so that there is no case where current clipping occurs at any end for external faults. The results presented below are for K i =1V/secA, i.e. one volt per CT secondary ampere. This is obtained by noting that for the Teed configuration shown in FIG. 6(a) the maximum possible through fault current (approximately 15 kA, allowing for current doubling due to full exponential transient offset) would occur at end R for a 3-phase fault on the R busbar. Thus for a 2000/1 CT ratio, K i will be set to a value of 10/(15.10 3 /2.10 3 )≃1.3 V/secA in order to keep within ±10 V range of linearity. The modal mixing circuit gain K m =1/29 3 ensures that the input to the A/D converters never exceed their 10 V rating.
The basic sensitivity level setting K S (equation 4) must be sufficiently high to ensure that any noise in either the differential or bias signals is ignored. The required settings are 80 and 60 quantisation levels for relay variants based upon total and superimposed components respectively, the lower setting associated with the latter being possible due largely to the steady-state harmonic rejection properties of the superimposed extraction digital filter of FIG. 3. Thus, for a 2 11 conversion process, these levels correspond to pick-up levels of 400 and 300 mV. The bias level K B of 1/4 (25%) was largely determined by simulating the scheme response under condition of CT saturation during high level external faults.
Using the circuit of FIG. 6(a) it can be shown that the relay is stable for all types of through faults. FIG. 7(a) shows the variations of the differential and threshold signals D(t) and S(t) for an external 3-phase-earth fault close to end Q. The very significant hf components in the spill output are apparent and as can be seen, these can momentarily exceed the threshold signal. A tripping decision based solely on the criterion given by equation 4 could thus give a false tripping decision. However, the nature of the decision logic process described fully stabilises the relay as shown by the zero valued decision counter output of FIG. 7(b). When considering the effect of CT saturation, FIG. 7(c) shows that when the CT at end Q is made to saturate for a b-c external phase fault at that end, the saturation causes the differential current to suddenly rise in the form of large short-duration pulses which momntarily exceed the dynamic threshold S(t). However, it can be clearly seen from FIG. 7(d) that although the decision counter gives up counts intermittently, the decision logic process inhibits it from going above a value of 2 at any time, thus preventing relay instability. It should be mentioned that CT saturation problems for internal faults are not anticipated because the HS relay operates well before the onset of CT saturation in any practical situation.
FIG. 8(a) shows how the relay responds for internal faults occurring at the maximum and minimum of the fault voltage. It can be seen that the relay operating times are more or less identical for both single-phase-earth and pure phase faults, those occurring near voltage zero being slightly higher than faults near voltage minimum in the two cases.
FIG. 8(b) shows the variation of the relay operating time with point on wave of fault, for a single-phase-earth fault near the T-point. It is interesting to note that the relay operating time is more or less constant for the majority of fault inception angles but increases as the inception angle approaches the zero degree point on wave. This phenomenon can best be explained with reference to FIG. 8(c) and 8(d) which show the variations of the differential and threshold signals for fault inception angles near voltage zero and 160° respectively. In the case of the former (FIG. 8(c)) it can be seen that the differential exceeds the threshold almost instantaneously on fault inception. In the case of the latter however, FIG. 8(d) shows that on fault inception, the differential signal is such that it stays below the threshold for a longer time on account of the fault inception angle causing the differential signal to undergo a polarity reversal shortly before reaching the positive threshold level. On polarity reversal, however, the negative level is exceeded and this in turn initiates tripping after an additional delay of approximately 2 ms.
It is clearly evident from FIG. 9 that the relay gives a significantly higher fault arc resistance coverage when the relay measurands are based on superimposed modal currents rather than total modal currents. The stepped response in the case of phase-earth faults is due to a reduction in relay sensitivity at higher fault resistances, thus resulting in the relay taking longer to operate. In the case of double-phase-earth faults however, the levels of fault currents are generally higher.
The greater earth fault sensitivity of the superimposed component measuring version of the relay derives largely from the previously mentioned higher basic sensitivity that in turn is attainable on account of the elimination of the system steady-state harmonic components.
In double circuit line applications, there is a possibility of relay instability on the healthy circuit when a fault occurs on an adjacent circuit, due to mutual coupling. This is a potential problem in HS applications where, due to the much wider bandwidth that must be employed, much larger hf components of differential current are admitted into the healthy circuit relay.
The healthy circuit waveforms shown in FIG. 10, which are for an a-earth fault on one circuit of the system shown in FIG. 6(b), typify the problems that can be caused by the mutual coupling effect. It can be clearly seen that in all the four cases considered, the differential signal D(t) momentarily traverses the threshold signal S(t). However, the form of the decision logic processes employed again prevent any maloperation.
A point to note about the waveforms shown in FIG. 10 is that the mutual coupling effect is much stronger in the case where Phase quantities (FIGS. 10(a), (c)) are considered than for the case where modal signals are used (FIGS. 10 (b), (d)).
The special filtering and signal processing techniques developed, inparticular the decision process, ensure maximum relay stability for through faults without affecting the HS capability of the relay for internal faults. As regards the relay performance, tripping times of the order of 3-4 milliseconds are obtained and when relaying measurands are based on superimposed rather than total modal currents, a much higher fault-resistance coverage is attained. Apart from the economic advantages, the use of modal currents rather than phase currents increases healthy circuit relay stability in double circuit line applications. The relay design described can be readily implemented using present generation digital processing hardware.
It will be appreciated that it is possible to apply the master station principles at all three ends. In this case, it is necessary to transmit data describing the variation of the modal currents measured at each end to all terminals. Tripping of each circuit breaker is, in this case, effected directly by the local equipment without the need for transmitting an intertripping signal. | Teed circuit protection is provided by a master unit at one terminal and slave units at the other terminals with broad band communication links between the master unit and the slave units. All units include line current transformers to the master unit signals derived from the current transformers to the master unit and circuit breakers controlled by operating signals sent from the master unit. The master unit has a logic decision-making facility which takes measurements of the amount by which a differential quantity proportional to the sum of the measurement signals exceeds a bias quantity proportional to the difference between the measurement signals proportional to the sum of the measurement signal exceeds slave units. The facility sends operating signals when that amount exceeds a threshold value. To prevent spurious operation of the circuit breakers a sequence of consecutive measurements may be taken all of which must exceed the threshold value. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional Patent Application No. 62/242,804, entitled “Implementing Atomic Layer Deposition Gate Dielectrics for MOSFET Devices” and filed on Oct. 16, 2015, the contents of which are hereby incorporated herein by reference, to the extent such contents do not conflict with the present disclosure.
FIELD OF INVENTION
[0002] The present disclosure generally relates to processes for manufacturing electronic devices. More particularly, the disclosure relates to forming a Transition Metal Silicate film through atomic layer deposition (ALD).
BACKGROUND OF THE DISCLOSURE
[0003] Atomic layer deposition (ALD) is a method for depositing a thin film on a substrate through sequential distribution of various precursors. A conventional ALD method can take place in a reaction system comprising a reaction chamber, a substrate holder, a gas flow system, and an exhaust system. Growth of the thin film takes place when the precursors adsorb onto active sites on the substrate such that only a monolayer of the precursor forms on the substrate. Any excess precursor may then be expunged from the reaction chamber through the exhaust. Another precursor may be introduced to form another monolayer. The process may be repeated as needed to form a desired film of a desired thickness.
[0004] ALD processes have been particularly effective in forming gate dielectrics in complementary metal oxide semiconductor (CMOS) devices. For many years, silicon oxide (SiO 2 ) has been used for components in CMOS applications as transistor gate dielectrics and gate dielectrics. However, with the reduction in size of the components, SiO 2 has demonstrated problematic effects in the form of increased leakage currents. Controlling leakage current with the size constraints has proved challenging for SiO 2 .
[0005] In the formation of gate dielectrics, a dielectric material with a high dielectric constant (“high-k dielectric”) has been shown to have the performance characteristics in order to achieve smaller device geometries while controlling leakage and other electrical criteria. With these desired goals in mind, U.S. Pat. No. 7,795,160 to Wang et al. discloses methods for controlled deposition of a conformal metal silicate film onto a substrate surface. Going away from the prior SiO 2 methods, the methods disclosed could be used to form, specifically, hafnium silicate (HfSiO x ) and zirconium silicate (ZrSiO x ) films for various applications, such as gate stacks in CMOS devices, dielectric layers in DRAM devices and components of other capacitor-based devices. HfSiO x and ZrSiO x offer thermal stability and device performance in integrated circuits in smaller device geometries.
[0006] Also going away from prior SiO 2 methods, U.S. Pat. No. 8,071,452 to Raisanen discloses a method for ALD deposition of a metal film layer in order for use in high-k dielectric materials. Specifically, a method for depositing a hafnium lanthanum oxide (HfLaO) layer is disclosed. The method allows a HfLaO dielectric layer to be engineered with a desired dielectric constant and/or other controllable characteristics.
[0007] As a result, a method for forming a transition metal film that attains desired dielectric constants as well as demonstrates reliability is desired.
SUMMARY OF THE DISCLOSURE
[0008] In accordance with at least one embodiment of the invention, a method of forming a film is disclosed. The method comprises: providing a substrate for processing in a reaction chamber; performing a silicon precursor deposition onto the substrate; and performing a metal precursor deposition onto the substrate; wherein the silicon precursor deposition step is performed X times; wherein the metal precursor deposition step is performed Y times; wherein a transition metal silicate film is formed; wherein a metal precursor from the metal precursor deposition step comprises a metal atom bonded to a nitrogen atom or a carbon atom.
[0009] In accordance with at least one embodiment of the invention, a method of forming a transition metal silicate film is disclosed. The method comprises: providing a substrate for processing in a reaction chamber; performing a silicon precursor deposition onto the substrate, the performing the silicon precursor deposition comprising: pulsing a silicon precursor; purging the silicon precursor from the reaction chamber with a purge gas; pulsing an oxidizing precursor; and purging the oxidizing precursor from the reaction chamber with the purge gas; performing a metal precursor deposition onto the substrate, the performing the metal precursor deposition comprising: pulsing a metal precursor; purging the metal precursor from the reaction chamber with a purge gas; pulsing an oxidizing precursor; and purging the oxidizing precursor from the reaction chamber with the purge gas; wherein the silicon precursor deposition step is repeated X times; wherein the metal precursor deposition step is repeated Y times; and wherein a transition metal silicate film is formed; wherein the metal precursor comprises a metal atom bonded to a nitrogen atom or a carbon atom.
[0010] For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention have been described herein above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught or suggested herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
[0011] All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments will become readily apparent to those skilled in the art from the following detailed description of certain embodiments having reference to the attached figures, the invention not being limited to any particular embodiment(s) disclosed.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0012] These and other features, aspects, and advantages of the invention disclosed herein are described below with reference to the drawings of certain embodiments, which are intended to illustrate and not to limit the invention.
[0013] FIG. 1 is a diagram illustrating a method in accordance with at least one embodiment of the invention.
[0014] FIG. 2 is a diagram illustrating a method in accordance with at least one embodiment of the invention.
[0015] FIG. 3 is a diagram illustrating a method in accordance with at least one embodiment of the invention.
[0016] FIG. 4 is a diagram illustrating a method in accordance with at least one embodiment of the invention.
[0017] FIG. 5 is a graph illustrating growth rate and silicon incorporation as a function of pulsing ratio in accordance with at least one embodiment of the invention.
[0018] FIG. 6 is a chart illustrating a Rutherford Back Scattering analysis in accordance with at least one embodiment of the invention.
[0019] FIG. 7 is a schematic of a reaction system in accordance with at least one embodiment of the invention.
[0020] It will be appreciated that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of illustrated embodiments of the present disclosure.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0021] Although certain embodiments and examples are disclosed below, it will be understood by those in the art that the invention extends beyond the specifically disclosed embodiments and/or uses of the invention and obvious modifications and equivalents thereof. Thus, it is intended that the scope of the invention disclosed should not be limited by the particular disclosed embodiments described below.
[0022] FIG. 1 illustrates a process in which a transition metal silicate film can be formed on a substrate according to at least one embodiment of the invention. The substrate may be a silicon substrate, a silicon-capped germanium substrate, a Ge substrate, a SiGe substrate, or a III-V semiconductor substrate (such as InGaAs). In order to form a metal silicate film, such as a Lanthanum Silicate (LaSiO) film, a master cycle may comprise two subcycles. One subcycle may be a silicon oxide subcycle 100 , while the other subcycle may be a metal oxide subcycle 200 . The silicon oxide subcycle 100 may be repeated via a repeat cycle 310 , while the metal oxide subcycle 200 may be repeated via a repeat cycle 320 . The entire process may be repeated via a master repeat cycle 300 . In accordance with at least one embodiment, the silicon oxide subcycle 100 may be repeated X times via the repeat cycle 310 and the metal oxide subcycle 200 may be repeated Y times via the repeat cycle 320 in order to complete one master cycle. The ratio of X:Y may be used to adjust the growth rate of the LaSiO film.
[0023] In at least one embodiment of the invention, the order of the subcycles may be varied such that an order of the subcycles could be in a sandwich structure. For example, if pulse ratio of the silicon oxide subcycle to the lanthanum oxide subcycle equals 2:1; then precursor deposition may proceed as one silicon oxide subcycle 100 , followed by a lanthanum oxide subcycle 200 , and then a silicon oxide subcycle 100 . In another embodiment of the invention, the order of the subcycles could be such that either subcycle could be first or last. Subcycles may be inserted at non-fixed ratios in order to effectively grade a composition of the film versus a vertical distance from the substrate.
[0024] It may also be possible that different orders for subcycles result in a film with the similar properties. FIG. 2 illustrates a process in accordance with at least one embodiment of the invention, where a metal oxide subcycle 200 comes before a silicon oxide subcycle 100 . In addition, in accordance with at least one embodiment of the invention, a lanthanum precursor pulse/purge followed by a silicon precursor pulse/purge, and then an oxygen precursor pulse/purge may result in a similar film as one produced by the sandwich order described above.
[0025] FIG. 3 illustrates a silicon oxide subcycle 100 in accordance with at least one embodiment of the invention. The silicon oxide subcycle 100 can comprise a Silicon (Si) precursor pulse/purge 110 and an oxygen precursor pulse/purge 120 . The Si precursor may comprise at least one of the following: a silicon halide based precursor such as Silicon tetrachloride (SiCl 4 ), trichloro-silane (SiCl 3 H), dichloro-silane (SiCl 2 H 2 ), monochloro-silane (SiClH 3 ), hexachlorodisilane (HCDS), octachlorotrisilane (OCTS), silicon iodides, or silicon bromides; or an amino-based precursor, such as Hexakis(ethylamino)disilane (AHEAD) and SiH[N(CH 3 ) 2 ] 3 (3DMASi), Bis(dialkylamino)silanes, such as BDEAS (bis(diethylamino)silane); and mono(alkylamino)silanes, such as di-isopropylaminosilane; or an oxysilane based precursor, such as tetraethoxysilane Si(OC 2 H 5 ) 4 . The typical temperatures for this process range from 100-450° C., or from 150-400° C., or from 175-350° C., or from 200-300° C., while pressures may range from 1 to 10 Torr.
[0026] In other embodiments consistent with the invention, the oxygen precursor pulse/purge 120 may involve a pulse and purge of at least one of: water (H 2 O); diatomic oxygen (O 2 ); hydrogen peroxide (H 2 O 2 ); ozone (O 3 ); oxygen plasma; atomic oxygen (O); oxygen radicals; or methyl alcohol (CH 3 OH). It may be possible that different oxidizing precursors could be used for the different cycles; for example, O 3 may be used for the silicon oxide subcycle, while water can be used for the lanthanum oxide subcycle. In other embodiments of the invention, it may be possible to use an oxygen source that does not comprise ozone, O 2 , H 2 O 2 , H 2 O, methyl alcohol, or oxygen plasma.
[0027] FIG. 4 illustrates a metal oxide subcycle 200 in accordance with at least one embodiment of the invention. The metal oxide subcycle (or a rare earth metal precursor subcycle) 200 may comprise a metal precursor pulse/purge 210 and an oxygen precursor pulse/purge 220 . In some embodiments of the invention, a rare earth metal precursor (such as Lanthanum (La), Scandium (Sc), Yttrium (Y), Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb or Lu, for example) may comprise a bond between the rare earth metal and Nitrogen or a bond between rare earth metal and Carbon. In some embodiments of the invention, the rare earth metal precursor may comprise a bidentate ligand bonded to lanthanum through two nitrogen atoms. In some embodiments of the invention, the rare earth metal in the rare earth metal precursor (e.g., lanthanum) has an oxidation state of +III. In some embodiments of the invention, the rare earth metal precursor has three organic ligands, such as ligands containing nitrogen or carbon. In some embodiments, the rare earth metal precursor (e.g., lanthanum) may not comprise Silicon or Germanium. In some embodiments, the metal precursor may comprise a metal atom bonded to a nitrogen atom or a carbon atom.
[0028] In at least one embodiment of the invention, a metal precursor in the metal precursor pulse/purge 210 may be one of the following: an amidinate based precursor, such as Lanthanum formamidinate (La(FAMD) 3 ) or tris(N,N′-diisopropylacetamidinato)lanthanum (La(iPrAMD) 3 ); a diketonate precursor, such as (La(THD) 3 ); a Cp(cyclopentadienyl)-based precursor such as Tris(isopropyl-cyclopentadienyl)lanthanum (La(iPrCp) 3 ); or an amido-based chemistry such as tris(bistrimethylsilylamido)-lanthanum (La[N(SiMe 3 ) 2 ] 3 ); or hybrid combinations of the above. In other embodiments consistent with the invention, the metal precursor may be a lanthanum or other rare earth metal precursor having a bond between nitrogen, such as a lanthanum amidinate, for example. The amidinate compounds may comprise delocalized electrons that result in the bond between the nitrogen and the lanthanum or rare earth metal. In other embodiments consistent with the invention, the metal precursor may be a lanthanum or other rare earth metal precursor having a bond with carbon, such as a lanthanum cyclopentadienyl, for example. This metal precursor may comprise delocalized electrons, which are considered to be compounds, in which the bond between the carbon and the lanthanum or rare earth forms. In other embodiments consistent with the invention, the metal precursor may be a lanthanum or other rare earth metal precursor having a bond with both nitrogen and carbon, such as a lanthanum amidinate and a lanthanum cyclopentadienyl compound, for example.
[0029] In other embodiments consistent with the invention, the oxygen precursor pulse/purge 220 may involve at least one of: water (H 2 O), diatomic oxygen (O 2 ), hydrogen peroxide (H 2 O 2 ), ozone (O 3 ), oxygen plasma, oxygen radicals, atomic oxygen, or methyl alcohol (CH 3 OH). The metal oxide subcycle 200 may be substituted with an yttrium oxide subcycle or another element's subcycle depending on what is the final desired product. Other elements could be lanthanides, erbium, erbium oxide, magnesium, magnesium oxide, scandium, or scandium oxide, among others. These other materials may also be preferable as they demonstrate an ability to cause the V t shift. For yttrium, the yttrium subcycle may comprise a yttrium pulse, a purge of the yttrium precursor, a H 2 O pulse, and a purge of the H 2 O precursor. The yttrium precursor could be one of the following: a Cp(cyclopentadienyl)-based chemistry, such as Y(EtCp) 3 and tris(methylcyclopentadienyl)yttrium (Y(MeCp) 3 ); an amidinate-based precursor, such as Tris(N,N′-diisopropylacetamidinato) Yttrium (TDIPAY); a diketonate precursor, such as (Y(THD) 3 ) and tris(2,2,6,6-tetramethyl-3,5-octanedionato)Yttrium (Y(tmod) 3 ); or an amide-based precursor, such as Tris[N,N-bis(trimethylsilyl)amide]yttrium. Typical temperatures for this process range from 100-450° C., or from 150-400° C., or from 175-350° C., or from 200-300° C., with pressures ranging from 1 to 10 Torr.
[0030] The pulse ratio X:Y of the silicon and metal oxide subcycles can allow for incorporation of Silicon (Si) into the metal silicate film. The pulse ratio X:Y may range to be 5:1, 7:1, 10:1, and 20:1. FIG. 5 illustrates a graph of silicon incorporation based on different pulse ratios X:Y. For higher X:Y pulse ratios, the incorporation of Silicon is greater, resulting in a higher silicon content. Control of the pulse ratio can enable Si incorporation to exceed 65%. Si content may vary from low levels to high levels. For example, the silicon content may range as being greater than 5 at-% Si, greater than 10 at-% Si, greater than 15 at-% Si, or greater than 20 at-% Si. A pure silicon oxide film may have a silicon content of approximately 33 at-%. In the case of forming a LaSiO film, a higher Si content may reduce the hygroscopic property of LaO and also improve the compatibility with the following high-k growth. The Silicon incorporation in excess of 65% is significantly higher than that for Aluminum Silicates (AlSiO), which tend to average about 30-40% (for TMA vs. AlCl 3 processes).
[0031] An additional benefit attained through at least one embodiment of the invention includes a lower carbon impurity level. Carbon is considered as a trap center and may degrade the performance of a device formed using the deposited film. As a result, a lower carbon level may be preferable.
[0032] Carbon may be formed easily if strong oxygen reactants, such as ozone or oxygen plasmas, are used. These strong reactants may result in greater oxidation of the substrate. Conventional LaOx films deposited through ALD indicate a high carbon impurity level between 15-20%. In addition, conventional LaOx films may also show high hydroxide impurities as well as low silicon incorporation.
[0033] In accordance with at least one embodiment of the invention, a combination of a silicon halide precursor, a rare earth precursor having a bond with a nitrogen/carbon atom, a proper oxygen precursor (such as water), and a high mobility channel material may be the reason for a lower carbon impurity level. The proper oxygen precursor may result in less oxidation of the substrate, potentially providing for a good surface or interface for subsequent deposition of additional materials, such as a high-k material formed by ALD.
[0034] As shown in FIG. 6 , LaSiO films deposited through embodiments in accordance with the invention indicate a much lower carbon impurity level less than 5% depending on the pulse ratio X:Y. These percentages are determined through the Rutherford Back-Scattering (RBS) analysis method. The LaSiO film may also demonstrate less than 10 at-% of hydrogen impurities, less than about 5 at-% of carbon impurities, and/or less than about 2 at-% of nitrogen impurities. In accordance with at least one embodiment of the invention, the LaSiO film may have a hydrogen content of less than 20 at-%, less than 15 at-%, less than 10 at-%, or less than 5 at-%. In accordance with at least one embodiment of the invention, the LaSiO film may have a carbon content of less than 10 at-%, less than 5 at-%, less than 2 at-%, or less than 1 at-%. In accordance with at least one embodiment of the invention, the LaSiO film may have a nitrogen content of less than 10 at-%, less than 5 at-%, less than 2 at-%, or less than 1 at-%.
[0035] In accordance with at least one embodiment of the invention, a lanthanum hydroxide film (La(OH) 3 ) may be formed. In at least one embodiment of the invention, for a pure lanthanum hydroxide (La(OH) 3 ) film, the hydrogen content could be less than 43%. In accordance with at least one embodiment of the invention, a lanthanum hydroxide film may have hydrogen impurities, ranging from less than 20 mol-% of hydroxide (OH), less than 15 mol-% of hydroxide (OH), less than 10 mol-% of hydroxide (OH), or less than 5 mol-% of hydroxide (OH).
[0036] FIG. 7 illustrates a reaction system setup capable of performing the method according to at least one embodiment of the invention. The reaction system includes four process modules. Process modules (PM) may include Pulsar® 3000 modules or Horizon modules provided by ASM International N.V. Other reaction system setups may include a mini-batch reactor, a dual chamber module reactor, a batch reactor, a cross-flow reactor, or a showerhead reactor. A wafer handling system may transfer a processed wafer to the different modules. In one process module, an interface layer for a Germanium/Silicon Germanium or a III-V substrate (such as InGaAs) may be formed via a method in accordance with at least one embodiment of the invention. In another process module, other development processes may take place, such as surface passivation of Ge/SiGe channels or a III-V substrate (such as InGaAs).
[0037] The particular implementations shown and described are illustrative of the invention and its best mode and are not intended to otherwise limit the scope of the aspects and implementations in any way. Indeed, for the sake of brevity, conventional manufacturing, connection, preparation, and other functional aspects of the system may not be described in detail. Furthermore, the connecting lines shown in the various figures are intended to represent exemplary functional relationships and/or physical couplings between the various elements. Many alternative or additional functional relationship or physical connections may be present in the practical system, and/or may be absent in some embodiments.
[0038] It is to be understood that the configurations and/or approaches described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are possible. The specific routines or methods described herein may represent one or more of any number of processing strategies. Thus, the various acts illustrated may be performed in the sequence illustrated, in other sequences, or omitted in some cases.
[0039] The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various processes, systems, and configurations, and other features, functions, acts, and/or properties disclosed herein, as well as any and all equivalents thereof. | A method for depositing a thin film onto a substrate is disclosed. In particular, the method forms a transitional metal silicate onto the substrate. The transitional metal silicate may comprise a lanthanum silicate or yttrium silicate, for example. The transitional metal silicate indicates reliability as well as good electrical characteristics for use in a gate dielectric material. | 2 |
FIELD OF THE INVENTION
This invention relates to pinch valves and more specifically to a latching pinch valve utilizing shape memory alloy materials.
BACKGROUND
In the field of fluid control various valves have been used to control the flow of the fluid. Well known in the field are two position valves which are either open or closed and proportional valves where the amount of fluid flowing is determined by the degree of openness or closure of the valve. Also known in the field are valves where the fluid flows directly through the valve and pinch valves where the valve operates on the external portion of the flow path to control the flow of the fluid along a flow path. An example of this latter case is a roller clamp used in the intravenous delivery of therapeutic solutions where the roller pinches the IV flow line based on its position along an inclined plane.
Also known in the art are bistable latching valves that may either be open or closed. These bistable latching valves are of particular importance when available power for operation of the valve is limited. In the case of these bistable latching valves power need only be applied to change the state of the valve; that is, from open to closed or from closed to open. Since these valves are stable in both the open position and the closed position, no power is needed to keep the valve in either the open or the closed position. Examples of latching valves are commercially available from the Lee Company of Westbrook, Conn.
Most latching valves are designed in such a manner that fluid flows through the valves. However, latching pinch valves are known, for example, solenoid latching pinch valves from the Farmington Engineering Company of Madison, Conn.
Valves taking advantage of the shape changing properties of shape memory alloys are also known. Krumme in U.S. Pat. No. 4,645,489 teaches the use of a shape memory allow to control the position of a valve closure element in a proportional valve. Edelman and Ritson in U.S. Pat. No. 4,878,646 teach the use of a shape memory alloy element to release the energy of a spring to close a pinch valve in an IV fluid delivery system. In this teaching, the shape memory alloy is only used to close the valve by releasing a latch. Reopening the valve and latching the valve open is done manually. In automatic fluid control systems, where both the closing and the opening of the fluid flow path should be done automatically under the control of an operating system, such a manual “reset” of the valve of Edelman and Ritson is impractical.
Recently, “closed loop” fluid systems for delivery of medications to patients have appeared where a fluid flow property is measured and the rate of fluid flow is adjusted based on the flow measurement. Notable examples are Sage, in U.S. Pat. No. 6,582,393, Connelly et al in U.S. Pat. No. 6,589,229 and Jerman in U.S. Pat. No. 5,533,412. While Connelly uses a piezoelectric pump and adjusts the output of the pump based on the monitored flow property, Sage and Jerman do not teach the details of the flow control means, although both do teach the flow measuring means. An automatic, low power, bistable latching pinch valve would be useful in the implementation of either the art of Jerman or Sage. None of the prior art teachings represent acceptable valves for use in these miniaturized fluid delivery systems where the fluid flow rate is measured and a microprocessor controls a valve based on the measured flow rate. Hence there remains a need for improved valving methods.
SUMMARY OF THE INVENTION
A miniature microprocessor controlled pinch valve is described. The valve may be bistable or may be a latching valve. The valve is operated by shape memory alloy elements wherein current is applied to the elements to change the length of the elements thereby activating the valve. In one embodiment, the force of a spring is applied to a valve closure element such that with no power applied, the valve is normally closed. To open the valve, current is applied to the shape memory alloy element thereby decreasing its length. The force resulting from the shape change is sufficient to overcome the force keeping the valve closed, hence the valve opens. A reduced “holding” current may be used to maintain the valve in the open position. To close the valve, current is removed from the shape memory alloy element.
Alternatively, in a second embodiment, the valve could be normally open with no power applied. In this case, when current is applied to the shape memory element, the valve is drawn closed since the force resulting from the shape change in the shape memory alloy is greater than the force keeping the valve open. To open the valve again, current is withdrawn from the shape memory element.
In a second embodiment, two shape memory alloy elements are used to operate a bistable latching valve. The valve may be normally open or normally closed, depending on the initial placement of the pinching element. In the normally closed version of this embodiment, a first shape memory alloy element is briefly energized to latch the valve in the open position. To close the valve, a second shape memory element is briefly energized to unlatch the pinching element. In the normally open version of this embodiment, the first shape memory alloy element is briefly energized to latch the valve in the closed position. To open the valve, the second shape memory alloy element is briefly energized to unlatch the pinching element, thereby opening the valve again. In drug delivery applications, the normally closed version is usually preferred since this is the position the valve will take in the event of a power failure.
In a third embodiment, a pinching element is made of a material attracted to magnets. In a first position, it is held in a position such that the flow path is pinched and flow is stopped. In a second position, it is held in position such that the flow path is open and fluid flows along the flow path. Shape memory alloy wires are used to overcome the magnetic force holding the pinching element in one or the other position thereby causing it to move from one position to the other position.
In any of the embodiments, the conduit for fluid flow is adapted to be removable from the pinching action of the pinching member. The valve is caused to be in the open position, allowing the fluid conduit to be removed from a position between the pinching member and a pinching plate. In this manner the fluid flow path is not breached, that is, the valve operates on the outside of the fluid path and does not touch the fluid. Such a non-contact feature is important for maintaining sterility of the flow path such as when the shape memory activated pinch valve is used in a drug delivery system.
The consistent theme of this invention is the automatic or logical control of both the opening and the closing of a shape memory alloy activated pinch valve. The valve may be normally open or normally closed. In general it is a latching valve in that it has two stable positions such that zero or small amounts of energy are required to maintain the valve in either of its two stable positions. It is not, however, a proportional valve where the amount of current in the shape memory element dictates the degree of openness or closure of the valve.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a schematic of an automatically operated normally closed shape memory alloy activated valve.
FIG. 2 shows a schematic of an automatically operated normally closed bistable latching valve activated by a shape memory alloy.
FIG. 3 shows a schematic of a shape memory alloy latching pinch valve with magnetic assist of opening and closing the valve.
DETAILED DESCRIPTION
The operation of one embodiment of the invention is described with the aid of FIG. 1 , which is a schematic of a normally closed pinch valve activated by a shape memory alloy element. FIG. 1 has three drawings; FIG. 1A which shows the valve in the normally closed, unactivated state, FIG. 1B which shows the valve in the activated or open state, and FIG. 1C which shows the valve returned to the normally closed unactivated state. The shape memory alloy element is nominally a shape memory alloy wire, but other shapes of materials such as strips and coils would also be appropriate. Shown in FIG. 1 is fluid reservoir 14 which is adapted to deliver fluid along flow path 13 . Flow path 13 may be any of compressible material such as silicone or may be of a laminate construction of sheet materials such that a fluid path is provided. This flow path is shown compressed in FIG. 1A between pinching element 15 and surface 12 . Pinching component 15 is shown contacting flow path 13 at two locations for redundancy. Pinching component 15 is shown cantilevered from wall 19 , such that flexure of pinching element 15 provides the force to compress flow path 13 . Other means of providing force to compress flow path 13 are possible including a compressed spring or additional mass attached to pinching component 15 . Pinching component 15 may have as few as one pinching point or may have two or more depending on the needed confidence of closure. Attached to pinching component 15 are two shape memory alloy elements 11 . Two elements 11 are shown again for redundancy, but one or more than two may also be used. Shape memory elements 11 are connected at the other end to a fixed connector block 18 . The connection provided by connector block 18 is an electrical as well as physical one so that current provided by current source 16 is provided to shape memory elements 11 . Logical circuit 17 provides signals to current source 16 in order to operate the valve at the proper times. Logical circuit 17 may receive its input from a number of sources that are not shown, such as manual input from a human interface, from a clock circuit, or from a flow sensor such as that taught in U.S. Pat. No. 6,582,393.
FIG. 1A shows the shape memory alloy activated valve in the normally closed position. FIG. 1B shows the valve in the open position. To activate the valve to the open position, logical circuit 17 sends a signal to current source 16 to supply current to shape memory alloy elements 11 through connector block 18 . Sending current through a shape memory alloy element raises its temperature, which causes a material phase change that results in a reduction in length of the shape memory alloy element. This shape change exerts a significant force overcoming the force causing pinching component 15 to compress flow path 13 and raising pinching component 15 above surface 12 thereby allowing fluid to flow along flow path 13 . Pinching component 15 remains in this position until such time that logic circuit 17 sends a signal to current supply 16 to discontinue providing current to shape memory allow elements 11 . Removing the current from shape memory elements 11 lowers the temperature of shape memory elements 11 thereby causing them to lengthen and return to their original length. The lengthening of shape memory alloy elements 11 allows pinching component 15 to compress fluid path 13 , thereby closing the valve. This configuration of the valve after removal of current from shape memory alloy elements 11 and the subsequent return of pinching component 15 is shown in FIG. 1C .
A second embodiment of the invention is shown in FIG. 2 . This second embodiment is a latching valve in that it may be in either position, the open position or the closed position without requiring any power to maintain that position. FIG. 2A shows the valve in the closed position with pinching element 15 pressing flow path 13 against surface 12 . Fluid to be controlled by the valve flows in flow path 13 from a fluid supply (not shown) similar to that shown in FIG. 1 . Pressure to close flow path 13 may be provided by the mass of the pinching element 15 , by pinching element 15 made of a flexible material and being already flexed in the position shown in FIG. 2A or by a spring (not shown but which is well known in the art) forcing pinching element 15 against flow path 13 . When the decision is made to open the valve, logic circuit 17 signals current source 16 to supply current to shape memory alloy elements 25 through interface block 24 . As in the previous embodiment, the number of shape memory alloy elements may vary according to the force requirements. This current causes shape memory alloy elements to shorten in length, moving latching element 23 to the position shown in FIG. 2C . The force keeping latching component 23 in the position shown in FIG. 2A may be provided by a spring (not shown) or may be due to stored elastic energy of the material of latching component 23 .
Once latching element 23 is in the position shown in FIG. 1C , logic circuit 17 signals current source 16 to supply shape memory alloy elements 21 through interface block 22 . This current causes shape memory alloy elements 21 to shorten in length, thereby raising pinching component 15 away from surface 12 and opening flow path 13 . Once pinching component 15 is raised away from surface 12 , current supply 16 withdraws current from shape memory alloy elements 25 allowing latching element 23 to resume its initial position. With pinching component 15 raised and latching component 23 in its original position, as shown in FIG. 1B , latching component 23 holds pinching component 15 away from surface 12 , allowing fluid to flow in flow path 13 . Current supply 16 now removes current to shape memory alloy elements 21 . In this state, no current is supplied to any of the shape memory alloy elements, yet the valve remains open.
Alternatively, this opening step may be taken without activating shape memory alloy elements 25 with an appropriate shape of latching component 23 . As shown in FIG. 2A , when current is applied to shape memory alloy elements 21 to pull pinching component 15 away from surface 12 , the motion of pinching element 15 away from surface 12 will also move latching element 23 to the right as it slides against latching component 23 . Given the force provided with latching component 23 to urge it to the position shown in FIG. 2A , once pinching element is above the latching component 23 as shown in FIG. 2B , latching component will return to the position shown in FIG. 2A thereby engaging pinching component 15 and holding it away from surface 12 .
To close the valve, logic circuit 17 signals current source 16 to supply current to shape memory alloy elements 25 through interface block 24 . This current causes shape memory alloy elements 25 to shorten in length, moving latching component 23 to the position shown in FIG. 2C . Latching component 23 in this position is no longer able to hold pinching component 15 above surface 12 so it springs back to its lower position where it compresses flow path 13 against surface 12 , closing the valve. When logic circuit 17 signals current source 16 to stop the flow of current to shape memory alloy elements 25 , they lengthen again, and latching component 23 returns to the position shown in FIG. 2A such that the valve is now ready to be opened again with signals from logic circuit 17 .
A third embodiment of the invention is shown in FIG. 3 . The shape memory alloy activated valve is designed to open or close flow path 13 by pinching flow tube 13 between pinching component 33 and pinch block 31 . This third embodiment latches the valve in the open or closed position by using magnets 31 , which is also pinch block 31 , and magnet 32 . Shown in FIG. 3A is the valve in the normally closed position with pinching component 33 pressing against flow path 13 . At a selected time current source 36 activates shape memory alloy wires 35 causing the wires shorten. This shortening of shape memory alloy wires 35 causes pinching component 33 to move upward. When pinching component 33 moves upward, it is pulled further upward by the magnetic field of magnet 32 , causing pinching component 33 to come to rest as shown in FIG. 3B . In this way the valve is opened by a single short pulse of current from current source 36 and is held upon by magnet 32 .
When a time arrives when the valve is to be closed, current from current source 37 activates shape memory alloy wires 34 causing them to shorten. The shortening of shape memory alloy wires 34 causes pinching component 33 to move downward. As pinching component 34 moves downward, the magnetic field of pinch block and magnet 31 pulls it down further causing it to come to rest firmly in the grip of magnet 31 , closing the valve as shown in FIG. 3C . In one embodiment of the magnetically assisted valve of FIG. 3 , magnet 31 exerts a larger magnetic force on pinching component 33 than magnet 32 thereby providing additional assurance that the valve is normally in the closed state. | A shape memory activated fluid control pinch valve is disclosed. The valve may be normally open or normally closed. In various embodiments of the valve, the valve may be a latching pinch valve and may operate with magnetic assistance. | 5 |
[0001] The present application is directed to a tent and its support system and to the method by which it is constructed.
BACKGROUND OF THE INVENTION
[0002] Tents have probably been used for shelter ever since animal skins became available for coverings. Many types and styles have been developed over the years from the compact mountain tents of backpackers to the huge enclosures used by circuses. Wall tents with straight relatively low sides and gable tops have been widely used for military and camping purposes. These have a ridgepole running the entire length supported by upright poles at each end. Similarly, pyramid-style tents have had wide military use. These are generally round with conical tops. They have a center pole and are stabilized by multiple guys on the outside. Pyramids are sized to hold from a few people up to a large number. Modified small wall tents or A-types are widely used by campers for light duty and may hold one to four people. These may have either internal or external support systems, the latter now being more common. Dome types with external support means are also popular for light camping since they offer a bit more usable floor space and headroom than the A-types.
[0003] One problem with most of the above tents, except for the very large ones, is restricted headroom. Even in the wall tents or pyramids, one can often stand erect only in the central location. This problem was partially solved by development of the so-called umbrella types. Originally these were supported by a center pole with radially extending spokes extending to the junction of the top and sidewall portions. Sidewalls were nearly vertical and the top was a low angle four-sided pyramid. Later, external supports were developed to eliminate the center pole. Some umbrellas are supplied with side rooms that require additional poles for support. The umbrellas are very popular for family camping since they are relatively easy to erect and have good headroom over most of the floor area.
[0004] One would think that tent development would have reached maturity many years ago but this is certainly not the case. A brief look at the patent literature and outdoor catalogs shows continuous development from early days to the present. One problem has remained constant—that of having a high ratio of headroom space to the total floor area. This is coupled with the need for ease and simplicity of erection along with minimum weight. The tent of the present invention serves those needs exceptionally well.
[0005] Among the prior known tents that are related to the present invention can be mentioned Doane, U.S. Pat. No. 214,996, which is an example of a large pyramidal tent with side walls. Eddy, in U.S. Pat. No. 2,236,677, shows a similar tent but one that has a peripheral frame supporting the juncture between the walls and top portions.
[0006] Recent U.S. Pat. No. 6,250,322 to Porter shows a circular umbrella-type having a conventional center pole with spokes connected to a peripheral roof ring located at the juncture between the top and side walls. The center pole is permanently anchored to the ground.
[0007] An early patent to Leavitt, U.S. Pat. No. 172,882 shows a tent that may be of circular, square, or oval configuration. This has a center pole and a rigid metal reinforcing ring at the periphery where the top and side walls are joined. The reinforcing ring may optionally be connected to the center pole by radial spokes. It is held to the roof/sidewall junction by twine or wire ties. A somewhat later patent to Smith, U.S. Pat. No. 1,409,316, shows a beach cabana in which the support is a center pole with a ring formed from a plurality of flexible sections at the top-sidewall juncture. This ring is also held in place by a series of internal tabs. Finally, U.S. Pat. No. 1,581,331 to Smith describes a larger tent of circular cross section using a center pole and a series of flexible jointed supporting rods located as a ring around the top-sidewall juncture. Once again, this ring is held in place by a plurality of supporting flaps or tabs which must be individually fastened.
[0008] The present invention is of the general type of construction as that shown in the last three patents noted above but represents a significant improvement in simplicity, stability, ease of erection, and compactness when stored.
SUMMARY OF THE INVENTION
[0009] The present invention is a tent having a novel support system that gives full headroom over the entire internal area and is easy and simple to erect. The tent will preferably be circular or essentially circular in cross section as seen in plan view. It may have an essentially vertical sidewall section when erected. This is joined at a well defined transition to a top section that preferably will be generally conical or have a conical portion atop one or more frustoconical sections. Alternatively, the top may be essentially flat although this is not preferred. Internally, at the transition between the sidewall and top portions, there is a circumferential, relatively narrow tension shelf The tension shelf may be a single or a superposed double ring of fabric. Located atop or within the tension shelf in the erected tent is a compression hoop bearing outwardly against the tent fabric. This shelf and hoop work as a unit to give support and stability to the tent without the need for an extensive external or internal pole system and without the need for a multiplicity of individual ties for the hoop. A center pole between the apex of the top portion and the lower surface upon which the tent is resting completes the structure. In larger tents the top portion may be constructed with two or even more vertices and two or more poles might be used. In some circumstances, e.g. when a convenient tree limb might be overhead for support, the center pole is not necessary.
[0010] One or more additional tension shelf/compression hoop configurations may be located above the one at the top-sidewall junction. These would typically be placed where there is a change of angle in the top portion, although it is not essential that they be so located nor is a change of angle in the top portion required.
[0011] The tent is preferably equipped with appropriate tabs for securing it to the ground or a tent platform and for attaching external guy lines for additional wind stability.
[0012] It is an object to provide a support system for a tent that is simple and gives exceptional stability even in high winds.
[0013] It is a further object to provide a tent that has headroom over the entire extent of the internal area.
[0014] It is another object to provide a tent using circumferential tension shelves and compression hoops for support and stability.
[0015] It is yet an object to provide a tent that may be readily and simply erected and taken down and which is extremely light in weight for the internal area covered.
[0016] It is also an object to provide a tent that may readily include windows or other openings.
[0017] It is still an object to provide a tent that may be easily and conveniently pitched on uneven terrain.
[0018] These and many other objects will become readily apparent upon reading the following detailed description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a perspective view seen from somewhat above of one version of the erected tent of the present invention.
[0020] [0020]FIG. 2 is a side elevation in outline of the tent of FIG. 1.
[0021] [0021]FIG. 3 is a section through line 3 - 3 of FIG. 2.
[0022] [0022]FIG. 4 is a cut away section seen from a somewhat elevated viewpoint of the circumferential tensioning system for the tent.
[0023] [0023]FIG. 5 is a depiction of the tent in an upside down position during initial insertion of one of the circumferential compression hoops.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] In the description that follows, like numbers will be used for like elements in all of the figures. Referring now to the drawings, FIG. 1 shows one version of the present invention. A circular tent, generally seen at 2 , has a sidewall section 4 and a top portion 6 , 8 . There is a clear transition 10 at the junction of the sidewall and top. The tent may optionally have a ground skirt 12 at the bottom of the sidewall. Stakes 14 are used to secure the lower edge of the sidewall to the ground. Similarly, optional guy lines 16 are secured to tie tabs 18 located around the outer edge of the transition between the sidewall and top. One or more door openings 20 allow access to the interior. These may be fastened with ties, Velcro strips, or zippers in a conventional manner.
[0025] In the version shown, tent 2 has a lower top portion 6 in the form of a truncated cone. Atop this is an upper conical portion 8 joined to the lower portion along transition zone 22 . This construction is preferred for a larger tent. A smaller tent might simply have a single conical top section. For very large tents additional stacked truncated sections might be used. Additional central area support poles and vertices may also be used. While the tent can be made in the smaller sizes often used by back-packers, it will most often be made in sizes suitable for so-called family camping. This use demands greater space and comfort and the sidewall will typically be sufficiently high so that most or all of the area under the top will at least be high enough to permit standing erect. Many other uses are contemplated such as emergency shelters or other applications where tents have been used or would be satisfactory.
[0026] Inside the tent are tension shelves 24 located at the transition between the sidewall and top and 26 placed at the transition between then lower and upper portions of the top. These are key to support of the tent and their construction and purpose will now be explained.
[0027] The tent is seen in profile in FIG. 2 and the construction of the tension shelves 24 , 26 are seen in the cut away of FIG. 3. The tension shelves are relatively narrow; e.g., 8-15 cm wide, and are sewn or otherwise affixed to the tent fabric at the respective transition zones. Above each of the tension shelves is a compression hoop that may be constructed of interlocking shorter sections of standard semiflexible aluminum, fiberglass tent poles, or similar suitable materials. Where closely superposed or double tension shelves are used the compression hoop is placed between them. Tension hoop 28 is located above shelf 24 . This may be temporarily held in place by optional ties or Velcro tabs 30 during erection of the tent. Preferably a drawstring 32 or similar tensioning device such as a length of elastic cord may be held in a fold or series of loops 34 on the outer edge of the tension shelf to draw it tight after erection. However, this is not essential. In similar manner, compression hoop 36 rests on shelf 26 . This may also be retained during tent erection by one or more Velcro tabs or ties 38 . Optional drawstring 40 is retained in the outer periphery of shelf 26 , as within a fold 42 . When fully erected the tent is supported by a center pole 44 sited between the reinforced apex 46 of top section 8 and a lower surface, normally the ground or a tent platform.
[0028] The construction of the tension shelves in an erected tent is seen in somewhat more detail in FIG. 4. Here it is seen that the sections of compression hoop 28 are held together by an internal elastic cord 48 , as is common practice.
[0029] [0029]FIG. 5 illustrates the tent during its erection phase. The tent is first spread out on the ground upside down. Compression hoop 28 has already been inserted adjacent tension shelf 24 and compression hoop 36 is presently being inserted adjacent tension shelf 26 . At some time after the hoops are inserted the drawstrings at the outer periphery of the tension shelves are tightened and tied. The draw cord, while not essential, helps to accommodate aberrations in the stretch and cut of the fabric. The tent is then inverted and center pole 44 inserted to erect the tent to its position of use. Edges around the perimeter may be staked down either before of after the tent is fully erected. If additional stability is desired; e.g., protection against high wind, guy lines 16 may be attached and staked down. Alternatively, the tent may be erected by staking down the perimeter, raising the center pole, and then inserting the compression hoops from within the tent. After insertion, the compression hoops bear outwardly against the periphery of the tent to assure that it will maintain its configuration in an extremely stable manner.
[0030] When secured at the base perimeter or with guy lines, the tension shelf, compression hoop or hoops, the external fabric, and the center pole work together to create a stable, wind-resistant structure. Upward tension on the external fabric balances compression forces downward on the center pole and inwardly on the compression hoop or hoops. Working as a unit, the structural elements create a tight wind-resistant shell. The tension forces on the fabric and tension shelf perfectly balance the compressive forces on the center pole and hoop. The tension shelf balances with the section of exterior fabric above the compression hoop to keep the fabric taut.
[0031] Lacking the tension shelf, the compression hoop would have to be of much heavier and more rigid construction to withstand the pressure from wind and fabric. While somewhat resembling an older center pole internal support umbrella-type tent, the tent of the present invention does not need the spreader bars attached to the center post or stays extending down from the apex. It has the significant advantage that it may have full unobstructed standing room over the entire internal area, a feature virtually unobtainable in most other tent constructions. The present tent is different from internal or external frame umbrella-types in that the fabric and support system are interdependent—they function as a unit. In umbrella tents the fabric simply drapes over a framework and is not integral with the support system.
[0032] In still conditions, the tension forces are evenly distributed around the tension shelf. However, when lateral wind forces are applied the forces in the tension shelves concentrate parallel to the applied force. The structure may then assume a slightly oval shape although this is resisted by the tension shelf and compression hoop.
[0033] Depending on its size, the tent may be readily erected by one or two people. In the larger sizes there is adequate room for amenities such as a wood stove, chairs, tables, etc., again made possible by the unobstructed headroom. The ratio of weight to useable area can be very low because of the simplicity of the support system based on the tension shelves.
[0034] In addition to use as a shelter for humans, the tent may have a transparent or translucent fabric for service as a greenhouse.
[0035] It will be evident to the reader that some variations in the construction may be possible that have not been described herein. As one example, tension shelves may be used in pairs to sandwich the compression hoop. This prevents any tendency to upward movement or downward slippage and provides additional strength in extreme conditions. The tent may be constructed with windows or skylights. It may additionally have an integral or separate floor. It is the intention of the inventors that these and many other possible variations should be included within the scope of the invention if encompassed within the following claims. | A tent is described that has a support system providing excellent head-room over the entire internal area. The tent is circular in cross section. A sidewall portion is joined at a defined transition to a generally conical roof section. Internally, there is a relatively narrow fabric tension shelf at the sidewall top transition. Atop the tension shelf is a semi-flexible compression hoop. The top portion may have additional tension shelves and compression hoops, depending on the size of the tent. An internal center pole completes the support system. The pole, tension shelf, compression hoop, and fabric act together as an engineered unit to provide an exceptionally stable structure. | 4 |
FIELD OF THE INVENTION
The present invention relates to warp pile fabrics comprising a ground weave of warp yarns crossed with weft yarns on which, on the reverse side of the weave, are situated the tops of the loops of pile yarns, whose branches pass through the thickness of the ground weave, between the warp and weft yarns, and extend, at the front of the ground weave, over a certain length to produce the pile effect of velvet.
Such a structure is well-known but has certain disadvantages. For example, with the majority of known methods of manufacture of pile fabrics, the securing of the pile in the ground weave is determined by various factors, such as: weft count, warp count, determination of blend and nature of yarns, type and length of fibres, finishing of the fabric (especially impregnation of the reverse side) and patterns of weave. The decision of choice in weaves is therefore limited by numerous imperatives and piles are in general only very dense and relatively heavy.
DESCRIPTION OF THE PRIOR ART
A method of manufacture of pile is already known from U.S. Pat. No. 2,252,433, in which it is attempted to secure the pile yarn loops in the ground weave by means of leno warp yarns. However, in this process, normal warp yarns are employed as leno yarns and these, in fact, form the ground weave, so that these leno yarns simply cover over, or sit astride the tops of the pile yarn loops on the reverse side of the fabric. It is therefore a disadvantage of this method that it does not secure the loops of pile yarn, in relation to the ground weave, with a suitable degree of strength. In order that the pile yarns may be held most firmly in the ground weave, (this, indeed, only within the limitations set by this process), it would be necessary to produce the densest possible weave, which would, of course, depart from the object of the method, i.e. to offer a velvet which is light and well-aerated.
The object of the invention is to produce a warp pile fabric which does not suffer from these disadvantages and limitations of known pile fabrics as described above.
SUMMARY OF THE INVENTION
According to the invention, the parts of each pile yarn loop adjacent the tops of said loops are firmly pinched against a warp yarn of the ground weave by an extra gauze-weave warp yarn, referred to an "leno yarn", which forms a first loop, the top of which lies on the same weft yarn of the ground weave as the top of the pile yarn loop, but on the front side of the ground weave, and a second loop, the top of which lies on an adjacent weft yarn, also on the front side of the ground weave, the two aforesaid loops of leno yarn being interconnected by an intermediate part of this yarn which passes under the warp yarn concerned, on the reverse side of the ground weave.
Due to this particular structure, each pile yarn loop is, in a way, knotted between three yarns, i.e. a weft yarn, a warp yarn and a leno yarn, so that it is most securely held in the ground weave and is thus much more resistant to rupture than pile yarn loops of known pile fabrics which are simply squeezed between the warp and weft yarns of the ground weave, or else the tops of which are simply covered over with one of the warp yarns of the ground weave to which a leno has been added, that is to say, without the knotting effect given by the leno yarn of the pile according to the invention. This special and novel feature renders impregnation of the reverse side of the fabric unnecessary and, in addition, makes it possible to produce pile fabrics which are as aerated as could be desired, that is to say, in which the width of the stitches in the ground weave is as large as one could wish, and in which the interval between two adjacent tufts of pile yarn can be chosen at will since each pile yarn loop is individually and very efficiently knotted by a leno yarn to a weft yarn and against a warp yarn.
In a fabric according to the invention, the leno yarn interlaces warp yarns and weft yarns in a manner similar to that of the leno yarns employed in the weaving of gauze and, in addition, it anchors the pile yarn. As will be seen hereinafter, on this principle, it is possible to produce a whole variety of pile fabrics according to the manner in which one combines the different elements each contains.
The invention further relates to a method of manufacture of this pile fabric, whereby a ground weave is formed from warp yarns crossed with weft yarns, incorporating therein pile yarns secured periodically below the path of insertion of the weft yarns, in such a manner as to form loops, the tops of which lie against weft yarns on the reverse side of the ground weave, and periodically above said path of insertion of the weft yarns, so that the branches of said pile yarn loops pass through the thickness of the ground weave, between the warp and the weft yarns, and extend, on the front side of the weave, over a certain length, to produce the effect of velvet, whilst the pile yarn loops are secured by gauze-weave warp yarns; said method is characterised in that, during the weaving operation described, extra warp yarns called "leno yarns" are employed as gauze warp yarns, the successive positions of which are so determined that they rise in relation to the ground weave warp yarns, each alternately on one side and then on the other of one of said warp yarns, so that they find themselves above the weft yarns at the moment these latter are inserted, and they form a first loop, the top of which lies on the same weft yarn of the ground weave as the top of a pile yarn loop, but on the front of the weave, and also a second loop, the top of which lies on an adjacent weft yarn, also on the front side of the ground weave, whilst the intermediate part of the leno yarn which links the first to the second loop passes snakelike under the warp yarn in question, on the reverse side of the ground weave. It is manifest that this general method lends itself to various methods of execution corresponding to the various kinds of pile fabric manufactured. It is applicable not only to pile fabric woven directly as single-cloth, but also to that produced by the double-cloth method, with subsequent separation of the two cloths by cutting the parts of the pile yarns which link them together.
Finally, the fabric of this invention is made with a loom for weaving the warp pile in double-cloth in order to carry out this method. This loom, which is of the type comprising, for each cloth, a harness with heddle frames for the warp yarns of the ground weave and for the pile yarns, is characterised in that the harness also comprises, for each of the two cloths, at least one frame with fixed heddles, and a system of mobile heddle frames with independent movement, for the formation of a leno by means of an extra leno yarn for the purpose of knotting the pile yarns in the ground weave formed by said warp yarns and weft yarns.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section, showing a first method of producing pile fabric according to the invention, with pile yarn loops in V-formation;
FIG. 2 is a bottom plan view of the pile of FIG. 1;
FIGS. 3 and 4 show, in longitudinal section and in bottom plan view thereof respectively, a second method of producing pile with double-cloth pile and pile yarn loops in V-formation;
FIGS. 5 and 6 show, in longitudinal section and in bottom plan view thereof respectively, a third method, with double-cloth pile with pile yarn loops in V-formation on both sides of the same warp yarn of the ground weave;
FIGS. 7 and 8 show, in longitudinal section and in bottom plan view thereof respectively, a fourth method of producing double-cloth pile with pile yarn loops in U-formation;
FIGS. 9 and 10 show, in longitudinal section and in bottom plan view thereof respectively, a fifth method of execution of the double-cloth pile with pile yarn loops in W-formation;
FIGS. 11 and 12 show, in longitudinal section and in bottom plan view thereof respectively, a sixth method of producing double-cloth pile, with pile yarn loops in W-formation, successively on one and on the other side of a pair of warp yarns of the ground weave;
FIGS. 13 and 14 show the main part of a loom for the manufacture of a single-cloth pile according to the invention, diagrammatically in profile and in two different positions, and
FIGS. 15 and 16 show the main part of a loom for the manufacture of a double-cloth pile according to the invention, diagrammatically in profile and in two different positions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The portion of warp pile according to the invention, shown in longitudinal section in FIG. 1 and from beneath in FIG. 2, comprises a ground weave F composed of warp yarns, e.g. C1, C2 and weft yarns, e.g. T1, T2, loops of pile yarn P, and a leno yarn t.
The top of each pile yarn loop P lies against the lower side of a weft yarn T1, that is to say it appears on the reverse side of the finished weave. Along one particular warp yarn C1, loops of pile yarn P are formed only on the weft yarns T1 which are of odd number. The branches of the pile yarn loops P pass through the thickness of the ground weave F, between the warp and weft yarns, and extend, on the front side of the ground weave F, over a certain length 1, to produce the pile effect. The leno yarn t forms a first loop, the top of which lies on the same weft yarn T1 of the ground weave as the top of the pile yarn loop P but on the front, not on the reverse side of the ground weave F, and a second loop, the top of which lies on an adjacent weft yarn, in this case on a weft yarn T2 of even number, also on the front side of the ground weave. The first loop of the leno yarn t lies against the pile yarn, that is to say on one side of the warp yarn C1, whilst its second loop lies on the other side of this warp yarn, so that, in the example in question, in order that this second leno yarn loop cannot return to the first side of the warp yarn C1 under the tension of the leno yarn (which would completely destroy the knotting effect desired), the second leno yarn loop passes beyond the following warp yarn C2 situated on said other side of the first warp yarn C1. Thus, against a weft yarn T2 of even number, a second leno yarn loop passes to the front, whilst the following warp yarn C2, mentioned above, passes to the reverse side and locks said second leno yarn loop at the side of the first warp yarn C1 opposite to the side of this warp yarn, along which lies the first leno yarn loop which pinches the pile yarn against the warp yarn C1. The first and second leno yarn loops are linked together by an intermediate part of this yarn which passes under the warp concerned (and also under the adjacent yarn C2 in the present example) at the reverse side of the ground weave F.
It will be readily understood that, due to the presence of the leno yarn t incorporated into the weave in the manner described and illustrated, each loop of pile yarn P is firmly knotted on a weft yarn against a warp yarn, so that it has become completely integral with the ground weave F, even though the construction of this latter is not of a kind to provide a strong fabric by itself.
The above description with reference to FIGS. 1 and 2 corresponds to a pile produced as single cloth, employing rods 11 for the formation of the upper, visible loops of pile yarn P. If these rods do not have a cutting edge, they leave the pile yarn loops closed, as shown in the right-hand part of FIG. 1, and the product is called uncut pile, whereas, if they carry an upper cutting edge, they snip the tops of the upper pile yarn loops, as shown at the left-hand side of the figure. Nevertheless, this does not effect the securing of the pile yarn loops to the ground weave by the leno yarn.
The same structure might quite easily be adopted in a double-cloth type of pile construction, as shown in FIGS. 3 and 4, FIG. 3 being a longitudinal section through the combination of the two cloths before their separation by cutting the pile yarn portions P which connect them, and FIG. 4 being a corresponding plan view, i.e. showing the lower cloth from the bottom after cutting. In these figures, the same reference numerals are employed as in FIGS. 1 and 2, so that the same explanation can be applied to the lower cloth 21 as was given for the single cloth of FIGS. 1 and 2, the only difference being that, instead of passing over rods, the upper pile yarn loops P pass over weft yarns of the ground weave of the upper cloth 22. The same description can be applied to the upper cloth, provided top and bottom are reversed in the explanations given with reference to FIGS. 1 and 2.
In the embodiments just described in FIGS. 1 to 4, it can be said that the pile yarn loops P present a V-shaped configuration. In FIGS. 5 and 6 a further method of execution is illustrated, having pile yarns in a V-shape, which is applicable more especially to heavy yarns. This embodiment differs from those described above in that the pile yarn loops P, on two successive weft yarns T1 of odd number, are situated alternately on one side and on the other of the same warp yarn C1; in this case, the leno yarn t snakes over the reverse side of the ground weave, embracing only the single warp yarn C1, instead of the two warp yarns C1 and C2 in the foregoing examples.
FIGS. 7 and 8 show a method of execution in which the pile yarns P show a U-shaped configuration, due to the fact that each pile yarn loop P embraces, not one single weft yarn of the ground weave, but two successive weft yarns T1 and T2 at one and the same time, as illustrated. In this example the leno yarn t behaves nevertheless in the same manner as in FIGS. 3 and 4, with the difference that, on the front side, only one loop out of two of this yarn serves to pinch a pile yarn loop. It may be said that this structure is obtained by the repetition of a (design) repeat 4.
FIGS. 9 and 10 show an example in which the pile yarn loops P show a W-type configuration, due to the fact that each pile yarn loop P passes not only under two weft yarns T1 of odd number, but also over the top of the intermediate weft yarn T2 of even number. Here also, the leno yarn t embraces only the single warp yarn C1, against which rest the pile yarn loops, whilst two of the first successive loops (mentioned above) of said leno yarn serve to pinch one and the same pile yarn loop.
FIGS. 11 and 12 show a modification of the embodiment of FIGS. 9 and 10, from which it differs in that the successive pile yarn loops P are situated alternately on one side and on the other of the warp yarn C1 in question, and that a second warp yarn C2 is also embraced by the leno yarn t and plays symmetrically the same role as the warp yarn C1.
In order to carry out the method of manufacture of pile according to the invention, a single-cloth loom may be employed, the main part of which is shown diagrammatically in FIG. 13. Here, once again, the yarns mentioned above can be seen, i.e. the two warp yarns C1, C2, the weft yarn T2, the pile yarn P, and the leno yarn t. The two warp yarns C1, C2 are threaded through the eyelets of two heddles 31, 32 respectively, mounted in corresponding mobile harness frames and the pile yarn P is passed through the eyelet of a third heddle 33 mounted in a corresponding mobile frame. As for the leno yarn t, it passes through the eyelet of a fourth heddle 34 mounted in a fixed frame, and also through the eyelet of a fork 36 mounted in a mobile half-frame and co-operating with two heddles 37, 38 mounted respectively in two other frames to form a leno. At 11 will be seen once again the position of the forming and cutting knife for the upper pile yarn loops P.
In the area of the reed 39, three levels of sets of yarns can be seen for the four yarns which have just been enumerated, i.e. the lower level in which is located at the moment the warp yarn C2, the intermediate level in which are located at the moment both the warp yarn C1 and the leno yarn t, and the upper level in which is located at the moment the pile yarn P. These four yarns pass between the two heddles 37, 38 for leno formation and through the same interval between two teeth of the reed 39. It will be observed that the path of the weft yarn T2 to be inserted lies between the lower level and the intermediate level, whereas the rod 11 for forming and cutting the pile yarn is located between the intermediate level and the upper level. As for the eyelet of the fixed frame carrying the leno yarn heddle 34, it remains permanently at the lower level.
After forming of the following shed, the different elements are situated in the positions shown in FIG. 14, i.e. the pile yarn P is in the lower level (no rod is introduced but instead the pick of the following weft yarn T1), the positions of the two warp yarns C1 and C2 have been interchanged and the leno yarn, after being lowered by the fork 36, has been raised once more to the same intermediate level, but it has passed into its position of crossing with the warp yarn C1, on the other side of the warp yarn C1 in respect of the pile yarn loop, to form a leno, as explained with reference to FIG. 2.
The production of the different possible structures of pile by carrying out the method in question on looms equipped with at least one extra feed frame and two extra mobile frames with a fork-type half-frame, is made possible by suitable programming, previously recorded in the cards of the dobby which controls the movements of the harness frames in which the corresponding heddles are mounted. Programming of this kind is within the ability of a man skilled in the art; it does not form part of the present invention and will not be described in detail here.
It is evident that, for the formation of the leno, instead of the system with two special heddles 37, 38 and fork 39, any other suitable and conventional system may be employed, for example needle heddles, or those of the Madras type.
In FIGS. 15 and 16 the main part of a loom for double-cloth weaving of ground weave is shown diagrammatically and, for the lower ground weave cloth, the same reference numerals have been retained as for the single cloth of the loom in FIGS. 13 and 14, since the same elements are to be found here. As for the upper ground weave cloth, all the same elements relating to the lower cloth will be found here once more, but upside down (with vertical directions of displacement reversed), except for the pile yarn which, in this example, is present only once for the two cloths, as is the case in the method of manufacture shown in FIGS. 3 and 4. In other words, the explanations given for the single cloth loom of FIGS. 13 and 14 apply to the double-cloth loom of FIGS. 15 and 16.
It should be noted that, in the double-cloth looms (see FIGS. 15 and 16) the mobile heddle frames for the formation of the leno have an independent movement, i.e. they do not all move together. By this means, on the same loom, it is possible to modify the interval between the two cloths and, consequently, the height of the pile, which would be practically impossible with leno heddles moving simultaneously together. | The invention is related to the textile industry and the weaving of pile wherein, the parts of the pile yarn loops adjacent the tops of these loops are pinched against one side of the warp yarn of the ground weave by an extra yarn, or leno yarn, similar to the leno yarn employed in the weaving of gauze. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to process for casting slip into ceramic products such as sanitaryware, water tanks, tiles, porcelain plates and pipes, gravestones or the like.
2. Description of the Prior Art
In the prior art slip casting process, slip is introduced under a pressure in the range of 3 to 20 kg/cm 2 into a pressure-resisting porous casting mold so that the water content of the slip may be extruded under the action of that pressure through the interface between the inner molding surface of the mold and the slip, via the thickness of the porous mold and eventually to the outside of the mold. This casting operation is continued until the slip in the region of the molding surface is dehydrated to deposit into a layer of a predetermined thickness. On attaining the predetermined thickness of the cast slip layer on the interior surface of the casting mold, the casting mold is rotated or inclined while being fed with compressed air (under a pressure within the range of about 1 to 2 kg/cm 2 ) for forcibly discharging the residual slip out of the mold via a slip discharge port in the mold. After this discharging, the discharge port is closed, and additional compressed air is fed into the mold to provide further dehydration or reduction in the water content of the slip cast layer.
The main disadvantage of the prior slip casting techniques is that the casting mold requires high pressure resistance sufficient to withstand the relatively high pressure under which the slip is being introduced thereinto, which can result in costly and time-consuming production of the casting mold.
Furthermore, the casting installation as well must be durable and heavy, which would degrade its profitability.
SUMMARY OF THE INVENTION
With the defects of the prior art technique in mind, therefore, an object of the present invention is to provide a process for efficiently casting the slip into a ceramic product by use of a unique lightweight casting mold as is easy to handle but need not have a highly durable pressure-resisting structure.
According to important aspect of the present invention, there is provided a process for casting slip into a ceramic product comprising the steps of:
providing at least one casting mold, the casting mold being formed of a plurality of porous mold parts each having a plurality of channels therein and having its respective outer face treated to be fluid-tight and having an inner molding surface, the mold parts being combined to define a molding cavity in the mold;
locating said at least one casting mold within a pressure-resisting container to establish a space surrounding the casting mold within the container, the space surrounding the casting mold being in communication with the molding cavity of the mold;
sealing the pressure-resisting container;
actuating a plurality of clamping means into engagement with the outer faces of the mold parts to clamp the casting mold firmly;
feeding slip under a first pressure into the molding cavity of the casting mold until the latter is filled with the slip;
the water in the slip in the region of the inner molding surfaces of the molding parts partially oozing into the channels;
supplying a fluid under a second pressure higher than the first pressure into the space surrounding the casting mold and communicating with the molding cavity thereof, thereby to apply the second pressure to the slip with which the molding cavity has been filled and thus to the molding surfaces of the mold parts whereby further water of the slip in the region of the molding surfaces of the mold parts may ooze into the channels to form a cast layer of a predetermined thickness within the molding cavity of the casting mold;
depressurizing the channels to drain the water accumulated therein therethrough;
discharging the residual slip in the molding cavity of the mold therefrom; and
removing the casting mold from the pressure-resisting container.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will become apparent from the following description when taken with reference to the accompanying drawings, in which:
FIGS. 1 and 2 are a partially sectional view and a general perspective view, respectively, showing a casting installation for carrying out a casting process of one embodiment of the present invention;
FIG. 3 is similar to FIG. 1, showing a modified casting installation; and
FIG. 4 is similar to FIGS. 1 and 3, showing another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Throughout the drawings, for ease of illustration, like elements are identified by like numerals.
In FIGS. 1 and 2, there is shown a pressure-resisting container 36 preferably made of cylindrical shape in which are located a plurality of rectangular casting molds 1a-d (only one is shown in FIGS. 1 and 2) which are carried on carrier 13 which may include a roller conveyor, a chain conveyor or the like. The conveyor, if used, may be arranged to move through the pressure-resisting container 36 and to be provided thereon with pallets for supporting the casting molds 1.
The cylindrical pressure-resisting container 36 is supported for rotation about its longitudinal axis by two sets of rollers 11 and 14 placed on a base 25, one of which roller sets is associated with a motor/reducer unit 12. The controlling of the motor/reducer unit 12 causes the rollers 11 to rotate a predetermined number of turns, which allows the cylindrical container to rotate about its axis by an angle at which the casting molds 1 contained in the container are being brought into its slip discharging position. Accordingly, in other words, the motor/reducer unit 12 causes the casting molds 1 in the container 36 to angularly displace between their upright casting position and include slip discharging position through the rollers 11 and 14.
The casting mold 1 consists of a plurality of parts, of which four parts 1a, 1b, 1c and 1d are shown in section in FIG. 1. Each of these mold parts 1a to 1d is preferably of a porous material such as gypsum or other comparable porous material. Each mold part 1a, 1b, 1c or 1d has its respective outer face 37 sealingly covered with a resin or the like to prevent any fluid such as air or water from passing therethrough. As shown in FIG. 1, the mold part 1a, 1b, 1c or 1d is provided therein with passageways or channels 2 in the form of a hollow pipe arranged in a network pattern (only a portion is shown in FIG. 1). The channels 2 of each mold part also are arranged to communicate with one another and are adapted to be operatively connected to an in-mold pressure-releasing flexible tube 40 extending through a pad 4 which is brought into or out of engagement with the casting mold 1 by the action of a cylinder unit 5. The in-mold pressure-reducing flexible tube 40 also is opened on one hand to the atmosphere through a valve 19 and connected on the other hand to a pressure reducer (not shown) through a valve 20. Alternatively, the passageways 2 of each mold part may be made operatively independent of those of the adjacent mold parts and separately connected to the in-mold pressure-reducing flexible pipe 40.
Each of the casting molds 1 also has a slip admission and discharge port 43 at its respective bottom portion for admitting and discharging the slip therethrough. The slip discharge port 43 of each casting mold is adapted to be operatively connected to a casting and draining flexible tube 39 extending at one end portion through a pad 6 which comes into and out of contact with the casting mold through the action of a cylinder unit 7. The other end of the flexible tube 39 is connected on one hand through a casting valve 21 to a slip source (not shown) and leads on the other hand through a slip discharging valve 22 to a slip reservoir (not shown).
As shown, a surrounding wall 27 is formed in the pressure-resisting container 36 along the cylindrical inner surface thereof so as to define a hollow area which may be rectangular in section in which the casting molds 1 are located with a small space or gap 32 between the inner surface of the wall 27 and the casting molds 1. Preferably, the surrounding wall 27 is formed of light aggregates. The space 32 in the pressure-resisting container 36 is equipped in its selected areas with a plurality of separate inflatable air bladders 3 which can cooperate to clamp the casting molds 1 against their motion. The air bladders 3 are connected with one another via air passageways or conduits 26 which are provided in the surrounding wall 27. These air conduits 26 in turn are connected on one hand to a compressed air source (not shown) through an air feed valve 24 and on the other hand to the atmosphere through an air release valve 23.
In order to reduce the amount of the compressed air to be fed to the air bladders 3 for fully clamping the molds 1, it is advantageous to produce narrower space 32 between the surrounding wall 27 and the outer mold faces 37 for example, by making the surrounding wall 27 more massive within the container 36.
In the present embodiment, as described above, the mold clamping means is composed of the inflatable air bladders 3 which are arranged along the sides of the casting molds 1 in the space 32 in the pressure-resisting container 36. As an alternative to the clamping means, pneumatic or hydraulic cylinder clamp units may be disposed in the pressure-resisting container 36 to clamp the casting molds 1 therearound. On the other hand, rather than subjecting the molds 1 to a clamping operation within the pressure-resisting container 36 after insertion thereinto, the casting molds may be clamped by any suitable clamping means prior to introduction thereof into the container 36.
Further included in the inventive casting installation are one or more auxiliary slip supply reservoirs 8 which are disposed outside the casting molds 1 within the surrounding wall 27 of the pressure-resisting container 36. The auxiliary slip supply reservoir 8 is connected at the lower portion thereof to the casting and draining flexible tube 39 through a slip supply flexible tube 38 communicating with a mold cavity 41 via a conduit 15, and at its upper portion to the space 32 via an air conduit 9. With the arrangement described above, it should be noted that the pressure on the slip being cast and the pressure in the space 32 can be substantially equalized.
Alternatively, it is possible to use as auxiliary slip supply means a longitudinal recess 108 provided either in any of the mold parts, e.g., 1a, of each mold as shown in FIG. 3. Otherwise, the auxiliary slip supply reservoir may be individually disposed outside of the pressure-resisting container 36.
A level controller 10 is associated with the slip supply reservoir 8 and controls the level of the slip within the mold during the casting operation.
In operation, the mold parts are set up to provide a plurality of casting molds 1, and then these molds 1 are conveyed successively one after another into the container 36 at the one end in the direction of arrow A as shown in FIG. 1 until a predetermined number of the molds 1 are disposed therein. The opening of an access door 33b at the introduction end of the pressure-resisting container 36 allows such introduction of the predetermined number of the molds 1 into the container 36. Although only one of the containers 36 is shown in FIG. 2, it is possible that a plurality of such containers 36 and their associated conveyor means and casting systems may be arranged in parallel side by side relationship so that similar operations may be performed simultaneously.
After introducing the predetermined number of casting molds 1 into that pressure-resisting container 36, the opposite doors 33a and 33b are closed to seal up the pressure-resisting container 36. The air release valve 23 is closed, and the air feed valve 24 is opened to causing the compressed air to flow from its source via the air conduit 26 into the air bladders 3 to thereby inflate the latter. Of course, the pressure of that compressed air is such as to be higher than that prevailing in the space 32. The individual air bladders 3 abut, when inflated, against the outer faces 37 of the casting molds 1 to clamp and fix them against movement thereof.
The cylinder 7 is actuated to bring the pad 6 into sealing engagement with the casting molds 1 and also to connect the casting and draining flexible tube 39 to the casting and discharging port 43. Simultaneously, the cylinder 5 at the side opposed to the cylinder 7 also is actuated to bring the pad 4 into sealing engagement with the casting molds 1 and to connect the in-mold pressure-reducing flexible tube 40 to the channels 2 in the mold parts of each mold. The slip discharging valve 22 is closed, and the slip feed valve 21 is opened to supply the slip typically under a pressure within the range of 0.1 to 20 kg/cm 2 from its source into the respective casting molds 1. The monitoring of the slip level in the casting molds 1 is performed by the level controller 10 associated with the supply reservoir 8, and the slip supply valve 21 is closed at the time when the slip in the supply reservoir 8 reaches a predetermined level.
Thereafter, the air release valve 17 is closed, and a compressed air feed valve 18 is opened to introduce the compressed air (normally under a pressure of 1 to 20 kg/cm 2 ) from its not shown source into the space 32 surrounding the casting molds 1. Since communication is being provided between the space 32 and the upper plenum of the slip supply reservoir 8, it is assured that the pressure in the space 32 is equal to that to be applied to the free surface of the slip in the auxiliary slip supply reservoir 8. Since, moreover, this slip supply reservoir 8 is in fluid communication with the mold cavity 41, the pressure on the slip free surface in the reservoir 8 is equal to that of the slip to be applied to the inner face of the casting mold 1. Accordingly, application of the common pressure to both the inner and outer faces of the casting molds 1 is achieved. Then, the water contained in the slip in the region of the molding surfaces of the casting mold 1 will exude or ooze out through the porous layers of the mold parts into the channels 2.
Next, with the air release valve 19 closed and the valve 20 opened, the pressure reducer connected to the valve 20 is actuated so that the pressure in the channels 2 in the mold parts 1a, 1b, 1c and 1d may be depressurized to drain the water collected therein to the outside of the casting molds 1 through the in-mold pressure-reducing flexible tube 40. In order to promote the oozing of the water content of the slip into the channels 2, the pressure reduction of the channels 2 of the mold parts may be performed simultaneously with the feed of the compressed air into the space 32.
When the slip is cast to a layer of a predetermined thickness 42 on the molding surfaces of each casting mold 1, the slip discharging valve 22 is opened with the casting valve 21 remaining closed. Next, the motor/reduction unit 12 is actuated to rotate the roller 11 a predetermined number of turns to turn the pressure-resisting container 36 a predetermined angle about its longitudinal axis. This also causes angular displacement of the casting molds from their casting position to their inclined discharge position, in which latter position the slip remaining in the casting mold 1, i.e., the slip having failed to form the cast layer 42 may be discharged from the respective molds 1 via their draining ports 43. When the slip in the supply reservoir 8 falls down to a predetermined level, the compressed air in the space 32 will flow into the mold cavity 41 via the feed conduit 15 to promote the discharge of the slip. The slip thus discharged from within the casting mold 1 and the supply reservoir 8 flows through the valve 22 into its reservoir, in which it is reserved for further use.
When this discharge is completed, the draining valve 22 is closed. Since, at this time, the compressed air feed valve 18 is still open, the compressed air successively coming from its source will further dehydrate the cast slip layer 42. After a predetermined period of time has elapsed, the compressed air feed valve 18 is closed, and the pressure resisting container 36 is returned to its initial position by the reverse operation of the motor/reduction unit 12. Next, the air release valve 17 is opened. Then, the space 32, the supply reservoir 8 and the mold cavities 41 all in the pressure-resisting container 36 are returned to the atmospheric state by releasing the residual compressed air to the atmosphere. Next, the cylinder 7 is actuated to bring the pad 6 out of contact with the casting mold 1. Simultaneously, the cylinder 5 is also actuated to bring the pad out of contact with the casting mold 1. After doing this, the air release valve 23 is opened to release the pressure in the air bladders 3 so that the casting molds 1 may be released from its clamped and set state, thereby completing the casting cycle.
In order to transfer the molds containing the castings to different stations for further processing of the castings, the molds can be removed from the container 36 by opening the door 33a of the container 36. To this end, a conveyor lifter 34 is available which may be located adjacent the pressure-resisting container 36 as shown in FIG. 2.
These stations may include those for feeding the setter, removing the castings from the molds, adhering, attaching an accessory mold, boring, rinsing the mold, setting the mold for further use and so on.
Conveniently, in removal of the molds 1 from the container 36, the door 33b is also opened and new casting molds can be inserted into the pressure-resisting container 36 while extracting the used casting molds therefrom. Thus, the casting cycle can be performed continuously.
Turning now to FIG. 4, a modified casting installation is shown which is similar to that shown in FIG. 1 except that an auxiliary slip supplying reservoir 208 is provided in an extended portion of the space 32 and is adapted to be connected through a valve 54 to a compressed air source and through an air release valve 55 to the atmosphere and that a space 32 is supplied with a pressurized water through a water feed valve 51.
The slip supply reservoir 208 can be made of a resilient material such as a rubber.
A level controller 56 is provided for detecting the level of the pressurized water at which the water overflows an air release valve 52 through which the space 32 communicates with the atmosphere.
Also, a water draining valve 53 is located underneath the pressure-resisting container 36 for allowing the pressurized water which has been fed into the space 32 to discharge.
The operation of the FIG. 4 apparatus is different from that of the apparatus described with reference to Figs. 1 and 3 in the following points.
After the slip feed valve 21 is closed, both of the air release and water draining valves 55 and 53 are closed and the pressurized water feed valve 51 is opened to introduce water under a pressure (normally 1 to 20 kg/cm 2 ) from its source (not shown) into the space 32 surrounding the casting molds 1. An air release valve 52 is closed as a level controller 56 detects the level of the pressurized water at which the water immediately overflows the valve 52. The elastic supply reservoir 208 is compressed by the pressure of the water so that the pressure in the space 32 balances the pressure of the slip in the supply reservoir 208, i.e., the pressure in the mold cavity 41.
When the slip is cast to a predetermined thickness 42 on the molding surface of each casting mold 1, the compressed air feed valve 54 is opened to introduce the compressed air (under the same pressure as of the pressure water).
Next, the slip discharge valve 22 is opened with the casting valve 21 remaining closed, and the motor/reduction unit 12 is actuated to rotate the roller 11 a predetermined number of turns to turn the pressure-resisting container 36 a predetermined angle about its axis so that the slip remaining in the casting molds 1, i.e., the slip having failed to form the cast layer 42 may be fully discharged out from the molds 1 via the respective discharging parts 43.
When the slip in the supply reservoir 8 falls down to a predetermined level, the compressed air will flow into the mold cavity 41 via the feed conduit 15 to promote the discharging of the slip.
The slip thus discharged from the casting molds 1 and the supply reservoir 8 flows through the valve 22 into its reservoir, in which it is reserved for further use.
When this discharge is completed, the draining valve 22 is closed.
Since, at this time, the compressed air feed valve 54 still remains open, the compressed air coming from its source will provide for further dehydration of the cast slip layer 42.
After a predetermined period of time has elapsed, the compressed air valve 54 is closed, and the pressure-resisting container 36 is returned to its initial state.
Next, the pressurized water feed valve 51 is closed and not only the air release valve 55 but also the water draining valve 53 and the air release valve 52 are opened to drain the water out of the space 32.
After doing this, the cylinders 7 and 5 are likewise actuated to bring the pads 6 and 4 out of contact with the casting mold 1, respectively. Then, the air release valve 23 is opened for release of the pressures in the air bladders 3 to complete the casting cycle.
As can be understood from the foregoing, the present invention employs the unique casting mold which is less heavy and bulky than in the prior art and which can withstand the same casting pressure of the slip to be fed to the mold as of the prior art. Likewise, the casting installation is light as well as highly durable. The casting efficiency can be two times as high as that of the prior art, and the cost for the facilities can be cut in half. This reduces the production cost for the casting mold to about one third as compared with the prior art.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced in a manner other than as specifically described. | A process for casting slip into a ceramic product using at least one unique casting mold. The casting mold is formed of a plurality of separate porous mold parts, each of which has a fluid-tight outer face, an inner molding surface and a plurality of channels therein. The mold parts are combined so that the inner molding surfaces define a molding cavity in the mold. The casting mold is positioned within a pressure container such that a space is established surrounding the casting mold within the pressure container. This space is in fluid communication with the molding cavity of the mold. The casting process further includes the steps of: sealing the pressure container; firmly clamping the casting mold; feeding slip under a first pressure into the molding cavity until the molding cavity is filled with slip; supplying a fluid under a second pressure higher than the first pressure into the space surrounding the casting mold thereby applying the second pressure to the slip in the molding cavity and to the inner molding surfaces of the mold parts to form a cast layer of a predetermined thickness within the molding cavity; depressurizing the channels to drain water accumulated therein; discharging residual slip from the molding cavity; and removing the casting mold from the pressure container. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to rotary valves, that is, valves in which a rotatable closure element is mounted in a flowway defined by the valve body so that it may be rotated between open and closed positions to control flow of fluids through the flowway and to seals used therein.
2. Description of the Background
Rotary valves, such as butterfly or disk valves, ball valves, plug valves, globe valves and the like, are used in numerous industrial and military environments. In a typical rotary valve assembly, the valve body defines a fluid flowway and a cavity in which the valve element is disposed. There is also a suitable sealing assembly disposed in the valve cavity such that sealing between the valve body and the valve element can be effected to thereby prevent the flow of fluid through the valve when the valve is in the closed position. The sealing assembly used in many rotary valves is conventionally of an elastomeric and/or polymeric material although there are rotary valves which employ metallic seals and metal-to-metal contact to effect sealing. Indeed, valves which are in environments subject to fire or intense heat, which would virtually destroy a valve seat of an elastomeric or polymeric material, generally are provided with valve seals which are either composite in nature in the sense that there is a primary sealing section of a polymeric material and a secondary or backup sealing section of metal. Thus, in the event that polymeric sealing section acts to effectively seal flow through the valve.
Although rotary valves employing only metallic seats do not suffer the disadvantages of having the seats destroyed when the valve is subjected to a fire or extremely intense heat, they suffer from certain infirmities. For one, fluid-tight sealing between a metal valve element and a metal seal is more difficult to achieve than sealing between a metal valve element and a resilient seal made of a polymeric material. Additionally, metallic seals are much more expensive to manufacture, present difficulties in installation and often times are subject to chemical attack by fluids flowing through the valve. Another problem with certain types of rotary valves employing metallic seals is that they present machining problems in that highly controlled tolerances must be maintained in order for the valve element and the valve seal to cooperate in effecting complete shutoff of flow through the valve.
Even in cases where metallic seals are employed in so-called fire-safe valves, it occasionally happens that the metallic seals, because they are constructed of very thin material, will distort under prolonged intense heat with the result that the valve will fail.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a rotary valve assembly which is fire safe.
Yet a further object of the present invention is to provide a rotary valve having an annular seal to comprise a heat activated material which can effect sealing between the valve body and the valve element when the valve is subjected to sufficient elevated temperature and/or fire.
Still a further object of the present invention is to provide a seal for use in a rotary valve assembly which incorporates an auxiliary, heat activated material which can effect fluid-tight sealing between the valve element and the valve housing in the event of failure of the primary valve seal material caused by heat or fire.
The above and other objects of the present invention will become apparent from the drawings, the description given herein and the appended claims.
In accord with one aspect of the present invention there is provided an annular seal for use in a rotary valve assembly, the assembly including a valve housing which defines a cavity for receiving a valve element to control the flow of fluid through the valve housing. An annular seal used to effect a seal between the valve element and the valve housing is comprised of a heat-activated or intumescent material which is heat responsive such that it can expand and form a fluid seal between the valve element and the housing in the event the valve assembly is subjected to high temperatures or fire which destroys the primary seal material, usually a polymeric or plastic material, or in the case of a metallic seal, deforms such seal to the extent that its sealing capabilities are impaired.
In another aspect of the present invention, there is provided a valve assembly which includes a valve housing defining an internal valve cavity, the valve housing further including a fluid flow passageway. A valve element is rotatably received in the valve cavity to control fluid flow through the flow passageway. A seating surface is defined on at least one of the valve housing or the valve element while the other of the valve housing or the valve element defines a seal carrying surface. The assembly further includes an annular seal carried on the seal carrying surface on one of the valve housing or the valve element for engaging the seating surface and effecting a seal between the valve housing and the valve element. The seal is comprised of a heat-activated or intumescent material.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by reference to the drawings in which:
FIG. 1 is a longitudinal view, partly in section, of a disk valve assembly according to the present invention and showing the disk in the closed position;
FIG. 2 is an elevational view taken at right angles to FIG. 1;
FIG. 3 is an enlarged, detailed, sectional view showing the peripheral edge of the disk valve element, the seal and the seating surface of the valve shown in FIGS. 1 and 2;
FIG. 4 is a view similar to FIG. 3 showing the valve assembly after being subjected to heat or fire sufficient to cause the seal to intumesce;
FIG. 5 is a cross-sectional view of one form of seal in accordance with the present invention; and
FIG. 6 is a view, similar to FIG. 5 and showing yet another form of seal in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While the present invention will be described with particular reference to a butterfly or disk valve assembly, it is to be understood that it is not so limited. The valve assembly seal described herein may be employed in any valve assembly having a rotatable valve closure element such as, for example, a ball valve, a plug valve, a globe valve, etc. wherein an annular seal is employed to seal between the valve element and the valve body.
Referring first to FIG. 1, there is shown a butterfly valve 10 having a generally annular housing 12 with a fluid flow passageway 14 therethrough. Housing 12 also defines a cavity 16, in open communication with passageway 14, for receipt of a valve element described hereafter. The valve housing 12 is typically adapted for positioning between opposed pipe flanges (not shown). Extending outwardly from valve housing 12 is a cylindrical neck 18 formed integrally with housing 12, neck 18 having a cylindrical bore 19 communicating with valve cavity 16. A circular flange 20 formed integrally with neck 18 provides a means for securing an actuator (not shown) to valve 10. Diametrically opposite neck 18, protruding from and integral with housing 12 is a boss 22 having a cylindrical bore 23 in open communication with valve cavity 16.
Pivotally supported in valve cavity 16 is a fluid control disk shown generally as 24 having first and second hubs 26 and 28, respectively. Disk 24 is supported in valve cavity 16 by means of upper and lower shafts 30 and 32 received in bore 19 of neck 18 and bore 23 of boss 22, respectively. Shaft 30 extends into valve cavity 16 and is received in a bore 34 in hub 26. A dowel pin 36 secures shaft 30 to hub 26. In like manner, shaft 32 extends into valve cavity 16 and is received in a bore 38 in hub 28, shaft 32 being pinned to hub 28 by means of dowel pin 40.
Shaft 30 is rotatably journaled in bore 19 by means of bushing 42. Fluids are prevented from escaping valve 10 through bore 19 by means of packing rings 44 which are held in position by means of a packing gland 46. A keeper ring 48 serves to hold packing gland 46 in bore 19.
Shaft 32 is journaled in bore 33 by means of a bushing 50, packing rings 52 serving to prevent leakage from valve 10 through bore 23. Bore 23 is counterbored and tapped as at 54 and receives a threaded plug 56 to thereby close bore 23.
The upper end of shaft 30 protrudes above circular flange 20 and is provided with opposed flats 49 to provide a means for securing a hand wheel, wrench or other device such as an actuator, for rotating shaft 30 and hence disk 24 to effect opening and closing of valve 10.
Disk 24 has an annularly extending peripheral surface 58, surface 58 further including an annularly extending radially outwardly opening groove 60 in which is received an annular seal ring 62 in the form of an O-ring. Seal ring 62 cooperates a generally conical seating surface 64, interiorly of valve housing 12 to effect a seal between valve housing 12 and disk 24. It can thus be seen that when the valve is closed, as in the position shown in FIG. 1, seal ring 62 is in interference contact with seating surface 64 and fluid flow through flowway 14 is effectively prevented.
Referring now to FIG. 3, there is shown an enlargement of a portion of the peripheral edge of the disk 24, the seal ring 62 and the seating surface 64 in the valve body 12. FIG. 3 shows the valve in a normal state, i.e. without having been subjected to intense heat or fire. In this state, seal ring 62 is in sealing engagement with seating surface 64 and the surfaceforming groove 60, thus preventing any fluid leakage through valve assembly 10. As more fully described hereafter, seal ring 62 is comprised, at least partly, of an intumescent material.
Reference is now made to FIG. 4 which shows valve 10 after having been subjected to heat or fire sufficient to at least partially cause seal ring 62 to intumesce. As seen, seal ring 62 has expanded so as to completely fill groove 60. In addition, the material of seal ring 62 has, in effect, been extended into the space between disk edge or surface 58 and seating surface 64, thereby maintaining a fluid-tight seal through valve 10. It will be appreciated that if seal ring 62 was made only of conventional materials, such as polymeric or plastic materials, e.g. rubbers, fluorinated hydrocarbon polymers, etc., and if subjected to sufficient heat, the seal ring 62 would be destroyed or at least lose sufficient structural integrity to permit leakage between the disk edge and the valve body. However, because of the presence of the intumescing seal ring 62, which has expanded because of being subjected to heat or fire, there is a bridging or auxiliary seal 68 formed between seating surface 64 and disk 24.
As noted above, seal ring 62 is comprised of an intumescent material. The term "intumescent material," as used herein, refers to a material or substance which will enlarge, swell or expand under the influence of sufficient heat to form or aid in forming a bridging seal or barrier to prevent fluid flow. Such intumescent materials are comprised of various composites employing materials such as ceramic fibers, asbestos, metallic fibers, aramid fibers, vermiculite and other mineral substances, neoprene rubber and other synthetic materials or polymers, and expanding granules as well as other ingredients which can be made flexible and may expand up to ten times their original volume when exposed to high temperatures, e.g. above 250° F. A typical example of such intumescent or heat-reactive substances are a series of heat-reactive materials known as INTERAM and marketed by 3M.
Generally speaking, the seal ring will be comprised of an intumescent material and a polymeric or plastic material which is ordinarily used to form seal rings for rotary valves. Thus, a mixture of an intumescent material and a rubber, a fluorinated hydrocarbon polymer or the like, formed into a generally homogeneous mixture wherein the intumescent material is uniformly dispersed throughout the polymeric matrix will be employed. When such a homogeneous composite of intumescent material and a polymeric or plastic material is employed in forming the seal of the present invention, the percentage of each such component or of the individual materials forming each component will vary depending upon the service in which the valve is placed, e.g. pressures, temperatures, chemical environments, etc. In general, it is only necessary that when the seal ring is formed in a composite manner wherein the intumescent material and the polymeric or plastic material are formed in a generally homogeneous mixture, that there be sufficient polymeric or plastic material to ensure fluid-tight sealing under normal operating conditions of the valve, i.e. when not subjected to heat or fire sufficient to destroy such polymeric or plastic material.
While, as described above, the seal can conveniently be made as a homogeneous mixture of intumescent material and polymeric or plastic material, the seal can also be constructed as a multi-piece composite seal in the form of a metallic sealing portion and an intumescent portion. There are many instances in which thin metallic seal rings are employed in various rotary valve assemblies, particularly in fire-safe valves, sealing being accomplished by metal-to-metal interference fit between the seating surface and the metallic seal member. While such metallic seals are generally fire resistant, in many cases the metal seal ring is, of necessity, quite thin so as to permit sufficient flexure and ensure sealing. In these cases, the thin metal seal ring may well deform under intense heat providing a leakage path through the valve. The presence of the auxiliary intumescent seal material will act, in a manner similar to that described above, to expand and fill any gaps between the metallic seal ring and the seating surface which may be formed by deformation of the thin metal seal ring.
The seal ring may also be made in other composite forms in which there is generally an outer layer of a polymeric or plastic material which encapsulates or partially encapsulates a core of intumescent material. Reference is now made to FIG. 5 for a typical annular seal member 70 which could be used in a disk valve. As can be seen, seal member 70 has a body portion 72 formed of a polymeric or plastic material or some other similar resilient material which defines an annularly extending, radially inward sealing surface 74 which is generally in the form of a trapezoid when viewed in transverse cross section. Body 72 is provided with an annularly extending, radially outwardly opening groove 76 which is filled with an intumescent material 78. It will be apparent that if seal member 70 were in a valve which was subjected to sufficient fire or heat to destroy or partially destroy, or at least deleteriously affect the structural integrity of body member 72 such that it could not effect a fluid-tight seal, intumescent material 78 would expand or extrude under the influence of such fire or heat and fill any gaps between the seating surface and the destroyed or deformed portion of body 72.
FIG. 6 shows yet another embodiment of the seal member of the present invention which is in the form of an O-ring, similar to seal ring 62 described above. Seal ring 80 includes a body 82 in the form of a toroid providing an annular core space 84 in which is received an intumescent material 86, intumescent material 86 substantially filling core space 84. In like manner as described with respect to seal member 70, it will be seen that if the outer sheath or covering 82 of seal member 80 is destroyed by fire or heat, intumescent material 86 will expand or extrude sufficient to fill the void between the seating surface of the valve and the disk or valve element thereby providing a fluid-tight seal.
With respect to the seal members shown in FIGS. 5 and 6 above, body portions 72 and 82 can be formed of any plastic, polymeric or resilient material as described above and which are conventionally used in forming seals for disk or other rotary valves. While the invention has been described with respect to a butterfly or disk valve in which the seal member is carried by the disk, it is well known that many butterfly valves employ resilient or polymeric seals which are received in a groove internally of the body, sealing being accomplished by an interference fit between the peripheral edge of a metallic disk and the rubber or polymeric seal carried by the valve housing. In such cases, the intumescent material can be incorporated, in any of the manners described above, into the seal carried by the valve housing as opposed to the seal carried by the disk or valve element.
While, as noted above, the invention has been described above with particular reference to a butterfly or disk valve, it will be apparent that the invention is not so limited. For example, in the case of ball valves, particularly of the floating type, wherein the ball valve element floats in a valve cavity under the action of line pressure to engage annular seal rings carried by the valve body, the seal rings could be comprised, in any of the manners described above, of an intumescent material such that if the ball valve were subjected to fire or heat, the seal rings would intumesce thereby forming a bridging seal or barrier to prevent fluid flow through the valve. In like manner, the invention can be utilized in globe valves or other such rotary valve assemblies. In general, the present invention is applicable to any valve assembly wherein a valve element is movable from a first position in which the valve is opened to a second position in which the valve is closed and in which the valve includes a surrounding, usually annular, seal which is normally heat or fire destructable, e.g. a polymeric seal, or deformable, e.g. a thin metal seat.
The materials of construction of the intumescent material will depend upon the application to which the valve is put. It is only necessary that the material forming the intumescent portion of the seal have a structure, when expanded, so as to be able to withstand fluid pressure to thereby effect a seal between the valve element and the valve body.
While the present invention finds particular utility with valve assemblies which utilize resilient seals such as seal rings made of rubber, polymers, both natural and synthetic, fluorocarbon resins and the like, it also has application in valves which employ metallic seats which are thin and subject to deformation under heat or fire, whereby such metallic seats lose their integrity and shape and permit leakage of fluid through the valve.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof, and various changes in the size, shape and materials as well as in the details of the illustrated construction may be made within the scope of the appended claims without departing from the spirit of the invention. | A valve assembly comprising a valve housing defining an internal valve cavity and a fluid flow passageway, a valve element rotatably received in the valve cavity to control flow through the passageway, one of the valve housing or the valve element defining a seating surface, the other defining a seal member carrying surface, and a seal member carried on the seal member carrying surface on either the valve housing or the valve element for engaging the seating surface and effecting a seal between the valve using the valve element, the seal member being comprised of an intumescent material. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of, and claims benefit under 35 USC §120 of copending PCT International Application Serial No. PCT/IL02/00145, in which the United States is designated, filed Feb. 26, 2002 (in English), which is hereby incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0002] Not applicable
BACKGROUND OF THE INVENTION
[0003] Clothes were traditionally dried by hanging the clothes or spreading the clothes flat and allowing evaporation to occur. This traditional approach is still used by many people. Although the traditional approach can work well, there- are drawbacks. The traditional approach does not work well in all conditions of temperature, humidity and wind speed. The traditional approach is less well suited to settings with high population densities. Depending on factors including the materials from which the clothes were made, minerals dissolved in local water and how much breeze is present during drying, the traditional approach often causes clothes to dry so that the clothes are stiff or wrinkled. Some people, correctly or incorrectly, associate traditional clothes drying methods with poverty. This perception, and the desire by many people to avoid appearing poor, discourages some people from employing traditional clothes drying methods. It is in large measure, because of the perception that traditional clothes drying is indicative of poverty, that some communities, by ordinance or by private land use restrictions, forbid (or otherwise restrict) outdoor drying of clothes.
[0004] Many people use equipment to dry clothes indoors. The “clothes dryers” overcome many of the problems described above. However, clothes dryers consume much energy. In many homes equipped with various appliances, the clothes dryer's energy consumption is second among the appliances only to the refrigerator.
[0005] In a typical household clothes dryer, the clothes being dried are in a clothes container commonly called the “drum” or “tumbler.” Typically, these clothes containers approximate right circular cylinders with nearly flat walls at the ends. Often there are baffles which protrude from the inner circumference of the clothes container. One of the nearly flat walls typically includes a door which can be opened to facilitate placing clothes in the clothes container and removing clothes from the clothes container.
[0006] Typically, while drying occurs, the clothes are agitated in a way commonly (and aptly) referred to as “tumbling.” The rotation causes the clothes to be lifted by the combination of the clinging of the clothes to the circumference of the clothes container (aided somewhat by centrifugal clinging) and the action of the baffles. However, the rotation is slow enough that the centripetal force is less than the weight of the clothes. Therefore, the clothes falls due to their own weight from near the top of the clothes container. This tumbling facilitates air circulation with the clothes and frequently changes the shape assumed by each garment which helps prevent wrinkling.
[0007] In the typical household clothes dryer, fresh air from outside of the dryer replaces the humid air inside the dryer. In most cases, the air taken into the clothes dryer is heated in a controlled manner. The heat facilitates effective evaporation of the water from the clothes. The evaporation is also facilitated by the replacement of the humidity-laden air resulting from the evaporation of the water from the clothes. Electric heating and gas heating are each frequently used to heat the air entering the dryer.
[0008] For conventional home clothes dryers, typically, air is drawn into the dryer, drawn through a heater, drawn into the clothes container, drawn through a lint screen, drawn through a fan and is blown out of the dryer. The pressure difference caused by the fan drives this flow. The exact pattern of air flow including the configuration of duct work and the placement of vents is quite variable. The flow through the clothes container is usually facilitated by small holes (typically approximately 0.7 cm) in either the curved surface of the clothes container or in the essentially flat end walls of the clothes container.
[0009] The “idealized interior surface area” of an object is taken in this disclosure to be the interior surface area that an imaginary object would have if that imaginary object had the same over-all shape as the actual object but was an entirely closed object lacking in local texture. By way of illustration, in the case of an essentially right circular cylindrical clothes container, the interior surface area would be 2(πr 2 )+2πrh where “r” is the radius of the cylinder and “h” is the height of the cylinder. This idealized interior surface area would not be influenced by holes in the surface of the actual object, even though the actual surface area would be influenced by that. Likewise, this idealized interior surface area would not be influenced by the surface texture of the actual object, even though the actual surface area would be influenced by that.
[0010] Similarly, the “idealized interior volume” of an object is taken in this disclosure to be the volume that an imaginary object would have if it had the same over-all shape as the actual object but was an entirely closed object. By way of illustration, in the case of an essentially right circular cylindrical clothes container, the idealize interior volume would be (πr 2 )h where r is the radius of the cylinder and h is the height of the cylinder. This idealized interior volume would not be influenced by holes in the surface of the actual object.
[0011] The term “openness factor” has been used by others to refer, conceptually, to the portion of the surface of a materials which is open (e.g. holes). However, the precise meaning is often unclear depending on the exact nature of the material. “Openness factor,” as used in this disclosure, is taken to be the total of the area of holes through the wall of the object divided by the idealized interior surface area. For these purposes, the narrowest cross-sectional area of each hole is used in the calculation.
[0012] Typically, the same electric motor powers the rotation of the clothes container and the fan. The rotation of the motor and the rotation of the clothes container are typically linked by a belt that goes around the entire clothes container and about a pulley on the motor shaft. The belt also typically goes around a tensioning pulley. Typically, the speed of the fan and the speed of the clothes container are linked by the specific design of the dryer and are not user controllable.
[0013] Although typically the same electric motor powers the rotation of the clothes container and the fan, the use of separate motors to power the fan and to rotate the clothes container is not entirely unknown. In U.S. Pat. No. 6,088,932, Adamski teaches the use of separate fan and clothes container motors in some embodiments of the invention which is the subject of that disclosure. However, that disclosure does not teach the use of a user adjustable fan speed.
[0014] Typically, the user of a home clothes dryer can set the temperature to which the air entering the dryer is to be heated. Typical setting options range from approximately 35° C. to approximately 90° C. Typically, the user can select to not have the air heated. However, that typically accomplishes drying very slowly and is used frequently to “fluff” clothes rather than to dry clothes.
[0015] The air flow in a typical conventional clothes dryer is approximately 175 cubic feet per minute. The idealized interior volume in a typical conventional clothes dryer is approximately 7 cubic feet. The openness factors of conventional clothes dryers vary considerably. However, an openness factor in the range of 1% is not atypical.
[0016] Typically, the heating of the air entering the clothes dryer involves far greater energy consumption than the mechanical rotation of the clothes container and operation of the fan. The other energy consumptions related to a clothes dryer, such as operation of controls, are usually quite minor components.
[0017] In U.S. Pat. No. 2,707,338, Morrison disclosed a clothes dryer that did not heat the air. The disclosed design includes a stationary shield which directs air in a manner which prevents it from bypassing the clothes container or passing through the perforated clothes container where there are no clothes.
[0018] In U.S. Pat. No. 3,3608,871, Wattenford discloses a clothes dryer with no air heating means. However, the invention disclosed in that patent is intended to use heat provided externally by an oil stove over which the disclosed clothes dryer is placed.
[0019] Conventional clothes dryers can be fire hazards. Approximately 14,600 residential structural fires were caused by clothes dryers in the United States in 1999. These resulted in 300 injuries and over $86 million dollars in property losses (“1999 Residential Fire Loss Estimates” U.S. Consumer Product Safety Commission, Released 2003).
[0020] Gas heated conventional clothes dryers can be carbon monoxide hazards (“Non-Fire Carbon Monoxide Deaths and Injuries Associated with the Use of Consumer Products Annual Estimates” U.S. Consumer Product Safety Commission, 2002).
[0021] Energy efficiency improvements of conventional clothes dryers have been driven by economics and the regulations of various governments. Much of that improvement has been based of better control of the process. For example, moisture sensing can facilitate more appropriate timing of when to stop the drying. However, greater energy efficiency is still desired.
BRIEF SUMMARY OF THE INVENTION
[0022] The invention disclosed here is a clothes dryer specifically designed to operate with air which is not heated. The invention is inexpensive to manufacture and can facilitate significant energy savings. This is accomplished in this invention by using far more air flow through the clothes dryer than flows through a conventional clothes dryer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0023] FIG. 1 is a perspective representation of the preferred embodiment of the invention. It is drawn as viewed from above and to the side of the front of the cabinet (from essentially the same point of view as FIG. 2 , FIG. 5 , FIG. 7 and FIG. 11 ). It shows selected exterior features of the preferred embodiment of the invention disclosed here.
[0024] FIG. 2 is a cut-away perspective representation showing selected features of the preferred embodiment of the invention. It is partially see-through to allow features behind the back wall of the clothes container to be shown. It was drawn as though the front of the cabinet was removed. It is drawn as viewed from above and to the side of the front of the cabinet (from essentially the same point of view as FIG. 1 , FIG. 5 , FIG. 7 and FIG. 11 ). It shows selected exterior and interior features of the preferred embodiment of the invention disclosed here.
[0025] FIG. 3 is a cut-away perspective representation showing selected features of the preferred embodiment of the invention. It was drawn as though the front of the cabinet was removed. It is drawn as viewed from straight in front of the cabinet. It shows, in context, selected features responsible for the support of the clothes container in the preferred embodiment of the invention disclosed here.
[0026] FIG. 4 is a cut-away perspective representation showing selected features of the preferred embodiment of the invention. It was drawn as though the rear of the cabinet was removed. It is drawn as viewed from straight in back of the cabinet. It shows the system that causes the rotation of the clothes container in the preferred embodiment of the invention disclosed here.
[0027] FIG. 5 is a see-through perspective representation showing, in context, the flow of air into and out of the preferred embodiment of the invention disclosed here. It is drawn as viewed from above and to the side of the front of the cabinet (from essentially the same point of view as FIG. 1 , FIG. 2 , FIG. 7 and FIG. 11 ).
[0028] FIG. 6 is a cut-away representation showing, in context, selected aspects related to the fan assembly of the preferred embodiment of the invention. It was drawn as though the front of the cabinet was removed. It is a non-perspective view from the front of the cabinet.
[0029] FIG. 7 is a perspective representation of the preferred embodiment of the invention. It is drawn as viewed from above and to the side of the front of the cabinet (from essentially the same point of view as FIG. 1 , FIG. 2 , FIG. 5 and FIG. 11 ). It shows selected exterior features of an alternative embodiment of the invention disclosed here. For clarity, those features shown essentially identically to those shown in FIG. 1 which are labeled on FIG. 1 are not labeled on this Figure, but should be understood to be the same.
[0030] FIG. 8 represents a small piece of the clothes container of the preferred embodiment of the invention disclosed here shown approximately to scale. The black represents the stainless steel rods. The purpose of FIG. 8 is to give a sense of the openness of the clothes container.
[0031] FIG. 9 represents in simplified schematic form the air flow into and out of the clothes container in the preferred embodiment of the invention disclosed here and selected prior art clothes dryers. The arrows represent air flow. The arrows with filled heads represent air leaving a clothes container. The arrows with non-filled heads represent air entering the clothes container. Three different arrangements are shown. Each clothes container is essentially a right circular cylinder. View “A” represents a conventional clothes dryer. Views “B” and “C” represent the invention disclosed by Morrison in U.S. Pat. No. 2,707,338. Views “D” and “E” represent the preferred embodiment of the invention disclosed here. Views “A,” “B” and “D” are viewed from a vantage that allows a broad view of one side of the curved part of the clothes container, and allows only a slight view of the front of the clothes container. Views “C” and “E” are approximately orthogonal to view “B” and “D” respectively. Views “C” and “E” are viewed from a vantage that allows a broad view of the front of the clothes container and allows only a slight view of one side of the curved part of the clothes container. The dotted lines in “B” and “C” represent the air blocking shield and “partition wall” of the Morrison disclosure.
[0032] FIG. 10 includes three depictions of the fan unit of the preferred embodiment of the invention disclosed here. View “a” is an exterior view of the fan unit with the vent hatch closed. View “b” is an exterior view of the fan unit with the vent hatch open. View “c” shows selected internal details of the fan unit.
[0033] FIG. 11 is a perspective representation of the preferred embodiment of the invention. It is drawn as viewed from above and to the side of the front of the cabinet (from essentially the same point of view as FIG. 1 , FIG. 2 , FIG. 5 and FIG. 7 ). It shows the relationship between the fan unit and the dryer as a whole.
DETAILED DESCRIPTION OF THE INVENTION
[0034] One object of the invention disclosed here is to improve the energy efficiency of the clothes drying process. This is accomplished, in brief, by not requiring the heating of air done by conventional clothes dryers.
[0035] Another object of the invention disclosed here is to allow less expensive manufacturing than is required for conventional clothes dryers. The reduced cost is principally due to the lack of an air heating means and the fact that heat resistant materials do not need to be employed.
[0036] Yet another object of the invention disclosed here is to reduce the fire and carbon monoxide hazards present in conventional clothes dryers.
[0037] The above stated objectives are accomplished in this invention by using far more air flow through the clothes dryer than flows through a conventional clothes dryer.
[0038] The preferred embodiment has a cabinet which is essentially a cube which is approximately 70 cm in each height, width and length. There is little air flow in or out of the cabinet other than through the vents described later. Inside that cabinet, an essentially cylindrical clothes container is mounted so that the clothes container can rotate about the cylinder axis.
[0039] The clothes container of this preferred embodiment is made of stainless steel rods which are each approximately 3 mm in diameter. The spacing of the rods is approximately 4 cm on center. This gives the clothes container an openness factor of approximately 85%. The design of the clothes container affords far more openness than the typical conventional clothes dryer. In fact, “basket” or “cage” would be a better term for the clothes container of the preferred embodiment than “drum.” That openness is conducive to far greater air flow in the invention disclosed here than the air flow in the typical conventional clothes dryer. It is important to note that the clothes container could take various specific forms in terms of materials and shapes in other embodiments of the invention.
[0040] In the preferred embodiment of the invention disclosed here, the clothes container is almost as large as can be accommodated in the cabinet. The clothes container has no baffles. A centrifugal fan is mounted along one side of the cabinet, near the bottom, in the space between the clothes container and the cabinet wall and immediately above the cabinet floor. The fan blows air into the clothes container across most of the depth of the clothes dryer. This fan speed can be adjusted by the user to blow approximately 900, 1100 or 1300 cubic feet per minute. The fan speed adjustment can be done by using a switch.
[0041] Referring to FIG. 1 , in the preferred embodiment of this invention, air is drawn in through a vent 10 . The vent 10 is attached to the rest of the fan unit by hinges 11 . The vent can be opened without the use of any tools. On the inside of the grill of the vent, an air filter is disposed to filter the incoming air. The clothes are placed in the clothes dryer and removed from the clothes dryer using a hinged door 12 on the front of the cabinet. A switch prevents, during times the door is ajar, powering of the fan motor or powering of the motor that causes the clothes container to rotate. (Conventional clothes dryers typically have a similar stop-when-ajar feature.) The clothes dryer is controlled by a user controlled timer 13 disposed on the front of the cabinet. The control 14 to allow the user to set the fan speed is also disposed on the front of the cabinet. The boundary 15 between the external face of the fan unit (discussed later in this disclosure) and the rest of the cabinet is shown.
[0042] Referring to FIG. 2 , which is another representation of the preferred embodiment of the invention disclosed here, the vent 20 and hinges 21 are again shown. In this view, certain internal features are represented. The clothes container 23 is represented. Near the front of the cabinet, two rollers 22 support the clothes container near the front. Those rollers 22 passively facilitate the rotation of the clothes container 23 . The boundary 24 between the external face of the fan unit and the rest of the cabinet is shown.
[0043] Referring to FIG. 3 , the rollers 31 are again shown supporting the clothes container 34 near the front in the preferred embodiment. Mounted to the back wall of the cabinet is a brace 32 (shown as partially “hidden” in drawing) to which a bearing 33 (shown as “hidden” in drawing) is attached. That bearing 33 connects to the rear wall of the clothes container 34 , supporting the clothes container in the back.
[0044] Referring to FIG. 4 , the clothes container 43 of the preferred embodiment is rotated by similar means to a conventional clothes dryer. An electric motor 41 is mounted on the base of the cabinet toward the back, toward one side of the cabinet. A belt 42 , goes around the shaft of the electric motor 41 and around the clothes container 43 . The belt is tensioned by a tensioning pulley 44 which deflects the path of the belt 42 . For clarity, the details of the tensioning mechanism are not shown. However, the mechanism is similar to that found typically on a conventional clothes dryer. Unlike in a conventional clothes dryer, the motor 41 in the preferred embodiment of the invention disclosed here is responsible only for the rotation of the clothes container, not for the driving of the fan. This allows the fan speed to be adjusted without the speed of rotation of the clothes container changing. The rate of rotation of the clothes container allows the clothes to “tumble” in a manner similar to a conventional clothes dryer.
[0045] Referring to FIG. 5 , the cabinet of the preferred embodiment is represented in see-through form without showing the internal structures. It shows where air enters 52 and where air exits 51 the clothes dryer in the preferred embodiment when the clothes dryer is in use. The exhaust vent would be placed at a window to allow the moist air to leave. A more detailed air path (including structures not shown in FIG. 5 ) is that the air enters through the in-vent grill 52 , passes through the filter, passes through the fan, passes into the clothes container, passes into the cabinet around the clothes container, and leaves through the out-vent 51 .
[0046] In cases of indoor use, the air that leaves the out-vent could be vented through a window or dedicated vent. That dedicated vent would be similar to those typically used in connection with conventional clothes dryers, except that a wider vent would be optimal to accommodate the greater air flow. An alternative embodiment of the invention disclosed here would have fittings to accommodate installation that included dedicated venting of exhaust air. It should be noted that the vent through which the exhaust air leaves the clothes dryer could be located almost anywhere on the cabinet of the clothes dryer.
[0047] It would be possible to equip the clothes dryer with a lint filter. However, experience with the preferred embodiment of the invention does not indicate a practical need for that. Although no measurements have been made, informal observation of the operation of the clothes dryer disclosed here suggests that it liberates far less lint than a conventional clothes dryer.
[0048] Referring to FIG. 6 , which shows certain features of the preferred embodiment of the disclosed invention, the centrifugal fan 62 draws air through the vent hatch 63 and blows the air into the clothes container 61 which contains the clothes. The hinges 64 attach the vent hatch 63 to the rest of the fan unit. By opening the vent hatch 63 , the air filter can be replaced. A dedicated electric motor turns the fan. The span of the air blowing portion of the fan is almost the entire depth of the clothes container. The fan unit can be removed for servicing of the components housed in that unit (discussed in more detail later in this disclosure).
[0049] FIG. 7 represents an alternative embodiment of this invention. The boundary 74 between the external face of the fan unit and the rest of the cabinet is shown. The clothes dryer is shown with the vent hatch 72 open. In this alternative embodiment, a small open-topped container 71 is mounted on the face of the fan unit 73 which is next to the vent hatch when the clothes dryer is in use. A volatile liquid can be placed in the container. The liquid can evaporate and impart a desired scent to the clothes.
[0050] FIG. 8 represents a small piece of the clothes container of the preferred embodiment of the invention disclosed here shown approximately to scale. In that figure, the black represents the stainless steel rods. This figure shows the high degree of openness of the clothes container.
[0051] FIG. 9 represents, in simplified schematic form, the air flow into and out of the clothes container in the preferred embodiment of the invention disclosed here and in selected prior art clothes dryers. The arrows represent air flow. The arrows with filled heads represent air leaving a clothes container. The arrows with non-filled heads represent air entering the clothes container. Three different clothes dryer types are shown. The clothes container of each clothes dryer is essentially a right circular cylinder. View “A” represents a conventional clothes dryer. Views “B” and “C” represent the invention disclosed by Morrison in U.S. Pat. No. 2,707,338. Views “D” and “E” represent the preferred embodiment of the invention disclosed here. Views “A,” “B” and “D” are viewed from a vantage that allows a broad view of one side of the curved part of the clothes container and allows only a slight view of the front of the clothes container. Views “C” and “E” are approximately orthogonal to view “B” and “D” respectively. Views “C” and “E” are viewed from a vantage that allows a broad view of the front of the clothes container and allows only a slight view of one side of the curved part of the clothes container. The dotted lines in “B” and “C” represent the air blocking shield and “partition wall” of the Morrison disclosure. The air flow pattern of the invention disclosed here is different from the other clothes dryers shown.
[0052] Referring to FIG. 10 , which includes three depictions of the fan unit of the preferred embodiment, the vent hatch 101 is shown closed (in “a”) and open (in “b”). There is a hinged connection 102 between the vent hatch and the casing of the fan unit. View “c” depicts selected internal details of the fan unit. For clarity, view “c” does not show the vent hatch. When in operation, a dedicated motor 104 causes the rotation of the fan 105 . When in operation, air is blown by the fan 105 through an opening 103 in the case of the fan unit.
[0053] FIG. 11 is a perspective representation of the preferred embodiment of the invention. It is drawn as viewed from above and to the side of the front of the cabinet (from essentially the same point of view as FIG. 1 , FIG. 2 , FIG. 5 and FIG. 7 ). It shows the relationship between the fan unit ( 112 , 113 ) and the clothes dryer 111 as a whole. When the fan unit 112 is installed in the cabinet of the clothes dryer 111 , only the face housing the vent hatch is on the exterior of the clothes dryer. The fan unit is also shown removed from the rest of the clothes dryer as 113 .
[0054] In an alternative embodiment, the clothes container has a net-like lining to retain smaller objects than can be retained by the metal clothes container described as the preferred embodiment. However, such a net-like lining does little to retard the air flow so important in this design.
[0055] In an alternative embodiment, the outer wall of the cabinet is open to air passage. This embodiment could be appropriate in outdoor settings such as a balcony of an apartment.
[0056] In an alternative embodiment, another type of closure (such as a screw-on lid) replaces the hinged door of the preferred embodiment.
[0057] In an alternative embodiment, there is no removable fan unit. In this alternative embodiment, the fan and the motor for the fan are mounted in the cabinet in a manner that is not conducive to easy, tool-free removal.
[0058] In an alternative embodiment, the clothes dryer is controlled by moisture sensing means instead of (or in addition to) a timer.
[0059] In an alternative embodiment, the clothes container can be equipped with baffles which would function similarly to the function of baffles in a clothes container of a conventional clothes dryer.
[0060] Key to the design of this invention is the large volume of air passing through the clothes dryer. The preferred embodiment of this invention can draw through approximately 200 times the volume of air as the volume of the clothes container. That is approximately eight times as much as in a typical conventional clothes dryer. The incoming air serves two distinct purposes. The air replaces air made more humid by evaporation of moisture on the clothes. It also supplies heat to the cloths which are cooled by evaporative cooling.
[0061] The invention disclosed here can operate far more energy efficiently than can a conventional clothes dryer. The preferred embodiment of this invention uses approximately 500 watts. A typical electric conventional clothes dryer with a similar capacity uses approximately 6000 watts.
[0062] In addition to the major advantages of lower manufacturing cost and lower energy uses, the invention disclosed here can be gentler to clothes in that the air is cooler than in a conventional clothes dryer.
[0063] Yet another advantage is that permanent-press clothes do not require the sort of “cool-down” period common in conventional clothes dryers.
[0064] Yet another advantage is that clothes need not be separated for drying on the basis of temperature sensitivity. This can result in a labor savings. It can also facilitate sorting based on other factors such as how thick the fabric is.
[0065] From the above description and drawings, it will be understood by those of ordinary skill in the art that the particular embodiments shown and described are for purpose of illustration only and are not intended to limit the scope of the invention. Those of ordinary skill in the art will recognize that the invention may be embodied in other specific forms without departing from its spirit or essential characteristics. References to details of particular embodiments are not intended to limit the scope of the claim. | An improved clothes dryer. The invention is a clothes dryer, which is capable of effectively drying clothes without heating the air used to dry the clothes. The dryer comprises a clothes container, a means to rotate said clothes container, and a system capable of blowing air with more than 75 times the idealized internal volume of the clothes container per minute through said clothes container. The invention can facilitate significant energy savings, is inexpensive to manufacture and has safety advantages. This is accomplished in this invention by using far more air flow through the dryer than flows through a conventional clothes dryer. The preferred embodiment has a clothes container with a high openness factor. In the preferred embodiment, the fan unit can be readily removed for servicing and cleaning. In the preferred embodiment the fan is capable of blowing approximately 200 times the volume of air as the volume of the clothes container each minute. The preferred embodiment consumes only approximately 500 watts. | 3 |
This is a continuation of U.S. patent application Ser. No. 08/366,826, filed Dec. 30, 1994, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to signal processing and, in particular, to computer-implemented processes and apparatus for efficient block comparisons in motion estimation systems.
2. Description of the Related Art
Motion estimation is commonly utilized by video encoders in signal processing techniques that compress successive frames of digital video data ("video frames"). When these video frames are to be transmitted via a communication medium of limited bandwidth, or are to be stored in a storage medium having limited storage capacity, it is often desirable to first compress the digital data which represents each frame, so as to reduce the amount of data that needs to be transmitted.
Motion estimation is one of the most computationally intense of the various techniques utilized to compress data. Motion estimation techniques exploit the temporal correlation that often exists between consecutive video frames, in which there is a tendency for objects or image features to move from one location to another on a display device from frame to frame.
For instance, frame 1 may contain an object, and frame 2 may contain a set of pixels corresponding to the same object spatially displaced by a few pixels from the location in frame 1. If frame 1 is transmitted to and received by a pixel processor or video processor (which performs any necessary decompression or other decoding), frame 2 may be transmitted without including the pixel data corresponding to the object. Instead, motion vectors (i.e. "pointers") are sent along with frame 2 (which may also be compressed using other techniques). These motion vectors may be utilized by the receiving video processor when decoding the received video frame 2 to reproduce the object from frame 1 at a new location within frame 2. Since such motion vectors can be represented with fewer bits than the pixels that comprise the object, fewer bits need to be transmitted (or stored) in order to recreate the object in frame 2.
The motion estimation procedure may be performed at the encoder level by comparing given regions or blocks within a current video frame to many regions or blocks within the previous video frame. The process of comparing a given block of one frame to a block of another frame is called "block matching." Blocks are matched by determining a "comparison measurement" between any given pair of blocks. A comparison measurement corresponds to some form of indication of a degree of "difference" between the two regions. If the comparison measurement is below a predetermined threshold, the blocks may be considered to be similar enough that a block match is indicated. If so, the block in the previous video frame may be utilized as described above by the video decoder to reproduce a duplicate block in the current video frame.
In performing such comparisons, a number of pixels from the previous video frame are accessed for each block of the current video frame that is subjected to motion estimation. In most general purpose video processing systems, the bit maps corresponding to the previous and current video frame pixels are stored in general purpose memory connected to the video processor through a bus. For each block matching procedure the video processor must access the memory many times, which may constitute a high amount of traffic on the bus and a high number of memory accesses. Because of the limited bandwidth of the bus by which the memory is accessed, these memory accesses can tie up use of the bus and memory and thus slow down overall operation of the video processing system.
To avoid this problem, the video processor performing the motion estimation step may contain, for example, a dedicated, special-purpose memory space to store the two video frames being compared so that there is less traffic on the bus. However, such a special-purpose memory space is often unavailable, unfeasible, or otherwise not desired because of the extra complexity of such a special-purpose memory. The special-purpose memory space may be too costly. Further, even a special purpose memory space may be accessed so often during block matching that the video processor may be slowed down.
What has been done in the past is to look at all the luminance values of the pixels within a block and to use a standard criterion (such as mean absolute error or mean square error) to accomplish accurate block matching. In their report of research done in connection with the Office of Naval Research under grant Number N00014-89-J1327, Andre Azccarin, et al, disclose a technique for using a pseudo-randomly selected subsampled set of pixel values in a target block to reduce the amount of computation needed for block matching. Their approach is useful in some circumstances, but does not take advantage of special identifying features of certain blocks.
It is accordingly an object of this invention to improve upon the techniques of the known art and to provide a method and apparatus that more efficiently uses available data to perform accurate and speedy block matching.
Further objects and advantages of this invention will become apparent from the Detailed Description of preferred embodiments which follows.
SUMMARY OF THE INVENTION
Applicant has discovered that a major benefit can be obtained by doing a simple analysis of the "target" block prior to comparing other blocks to it in a block matching search. This analysis is for the purpose of identifying special, (i.e. "prominent") features of the target block. Then, instead of using all the pixels in the target block for matching purposes, mainly the pixels of the special features of the block are used (along with a few general pixels) to do comparisons with other blocks. In other words, a special mask is created that identifies mainly the pixels of the target block that are associated with prominent features of that block. Then comparisons with other blocks are done using just the pixels in the other blocks that correspond to the target block's mask pixels. This allows accurate block matching while comparing many fewer pixels in the respective blocks than would otherwise normally be used with prior art techniques. By using a few extra computations to identify the suitable mask pixel locations of the target block, a very significant improvement in the efficiency of the search for a suitable matching block is accomplished.
BRIEF DESCRIPTION OF THE DRAWING
These and other features, aspects, and advantages of the present invention will become more fully apparent from the following description, appended claims, and accompanying drawing, in which:
FIG. 1 is a computer-based encoding system for encoding video signals, according to a preferred embodiment of the present invention;
FIG. 2 is a computer-based decoding system for decoding the video signals encoded by the computer system of FIG. 1, according to a preferred embodiment of the present invention;
FIG. 3 depicts reference and search frames having reference and search blocks and a search area utilized in motion estimation by the computer system of FIG. 1, according to a preferred embodiment of the present invention;
FIGS. 4A and 4B illustrate the ordering of pixels within the search block of FIG. 3, and the ordering of search blocks within the search frame of FIG. 3, respectively.
FIG. 5 shows an example of a typical 8×8 target block with luminance ("Y") values for the 64 pixels thereof.
FIG. 6 shows a way to divide an 8×8 block into sectors.
FIG. 7 depicts the calculated internal "slope" values for the block of FIG. 5.
FIG. 8 is an example of a target "mask" that could be used to identify prominent features of the target block of FIG. 5.
FIG. 9 shows the internal "variance" values V 1 for the target block of FIG. 5.
FIG. 10 shows the internal "variance" values V 2 for the target block of FIG. 5.
FIGS. 11-15 show possible target block masks that could be used if the target block does not have any significant identifying features.
DETAILED DESCRIPTION
Referring now to FIG. 1, there is shown a computer-based encoding system 100 for encoding video image signals, according to a preferred embodiment of the present invention. Analog-to-digital (A/D) converter 102 of encoding system 100 receives analog video image signals from a video source. The video source may be any suitable source of analog video image signals such as a video camera or VCR for generating local analog video image signals or a video cable or antenna for receiving analog video image signals from a remote source. A/D converter 102 decodes (i.e., separates the signal into constituent components) and digitizes each frame of the analog video image signals into digital image component signals (e.g., in a preferred embodiment, Y, U, and V component signals).
Capture processor 104 receives, captures, and stores the digitized component signals as subsampled video images in memory device 112 via bus 108. Each subsampled video image is represented by a set of two-dimensional component planes or pixel bitmaps, one for each component of the digitized video image signals. In a preferred embodiment, capture processor 104 captures video image signals in a YUV 4:1:1 format, in which every (4×4) block of pixels of the Y component plane corresponds to a single pixel in the U component plane and a single pixel in the V component plane. Alternatively, a YUV 2:1:1 format can be used.
Pixel processor 106 accesses captured bitmaps from memory device 112 via bus 108 and generates encoded image signals that represent one or more of the captured video images. Depending upon the particular encoding method implemented, pixel processor 106 applies a sequence of compression techniques to reduce the amount of data used to represent the information in each image. The compression method of motion estimation in accordance with the present invention will be further described below. The encoded image may then be stored to memory device 112 via bus 108 for transmission to host processor 116 via bus 108, bus interface 110, and system bus 114 for storage in host memory 126. Pixel processor 106 also may contain local memory 130, which is a tightly-coupled on-chip memory suitable for locally storing a number of pixels and other data. Those skilled in the art will appreciate that system bus 114 and bus 108 may be merged into the same system bus 114. It will further be understood that host processor 116 may in alternative preferred embodiments perform the functions of pixel processor 106 described herein. Similarly, in alternative preferred embodiments a general memory device such as host memory 126 or memory device 112 may perform the functions of local memory 130 described herein.
Host processor 116 may transmit the encoded image to transmitter 118 for real-time transmission to a remote receiver (not shown in FIG. 1), store the encoded image to mass storage device 120 for future processing, or both. In addition, digital-to-analog converter 122 may receive and convert digital image signals to analog image signals for display in one or more windows on monitor 124. These image signals may correspond, for example, to raw captured video images or companded video images (i.e., the results of compressing and decompressing selected captured video images).
Referring now to FIG. 2, there is shown a computer-based decoding system 200 for decoding the image signals encoded by encoding system 100 of FIG. 1, according to a preferred embodiment of the present invention. Host processor 208 of decoding system 200 receives encoded image signals via system bus 206 that were either stored in mass storage device 212 or received by receiver 210 from a remote transmitter, such as transmitter 118 of FIG. 1. The host processor 208 temporarily stores the encoded image signals in host memory 214.
Host processor 208 decodes the encoded image signals and scales the decoded image signals for display. Decoding the encoded image signals involves undoing the compression processing implemented by pixel processor 106 of encoding system 100 of FIG. 1. Scaling the decoded image signals involves upsampling the U and V component signals to generate full-sampled Y, U, and V component signals in which there is a one-to-one-to-one correspondence between Y, U, and V pixels in the scaled component planes. Scaling may also involve scaling the component signals to a display size and/or resolution different from the image signals as original captured. Host processor 208 then stores the scaled decoded image signals to host memory 214 for eventual transmission to digital-to-analog (D/A) converter 202 via system bus 206. D/A converter converts the digital scaled decoded image signals to analog image signals for display on monitor 204.
Referring again to FIG. 1, encoding system 100 is preferably a general microprocessor-based personal computer (PC) system with a special purpose video-processing plug-in board. In particular, A/D converter 102 may be any suitable means for decoding and digitizing analog video image signals. Capture processor 104 may be any suitable processor for capturing digitized video image component signals as subsampled frames. Pixel processor 106 may be any suitable means for encoding subsampled video image signals, where the means is capable of implementing functions such as a forward discrete cosine transform and a motion estimation and block matching procedures as described in further detail below. Memory device 112 may be any suitable computer memory device and is preferably a dynamic random access memory (DRAM) device. Bus 108 may be any suitable digital signal transfer device and is preferably an Industry Standard Architecture (ISA) bus or Extended ISA (EISA) bus or a Peripheral Component Interface (PCI) bus. Bus interface 110 may be any suitable means for interfacing between bus 108 and system bus 114. In a preferred embodiment, A/D converter 102, capture processor 104, pixel processor 106, bus 108, bus interface 110, and memory device 112 are contained in a single plug-in board, such as an Intel® ActionMedia®-II board, capable of being added to a general microprocessor-based personal computer (PC) system.
Host processor 116 may be any suitable means for controlling the operations of the special-purpose video processing board and is preferably an Intel® general purpose microprocessor such as an Intel® Pentium® processor. Host memory 126 may be any suitable memory device used in conjunction with host processor 116 and is preferably a combination of random access memory (RAM) and read-only memory (ROM). System bus 114 may be any suitable digital signal transfer device and is preferably a PCI bus. Alternatively, system bus 114 may be an Industry Standard Architecture (ISA) bus or Extended ISA (EISA) bug. Mass storage device 120 may be any suitable means for storing digital signals and is preferably a computer hard drive. Transmitter 118 may be any suitable means for transmitting digital signals to a remote receiver and is preferably transmits digital signals over PSTN lines. Those skilled in the art will understand that the encoded video signals may be transmitted using any suitable means of transmission such as telephone line (PSTN or ISDN), RF antenna, local area network, or remote area network.
D/A converter 122 may be any suitable device for converting digital image signals to analog image signals and is preferably implemented through a personal computer (PC)-based display system such as a VGA or SVGA system. Monitor 204 may be any means for displaying analog image signals and is preferably a VGA monitor.
Referring now again to FIG. 2, decoding system 200 is preferably a general microprocessor-based personal computer (PC) system similar to the basic PC system of encoding system 100. In particular, host processor 208 may be any suitable means for decoding and scaling encoded image signals and is preferably an Intel® general purpose microprocessor such as an Intel® Pentium® processor. Host memory 214 may be any suitable memory device used in conjunction with host processor 116 and is preferably a combination of random access memory (RAM) and read-only memory (ROM). In an alternative preferred embodiment, decoding system 200 may also have a pixel processor similar to pixel processor 106 of FIG. 1 for decoding the encoded image signals and a display processor such as an Intel® i750® Display Processor for scaling the decoded image signals.
System bus 206 may be any suitable digital signal transfer device and is preferably an Industry Standard Architecture (ISA) bus or Extended ISA (EISA) bus. Mass storage device 212 may be any suitable means for storing digital signals and is preferably a CD-ROM device. Receiver 210 may be any suitable means for receiving the digital signals transmitted by transmitter 118 of encoding system 100. D/A converter 202 may be any suitable device for converting digital image signals to analog image signals and is preferably implemented through a personal computer (PC)-based display system such as a VGA or SVGA system. Monitor 204 may be any means for displaying analog image signals and is preferably a VGA monitor.
In a preferred embodiment, encoding system 100 of FIG. 1 and decoding system 200 of FIG. 2 are two distinct computer systems. In an alternative preferred embodiment of the present invention, a single computer system comprising all of the different components of systems 100 and 200 may be used to encode and decode video image signals. Those skilled in the art will understand that such a combined system may be used to display decoded video image signals in real-time during the capture and encoding of other video signals.
Referring now to FIG. 3, there are shown current frame 310 and search frame 311 stored in memory device 112. Current frame 310 and search frame 311 are two of the most recent video frame frames of a plurality of consecutive video frames. Current frame 310 is the current video frame being compressed, and search frame 311 is a previously-decoded video frame, preferably the immediately previously-decoded video frame, which is searched by a motion estimation procedure for block matches between search frame 311 and current frame 310. Current frame 310 contains reference block 302, and search frame 311 contains search block 304 and search area 305.
Reference and search frames 310 and 311 may be of any pixel size, and in a preferred embodiment have a size of (240×352) pixels, i.e. 240 rows ×352 columns of pixels. When performing block matching operations for motion estimation, current frame 310 is divided into a number of smaller regions or blocks such as reference block 302. Reference block 302 (as well as search blocks such as search block 304) may be of various sizes and shapes. In a preferred embodiment, reference block 302 contains an 8×8 array of pixels. In an alternative preferred embodiment of the present invention, reference block 302 contains a (16×16) block of pixels. In further alternative preferred embodiments, reference block 302 contains, in general, (n ×m) pixels, where n is the number of rows and m is the number of columns.
When performing block matching for purposes of motion estimation, reference block 302 is compared with various search blocks such as search block 304 of search frame 311, and the aforementioned comparison measurement which represents an indication of a degree of variation between a reference block 302 and a given search block 304 is determined. If this comparison value is sufficiently low, e.g. below a predetermined threshold value, a match is indicated. If a match is indicated, a motion vector which indicates the location of the matching search block 304 in search frame 311 as well as the location of reference block 302 in current frame 310, may be transmitted by pixel processor 106 to remote receiver 210. It will be appreciated that other data corresponding to current frame 310 may be transmitted as well, for example data compressed with other techniques that represent other blocks within current frame 310.
Since the decoding system of FIG. 2 should already have received previously-transmitted search frame 311 containing search block 304 (where search frame 311 may have itself been compressed and then decompressed), search block 304 from search frame 311 may be used with the transmitted motion vector to reproduce reference block 302 when decompressing current frame 310. It will be understood that if a lower threshold value is utilized in block matching, it will be more difficult to find a matching block, and the motion estimation procedure may take longer, but more accurate results may be obtained. By the same token, if a higher threshold value is utilized a "match" will likely be found more quickly but potentially less accurate results might be obtained. In practice it is sometimes desirable to employ two thresholds: (1) a "stopping" threshold, which, when reached, promptly stops the search altogether; and (2) a "matching" threshold, which is typically greater than (but never less than) the stopping threshold. If the stopping threshold is never reached, then, upon completion of the search, a match is declared for the block that yields a comparison value furthest below the matching threshold. It will further be understood that if no match is found during the motion estimation process then reference block 302 might not be able to be reconstructed from a similar block from the previous search frame 311, and may therefore need to be transmitted in its entirety (for example, after being compressed by other data compression methods such a discrete cosine transform, or a slant transform).
Given two blocks such as reference block 302 and search block 304 which are to be compared with each other to determine if there is a match, a comparison measurement is performed by encoding system 100. The basis of such comparison is often a standard calculation known as the "L 1 Norm" (i.e. the "absolute value of the difference" norm) which has the following form: ##EQU1## where: a ij is a value of a pixel in the ith row and jth column of search block 304;
b ij is a value of a pixel in the ith row and jth column of reference block 302;
n is the number of rows in a block; and
m is the number of columns in a block.
It will be appreciated that the lower the difference indicated by the L 1 Norm calculation, the more similar are the reference and search blocks being compared. It will further be appreciated that the likelihood of finding a match increases if more search blocks are compared against reference block 302, i.e. if more comparison measurements are determined. For example, an exhaustive block matching comparison may be performed, where, for each reference block 302 within current frame 310, the L 1 Norm is calculated for every search block 304 within search frame 311, or at least until a "match" below a certain threshold is found. It will be understood that the search blocks within search frame 311 may be displaced from each other by only one pixel or one fractional pixel horizontally or vertically and thus may overlap many neighboring search blocks by a substantial number of pixels. With fractional pixels, typically, linear interpolation is used; however, higher order interpolation such as "cubic" or "spline" can be used. In such an exhaustive search, the first search block 304 may be chosen as the search block in the uppermost and left most corner of search frame 311, the next may be the search block one pixel displacement to the right of this block (which overlaps the previous search block to some extent), and so on until reference block 302 is exhaustively compared against each possible search block 304 within search frame 311. Once the best integer pixel position is found, then a fractional pixel search nearby can be employed to find the best match.
Because such an exhaustive motion estimation procedure may be very computationally intensive, often the block matching performed by pixel processor 106 during the motion estimation procedure is performed on only a subset of possible search blocks within search frame 311. Because oftentimes a temporal correlation occurs between successive video frames such as search frame 311 and current frame 310, it is often statistically likely that any potential matches that exist will be found within a local region surrounding the location of reference block 302, perhaps even at the same location as reference block 302. The reason for this is that image features often will not move by very many pixels, if at all, from frame to frame. Therefore, a search area such as search area 305 may be selected as a subset of search frame 311. However, it will be understood that search area 305 may be as large as search frame 311 itself. When, for example, an exhaustive block matching comparison is performed by comparing a reference block 302 to each search block 304 within search frame 311, search area 305 may be considered to be equal to the entire search frame 311. In a preferred embodiment, search area 305 is a proper subset of search frame 311 and any given search block 304 is selected from search area 305, thus yielding a smaller possible number of search blocks, and consequently a smaller number of L 1 Norm measurements and related determinations and computations that must be performed. Those skilled in the art will appreciate that search area 305 may be (in alternative preferred embodiments) of any generalized size (p×q), to contain a selected number of search blocks 304.
Referring now to FIGS. 4A and 4B, there is illustrated the ordering of pixels within search block 304 and the ordering of search blocks such as search block 304 within search frame 311. As shown in FIG. 4A, a given pixel i,j of an (8×8) search block 304 is located at the ith row and jth column of the block. Thus, pixel 0,0 is located in the upper left corner of search block 304 while pixel 0,7 is located in the upper right corner of search block 304. FIG. 4B shows the ordering of possible search blocks 304 within search frame 311, which are labelled in a manner similar to the pixels of FIG. 4A, where there are (M×N) search blocks within search frame 311.
It will be appreciated that calculations other than the above-described "L 1 Norm" may be utilized to perform comparison measurements between reference and search blocks. For example, an "L 2 Norm" (i.e. the "square of the absolute value of the difference" norm) has the following form: ##EQU2##
The above-described norms (L 1 and L 2 ) are useful for block matching comparisons, but a great deal of computation is necessary to proceed with "brute force" block matching based thereon.
One method of speeding up the desired block matching relates to simplifying the block matching criteria. Instead of using the pseudo-random selection techniques of Andre Zacherin (as mentioned in the BACKGROUND section of this Application), the instant invention involves the selection of target block pixel masks based upon special features of the video image. In particular, Applicant has discovered that it is very useful to take the time to analyze a target block to determine if it exhibits any relatively steep "slopes" or "variances" or other unusual characteristics within the area of the block. (This is somewhat analogous to identifying a person by means of a facial scar rather than by the person's face alone.) It should be noted that the efficiencies of this technique arise because only the target block need be analyzed for special features, since the blocks to be compared with it will have the pertinent pixels identified by means of a "mask" determined from the already-accomplished target block analysis. So, once the mask pattern has been determined, a large reduction in the number of calculations necessary to compare other blocks with the target block is achieved. In other words, it is only necessary to calculate the positions of the prominent pixels for the target block, and not for each of the blocks against which it is being matched. Then a much-reduced group of pixels values in the target block is compared with pixel values of the same locations in the other blocks.
Referring now to FIG. 5, therein depicted is an 8×8 block of sample pixel luminance (i.e."Y") values in the range of 1 through 9. Careful perusal thereof clearly indicates that the sixth column to the right thereof is substantially in the middle of a transition region between dim and bright (i.e. a luminance "edge"). One way to easily determine the existence of such an edge is to apply a specialized "slope" computation for all the pixels in the block that are not touching the outside edges of the block as follows.
For an internal pixel x surrounded by two vertically adjacent pixels with values a and c and two horizontally adjacent pixels with values d and b, to wit, for the pixel matrix ##EQU3## define an internal slope
S.sub.I =(a-c).sup.2 +(b-d).sup.2.
Slopes associated with the pixels of the outside edges can also be defined as: ##EQU4## These are useful when the block comes up against the edge of the picture.
FIG. 6 depicts a useful layout for an 8×8 block showing the edges and four internal sectors (along with an alpha-numeric system of identifying all individual pixels as shown).
FIG. 7 shows the internal slope values (calculated in accordance with the above-defined S I ) for the Y values of FIG. 5. The eight slope values of greatest magnitude are found in the pixels of column 6, along with pixels f5 and g5.
In accordance with the concept of Applicant's invention, FIG. 8 depicts a possible prominent pixel mask for the target block values of FIG. 5, with the H's representing "High" slope values. To make the method work even better, Applicant has observed that it is desirable to include in the mask a few pixel locations from several regions of the block. One such pixel location from each quadrant is shown picked in FIG. 8. These four pixel locations, labeled L 1 , L 2 , L 3 , and L 4 are located at alpha-numeric locations b7, b2, g2, and g7 respectively as shown in FIG. 6. These are picked to give some consideration, i.e. "weight," to each of the internal quadrants I-IV of FIG. 7. The chosen mask, in this case, consists of the locations of eight "high-slope" pixels and four fixed location pixels. So, to perform block matching comparisons with the pixel values of the block of FIG. 5, other blocks' values are compared only in these special 12 pixel locations instead of all 64 of the respective blocks. This results in a major savings of computation time, while yielding comparable matching results vis-a-vis the "brute force" approach of the prior art.
Another useful technique is to use the pixel locations of the two highest slope values in each of the four quadrants. For the slopes of FIG. 7, a suitable mask would thus consist of the following eight pixel locations: c6, d6, b2, b3, f4, g4, e6, and f6.
It should be noted that the entire block of slope values for FIG. 7 can be calculated in accordance with the above-stated slope equations, and the corresponding prominent pixel mask can be used. The above-given example used only the "internal" slope values for reasons of increased efficiency in finding a suitable prominent pixel mask, keeping in mind that the edge pixel values are used in calculating the internal slope values (i.e. the edge pixel values are not ignored completely in the process of determining a suitable mask).
Another technique for finding the most prominent "features" of a block of pixel values is to use a "variance" calculation instead of a slope calculation on the pixel values of the target block. For example, for an "internal" pixel surrounded by adjacent horizontal and vertical pixels, to wit ##EQU5## various "variance" measurements can be defined, for example, as follows:
V.sub.1 =(x-a).sup.2 +(x-b).sup.2 +(x-c).sup.2 +(x-d).sup.2
and
V.sub.2 =|x-a|+|x-b|+|x-c|+.vertline.x-d|.
FIGS. 9 and 10 show the "internal" variance values, corresponding to these equations, for the pixel value block of FIG. 5. The reader will note that the prominent pixel masks that would be chosen using the V 1 or V 2 blocks of FIGS. 9 and 10 are substantially equivalent to the mask of FIG. 8 that was chosen by the previously-described "slope" technique. This is, of course, a special case, and generally the maps corresponding to S, V 1 , and V 2 would vary somewhat. Nonetheless, the simple V 2 calculations can often be adequate for determining a useful (even if not ideal) prominent pixel mask. Another variance definition could be
V.sub.3 =(x-1/2a-1/2c).sup.2 +(x-1/2b-1/2d).sup.2.
Various combinations of S, V 1 , V 2 , and V 3 could also be used to determine a suitable mask. Those skilled in the art could also come up with several other similar ways to choose a prominent pixel mask that in some way characterizes the significant features of the target block. For example, hue values could be used instead of or in addition to luminance values.
The above-described techniques are especially useful and powerful for target blocks that have special features. It is not uncommon, though, to encounter a substantially uniform target block, i.e. one that is nearly "featureless". In such cases, the corresponding S, V 1 , or V 2 blocks will consist of all (or nearly all) zeros, and will therefore not be very useful in determining a suitable sampling mask. In these cases, a simple uniform target mask such as depicted in FIG. 11 or FIG. 15 can be employed to good effect. This works well for a single target block, but, if this technique is used over a large area of target blocks with the same regular mask pattern, it has been observed that a systematic interference between the pattern and the image structure may occur. For this reason it is better to alternate mask patterns, such as shown in FIGS. 11-15, in block-to-block sequential manner (or in a random or pseudo-random manner, as needed) to avoid such interference.
Although the invention has been described herein with regard to certain specific examples and preferred embodiments, the scope of the invention is not limited thereto, but rather is | In a digital video motion estimation compression and decompression system, pixel block-matching is accomplished by comparing pixels in target block regions of high gradients of luminance or hue. A few pixels from low-gradient regions are also preferably used. A mask defining these pixel locations in the target block is created, and the block comparisons with other blocks are based only on the relative values associated with the pixels in these locations. Major computational time savings are accomplished with negligible degradation of image quality. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claim priority from Korean Patent Application No. 2008-0126417, filed on Dec. 12, 2008 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a non-halogen flameproof polycarbonate resin composition.
BACKGROUND OF THE INVENTION
[0003] Generally, polycarbonate resins have transparency, high impact strength, heat resistance and electrical properties. Therefore, polycarbonate resins have been widely used in the production of large injection molded products, such as electric or electronic goods and office equipment which emit a lot of heat. Accordingly, flame retardancy, heat resistance and high mechanical strength are important factors that should be considered when manufacturing a polycarbonate composition.
[0004] Conventionally to provide a polycarbonate resin with good flame retardancy, a halogen-containing flame retardant or an antimony-containing compound were used. However, halogen-containing compounds can corrode a mold due to hydrogen halide gases released during the molding process. In addition, there are safety concerns associated with the use of halogen-containing compounds because toxic gases can be liberated in the case of fire.
[0005] One method to impart flame retardancy to a polycarbonate resin without using a halogen-containing compound is to employ a phosphoric acid ester compound as a flame retardant. However, a juicing phenomenon can occur when using a phosphoric acid ester compound due to the migration of the flame retardant agent to the surface of the molded article during the molding process. Further, the heat resistance can be rapidly deteriorated.
[0006] EP 0 728 811 discloses a thermoplastic resin composition comprising an aromatic polycarbonate, a graft copolymer, a vinyl copolymer and a phosphazene. EP '811 states that no dripping occurs during combustion when using a phosphazene as a flame retardant even though an additional anti-dripping agent is not employed, and that the resin composition has excellent heat resistance and impact strength. However, in EP '811, when using phosphazene as a flame retardant, an increased amount of flame retardants should be used to maintain a certain degree of flame retardancy.
SUMMARY OF THE INVENTION
[0007] The present invention provides an environmentally friendly flameproof polycarbonate resin composition which can have good flame retardancy and heat resistance without releasing hydrogen halide gases during combustion by employing a phosphorus compound having a new structure as a flame retardant with a polycarbonate resin.
[0008] The present invention provides an excellent flameproof polycarbonate resin composition.
[0009] The present invention provides a flameproof polycarbonate resin composition which employs a phosphorus compound having a new structure as a flame retardant.
[0010] The present invention further provides an environmently friendly polycarbonate resin composition by employing a phosphorus compound having a new structure as a flame retardant which does not release hydrogen halide gases during preparation of the composition or an article therefrom or during combustion.
[0011] The present invention further provides a molded article produced from a non-halogen flameproof polycarbonate resin composition.
[0012] A non-halogen flameproof polycarbonate resin composition of the present invention comprises about 100 parts by weight of a polycarbonate resin; and about 0.5 to about 10 parts by weight of a phosphorus compound represented by the following Chemical Formula (1) or a combination thereof.
[0000]
[0013] wherein R 1 and R 2 are each independently C 1 to C 6 alkyl and n is 1 or 2.
[0014] In exemplary embodiments of the invention, examples of the phosphorus compound may include without limitation 2,4-di-tert-butylphenyl diphenyl phosphate represented by the following Chemical Formula (2-1), bis(2,4-di-tert-butylphenyl)phenyl phosphate represented by the following Chemical Formula (2-2), and combinations thereof.
[0000]
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention now will be described more fully hereinafter in the following detailed description of the invention, in which some, but not all embodiments of the invention are described. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.
[0016] (A) Polycarbonate Resin
[0017] The polycarbonate resin used in the resin composition of the present invention may be prepared through a conventional method as known in the art. The polycarbonate resin is not limited and can be any commercially available polycarbonate.
[0018] The polycarbonate resin may be prepared by reacting a diphenol compound represented by the following Chemical Formula (1) with a phosgene, a halogen formate or a carboxylic acid diester:
[0000]
[0019] wherein A is a single bond, C 1 to C 5 alkylene group, C 1 to C 5 alkylidene group, C 5 to C 6 cycloalkylidene group, —S— or —SO 2 —.
[0020] Examples of the diphenols of Chemical Formula (1) may include without limitation 4,4′-dihydroxydiphenol, 2,2-bis-(4-hydroxyphenyl)-propane, 2,4-bis-(4-hydroxyphenyl)-2-methylbutane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, 2,2-bis-(3-chloro-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane and the like, and combinations thereof. Hydroquinone, resorcinol, and combinations thereof can be used. In exemplary embodiments, the diphenol used in the present invention can be 2,2-bis-(4-hydroxyphenyl)-propane (also called ‘bisphenol-A’).
[0021] In the present invention, the polycarbonate resin can have a weight average molecular weight (M w ) of about 10,000 to about 500,000 g/mol, for example about 15,000 to about 100,000 g/mol. If the weight average molecular weight of the polycarbonate resin is less than about 10,000 g/mol, physical properties and thermal resistance may be deteriorated. If the weight average molecular weight of the polycarbonate resin is more than about 500,000 g/mol, moldability may be deteriorated.
[0022] Examples of the polycarbonate resin can include without limitation linear polycarbonate resin, branched polycarbonate resin, polyester-carbonate resin, and the like, and combinations thereof. The polycarbonate resin may be prepared by using about 0.05 to about 2 mol %, based on total quantity of diphenols used, of tri- or higher functional compounds, for example, those with three or more phenolic groups. The polyester-carbonate resin may be obtained by polymerization in the presence of an ester precursor, such as a difunctional carboxylic acid. Further, a homopolymer of polycarbonate, a copolymer of polycarbonate or a combination thereof may be used in this invention.
[0023] (B) Phosphorus Compound
[0024] The phosphorous compound of the present invention is represented by the following Chemical Formula (1):
[0000]
[0025] wherein R 1 and R 2 are each independently C 1 to C 6 alkyl and n is 1 or 2. The alkyl may have a linear or branched structure.
[0026] In one exemplary embodiment, R 1 and R 2 are each independently C 3 to C 6 branched alkyl. For example, R 1 and R 2 may be each independently isopropyl, sec-butyl, tert-butyl, or isoamyl.
[0027] Examples of the phosphorus compounds can include without limitation 2,4-di-tert-butylphenyl diphenyl phosphate represented by the following Chemical Formula (2-1), bis(2,4-di-tert-butylphenyl)phenyl phosphate represented by the following Chemical Formula (2-2), and combinations thereof.
[0000]
[0028] The phosphorus compound represented by Chemical Formula (1) or a combination thereof is used in an amount of about 0.5 to about 10 parts by weight, for example about 1 to about 8 parts by weight, and as another example about 3 to about 5 parts by weight, per about 100 parts by weight of a polycarbonate resin.
[0029] If the amount of the phosphorus compound represented by Chemical Formula (1) is more than about 10 parts by weight, the balance of physical properties of the resin may be deteriorated. If the amount of the phosphorus compound represented by Chemical Formula (1) is less than about 0.5 parts by weight, flame retardancy may be deteriorated.
[0030] As indicated by the following Reaction Formula I, phosphorus oxychloride can react with 2,4-dialkylphenol represented by Chemical Formula (3) to prepare a phosphate compound represented by Chemical Formula (4), and the resulting phosphate compound represented by Chemical Formula (4) can react with phenol to obtain the phosphorus compound represented by Chemical Formula (1) of the present invention.
[0000]
[0031] wherein R 1 and R 2 are each independently C 1 to C 6 alkyl and n is 1 or 2.
[0032] In exemplary embodiments of the invention, the phosphate compound represented by Chemical Formula (4) can be prepared by dehydrochlorination of phosphorus oxychloride and 2,4-dialkylphenol.
[0033] Examples of the 2,4-dialkylphenol compound may include 2,4-di-tert-butylphenol represented by the following Chemical Formula (5).
[0000]
[0034] An excess mole ratio of the phosphorus oxychloride can be used, per one mole of 2,4-dialkylphenol, for example 3 to 6 mole ratio phosphorus oxychloride per one mole of 2,4-dialkylphenol, as another example 4 to 6 mole ratio phosphorus oxychloride per one mole of 2,4-dialkylphenol, and as yet another example 5 mole ratio phosphorus oxychloride per one mole of 2,4-dialkylphenol.
[0035] One mole of the phosphorus oxychloride can react with a maximum 3 moles of the 2,4-dialkylphenol compound because one molecule of phosphorus oxychloride contains 3 atoms of chlorine which can participate in dehydrochlorination.
[0036] However, if an excess of the phosphorus oxychloride is used, per one mole of the 2,4-dialkylphenol compound, phosphorous oxychloride and 2,4-dialkylphenol compound can react in a mole ratio of 1 to 1 to obtain 2,4-dialkylphenyl dichlorophosphate represented by the following Chemical Formula (4-1).
[0000]
[0037] wherein R 1 and R 2 are each independently C 1 to C 6 alkyl.
[0038] However, if the 2,4-dialkylphenol compound reacts with 2 chlorine atoms in one molecule of the phosphorus oxychloride, bis(2,4-dialkylphenyl) chlorophosphate represented by the following Chemical Formula (4-2) can be prepared.
[0000]
[0039] wherein R 1 and R 2 are each independently C 1 to C 6 alkyl.
[0040] In exemplary embodiments of the present invention, the phosphorous oxychloride can react with the 2,4-dialkylphenol compound in the presence of a metal catalyst.
[0041] Examples of the metal catalyst can include without limitation magnesium chloride, aluminum chloride calcium chloride, and the like, and combinations thereof.
[0042] The metal catalyst can be used in an amount of about 0.01 to about 10 mole ratio, per one mole of the 2,4-dialkylphenol compound, for example, about 0.001 to about 5 mole ratio per one mole of the 2,4-dialkylphenol compound, and as another example about 0.01 to about 1 mole ratio per one mole of the 2,4-dialkylphenol compound.
[0043] The phosphate compound represented by the Chemical Formula (4) can be prepared by reacting a phosphorus oxychloride with the 2,4-dialkylphenol compound at a temperature of about 100° C. to about 150° C. for about 3 hours to about 10 hours, optionally using a metal catalyst under a nitrogen atmosphere.
[0044] After the above reaction, remaining unreacted phosphorus oxychloride can be collected or recovered.
[0045] If the 2,4-dialkylphenol compound, phosphorous oxychloride and metal catalyst react in a mole ratio of 1:3 to 6:0.001 to 10, the phosphate compound represented by the Chemical Formula (4) and remaining unreacted phosphorus oxychloride can be prepared. The temperature of the product can be reduced at about 50° C. to about 90° C., for example about 90° C. Then, the pressure of the product is released to collect the remains of the unreacted phosphorus oxychloride.
[0046] Continually, the phosphorus compound represented by the Chemical Formula (1) can be prepared by reacting the phosphate compound represented by the Chemical Formula (4) with phenol.
[0047] In exemplary embodiments, the phosphorus compound represented by Chemical Formula (1) can be prepared by reacting the product from which unreacted phosphorus oxychloride has been removed with phenol. The phenol can be added in a mole ratio of about 2 to about 3, for example about 2, per one mole of the 2,4-dialkylphenol compound represented by the Chemical Formula (3).
[0048] The phosphorus oxychloride may be reacted with the 2,4-dialkylphenol compound in the presence of an organic solvent. Examples of the organic solvent can include without limitation benzene, toluene, xylene, 1,4-dioxane, methylene chloride, ethylene chloride, and the like. The organic solvents may be used singly or in combination.
[0049] The phosphorus compound represented by the Chemical Formula (1) can be prepared by reacting the phosphate compound represented by the Chemical Formula (4) with phenol at a temperature of about 100° C. to about 150° C. for about 3 to about 7 hours under a nitrogen atmosphere.
[0050] Finally, in order to separate the phosphorus compound represented by the Chemical Formula (1) which is manufactured, water can be added to the reactor when the reaction is completed and the mixture can be stirred and evaporated under reduced pressure to remove the organic layer.
[0051] The flameproof polycarbonate resin composition of the present invention may further include other additive depending on its use. Examples of such additives may include without limitation plasticizers, heat stabilizers, anti-dripping agents, antioxidants, compatibilizers, light-stabilizer, pigments, dyes, and/or inorganic fillers and the like, and combinations thereof. Examples of the inorganic fillers may include without limitation asbestos, glass fibers, talc, ceramic, sulfates, and the like, and combinations thereof. The additive can be employed in an amount of about 30 parts by weight or less, for example about 0.001 to about 30 parts by weight, per about 100 parts by weight of the polycarbonate resin.
[0052] The flameproof polycarbonate resin composition of the present invention can be prepared by a conventional method. For example, all the components and optionally additives can be mixed together and extruded through an extruder and can be prepared in the form of pellets.
[0053] The flameproof polycarbonate resin composition according to the present invention can have good flame retardancy and can be used in the manufacture of electric or electronic goods such as TV housings, computers, audio sets, air conditioners, automobile parts, housings for office automation devices, and the like which require good flame retardancy.
[0054] Another aspect of the present invention provides an article molded from the foregoing resin composition. The resin pellets can be molded into various molded articles using molding methods such as extrusion, injection, vacuum molding, casting molding and the like, but the present invention is not limited to these methods.
[0055] The invention may be better understood by reference to the following examples which are intended for the purpose of illustration and are not to be construed as in any way limiting the scope of the present invention, which is defined in the claims appended hereto.
EXAMPLES
[0056] The components to prepare the flameproof polycarbonate resin compositions in Examples 1 to 2 and Comparative Examples 1 to 2 are as follows:
[0057] (A) Polycarbonate Resin
[0058] Bisphenol-A type polycarbonate with a weight average molecular weight (M w ) of about 25,000 manufactured by TEIJIN Co. of Japan (PANLITE L-1250WP) is used as a linear polycarbonate resin.
[0059] (B) Phosphorus Compound
[0060] Phosphorus oxychloride (767 g, 5.0 mol), 2,4-di-tert-butylphenol (206 g, 1 mol) and magnesium chloride (0.95 g, 0.01 mol) are added into a reactor and stirred at 130° C. for 6 hours under a nitrogen atmosphere to obtain 2,4-di-tert-butylphenyl dichlorophosphate and bis(2,4-di-tert-butylphenyl) chlorophosphate. The 2,4-di-tert-butylphenyl dichlorophosphate is prepared in an amount of 0.98 mol and bis(2,4-di-tert-butylphenyl) chlorophosphate is prepared in an amount of 0.02 mol.
[0061] The temperature of the product is reduced at 90° C. and the pressure of the product is released to collect remaining unreacted phosphorus oxychloride. Then, phenol (188 g, 2 mol) and toluene (1 L) are added into the reactor and stirred at 130° C. for about 5 hours under a nitrogen atmosphere. After the completion of the reaction, the temperature of the mixture is reduced to room-temperature, water is added (1 L) and the mixture is stirred. After the organic layer is removed, the mixture is evaporated under reduced pressure to obtain a mixture of 2,4-di-tert-butylphenyl diphenyl phosphate (0.98 mol) represented by Chemical Formula (2-1) above and bis(2,4-di-tert-butylphenyl)phenyl phosphate (0.02 mol) represented by Chemical Formula (2-2) above.
[0062] (C) Aromatic Phosphoric Ester Compound
[0063] Bis(dimethylphenyl) phosphate bisphanol-A made by Daihachi Chemical of Japen (product name: CR741S) is used.
Examples 1 to 2 and Comparative Examples 1 to 2
[0064] The components as shown in the following table 1 are added to a conventional mixer and the mixture is extruded through a conventional twin screw extruder at a temperature range of about 200° C. to about 280° C. to prepare pellets. The prepared pellets are dried at 80° C. for 2 hours and molded into test specimens for flame retardancy in a 6 oz injection molding machine at about 180 to about 280° C. with a mold temperature of about 40 to about 80° C. Flame retardancy is measured in accordance with UL 94 VB under a thickness of ⅛″.
[0000]
TABLE 1
Examples
Comparative Examples
1
2
3
4
A
100
100
100
100
B
3
5
—
—
C
—
—
3
5
The first Average
1.0
0.6
11.5
6.1
Flame Out Time(sec)
The second Average
5.8
3.1
1.0
3.5
Flame Out Time(sec)
UL 94 flame
V-0
V-0
V-1
V-0
retardancy (⅛″)
[0065] As shown in Table 1, the resin compositions employing a new phosphorous compound show good flame retardancy and a short average flame out time.
[0066] Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims. | A non-halogen flameproof polycarbonate resin composition of the present invention comprises about 100 parts by weight of a polycarbonate resin; and about 0.5 to about 10 parts by weight a phosphorus compound represented by the following Chemical Formula (1) or a combination thereof. The present invention can provide an environmentally friendly polycarbonate resin composition which can have excellent retardancy without releasing hydrogen halide gases during preparation or combustion.
wherein R 1 and R 2 are each independently C 1 to C 6 alkyl and n is 1 or 2. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a calibration process of at least one sensor of a wind power plant and a corresponding wind power plant.
2. Description of Related Art
Due to the continuously growing size of rotors of wind power plants, control strategies for the minimization of loads on the wind power plant, in particular a control strategy for a blade revolution pitch, continue to gain in importance. For example, each rotor blade is hereby individually turned into the wind (pitched) during the revolution so that the total mechanical load, which is conveyed into the tower via the rotor shaft and the nacelle, can be minimized. As an important measurement variable, blade bending moments are hereby required for each rotor blade or other bending moments of the wind power plant, for example on a generator shaft or the rotor hub or other rotating parts. Corresponding load measurements are also required by corresponding sensors for load measurements of the wind power plant.
Sensors can hereby not be attached one hundred percent exactly at the location where they should be attached, and the sensor properties can change over time so that a calibration of the sensors is necessary, which is normally performed manually. The load on the rotor blade root in modern wind power plants is mainly characterized by a superimposition of the bending moments from aerodynamics (mainly perpendicular to the rotor plane, according to the impact moment) and the bending moment, which from the tare weight of the rotor blades, mainly in the rotor plane (swing moment) and normal forces resulting from the tare weight and the centrifugal force (depending on the rotor speed) and forces and moments from the dynamic of the rotors, which are of particular importance when there are undesired vibrations (see DE 102 19 664 A1).
In order to perform load measurements, strain gauges are normally used, which are normally connected such that only bending strains, but not normal forces from temperature strains or centrifugal forces, are taken into consideration. The calibration of the blade root bending moments takes place against the gravity bending moment from the known mass and the known center of gravity distance of the blade from the measurement point when the rotor blade is placed horizontal. In order to determine the zero point of the bending moment measurements, the rotor blade is set vertically or, alternatively, horizontally, wherein the rotor blade is rotated around the rotor blade longitudinal axis (pitched) in order to determine the zero point for the horizontal positioning. The impact or swing bending moment is accessible by rotating the blade pitch angle by 90°, which the selected calibration method can easily do. Thus, for selection and calibration, the system must be shut down for a short period of time according to the article entitled “Messung von Lastkollektiven in einem Windpark” (Measurement of Load Collectives in a Wind Farm) by H. Seifert and H. Söker in DEWI, 1994, pages 399 through 402. For this, the data is output via a notebook and evaluated accordingly in order to perform a calibration.
BRIEF SUMMARY OF THE INVENTION
The object of the present invention is to specify a calibration method of at least one sensor of a wind power plant and a wind power plant, by means of which it is efficiently possible to obtain reliable data on loads and components of the wind power plant.
This object is solved through a method for the calibration of at least one sensor of a wind power plant, wherein the wind power plant has at least one movable component, wherein the component is pivoted or rotated on a predeterminable axis and wherein a measurement value, which is a measure for the load of the component, captured by the at least one sensor is evaluated. The evaluation hereby includes, in particular, a comparison of the measurement value adjusted by a calibration function with a specifiable and/or saved setpoint value or a reference, which can be a function, a value or a matrix. The calibration function can be a factor or a matrix or a function, which is dependent on one or more operating parameters of the wind power plant.
When the evaluation includes that, in the case of a deviation of the measurement value adjusted by a calibration function from a specifiable and/or saved and/or determined reference, which is greater than a specifiable deviation threshold value, the measurement value adjusted by the calibration function is the basis for the creation and saving of an adjusted calibration function, it is possible in the case of changing framework conditions to appropriately adjust the calibration function in the case of an increasing temperature and/or a temperature drift of a corresponding sensor or in the case of an aging effect of the sensor or other effects, which lead to undesired measurement effects and measurement effects causing incorrect moments. The calibration function is hereby in particular updated, wherein the previous saved calibration function is taken as the starting point and a new calibration function is determined based on it, and is saved accordingly if applicable. Within the framework of the invention, the deviation threshold value is also understood in particular as the term deviation setpoint value. When the deviation setpoint value is discussed below, a deviation threshold value is also meant.
Alternatively, an advantageous embodiment of the invention provides that the reference is designed such that it can be directly compared with the sensor measurement data. The advantage of this process is that an existing, saved calibration function does not need to be accessed in order to determine the new, adjusted calibration function. The calculation of the calibration function can then be more complex. The raw sensor data then only needs to be averaged (e.g. temporal average of measurement values captured with a high sample rate), if applicable, in order to obtain sensor measurement data comparable with the reference.
The calibration method is especially efficient when a plurality of measurement values of the at least one sensor is recorded or evaluated during the pivoting or rotation of the component. This enables a very exact adjustment of the calibration function.
The reference preferably comprises a plurality or a function of setpoint values, which are specifiable and/or saved and/or determined. If the creation and the saving of an adjusted calibration function are repeated, in particular preferably multiple times, a secure measurement result is given.
It is particularly preferred and of its own inventive value when the evaluation and/or the calibration process takes place or is executed automatically. Within the framework of the invention, automatic occurrence is in particular understood in that it can be performed without action from an operating person, i.e. the evaluation and/or the calibration process is performed automatically after an initiation signal, which can possibly also be given by an operating person, i.e. without further action from the operating person, wherein the result can then be a new calibration function but also just the presence of corresponding load measurement values, which are used for the control and/or regulation of the wind power plant. The initiation signal of the evaluation and/or the calibration process can also be created without the aid of an operating person, for example when there is a predeterminable time interval and/or advantageous environmental conditions, for example a wind speed that lies below a specifiable threshold speed like 7 m/s and/or an individual event, e.g. an abnormal signal deviation, such as drifting of a sensor signal after a plausibility check, correspondingly specifiable temperature fluctuation, an emergency stop or a manual request.
The measurement values are preferably recorded with a frequency of 0.01 to 1000 Hz, in particular 10-500 Hz.
Furthermore, the measurement values are preferably recorded over the entire range of the pivoting or rotating, resulting in a very exact calibration process.
The component is preferably a rotor blade and/or a hub and/or a shaft of a wind power plant. The axis is preferably a rotor shaft axis or a rotor blade longitudinal axis. The method is particularly efficient when the component is a rotor blade and the pivoting or rotating occurs over more than 90°, in particular more than 100°, in particular more than 120°, in particular more than 180°, in particular more than 270°, in particular more than 360°. A very exact calibration process is possible when the component is a hub and/or a shaft, wherein the pivoting or rotating occurs over several revolutions.
When an error signal is created, inasmuch as a preceding calibration process in a specifiable number of iterations repeatedly leads to the fact that the deviation of the measurement value adjusted with the calibration function from the reference is greater than a specifiable deviation setpoint value, it is easy to identify defective sensors. A plurality or a function and an interpolation of the measurement values can hereby be provided.
The calibration process can preferably be performed on an idle wind power plant if the calibration needs to be performed by sensors on the rotor blade or on the rotor blade root or on the rotor blade flange.
For the calibration of these sensors, a trundling wind power plant can also be provided, i.e. a wind power plant, the rotor blades of which rotate slowly around the rotor axis. The individual measurement values can then be compared with the reference, and namely after use of the calibration function on the measurement values, for example multiplication of the calibration function with the measurement values or another operation that can be provided accordingly. The reference can in particular be a function, but also an individual value. The calibration process can thus also be performed on a trundling, i.e. slowly moving, wind power plant, wherein the calibration function can hereby be determined through statistics, in particular multiple performances of the calibration, in order to compensate, for example, for uneven wind strengths and uneven speeds. An assessment is hereby provided with an average value and a standard deviation. A corresponding repetition of the calibration should preferably be performed until a specified accuracy is reached.
It can also be provided to hold two rotor blades at a lower and more constant speed when there is little wind, while the third rotor blade is calibrated rotating around the pitch axis, wherein correspondingly fast control algorithms are naturally needed in order to actually maintain a constant speed and in order to thus be able to implement the calibration accordingly exactly. For this, the performance of several completed calibration processes is also recommended in order to obtain sufficiently good statistics. A completed calibration process is understood to be a complete run-through of the calibration process, in which for example, the measurement values determined by the sensors are converted into loads on the component, i.e. are applied to the calibration function or the calibration function is applied to the measurement value. A pivoting of a rotor blade from −190° to +190° or from 0° to +92° can hereby be provided for example. The thereby determined measurement values are then further processed accordingly, wherein the calibration process is complete at +190° or at 92°, in order to remain with the examples. Repeated run-throughs of the calibration process can then be provided for better statistics.
This process is preferably performed, one after the other, for all blades and preferably in particular multiple times until a sufficient calibration accuracy is reached. The calibration process is preferably performed when there is little wind in order to ensure no or little output loss and an increased accuracy. When there is no wind, it is preferred that the rotor is positioned accordingly via motor-driven drives so that, for example, the sensors of a rotor blade can be calibrated, wherein the rotor blade longitudinal axis is then mainly placed horizontal.
In the case of normally used or usable sensors, an offset, a slope and if applicable a nonlinearity and a false positioning of the sensors will need to be calibrated. A coordinate transformation can take place in the case of a false positioning of the sensors.
The object is also solved through a method for the operation of a wind power plant including a calibration process of at least one sensor, in particular as described above, wherein the calibration process is executed automatically. Within the framework of the invention, an automatic execution of the calibration process means, in particular, that it is performed or completed without action from an operating person. We refer, in particular, to the above definition of an automatic calibration process. The at least one sensor is preferably a load sensor.
A control and/or regulation device and also a calibration module are also preferably provided, wherein the calibration module performs the calibration of the measurement values and transfers the calibrated values to the control and/or regulation device as input parameters. The operation of the wind power plant is controlled and/or regulated by means of the control and/or regulation device. The control and/or regulation device can be or include the operating control.
The calibration process is preferably initiated by a calibration signal. The calibration module is preferably integrated in the control and/or regulation device, whereby fast processing is possible.
The wind power plant is preferably stopped after the initiation of the calibration process by the calibration signal. The calibration process described above can hereby be performed. The wind power plant can also be further operated while trundling after the initiation of the calibration process, wherein several measurement series are then preferably performed in order to obtain statistics that are meaningful and sufficiently exact. A rotor blade of a wind power plant is preferably brought into a specifiable position after the initiation of the calibration process by the calibration signal. The bringing into a specifiable position preferably occurs through movement around two movement axes: on one hand through rotation around the tower vertical axis by the wind azimuth system, whereby the rotor plane is brought into a predetermined angle with respect to the wind direction, preferably perpendicular to the wind direction (approx. 90°) or perpendicular (approx. 90°) to the perpendicular of the rotor plane. Further through rotation around the rotor axis, wherein the rotor blade to be calibrated is brought into a specifiable angle to the horizontal, in particular into a horizontal position.
The object is also solved through a wind power plant with a calibration module for, in particular automatic, calibration of at least one sensor, which measures the load of a moveable component of the wind power plant.
The calibration module is preferably designed for the execution of a calibration process, as described above. A control and/or regulation device is also preferably provided, which is connected with the calibration module or into which the calibration module is integrated so that the wind power plant can be controlled or regulated by the control and/or regulation device, and namely depending on the measurement signals of corresponding load sensors calibrated by the calibration module.
The invention is described below, without restricting the general intent of the invention, based on exemplary embodiments in reference to the drawings. We expressly refer to the drawings with regard to the disclosure of all details according to the invention that are not explained in greater detail in the text.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic representation of a wind power plant,
FIG. 2 shows a schematic representation of a part of a wind power plant,
FIG. 3 shows a schematic view of a rotor blade from the blade flange into a horizontally positioned rotor blade,
FIG. 4 shows a representation as in FIG. 3 just with a different alignment or a different pitch angle of the rotor blade,
FIG. 5 shows a schematic view of a wind power plant,
FIG. 6 shows a measurement signal diagram, and
FIG. 7 shows a representation of a diagram of calibrated measurement signals and theoretic values.
DETAILED DESCRIPTION OF THE INVENTION
The calibration of a system is the identification and determination of a functional connection between an enumerable or measurable variable and an object property to be determined. In the exemplary embodiments according to FIG. 1 through 7 , a measurement variable monotonously changing with the blade bending moment, e.g. a bridge voltage of a strain gauge strip measurement bridge, is set in relation to a known static blade bending moment. After delivery of a rotor blade, there is generally a weight protocol from the manufacturer for each individual rotor blade. The center of gravity distance to the blade flange and the total blade weight can be obtained from this.
The calibration of the measurement variable is necessary because in the hitherto implemented measurement processes no fixed transfer function of the values resulting from the measurement signals of sensors to corresponding moments could be defined. When, for example, the blade strain in the cylindrical part of the blade root is measured, then the strain value could not previously be calculated back accurately enough to the real bending moment due to the inhomogeneity of the fiber composite material. Moreover, Wheatstone measurement bridges get out of tune easily so that each adjustment of the measurement point requires a recalibration.
FIG. 1 , which shows a schematic representation of part of a wind power plant 10 , is provided to define terms. A nacelle 40 is positioned on a tower 41 , which is shown schematically. A shaft axis 20 , which is aligned with an angle σ, which defines an axis tilt, to the horizontal, is provided in the nacelle 40 . A shaft 17 is connected with rotor blades 15 , 15 ′ via a hub 16 . The rotor blades 15 , 15 ′ stick out from the perpendicular of the shaft axis 20 with a cone angle β.
FIG. 2 shows a schematic view of part of rotor blades 15 through 15 ″ and a hub 16 , with which the coordinate system of the blade flange should be shown. The rotational axis of the rotor blade is specified by ZB. The orthogonal axes here are XB and YB. A rotation on axis YB gives an impact moment (Schlagmoment), which is specified with M YB and one that represents moment on axis YB. YB lies in the plane which is spanned by the rotor blade longitudinal axes. Within the framework of the invention, M YB is also called M F . The engagement direction of the force belonging to this moment is in direction XB. The moment around axis XB correspondingly defines the swing moment (Schwenkmoment), which is specified with M XB and is also called M S within the framework of the invention. The engagement direction of the force of this moment is in the direction of axis YB.
During operation, an impact and swing moment affects each rotor blade 15 through 15 ″ relating to the blade flange coordinate system according to FIG. 2 . The swing moment mainly results from the weight load of the rotor blade; a share also comes from the torque driving the rotor. The impact moment is created from the wind load on the rotor. If the rotor blade 15 , 15 ′ or 15 ″ is turned (pitched) aerodynamically from the wind during regulation, then this moment can be decreased in the impact direction. A rotor blade has a tare weight moment MBL, which results from the multiplication of the center of gravity distance from the rotor hub to the center of gravity of the rotor blade with the total blade mass and the gravitation acceleration (for example 9.81 m/s 2 ).
The center of gravity distance to the sensor position should preferably be taken into consideration for the referencing of the sensor signals. Both geometric data (axis tilt, sensor position and orientation, blade and/or rotor position) as well as component parameters (mass, center coordinates, potential structure data, if deviating from the simplified assumption of even load distribution in the cylindrical blade root) should generally be taken into consideration for the reference.
It has been proven in the measurement practice to attach or arrange strain gauges on the inner wall of the rotor blade in the cylindrical part of the rotor blades near the blade flange. Alternatively, other sensors, for example measurement strain bolts of the blade flange bearing connection or other strain gauges, can also be used. With reference to FIG. 3 and FIG. 4 , which show a schematic view from the blade flange 18 to the rotor blade, wherein a single profile of the rotor blade is shown in the center of the rotor blade, the position of sensors 11 through 14 is indicated. Two similar sensors 11 and 13 or 12 and 14 are arranged opposite each other. The axes through the sensors 11 and 13 as well as 12 and 14 lie mainly perpendicular to each other.
In FIG. 3 , in which the scenario of an operating position of the rotor blade 15 with a blade angle close to 0° is shown, the main axes YB′ and XB′ of the rotor blade cut 15 coincide with the blade flange axes YB and XB. With the simplified assumption that the blade bending moments are supplied homogeneously to the cylindrical part, sensors that are installed or arranged in the main blade axes are generally used. These sensors 11 - 14 are also shown schematically. They can also naturally be installed inside the blade flange 18 . FIG. 3 also shows that the sensors 11 - 14 are connected with calibration modules 22 , 22 ′, which are connected with a control and/or regulation device 23 . In an advantageous further embodiment, the calibration modules 22 , 22 ′ are combined in one single unit.
FIG. 4 shows a corresponding representation of a rotor blade 15 twisted with pitch angle 42 . The corresponding main axes YB′ and XB′ are twisted around the pitch angle 42 of the axes YB and XB. A wind 24 with a corresponding wind direction is also shown.
In a first step for the calibration process, the rotor blade 15 to be calibrated according to FIG. 5 can be aligned horizontally or level, i.e. the blade axis 19 is aligned horizontally. The rotor azimuth angle α for this blade is thus 90°. In the case of little wind, i.e. in the case of a wind speed that lies clearly below the startup speed of the wind power plant, the wind power plant 10 can remain idle directly in the wind.
FIG. 5 shows a situation, in which the average wind speed of the nacelle anemometer, not shown, lies between a startup speed of the wind power plant and 7 m/s. The nacelle has hereby been moved counter-clockwise by 90° when seen from above so that the rotor blade 15 is arranged in the wind direction or in a type of feathering position. The rotor blade 15 can now be pitched in a range from −190° to 190° so that corresponding sensor signals can be recorded. A corresponding representation of signals measured in this manner is shown in FIG. 6 . The cone angle β preferably has no impact on the moment progression in the case of a blade rotation shown above.
FIG. 6 shows raw signals from two sensors 11 to 14 , wherein two orthogonally aligned sensors, for example sensors 11 , 12 or 13 , 14 can be used. The measurement curve 30 concerns the signal for the impact moment and the measurement curve 31 concerns the signal for the swing moment. A voltage in volts is shown on the ordinate, wherein this voltage is connected to the operational amplifier, which amplifies the signal of the respective sensor. The pitch angle positions of the rotor blade are shown on the abscissa. The graphic in FIG. 6 shows the raw signals of two sensors 11 and 12 in the main axes or more exactly with an angular offset to the main axes. Strain gauge strip measurement points were hereby used. The measurement point in the swing direction was attached to the blade bond seam offset by 5.8° so that a displacement of the maxima relative to the zero point or to 90° results. The measurement signals are applied via the pitch angle of the rotor blade in the case of a pitch run of −190° to 190°.
Taking into consideration the present axis tilt of 6° and the idealized assumption that the cylindrical part behind the blade flange can be considered a homogeneous cylinder and the mass center lies on the pitch rotational axis, it is assumed that in the case of angle −186°, −96°, −6°, 84° and 174° the static tare weight moments with respect to impact moment and swing moment reach their maximum. Measurement voltages SF and SE are now collected at these points. Based on these collected measurement voltages, the bending moments are determined with known crosstalk coefficients. The crosstalk coefficients serve to be multiplied with an analogous measurement signal in order to determine the current bending moments. The crosstalk coefficients thus determined for certain angles then apply to the entire curve, i.e. also for other angles.
From the initial equations
S F =A 1 ×M F +A 3 ×M E (1.1) Equation 1
and
S E =A 2 ×M F +A 4 ×M E (1.2) Equation 2
wherein these initial equations are used for linear sensors, the coefficients A 1 through A 4 can be determined directly from the signal values SF and SE from the graphic from FIG. 6 at the corresponding positions −186°, −96°, −6°, 84° and 174° (in the case of an axis tilt of 6°). It should hereby be taken into consideration that S F is the measurement signal for the impact moment and S E is the measurement signal for the swing moment and M F the impact moment and M E the swing moment.
A pitch angle of −180°, 0° or 180° is provided for the first case. The pitch angles are idealized. The axis tilt must also be taken into consideration, i.e. a pitch angle of −186°, −6° and 174° must be selected for example like above. The impact moment is hereby 0 so that A 3 and A 4 directly result when the swing moment is known. In the case of an angle of −90° and 90° (or −96° and 84°), the swing moment is equal to 0 so that the coefficients A 1 and A 2 directly result when the impact moment is known.
Thus, for the impact moment M F =D 1 S F +D 3 S E and for the swing moment M E =D 2 S F +D 4 S E with N=A 1 ×A 4 −A 2 ×A 3 and D 1 =A 4 /N, D 3 =−A 3 /N, D 4 =A 1 /N, D 2 =−A 2 /N.
In the case of angle-offset sensors, the angle offset should be compensated for mathematically through recourse to the approximately orthogonally located sensors. The mathematical compensation takes place for example via known transformation matrices containing mainly sine and cosine shares. In this case, as opposed to the arrangement shown in FIG. 3 , it is advantageous if the calibration module for all four shown sensors is designed as one single unit. Then the complete calibration, including the compensation of the incorrect position of the sensors, can take place before the sensor signals are fed to the regulation device 23 . The embodiment of a single calibration module for all sensors also has the advantage that a statistical evaluation process can also average all sensor information without problem.
This results in correspondingly calculated or calibrated impact moments 32 and a calibrated swing moment 33 from FIG. 7 . The Y axis or abscissa is shown standardized in FIG. 7 , i.e. a 1 equals the static nominal moment. In order to confirm the theory, the resulting moment from the impact and swing moment is given as an ideal line. This is shown as the calibrated total moment 34 in FIG. 7 . The ideal or the theoretical impact moment 35 calculated from the sine of the pitch angle plus the axis tilt sigma multiplied with the static tare weight moment (sin(pitch angle+σ)×M Stat ) runs mainly exactly like the calibrated impact moment 32 . The curve 35 , namely the theoretically calculated impact moment and the calibrated impact moment 32 , correspond to a high degree. For certainty, the measured pitch angle 36 was also applied in the range of −10 to 100°.
Alternatively, it is possible not to measure the full angle area of −190° to 190° or −180° to 180° and to determine the pitch angles A 1 through A 4 by setting the moments for certain pitch angles to zero. Instead of this, the impact moment can be calculated by the formula M F =sin(pitch angle+σ)×M Stat or the swing moment by M E =cos(pitch angle+σ)×M Stat . This even results in correspondingly many initial equations in the case of a pitch run e.g. from 0 to 92° so that the coefficients A 1 through A 4 can be determined with a sufficient quality. This can take place with a compensation calculation, with which the coefficients are determined, in which the sum of the quadrates of the deviation, for example with the Gaussian principle of compensation, will be a minimum. For this, the rotor blade is preferably brought into the horizontal position and wind loads are minimized to the greatest extent possible.
The calculations just shown apply to sensors, for which a linear connection can be assumed between bending moments and sensor signal. This applies, for example, to the conventional strain gauge strip measurements. For other sensors, for example those with a hysteresis that measure axial bolt forces, it makes sense to provide or adjust the conversions more exactly, for example by using a Taylor series, which is broken off after the quadratic or the cubic member. In order to provide an automatic calibration routine, it is particularly preferred to specify the rotor azimuth angle a with an accuracy of at least +/−1°.
A calibration process according to the invention can now be designed such that the wind conditions are first checked. A 5-minute average can be selected for this for example. If the wind speed is less than e.g. 3 m/s or 5 m/s or 7 m/s in the 5-minute average, a calibration is performed.
The system is then stopped and the rotor blade, on which the sensor(s) to be calibrated are arranged, is stopped at an angle position of 90° (preferably +/−0.5°). A rotor brake is then inserted. If applicable, the system is turned out of the wind, the nacelle is moved e.g. 90° to the left when seen from above, when the wind speed is below a specifiable startup wind speed. A pitch run for the rotor blade is performed in a maximum potential range, for example −190° through +190°. Driving speeds less than or equal to 6°/s come into consideration as the pitch rate.
The signals S F and S E , i.e. raw data from the sensors on the swing moment and the impact moment, and the pitch angle should be recorded as measurement variables. These signals are preferably captured with a sample rate of at least 100 ms. An even shorter distance between the measurements is preferably provided. The crosstalk coefficients, as described above, are determined from the determined measurement values. A moment progression with an idealized calculated moment progression is now compared with the determined coefficients for the measurement pitch run. If the deviations between the measured moment progression or the calibration impact moment and the calibrated swing moment deviate by less than 3% when compared with the theoretical moments, then the measurement is considered valid and the system is released and restarted. If the deviation lies outside of the tolerance range of 3%, the crosstalk coefficients are correspondingly adjusted and the measurement process is performed again. If the deviation is still too high after several of these iteration steps, an error signal can be created, which thereby enables the specification that one or more sensors are defective or that the environmental conditions, e.g. due to a wind speed that is high and/or wind turbulence, do not permit a sufficiently exact calibration.
Alternatively to the securing or braking of the wind power plant or of the rotor, the calibration process can also take place during the trundling of the rotor blades, wherein a statistical evaluation hereby takes place through the recording of several similar signals, i.e. several measurement signals at the same pitch angle, but at different rotor azimuth angles α. An averaging of the measured impact moments and swing moments is then performed for different azimuth angles α and the same pitch angles and these are then compared with the idealized curve or the idealized moment progression.
A calibration process for a hub or shaft sensor system can be designed such that several rotations of the rotor (hub or shaft) can be provided, while the rotation angle and the corresponding moments are recorded by the corresponding sensors. A calibration of the sensors can then take place through a least squares procedure or corresponding statistics.
The calibration process is preferably performed when there is little to no visibility, for example in the dark or in the fog. Visibility detection is preferably provided for this or a method or a device for visibility detection, which outputs a signal, which specifies in particular an authorization for the performance of a calibration process if a specifiable visibility is not met.
LIST OF REFERENCES
10 Wind power plant
11 - 14 Sensor
15 , 15 ′, 15 ″ Rotor blade
6 Hub
17 Shaft
18 Blade flange
19 Blade axis
20 Shaft axis
22 , 22 ′ Calibration module
23 Control and/or regulation device
24 Wind
30 Measurement curve impact moment
31 Measurement curve swing moment
32 Calibrated impact moment
33 Calibrated swing moment
34 Calibrated total moment
35 Theoretical impact moment
36 Measured pitch angle
40 Nacelle
41 Tower
42 Pitch angle
α Azimuth angle
σ Axis tilt
β Cone angle
XB Axis
YB Axis
ZB Axis
M YB Moment around axis YB
M XB Moment around axis XB | The invention relates to a method for the calibration of at least one sensor ( 11 - 14 ) of a wind power plant ( 10 ). The invention also relates to a wind power plant ( 10 ). The calibration process according to the invention is captured by the at least one sensor ( 11 - 14 ). The measurement value ( 30, 31 ), which is a measure for the load of a component ( 15 - 17 ), is evaluated, wherein the wind power plant has at least the moveable component ( 15, 15′, 15″, 16, 17 ), wherein the component ( 15 - 17 ) is pivoted or rotated around a predeterminable axis ( 19, 20 ). The wind power plant according to the invention is provided with a calibration module for the automatic calibration of at least one sensor ( 11 - 14 ), which measures the load of a movable component ( 15 - 17 ) of the wind power plant. | 5 |
FIELD OF THE INVENTION
The present invention relates to a sulky comprising two wheels, individually fastened, but located along the same rotational axis, to a common frame provided with a driver's seat and shafts leading towards the draught animal.
DESCRIPTION OF RELEVANT ART
Sulkies of this type are used for trotting races and the most important requirements are that they have a lightweight construction, that they are easy-running, and that they are strongly built to endure the specific strain during excercise and competitions.
To obtain constructions of a sufficiently stiff and stable structure and at the same time of lowest possible weight, sulkies so far have been manufactured as welded steel constructions as this has led to the most lightweight construction combined with sufficient strength.
Certainly there have earlier been attempts to build sulkies of aluminium, however such sulkies have got a rather bad reputation due to poor strength qualities.
A conventional sulky has its shafts fastened approximately 10 cms inside of the wheels. This fact leads to a construction well adapted for welded steel pipes, but it is unsuitable when light metals are used because the construction then requires welding. This is probably the reason why earlier attempts using aluminium have failed, as the design then has been similar to the conventional steel constructions requiring a welding process. It is a fact that aluminium and other light metals are difficult to weld, in particular weaknesses in the metal can not be allowed at, or close to, the welding points.
Storing and transportation of conventional sulkies has led to difficulties due to the sulkies having an awkward shape. The manufacturing process has also been expensive and much handwork has been required. Sulkies having even less weight have always been desirable, even if specialists in this field of technique have been convinced that still lighter sulkies could not be manufactured without a corresponding strength reduction.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a new sulky construction having such a design that it may be manufactured of light metal and other lightweight and yet durable materials.
A further object of the present invention is to provide a sulky which may be assembled easily by a user himself, from substantially flat elements requiring only a small space during storage and transportation, said elements being easily dispatched in a flat package.
Still a further object of the present invention is to build up a sulky from inexpensive semi-produced components as casted elements and extruded profiles.
Still a further object of the present invention is to provide a sulky having a stable construction as the shafts as well as the crossbar transfer substantially all the load to the wheel planes only.
Finally it may be mentioned that an object of the present invention is to provide a sulky which easily may be assembled by the user himself by means of ordinary hand tool, and where all the connections become secure, without any play, even if the single components are produced with ordinary manufacturing tolerances.
It should be mentioned that the new sulky construction having shafts fastened to the frame in the planes of the wheels results in the possibility of avoiding the traditional manual manufacturing process including welding of each individual sulky and instead using casting and mass production with corresponding low expenses. By changing to a casting process many of the details required in connection with the wheel suspension, the fastening of the shafts and the crossbar to the frame, may be integrated in the casting process without any additional expenditures. A design of the end frames as stated in connection with the present invention is also required to obtain a structure being well suited for box packaging and do-it-yourself kits based on simple threaded connections.
There is also obtained a weight reduction of approximately 40% for the complete sulky which has a total weight of approximately 18 kg in a ready-to-use state.
Finally it should be mentioned that a sulky according to the present invention in particular is designed to be colored by applying color tapes in all recesses of the profiles, a solution which leads to an inexpensive and individual color display system important for the end users.
BRIEF DESCRIPTION OF THE DRAWINGS
To give a clear understanding of the present invention reference is made to the detailed description of an embodiment given below, and to the accompanying drawings in which:
FIG. 1 illustrates a side view of a sulky according to the present invention,
FIG. 2 illustrates a top view of a sulky according to FIG. 1,
FIG. 3 illustrates a cross section of the crossbar at the connection to an end frame,
FIGS. 4A-4C show an end frame in more detail, and
FIG. 5 shows how a dismantled sulky may be arranged in a flat package.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In all of the Figures the same reference numbers are used for components having the same function, when appropriate.
In FIG. 1 the sulky 1 is shown in a side view, and it may be seen that both the wheel 2 and the shaft 3 are mounted to the end frame 5.
When FIG. 2, which shows the same sulky as in FIG. 1, but now seen from above, is compared with FIG. 1, where the same reference numbers are used, it may be seen that the driver's seat 4 is arranged centrally on the crossbar 6 which is fastened to the mounting bushings 7 in the end frames 5.
In FIG. 2 the foot treads 8 fastened to the shafts 3 also are shown, and FIG. 2 in particular shows how the end frames are shaped so that the wheel-fastening, shaft-fastening and crossbar-fastening devices all are arranged in the same vertical plane. This is important to obtain a best possible load situation.
As shown in FIGS. 1 and 2 the end frames 5 are arranged symmetrically related to the plane of the wheels 2. This leads to a stable construction of the sulky, but differs from conventional solutions. It may also be understood from FIGS. 1 and 2 that the crossbar 6 is adapted to the mounting bushings 7 and may be fastened thereto. An example of the assembly of those joints is described in more detail below. The details of these joints are important to obtain a stable and rigid frame which may resist the strain occuring during use, and this may be obtained without demanding requirements on the materials in these components or to the manufacturing tolerances of same. According to a preferred embodiment of the present invention the end frames 5, preferably of aluminium or a similar light metal, are casted, e.g. by means of a chill-casting or press-casting process using a light metal, or alternatively by producing the frames of reinforced plastics while the crossbar 6 may be manufactured of extruded aluminium or a similar light metal. Despite the inexpensive process and easily workable materials the geometric design leads to a stable and reliable construction.
The wheels may be fastened to a fork section 9 of the end frames 5 by means of conventional fastening technique, and in a similar manner the shafts 3, which may be made of light metal or plastics reinforced e.g. by carbon fibers, may be fastened to the end frames 5 by means of horizontally arranged fastening bolts 16 and further fastening screws 17 arranged in corresponding holes in the shaft 3. Thereby a fastening of the shaft so as to be adjustable in a longitudinal direction is obtained.
Finally it may be mentioned that the driver's seat 4 is fastened to the crossbar 6 by means of extruded brackets 12 which, if required, may be clamped thereto by means of conventional clamping devices comprising screws or bolts.
The crossbar 6 and the fastening of the same in one of the mounting bushings 7, is shown in more detail at the cross section illustrated in FIG. 3. The crossbar may be designed as an extruded aluminium profile 13 having a closed cross section with internal extending protrusions 14 and 15. In addition there are strengthening elements 18, 19 adapted to fit in with friction between the protrusions 14 and 15. Centrally in these strengthening elements threaded holes 20 and 21 are arranged, and the strengthening elements may be shifted along the aluminum profile 13 to a suitable place so that the threaded holes 20 and 21 coincide with the assembling recesses in the profile 13 and the mounting bushing 7. It may be noted that the strengthening elements 18, 19, arranged on diametrically and opposite faces of the aluminium profile 13, may be combined in one common integrated part as they may be designed, for example as a U-shaped or O-shaped bracket which may be shifted within the track made up of the protrusions 14 and 15. The material of the strengthening elements 18 and 19 may be stainless steel or a similar material having a higher rigidity than the material of the extruded profile 13.
In FIG. 3 one of the mounting bushings 7 is shown together with through screws 22 adapted for fastening the crossbar 6 to the mounting bushing 7. In this connection it is important that the manufacturing tolerances during extruding and casting allow easy introduction of the extruded profile 13 in the mounting bushing 7 with suitable play, however, in such a manner that the materials have a flexibility and deformability adapted so that when the screws 22 are tightened, the extruded profile and mounting bushing 7 will be pulled together by the strengthening elements 18 and 19 respectively, and possibly between oppositely arranged, external strengthening washers 23. After this tightening process the surfaces of the crossbar 6 and the mounting bushing 7 have been somewhat deformed, and therefore an exact adaptation is obtained. It should also be noted that outside the mounting bushing 7 there may also be placed strengthening washers 23, possibly counter bored in the bushing wall so that the material of the bushing 7 and the material of the extruded profile 13 are squeezed between element 19 and a washer of non-corrosive material 23, respectively, and are forcibly pressed towards the rigid bushing 7. Even if the manufacturing tolerances of the extruded profile and the bushing initially left some mutual play, the tightening of the bolt 22 deforms the material so that a close and durable connection is obtained. This connection method ensures a stable and reliable assembly using very simple means.
In FIGS. 4A-4C still more details of the end frame 5 are shown. Here the cross sections of the different parts of the frame also are illustrated. It may in particular be mentioned that the mounting bushing 7 has a cross section that with a certain play is adapted to the external section of the extruded aluminium profile which constitutes the crossbar 6 and is shown in FIG. 3. The loads are evenly distributed due to the symmetrical design of the end frames relative to the wheel planes, and this fact also contributes to a reliable solution in spite of the simple mounting process. The end frame has such a design that it may be cast in a tool comprising only one core and two side walls. The core may be pulled out vertically in a downward direction on the drawing, while all the side elements are bent out to slip the casted element, and the inside and outside of the mounting bushing 7 are formed in contact with the side elements.
The right and the left end frames are preferably casted in the same tool and are therefore quite identical when casted. The tool expenses therefore are reduced and also the storing charges as the number of spare parts also are reduced. In the shown embodiment the external part of the mounting bushing 7 is removed from opposite sides of the end frames before the assembly process, and the resulting holes are covered by caps. However, the invention comprises embodiments where the two end frames are maintained identical also after assembly.
If the qualities of the material and the cross section so allow, the central parts of the crossbar, i.e. the region where the bending moment reaches its maximum value during use, may be reinforced by introducing a square profile between the protrusions 14 and 15.
An important advantage of the present invention is that the complete sulky may be packed into a flat box for storing and transportation to distributers. The user may then buy the sulky as a construction kit and mount the parts himself in a quarter of an hour and then obtain a reliable and professional sulky having a lower total weight but with user qualities equal to those of traditional sulkies. It should also be mentioned that the end frames 5 are identical during production and thus freely may be used on the right or the left side of the sulky. The protruding part of the mounting bushing 7 may then be removed by a simple cutting process before assembly. | Sulky comprising two wheels individually fastened along the same rotational axis, to a common structure provided with a driver's seat (4) and shafts (3) leading towards the draught animal. The sulky (1) consists of a construction kit comprising a plurality of substantially flat elements (2, 3, 4, 5, 6) adapted to be assembled by the end user by means of ordinary hand tools. Two of these parts are end frames (5) adapted for fastening of a wheel (2), a shaft (3), and the crossbar (6) in the same vertical plane. | 1 |
BACKGROUND OF THE INVENTION
This invention relates generally to gas turbine engines and, more particularly, to start systems for gas turbines of the turbofan type.
The method by which gas turbine engines are started is by rotating the high pressure compressor up to a speed sufficient to provide air, under pressure, to support combustion in the combustion chamber. After the engine is fired, the starter must assist the engine until it has reached the self-accelerating speed, with the torque required being in excess of the torque required to overcome rotor inertia, engine accessory loads, the friction loads of the engine, and the extracted loads of aircraft accessories. Various power sources are used to start a gas turbine engine, among which are the use of electricity, gas, air and hydraulic pressure. Whichever method is used, it must be capable of developing a very high amount of power in a short time and transmitting it to the engine rotating assembly in a manner which provides a smooth acceleration from rest, up to a speed at which the gas flow provides sufficient power to the engine turbine to enable it to take over. This requirement is easily met by many different types of on-ground power supply systems or from power systems carried aboard the aircraft. If a flameout occurs to an engine during flight, the supply of thermal energy to the turbines will discontinue and the rotational speed of the compressor spool will accordingly decrease considerably; however, the engine will continue to rotate due to the flow of air through the compressor, a phenomenon which is commonly referred to as windmilling. In a turbojet engine, there is a large volume of air which passes through the compressor following a flameout, and the windmill speed of the core engine is sufficient for an in-flight start.
In the case of a turbofan engine, however, wherein a good portion of the air which enters the inlet of the engine passes around the engine core, the high pressure compressor rotor receives a smaller portion of the available ram energy and therefore does not attain as high a windmill speed as in turbojet engine. This is particularly true of a turbofan of the mixed-flow type where a common nozzle provides additional restriction to core airflow and lowers windmill speed. If the windmill speed of the core is not sufficient, then an air start cannot be obtained without some kind of starter assist. Since the ability of an engine to relight varies with altitude and forward speed of the aircraft, a starter assist may not be required over the entire flight envelope of an aircraft, but only over a portion thereof, such as, for example, during periods of low-speed flight.
One method by which a starter assist is provided for air starts is that of an auxiliary power unit (A. P. U.) wherein a gas turbine located aboard the aircraft provides shaft power to the core by way of a gearbox. After the engine is started and a predetermined engine speed is attained, a control valve is automatically closed and automatically disengages the drive mechanism. Another method employed is that of cartridge starting, wherein the starter motor is basically a small impulse-type turbine which is driven by high velocity gases from a burning cartridge. The power output of the turbine is passed through a reduction gear and an automatic disconnect mechanism to rotate the engine. Another method employed is that of the combustor air starter wherein the starter unit has a small combustion chamber into which high pressure air from an aircraft-mounted storage bottle along with atomized fuel are introduced and ignited to generate resultant gases which are directed onto the air-starter turbine.
Whatever method is used, auxiliary torque sources which need start-up or which can only be used once per flight are restrictive in their use.
It is therefore an object of the present invention to provide for a turbofan engine an improved starter-assist system which is always ready for quick and reliable application.
Another object of this invention is to provide a means by which a turbofan engine can be air started over a much larger portion of the flight envelope.
Still another object of this invention is the provision in a turbo-fan engine for an air-start assist system which is relatively light in weight, effective in use, and simple in operation.
These objects and other features and advantages become more readily apparent upon reference to the following description when taken in conjunction with the appended drawings.
SUMMARY OF THE INVENTION
Briefly, in one aspect of the invention, power is selectively derived from the rotation of the windmilling fan of an in-flight engine to be started. This power is then applied to rotate the compressor rotor of the engine to a speed sufficient to allow a relight of the engine. After the compressor reaches a predetermined speed, the drive system is automatically disconnected from the core.
By another aspect of this invention, a torque converter transmits power from the windmilling fan of the turbofan engine to drive the high pressure compressor rotor. An electrohydraulic servovalve automatically inactivates the torque converter by removing the hydraulic fluid therefrom during periods in which the starter assist system is not required. An overrunning clutch is further provided to ensure that system is decoupled when the core rotational speed exceeds the converter output.
In the drawings as hereinafter described, a preferred embodiment is depicted; however, various other modifications and alternate constructions can be made thereto without departing from the true spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a gas turbine engine in which the present invention is embodied; and
FIG. 2 is a schematic representation of the hydraulic and control portion in accordance with one embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the present invention is shown generally at 10 as installed in a turbofan engine 11 having a fan rotor 12 and a core engine rotor 13. The fan rotor 12 includes a plurality of fan blades 14 mounted for rotation on a disc 16 and a low pressure or fan turbine 17 which drives the fan disc 16 in a well-known manner. Core engine rotor 13 includes a compressor 18 and a high pressure turbine 19 which drives the compressor 18. The core engine also includes a combustion system 21 which combines a fuel with the airflow and ignites the mixture to inject thermal energy into the system.
In operation, air enters the gas turbine engine 11 through an air inlet 22 provided by means of a suitable cowling or nacelle 23 which surrounds the fan rotor 12. Air entering the inlet 22 is compressed by means of the rotation of the fan blades 14 and thereafter is split between an annular passageway 24 defined by the nacelle 23 and an engine casing 26, and the core engine passageway 27 having its external boundary defined by the engine casing 26. The pressurized air which enters the core engine passageway 27 is further pressurized by means of compressor 18 and thereafter is ignited along with fuel from the combustion system 21. This highly energized gas stream then flows through the high pressure turbine 19 to drive the compressor 18 and thereafter through the fan turbine 17 to drive the fan rotor disc 16. Gas is then passed out the main nozzle 28 to provide propulsion forces to the engine in a manner well known in the art. Additional propulsive force is obtained by the exhaust pressurized air from the annular passageway 24.
It should be recognized that, although the turbofan 11 is depicted as having a short cowl or nacelle 23, it may very well have a long duct nacelle which extends aft to the main nozzle or it may be of the mixed flow type wherein a mixer is provided to combine the gas stream flow from the fan duct annular passageway 24 and that from the core engine to exhaust from a single nozzle.
Assume now that the present turbofan engine, during in-flight operation, suffers a flameout, such as may occur by a malfunction of the fuel system or from a compressor stall condition wherein the air supply to the combustor is drastically disrupted. Since the flow of combustion gases to the turbines 19 and 17 will discontinue, the driving power to the compressor 18 and the fan rotor 12 will be removed and they will accordingly coast down in rotational speed. However, since the forward speed of the engine will cause the air to continue to flow through the passageways 24 and 27, both the fan rotor 12 and the core engine rotor 13 will continue to rotate because of the well-known windmill effect. The relative amount of air which flows into the passageways 24 and 27 will depend on their respective sizes, the ratio of which determines the bypass ratio of a turbofan engine. During certain operational conditions, as for example at high speeds, the airflow through the compressor will be sufficient to windmill the compressor rotor to a speed which will allow a relight of the engine, but there will be other periods of operation during which this rotational windmill speed will not be sufficient to support a relight. The present invention is designed for use during such periods of operation.
Whether dealing with a high bypass ratio or a low bypass ratio turbofan, it will be recognized that all of the air which enters the inlet 22 passes through the plane of the fan blades 14 to thereby impart a windmilling effect thereto, but only a portion thereof passes through the compressor 18. Accordingly, it is understandable that a great deal more energy is transmitted to the fan rotor 12 than to the core engine rotor 13 during windmilling conditions of operation. Since it is the core rotor rather than the fan rotor which must be turning at a minimum speed in order to obtain an engine relight, power may be tansmitted from the fan rotor to the core rotor during such periods of operation. One method of transmitting this power is shown schematically in FIG. 1.
A drive mechanism with associated gearbox 29 is connected to the front end of and driven directly by the fan rotor 12 whenever it is rotating, either by power received from the turbine 17 or by way of the windmilling of the fan blades 14 during periods in which the engine is in flight but is not lit off. The gearbox 29 is in turn mechanically connected through a shaft 31, a bevel gear 32, and a drive shaft 33, to a torque converter 34, which in turn transmits power through an output shaft 36, an output bevel gear 37 and a shaft 38 to a drive gear 39 adapted to drive the core engine rotor 13. By way of this gear train, wherein the radially extending shafts 31 and 38 are disposed within appropriate struts as shown, and the axially extending torque conversion equipment are placed in the nacelle 23, rotary power may by transmitted from the fan rotor 12 to the core rotor 13 during periods in which the windmilling fan rotor has an abundance of unused energy and the core engine rotor is not rotating at sufficient speeds to relight the engine. Control logic is provided to appropriately switch in the torque conversion apparatus during selected periods in which engine relight is required, and to switch out the system during all other times such as, for example, when the airplane is on the ground or when the engine is started and up to speed.
Referring now to FIG. 2, the torque converter 34 is shown with its input shaft 33 and its output shaft 36. Power is transmitted between the two shafts by way of input and output impellers 41 and 42 acting through a medium of hydraulic fluid within the torque converter housing as is well known in the art. As long as there is hydraulic fluid within the torque converter 34, the rotating input impeller 41 will tend to cause a swirling of the fluid which in turn will cause the turning of the output impeller 42 and therefore the output shaft 36. It should be understood that a gear train of either the fixed or variable gear ratio type may be incorporated between the fan and core rotors so as to obtain greater speeds of the core shaft.
Assume now that a flameout has occurred and that the torque converter has been activated so as to connect the rotary power of the fan rotor 12 to that of the core rotor 13 to boost its speed up to that sufficient for a relight. Following relight, the core engine rotor speed will increase to an angular velocity greater than that of the fan rotor 12, and if it were only a rigid gear train interposed between the two rotors, the core engine rotor 13 would tend to pump energy back into the torque converter 34 to thereby impart rotary motion to the fan rotor. This direct gear drive between the two independent systems during normal flight operation is undesirable for obvious reasons, and it is therefore necessary to disengage the drive train during such periods to prevent the transmission of power in the reverse direction. An overrunning clutch 43 is therefore placed at the output of the torque converter 34, wherein it allows power to be transmitted from the fan to the rotor (left to right), but does not allow power to be transmitted from the core rotor to the fan rotor (right to left). It accomplishes this by automatically decoupling the system whenever the core rotational speed exceeds that of the converter output.
It will be recognized that when an engine has been satisfactorily started and has reached a speed sufficient to sustain combustion, even though the gear train may have been decoupled by operation of the overrunning clutch 43, the driving of the torque converter 34 imposes a load on the fan rotor 12 which is not desirable. Accordingly, an electrohydraulic servovalve 50 is provided to inactivate the torque converter during periods in which its operation is not desired. The hydraulic system associated with the torque converter 34 includes an oil supply tank 44, a boost pump 46, an oil supply line 37 which routes oil into the torque converter, and an oil drain line 47 which returns oil back to the supply tank 44. A hydraulic cylinder 49 is placed in the system so as to mutually pass through the oil supply line 47 and the oil drain line 48, the effect being that both the hydraulic fluid going to the torque converter 34 and that returning to the tank must pass through the cylinder 49. Disposed within the cylinder 49 is a reciprocal piston 51 having a pair of spools 52 and 53 being spaced in such a manner that when the piston is moved to the right end of the cylinder as is shown in FIG. 2, the spool 52 is aligned with the oil drain line 48 to thereby act as a shut-off valve to prevent the return of oil to the oil supply tank 44, whereas the spool 53 is offset to the right from the oil drain line 47 to thereby allow the oil from the pump 46 to pass through the oil supply line 47 and the cylinder to the torque converter 34. The valve piston 51 is moved to the position shown, against the leftward biasing force of a spring 54, by way of a typical solenoid 56 electrically energized through line 57. When the energy to the solenoid 56 is removed, the biasing spring 54 pushes the piston to the left so that the spool 52 no longer is aligned with the oil drain line 48 and the spool 53 is now aligned with the oil supply line 47. Thus the supply of oil from the pump 46 to the torque converter 34 is cut off and that oil which is in the torque converter 34 is allowed to drain through the oil drain line to the oil supply tank. Such is the position of the valve during periods in which torque is not required to be transmitted to the core engine rotor, and during which the torque converter is decoupled by removal of the hydraulic fluid to thereby remove the load from the fan rotor.
The solenoid 56 of the servovalve 50 controlled through lead 57 by way of an AND circuit which operates in response to the core speed and throttle setting inputs along lines 59 and 61, respectively. More specifically, if the core speed is greater than a predetermined rotational speed (e.g., engine idle speed), then the AND circuit 58 will act to de-energize the solenoid and move the servovalve so as to allow the hydraulic fluid to drain from the torque converter 34. Similarly, if the throttle is placed in an off position to indicate that the pilot does not desire that the engine be lit off, then the AND circuit 58 will also prevent the solenoid 56 from being energized.
Consider now a situation where a flameout has occurred to the engine and the windmill speed to the core is not sufficient for a relight. Since the core rotational speed is less than that at idle, and since the throttle is placed in an "on" position, the AND circuit 58 will activate the servovalve 50 and allow for the torque converter to be filled with hydraulic fluid. Rotary motion will then be transmitted from the fan rotor to the core rotor so it reaches a speed sufficient to sustain a relight. Following a successful relight, the core speed will accelerate to speed greater than that of the fan rotor speed, and the overrunning clutch 43 will automatically disengage the gear train between the two rotors. At the same time the core speed will have reached a point where the signal along line 59 into the AND circuit 58 will be lost to thereby de-energize the solenoid 56 and allow the piston 51 to move to the left to shut off the oil supply to the torque converter 54 and to further allow the oil within the torque converter to drain into the supply tank 44 along line 48. The system will then remain in this condition until such time as the core speed again is reduced to a point below idle speed as would happen if a flameout again occurred. | A torque converter is interconnected between the fan and core rotor of a turbofan engine such that the speed of the core rotor can be boosted from windmill speed to a speed sufficient to allow an in-flight start by selectively extracting power from the windmilling fan during the start sequence of the engine. Control logic is included to automatically drain the oil from, and thereby unload, the torque converter whenever the engine is in the operating speed region. Further assurance is provided by an overrunning clutch which decouples the system when the core rotational speed exceeds the converter output. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to self-tightening chucks, particularly as used in textile machines for holding bobbin sleeves during winding or spooling operations and the like. In general, the chuck used for this purpose is a sleeve holding device which is mounted on a rotary, cantilevered shaft projecting outwardly from the side of the machine with stop means to receive the inner end of the sleeve facing the machine side and which has releasable clamping or gripping elements to secure the bobbin sleeve in place.
In recent years, the development of spinning machines for the production of synthetic fibers has led to a very substantial increase in spinning speeds, i.e. the winding speeds required to take up the freshly spun filaments or threads. Because of these rapid winding speeds, e.g. over 3,000 m/min and preferably up to 5,000 m/min or more, considerable time and effort have been spent in attempting to reduce as far as possible the amount of waste thread which accumulates during the necessary exchanges of bobbins or spools, i.e. replacing a full bobbin with an empty bobbin sleeve. In order to reduce the time needed to make this exchange, there have been a number of proposals to provide so-called automatic chucks in the form of sleeve holders which have self-tightening characteristics which permit a substantial reduction in the time needed to remove a full bobbin and insert an empty bobbin sleeve. Although the present state of this art offers a number of different self-tightening chuck or sleeve holder constructions, all of them suffer from various disadvantages.
For example, in the German patent specification (DE-AS) No. 1,038,709, there is described a special chuck or bobbin holder for use in spinning machines for producing synthetic threads wherein frictional gripping contact with the bobbin sleeve is produced by a two-arm rocker lever which is spring-actuated when pushing on the bobbin sleeve so as to press the forward end of the two-armed lever against the inner wall of the sleeve. Centrifugal forces, which occur during the winding, are supposed to reinforce the clamping or gripping action of this chuck. Due to the large number of pivot positions required and the open construction of this mechanism, the chuck is unusually subject to fouling and is therefore difficult to operate and maintain under typical working conditions. Moreover, in order to avoid deformation of the bobbin sleeve caused by the point-like pressure of the gripping positions on the sleeve circumference, the contact pressure of each position must be reduced to a value which no longer guarantees the secure holding of the bobbin, especially in handling large and relatively heavy windings.
In a sleeve coupling for twist spindles disclosed by the German patent specification (DE-AS) No. 1,061,242, a rubber ring is used to achieve a frictional locking connection between the sleeve holder and the bobbin sleeve. In its relaxed position, the rubber ring is free of contact with the inner wall of the sleeve, but with the aid of several gripping elements which are pivoted to swing outwardly to the circumference of the holder, the rubber rings are distended or stretched outwardly to make contact with the inner wall of the sleeve. During operation of this spindle, centrifugal forces also act outwardly to stretch the rubber rings and bring them into gripping contact with the sleeve. The greatest disadvantage of this particular sleeve couplings resides in the fact that the sleeve is firmly gripped only at high rotational speeds. At lower speeds or at rest, the bobbin sleeve sits loosely on the spindle and a firm gripping action is not possible, thereby causing problems in unloading the full bobbin and inserting an empty sleeve. Besides, this device permits only a pointwise bracing or gripping of the sleeve which causes deformation of the sleeve wall.
Another winding mandrel with an automatic chucking feature is disclosed in U.S. Pat. No. 3,495,781, corresponding to DE-AS No. 1,574,399, wherein the bobbin sleeve is secured in position with the aid of two rubber rings. This is a very expensive construction, requiring in each case a hydraulic or pneumatic chucking device and braking device. The release of the full bobbin and the clamping of the empty bobbin sleeve occur automatically in lifting off the bobbin from the drive roller or in adding on the empty sleeve. Such devices tend to suffer from frequent mechanical failures which cannot be anticipated or prevented by normal maintenance of the machinery.
A recent chuck assembly for textile bobbins is disclosed in U.S. Pat. No. 4,202,507, issued May 13, 1980, wherein the problems in this art are to be solved by using two rubber O-rings, one at the inboard end and the other at the outboard end of the chuck, the inboard O-ring actuating the outboard O-ring over a set of two-armed levers, the two O-rings being pressed between the inner surface of the sleeve and a circumferentially grooved segment of the chuck shaft. The use of mechanical levers set into the chuck shaft is still relatively complicated and is subject to fouling as well as general maintenance problems.
SUMMARY OF THE INVENTION
The problem of providing an effective, easily maintained and relatively inexpensive self-tightening chuck or sleeve holder is solved in a particularly satisfactory manner by the present invention, especially in textile machines or the like in which a sleeve holder is carried conventionally on the machine by a rotary, cantilevered shaft with a machine-side stop means for the sleeve, i.e. a stop means at the inboard receiving end of the chuck assembly.
In its broadest aspect, the self-tightening sleeve holder of the invention comprises (1) a tube member which is axially slidable on the rotary, cantilevered shaft between the stop means and a collar member rigidly fixed to the shaft, a plurality of axially elongated linking members on said tube member extending through a corresponding plurality of axial openings in said collar to hold a push means arranged about the shaft in front of the collar, (2) a first machine-side gripping ring arranged on the circumference of the tube member in a position to be pushed and frictionally engaged by the sleeve, during slipping of the sleeve onto said tube member, from a small diameter bed over a roll surface which mounts in the push direction and then into a larger diameter bed where said first ring tightly secures the sleeve to the tube member, and (3) a second gripping ring arranged on the circumference of the collar member in a position to be moved by said push ring and placed in frictional contact with said sleeve, said movement taking place from a small diameter bed over a roll surface which mounts in the push direction and then into a larger diameter bed where said second ring also tightly secures the sleeve to the tube member.
The invention further provides an accumulator means interposed between the slidable tube member and the stop means to act resiliently against the force used for pushing the tube member axially toward the stop means. This accumulator means preferably comprises a compression spring, e.g. in the form of a coil spring or plurality of coil springs which can be mounted in opposing recesses in the facing end surfaces of the tube member and the stop means, thereby separating the tube member from the stop means and resiliently pushing them apart.
A number of advantages and improvements are achieved with the self-tightening sleeve holder of the invention as described more fully hereinafter together with the attached drawings which illustrate the preferred embodiments of the invention without any intention of limiting the invention to these particular embodiments.
THE DRAWINGS
FIG. 1 is a partly schematic sectional view taken on line 1--1 of FIG. 2, illustrating one preferred embodiment of the self-tightening chuck or bobbin sleeve holder according to the invention;
FIG. 2 is a cross sectional view taken on line 2--2 of FIG. 1 with the bobbin sleeve being omitted; and
FIG. 3 is a partial sectional view at the inner end of the sleeve holder to illustrate an alternative construction of the chuck assembly according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, the self-tightening sleeve holder of the invention is illustrated at one high speed winding position to a textile machine for taking up a thread onto a bobbin package, using a conventional elongated, cantilevered shaft 1 mounted on the machine side or inner end in suitable bearings (not shown) for rotation about its longitudinal axis. Near the free or outer end 10 of this rotary shaft 1, a shaped or profiled collar 11 is attached in a fixed position, i.e. without movement longitudinally or circumferentially with respect to the shaft 1 by means of a key and slot arrangement 11a and/or at least one set screw 11b as indicated in FIG. 2. A feather key as an axially elongated member may also be inserted in slot 11a and an opposing slot of similar shape and size in the collar 11 and also in the tube 7 (not shown). Collar 11 can be easily replaced by a differently profiled collar for adaptation to different sizes or weights of bobbin sleeves and their yarn packages.
The profiled collar 11 is shaped in such a way as to provide on its circumference two axially consecutive beds or grooves 15 and 17 which provide an outer open position and an inner closed or locked position, respectively, for a rubber gripping ring 12 (hereinafter to be identified as the second of two gripping rings) in the loading and unloading of a bobbin sleeve 6 onto the shaft 1. The beds 15 and 17 are nearly semi-circular in cross section, and each bed exhibits a different root diameter in seating the gripping ring 12. The first bed 15 is of smaller diameter, being sufficiently small that the outer diameter of the gripping ring 12 seated therein is less than the inner diameter of the bobbin sleeve 6 being pushed onto the chuck assembly (to the right). Thus, when this sleeve 6 is initially pushed onto the shaft 1 over the fixed collar 11, it rides freely over the gripping ring 12 inserted in the first bed 15.
The second bed 17, having a larger root diameter than the first bed 15, is joined with said first bed by a circumferential hump or rolling surface 16 which mounts or ascends in the initial push direction with at least a small portion of this rolling surface 16 being of larger diameter than the root diameter of the second bed 17, thereby ensuring a secure locking of the ring 12 in the second bed 17. The rolling surface 16 is preferably smoothly rounded in forming a circumferential hump or bulge around the collar 11 so that the rubber ring 12 will be rolled or slidingly urged without damage from bed 15 over hump 16 and then into bed 17 where a secure, friction-type locking is produced between the profiled collar 11 and the bobbin sleeve 6.
The profiled collar contains a plurality of openings 14 at positions which are preferably equidistantly spaced around the circumference of the collar as viewed in cross section (FIG. 2). With the aid of the axially elongated linking members or fingers 20, which are finger-like extensions of the push tube member 7, a fixed connection is made with the push ring 13 so that it will slide back and forth together with the tube member 7. This fixed connection is preferably accomplished by threading the push ring 13 onto mating threads 21 in the fingers 20, or by at least one set screw similar to 11b but connecting the ring 13 to the fingers 20. The push ring can then be removed and suitably replaced with a different push ring adapted to varying sizes or weights of the bobbin sleeves and packages. The function of the push tube 7 with its push ring 13 will be apparent from the description of the chucking operation given below.
At its machine-side or inboard end, the shaft 1 carries a fixed stop member 18 which preferably has an added shoulder or outwardly facing support member 19 as a means to center the bobbin sleeve 6. The outer diameter of the shoulder support member 19 is thus preferably adapted to fit within the inner diameter of the sleeve 6.
A push tube 7 acts as a single axially slidable unit in performing a chucking function and is preferably proportioned so that it can be axially shifted with only a little play on the shaft 1, the fingers 20 being in sliding contact with the openings 14 of the fixed collar 11 so that the tube 7 also has just a little play in the circumferential direction. Rotation of the push tube 7 together with the shaft 1 is thereby guaranteed without depending upon any other connecting or chucking means for this purpose.
At its inboard end, the push tube 7 as shown in FIG. 1 also has two approximately semicircular grooves 3 and 5 which extend around the circumference of the tube and are smoothly connected by the rolling surface 4 to provide an outer sleeve engaging position and an inner closed or locking position, similar to the arrangement on the shaped collar 11. In this case, however, the outermost groove or smaller diameter bed 3 has a root diameter in seating the first rubber gripping ring 2 which is still sufficiently large so that the outer diameter of this gripping ring 2 is larger than the inner diameter of the bobbin sleeve 6. When initially pushing the sleeve 6 onto the tube 7, it will engage the first gripping ring 2 and roll or slide it over the rolling surface 4 and then into its locking position in the larger diameter bed 5.
A compression spring means in the form of a plurality of coil springs 8, preferably at least three such springs or four as illustrated, are inserted between the inner facing end 9 of the push tube 7 and the outer facing end surface of the stop means 18. The mounting of these springs 8 is most easily accomplished by providing one set of cylindrical recesses 22 spaced equidistantly about the circumference of the face end of the push tube 7 and a corresponding set of cylindrical recesses 23 in the opposite face of the centering support member 19. Each recess is adapted to receive one end of a coil spring and also acts as a guide for the compressed and expanded coils. The function of these coil springs is described more fully below.
As noted above, the openings 14 in the fixed collar 11 permit a rigid connection or linkage between the main barrel or body of the push tube 7 and the push ring 13 by means of the extending fingers 20 of tube 7 which pass through openings 14 to be fastened to the push ring 13. Therefore, when the first gripping ring 2 is engaged by the bobbin sleeve 6 and pushed inwardly out of bed 3 over hump 4 and into bed 5, the push tube 7 is caused to move toward the stop member 18 and at the same time the push ring 13 engages the second gripping ring 12 to push it inwardly out of bed 15 over hump 16 and into bed 17. The movement of the two gripping rings 2 and 12 is thus actuated by the force of pushing sleeve 6 onto the chuck or sleeve holder, both of these gripping rings being pushed forwardly in tandem. The pushing ring 13 in its outermost or loading position is preferably arranged concentrically around the shaft 1 and directly adjacent to the outermost bed 15 in collar 11. Only a short inward axial thrust is then required to move both gripping rings into their innermost locking beds 17 and 5, respectively.
In FIG. 3, the inner end 9 of the push tube 7 is also equipped with a replaceable collar piece 24 containing four equidistantly spaced recesses 25 to mount the coil springs (not shown) and being fastened to the tube by the mating threads 26. A first circumferentially grooved bed 27 of smaller root diameter is connected to a second bed 29 of larger root diameter over the hump or rolling surface 28 in the same manner as the beds 3, 5 and hump 4 of FIG. 1 except that the shape and configuration of these parts is varied to accomodate a different sleeve or a different rubber gripping ring.
In general, this collar piece 24 will preferably have a profiled outer circumference closely matching that of the fixed collar member 11, especially so as to provide about the same gripping or locking effect in the innermost beds 29 and 17 in cooperation with their respective first and second gripping rings. The frictional locking force will then be approximately equal at both ends of the bobbin sleeve 6 and the self-tightening characteristics will also be about equal with the outwardly exerted gripping pressure being spread over the circumferential area of contact between the gripping rings and the inner surface area of the sleeve.
The automatic function and operation of the chuck or sleeve holder of the invention is basically the same in all embodiments of the invention and will be readily understood with reference to the drawings and especially FIG. 1 where the sleeve 6 is shown after being slipped onto the shaft 1 over the push tube 7 just before engaging the gripping ring 2.
When an empty bobbin sleeve 6 is shoved or slipped from the free end 10 of shaft 1 onto the slf-tightening sleeve holder up to the position shown in FIG. 1, it will slide practically free of contact with the second or outermost gripping ring 12 which is seated in the first smaller bed 15 of collar 11.
Both the first and second rings 2 and 12 rest securely in their outermost beds since they are made of rubber or a similar elastomeric material which can contract or expand in diameter will also being resiliently compressed when being squeezed between the outer profiled surfaces on the tube 7 or collar 11 and the inner surfaces of the bobbin sleeve 6. These gripping rings preferably have a round cross section, i.e. in the form of typical O-rings, and are made of any suitably soft rubber or other highly elastic material.
After reaching the position shown in FIG. 1, the bobbin sleeve 6 is pushed either manually or by a loading device in axial direction toward the stop member 18. This causes the first gripping ring 2 to be engaged by the inner end of the sleeve 6 so as to roll or push the ring 2 along the smooth rolling surface 4 and into the bed 5, simultaneously compressing the rubber ring between the tube 7 and inner wall surface of the sleeve 6. Through this movement, the frictional contact of the ring 2 between tube 7 and sleeve 6 becomes sufficiently strong or intensive as the ring 2 rides up the increasing diameter of the rolling surface 4 and into larger diameter bed 5 so that the further axial pushing of the sleeve 6 inwardly toward stop member 18 causes the push tube to be driven in the same direction against the action of the springs 8. At this movement, however, the push ring 13 is also moved with the help of fingers 20 so as to be advanced toward the stop member 18 and to become engaged with and push the second gripping ring out of bed 15 to roll or slide over the rolling surface 16 until it locks or catches in the bed 17. In this manner, a secure frictional connection is made between the sleeve holder and the bobbin sleeve.
The coil springs 8 used as an accumulator means in the illustrated embodiments have an important function. In the loading operation described above, the bobbin sleeve 6, as it is pushed onto the shaft and tubular support means of the chuck, comes into contact with the gripping ring 2 and pushes it over the hump or roller surface 4 into bed 5 without too great a consumption of energy or any need to provide too great a force. However, once the first gripping ring 2 becomes seated in bed 5, the frictional coupling between the push tube 7 and bobbin sleeve 6 becomes so secure or tight that the push tube is now taken along from its position shown in FIG. 1 toward the stop member 18 against the action of the springs 8. Thus, there is a first movement axially inwardly of the gripping ring 2 from bed 3 into bed 5 and only when is sufficient force exerted to move the entire push tube 7 axially inwardly against coil springs 8. The innermost lip 30 of the bed 5 is steep enough and/or high enough to prevent the gripping ring 2 from being dislodged and carried off the inner end 9 of the push tube 7.
As the push tube 7 moves axially inwardly in the loading direction, the push ring 13 presses the second or outermost gripping ring 12 out of its first small bed 15 into the larger bed 17. At the same time, this second locking movement of ring 12 provides enough additional frictional contact with the sleeve 6 to further compress the springs 8 between the stop member 18 and the push tube 7.
The intervals between the inner end 9 of the push tube and the stop 18 as well as the intervals between the beds 15 and 17 are determined such that the bobbin sleeve rests on the stop 18 when the gripping ring 12 has been inserted into the locking position of the larger bed 17. In general, the maximum intervals which correspond to the travel stroke of the compression spring means, e.g. coil springs 8, amounts to about 3 to 15 mm and preferably about 5 to 8 mm in typical textile machines using conventional bobbin sleeves.
It is important to design the compression spring means or other accumulator means such that the spring force or the force of accumulator resistance exceeds that force which is initially required to push the first gripping ring 2 into its larger diameter bed 5, but remains less than that force which would move or dislodge the second gripping ring 12 out of its larger diameter bed 17 once pushed into this inner closed or locking position.
In withdrawing or pulling off a full bobbin after completion of the usual winding operation, relatively less force is required to move the two gripping rings 2 and 12 from their beds of larger diameter 5 and 17 into their beds of smaller diameter 3 and 15, respectively. The closed or locked position in which the bobbin sleeve is securely held by the two gripping rings thus remains secure even during starting and stopping the winding, but at the same time excessive force is not needed to remove a full bobbin package or to slip on an empty bobbin sleeve.
In addition to providing a secure gripping of the bobbin sleeve at all stages of the winding operation, the automatic chuck or sleeve holder of the present invention has the advantage of a very simple and inexpensive construction. Also, a very minimal amount of time is needed for exchanging bobbins so as to reduce the accumulation of waste threads. Aside from the cooperating push tube and push ring and the two gripping rings there are no moving parts which can malfunction or become worn over long periods of use.
Most importantly, there are essentially only two locking members subject to wear, namely the rubber or elastomeric gripping rings, and these lie openly for inspection after removal or discharge of the fully wound bobbin and before insertion of an empty bobbin sleeve. These rings, e.g. as simple rubber O-rings, are inexpensive and can be easily replaced as needed. Finally, the fully closed and smoothly profiled circumferential surfaces of the chuck assembly avoid any accumulation of fiber dust or other fouling material, and all parts are very quickly and easily cleaned because all exposed surfaces are readily accessible as well as being highly visible for inspection. Operating disturbances are quite minimal, thereby greatly increasing the efficiency of winding operations. | A self-tightening sleeve holder or chuck assembly designed particularly for high speed textile winding machines wherein the bobbin sleeve is releasably held by two elastomeric gripping rings which are stretched or distended radially outwardly in automatic sequence in response to the coordinated movement of a cooperating push tube and push ring actuated by the bobbin sleeve as it is pushed onto the sleeve holder, the gripping rings being moved from a first small diameter bed to a larger diameter bed to securely lock the bobbin sleeve in place. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a sewing station for pieces of material with processing stations, for instance for the hemming, trimming or the like, and with a first conveyance device for the pieces of material cut in lengths from a stock source, which delivers these pieces of material to a second conveyance device, which can be raised by means of a lifting device for introduction of the pieces of material and can be lowered for picking up the piece of material and for its further conveyance to at least one work station.
In such a sewing station, pieces of material receive and preserve certain tensions during their manufacture and finishing. It has particularly been proven that following the cutting of pieces of the material coming from a stock supply (uncut length of fabric) the pulled away materials, which generally are woven printed jacquard or have special patterns, must be straightened out, since otherwise subsequent processing of the piece of material can lead to defects, blemishes or obstructions. The tension in the piece of material indeed is modified following the cutting step and causes imprecisely definable oblique positioning of the piece of material. The result of this is that the forward moving or front edge of a piece of material, for instance in the case of hemming of the cut edges, no longer runs flush with the hems which are produced. The result is a defective piece of material.
In order to overcome the aforementioned imperfections, devices are already known (U.S. Pat. No. 3,906,878) which are integrated into the assembly for hemming the piece of material. These devices have endless transport arrangements which should provide alignment corresponding to the original alignment by modification of their rotary velocity. This method however has the drawback that stresses or tensions occur in the pieces of material during and at the same time as the formation of the hem, which subsequently can be modulated only with great difficulty. Correction of the positioning of the piece of material in this case is further complicated in that with the hemming procedure the material already must be guided exactly and securely, which condition however essentially prevents any subsequent position correction. Then when on the one hand the pieces of material are guided securely and without slippage, on the other hand the oblique positioning of the pieces of material can no longer be corrected. Now the hemming assembly is constructed so that the pieces of material can be subjected to correction of their oblique positioning even during the hemming procedure, which is possible only with less secure guiding and control of the pieces of material, and then too a uniform hem formation, especially with different qualities of material, can no longer be guaranteed in this case.
SUMMARY OF THE INVENTION
The object of the invention is to avoid the aforementioned difficulties and to further develop a sewing station of the aforementioned structural type so that the pieces of material are brought into position without any hindrances, as required for any processing, before reaching the processing station or stations.
This positioning is attained according to the invention in that in the area of the second conveyance device and in the direction of movement of the piece of material as considered before the processing station a device is provided which can be raised and lowered and is horizontally adjustable for alignment of the forward moving (front) edge of the border of the piece of material, which controls sensing elements sensing the arrangement of this edge of the piece of material and thus can be placed on a piece of material and according to the oblique positioning of the forward moving edge of the piece of material can be moved in the direction of or counter to the direction of conveyance of the piece of material while simultaneously gripping the same, until the oblique position of the forward moving edge of the piece of material is deleted or lies within the range of allowable tolerance, and that then the piece of material subsequently conveyed to the processing station by means of the second conveyance device. The alignment process takes place while the second conveyance device is raised. Then when the piece of material is removed from the second conveyance device for further conveyance to the relevant processing station, it has a suitable position with no obstacles present for the relevant processing and therefore can be guided precisely into the position and be processed following its introduction into the relevant processing station. Any subsequent correcting device, for instance in the hemming assembly, as is practiced in the present state of the art, is thus no longer necessary and is deleted. The oblique position of the forward moving edge of the piece of material can thus be measured for all practical purposes by any desired type of sensing elements, but photocells are preferred for this purpose.
Refinements of the invention are disclosed in the dependent claims. Thus it is claimed as advantageous that the alignment device be movable during an alignment procedure synchronously with the first conveyance device in the direction of conveyance. The sewing station can then advantageously continue working continuously (in other words even during the procedure of trimming or hemming the piece of material), which increases its high production rate correspondingly.
A structurally simple refinement of the invention, requiring relatively little mounting area, is characterized in that the alignment device has at least one alignment strip and is horizontally adjustable and can be placed on the piece of material adjacent to its edge which is to be processed parallel to the conveyance device for the piece of material. This alignment strip can be provided with a friction coating on its bottom edge which correspondingly increases the gripping effect.
According to still another embodiment of the invention the alignment strip can be mounted to be vertically movable on a carriage and can be raised and lowered by a lifting member, for instance a lifting cylinder, while this carriage can be moved back and forth by means of a power drive adjusting the final control of the setting along a stationary horizontal guide. This power drive for the adjustment of the final control of the setting is controlled by the sensing elements sensing the arrangement of the forward moving (front) edges of the pieces of material and then according to the results of the measurements is driven in one or the other direction, in order to move the alignment strip placed on the piece of material in the direction of or counter to the direction of conveyance of the relevant piece of material.
If according to still another embodiment of the invention also the power device adjusting the final control of the setting fastened to a carriage which is mounted on a stationary horizontal guide and can be moved in the direction of conveyance of the piece of material synchronously with the first conveyance device for the piece of material, then it is advantageous that the sewing station also continue to run during the alignment process.
A structural simplification and reliable synchronous movement of the alignment device with the first conveyance device is thus guaranteed in that the carriage carrying the power device adjusting the final control of the setting may be coupled to the first conveyance device for the pieces of material for synchronous movement with this device.
Another embodiment of the invention which enhances structural simplification is characterized in that the two carriages carrying the power device for adjusting the final control of the setting and the alignment strip are mounted on the same stationary horizontal guide.
Any oblique position of the forward moving edge of the piece of material can be measured and corrected simply in that the power device for adjustment of the final control of the setting intended for positioning of the alignment strip is controlled by means of two sensing elements, for instance photocells, which are arranged at some distance from one another, viewed from the direction of conveyance. The method of operation of the photocells for instance can then be such that when the correct position of the forward moving (front) edge of a piece of material is within the tolerance range one photocell is activated and the other photocell becomes inoperative. On the other hand, if both photocells either are activated or become inactive, then the alignment strip executes a correction procedure.
It is advantageous that the two sensing elements controlling the power device for adjusting the final control of the setting for the horizontal positioning of the alignment strip are fastened to the carriage carrying the power device for adjusting the final control of the setting.
Still another refinement of the invention is characterized in that also a sensing element controlling the coupling of the carriage carrying the power device for adjusting the final control of the setting relative to the conveyance device and the lowering of the alignment strip, for instance a photocell, is fastened to the carriage carrying the power device for adjusting the final control of the setting.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail hereinafter relative to the drawings of exemplary embodiments. In the drawings:
FIG. 1 is a planar view of the parts of a sewing station essentially for the present invention with a first and a second conveyance device and the alignment device according to the invention, arranged in mirror-inverted image relative to two edges of the piece of material facing one another and ready for processing, and indeed in an embodiment for a discontinuous method of operation;
FIG. 2 shows a side view of a part of the sewing station shown in FIG. 1 in the area of the alignment device;
FIG. 3 shows a planar view of the part of the unit shown in FIG. 2, but with only one half of the alignment device according to the invention;
FIG. 4 shows a partial side view of the sewing station similar to that of FIG. 2 but in this case in the embodiment suitable for a continuous method of operation;
FIG. 5 shows a planar view of the arrangement shown in FIG. 4, including one half of the alignment device;
FIG. 6 shows a planar view of a part of a piece of material in the sewing station for illustration of the correct position as well as the oblique positions of the forward moving (front) edge of the piece of material in the area of the alignment device which itself is not shown in this case;
FIG. 6A shows a frontal view and different planar views of a part of a piece of material with a hem or the like;
FIG. 7 shows a frontal view of a part of the first and second conveyance device and one half of the alignment device according to the invention during the guiding of a piece of material;
FIG. 8 shows a planar view of the same part of the assembly shown in FIG. 7, in which in this case the forward moving or front edge of a portion of a piece of material is shown in an optimum middle position;
FIG. 9 shows a frontal view similar to that of FIG. 7, in which the first conveyance device has already been raised and the second conveyance device is activated;
FIG. 10 shows a partial frontal view similar to that of FIG. 7, in which the alignment strip of the alignment device is lowered for the purpose of undertaking a correction of the alignment of the piece of material, while the second conveyance device is still raised;
FIG. 11 shows a planar view of the arrangement shown in FIG. 10, in which the front or the forward moving edge of a piece of material takes an oblique position (one edge leading position), which is to be corrected, and
FIGS. 12 and 13 show a frontal and a planar view similar to those of FIGS. 10 and 11, in which in FIG. 13 the forward moving (front) edge of the piece of material is shown in one further possible oblique position (one edge trailing position), which makes a correction obligatory.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the sewing station shown only in part in FIG. 1, pieces of material 10, 10', 10" and so forth are provided on two opposite edges with for instance a hem or border 11 on each edge. Other edge treatments applied to these edges of the pieces of material can also be carried out within the scope of the invention. Also, elastic strips could be sewn into each hem 11, for instance in order to produce fitted sheets. In the case of the pieces of material 10, 10', 10" and so forth, it can also be a matter of a material serving for instance for the production of hand towels. An uncut section of fabric 12 serves as the original material source for the pieces of material 10, 10', 10" and so forth, the original material drawn from a supply stack or delivery spool by means of a gripping device 13. Gripping device 13 is a unit or assembly which is known in such sewing stations, which needs no further explanation. Gripping device 13 picks up uncut piece of fabric 12 by one cut edge 14 and draws a desired length in the direction of the arrow, whereupon a cutting blade which is operable by a motor 16 is set in operation in order to sever a piece of material 10 from the uncut piece of material coming from the delivery spool or supply stack. Piece of material 10 is then picked up by a first conveyance device 17 to be carried in the direction of the arrow. Conveyance device 17 is shown in FIG. 1 on the left in dot-dash lines in its one edge position (starting position) and on the right in full lines in its other edge position (delivery position).
The first conveyance device 17 has a carriage 19 mounted on a guide bar 18, which carries two gripper strips 20. Guide bar 18 is mounted on the frame of the assembly (not shown) parallel to the conveyance device for pieces of material 10, 10', 10" and so forth. Gripper strips 20 are mounted separately on each of two guide bars 21 and the piston rods of two lifting cylinders 22. These cylinders are then in turn mounted on the carriage 19, while guide rods 21 are mounted to be vertically movable on carriage 19. Furthermore, the two ends of a chain 23 are also fastened to carriage 19, wherein chain 23 runs over two sprocket wheels 24, of which the left sprocket wheel 24 as shown in FIG. 1 is driven alternately in either direction by a motor 25. The right sprocket wheel 24 is mounted to be freely rotatable on guide rod 18. Motor 25 is mounted on a part projecting from guide rod 18.
Gripper strips 20 have friction coating on their bottom surfaces and for the conveyance of pieces of material 10, 10' and so forth they are brought into contact with the pieces of material in the direction of the arrow by lifting cylinder 22, and actually are placed on the two facing edge areas of pieces of material 10, 10' and so forth, which rest on mounting plates 26. The two mounting plates 26 are fastened at some spacing from one another on either side and parallel to the direction of conveyance of pieces of material 10, 10' and so forth on the frame of the assembly.
Conveyance device 17 moves the piece of material 10 as shown in FIG. 1 to the right into a delivery position, which is indicated by 10' and in which the piece of material can be picked up by a second conveyance device 27. Along the two lengthwise edges of conveyance device 27 are arranged for instance a folding device 28 and a sewing machine 29 on each side and opposite one another. Folding devices 28, indicated only diagrammatically, serve for the formation of the hem or the like 11, while sewing machines 29 sew said hems or the like 11 (cf. also FIG. 6a).
The second conveyance device 27 has two endless conveyor belts 30, which are guided over not shown rollers, and one pair of rollers forms the drive rollers for conveyor belts 30, which for this purpose are mounted on a motor-powered shaft. Gripper strips 20 of the first conveyance device 17 are arranged so that they can enter the space between the two conveyor belts 30 of second conveyance device 27, in order to bring the piece of material 10 into receiving position for the second conveyance device 27, which is indicated with 10' in FIG. 1. For the purpose of picking up the piece of material 10, conveyor belts 30 of the second conveyance device 27 may be raised by a lifting device 31 (FIGS. 2 and 4) over the major portion of their length. This lifting device 31 may also be moved back and forth in the direction of conveyance of pieces of material 10, 10', 10" and so forth, in order to facilitate transfer of the pieces of material to the second conveyance device 27 without interruption, in other words "during operation" of the sewing station.
Reference is now to be made to FIGS. 1, 6 and 6A. The uncut piece of material 12 includes tensions of different origins. Following the separation of a piece of material 10 from uncut piece of material 12, the tension in a piece of material 10 is modified and can lead to oblique positioning of the same on mounting plates 26 which cannot be predicted or even foreseen beforehand. Thus the forward moving or front edge 32 of pieces of material 10, 10' also takes a corresponding oblique position (FIGS. 11 and 13), which must be corrected before pick-up of piece of material 10' by second conveyance device 27, since otherwise obstacle-free production of hem 11 on the cut edges 14 of pieces of material 10, 10' and so forth is not possible, as shown in FIGS. 6, 6A. When forward moving edge 32 of piece of material 10, 10' forms a right angle to the cut edge 14 and thus also to the direction of conveyance, as is shown in full line in FIG. 6, the middle point 33 of hem 11 is in flush alignment with forward moving edge 32 and a process of alignment is thus no longer necessary. However, as is shown in dot-dash lines at 32 a and 32b in FIG. 6, when the forward moving edge of piece of material 10' has a one edge leading position or a one edge trailing position, without correction beforehand, then a withdrawn or a projecting middle point 33 occurs during formation of the hem, as is shown in FIG. 6A at 32b and 32a. In both cases the beginning and the end of hem 11 in the relevant piece of material 10" are defective. Here then the invention is to be used and it executes an alignment of the piece of material 10', so that middle point 33 is flush with forward moving edge 32. An alignment device 34 is provided in the direction of conveyance of pieces of material 10, 10' for this purpose before folding devices 28 at the delivery point of a piece of material 10' from first conveyance device 17 to second conveyance device 27, which is to be described hereinafter.
Since in the exemplary embodiment both cut edges 14 of any piece of material 10" are to be processed, in other words in this case are to be provided with a hem 11, it is necessary to align the forward moving edge 32 of piece of material 10' in the areas of both of the cut edges 14, particularly in case an oblique position or oblique angling of the same has been determined. Alignment device 34, therefore includes suitable means of correction in the areas of both of the facing cut edges 14 of piece of material 10', which means are arranged in the same manner and in mirror image to each other, so that it suffices to describe only one side of alignment device 34.
Arms 35 are fastened to the right side of guide rod 18 as shown in FIG. 1, and said arms in turn carry horizontal guides 36 for cartridges 37 on their free ends. Guides 36 run parallel to the direction of conveyance of pieces of material 10, 10', 10" and so forth. Each carriage 37 carries an alignment strip 38 which can be raised and lowered, which likewise extends parallel to the direction of conveyance of pieces of material 10, 10', 10" and so forth. In particular, each alignment strip 38 is guided by a guide rod 39 (FIG. 2) on carriage 37. A lifting cylinder 40 is also fastened to carriage 37, by means of which alignment strip 38 is raised or can be set on the piece of material 10' which is to be aligned. Alignment strip 38 is placed on piece of material 10' at a certain short distance from its cut edge 14.
An outwardly cantilevered arm 41 is fastened by a bracket to each guide 36, and a power device 42 for adjusting the final control of the setting is flanged onto it. Power drive 42 for adjustment of the final control of the setting is connected through a drive shaft 43 with carriage 37, which according to the direction of rotation of drive shaft 43 is set in the direction of conveyance or counter to the direction of conveyance of pieces of material 10, 10', 10" along guide 36. Alignment device 34 as shown in FIGS. 1-3 is laid out in such a manner that an alignment procedure can be carried out only when the piece of material 10' is at rest. This means that in the course of delivery of piece of material 10' from first conveyance device 17 to second conveyance device 27 for conveyance of the piece of material 10', a resting point occupies one short moment while the piece is on mounting plates 26. The material delivery is then discontinuous for a moment at this point.
An inwardly projecting arm 44 which incorporates three sensing elements 45a, 45b and 46, which are preferably photocells, is mounted on each guide 36. Sensing elements 45a and 45b are arranged at a certain spacing from one another in the direction of conveyance of pieces of material 10, 10', 10" and by the results of their sensing of the forward moving or front edge of the piece of material they control power device 42 for adjustment of the final horizontal setting of alignment strip 38. Sensing element 46 controls lifting cylinder 40 of alignment strip 38. The method of operation of alignment device 34 as shown in FIGS. 1-3 will be further explained hereinafter in connection with FIGS. 7-13.
When first conveyance device 17 of piece of material 10' moves into the delivery position shown in FIG. 1, sensing element 46 senses the arriving or forward moving edge 32 of piece of material 10' and produces a signal for lifting cylinder 40, which thereupon lowers alignment strip 38 and places it on piece of material 10'. The bottom fixtures of conveyor belts 30 of second conveyance device 27 are raised during this work phase of the sewing assembly (as shown in FIG. 2), so that the piece of fabric 10' can be moved from first conveyance device 17 to beneath second conveyance device 27. Now when the front or forward moving edge 32 of piece of material 10' occupies a correct position, in other words forms an angle of 90° with the cut edge 14 of piece of material 10', as shown in FIGS. 1, 3 and 8, only the one sensing element 45a is activated, while the other sensing element 45b remains out of operation. This alternating state of sensing elements 45a and 45b results in the condition wherein power drive 42 for adjustment of the final control of the setting remains disconnected and furthermore the raised bottom fixtures of conveyor belts 30 of second conveyance device 27 are lowered by a not shown control mechanism and are brought into position in contact with piece of material 10', in order to feed this piece of material to folding devices 28 with series-connected sewing machines 29, which form and stitch hems 11. While conveyor belts 30 are being lowered, piece of material 10' is affixed by alignment strips 38 in the area of its cut edges 14 and only following engagement of conveyor belts 30 with piece of material 10' are alignment strips 38 raised by lifting cylinder 40, as shown in FIG. 9.
However, when the forward moving edge of piece of material 10' runs at a right angle to cut edge 14 and for instance is in a so-called one edge leading position, as shown in FIGS. 6 and 11 at 32a, both sensing elements 45a and 45b are then activated, which has as a result that alignment strip 38, lowered by lifting cylinder 40 and found in friction contact with piece of material 10', is moved for a sufficient distance in the direction of the arrow counter to the direction of conveyance of pieces of material 10, 10', 10" until forward moving edge 32 in the area of cut edge 14 forms a right angle to the cut edge and thus sensing element 45b becomes inoperative. When this alignment procedure has been completed, the raised bottom fixtures of conveyor belts 30 of second conveyance device 27 are lowered to pick up the piece of material 10' which is being held by alignment strips 38 and carry it further in the direction of folding device 28 and sewing machines 29.
In FIGS. 6 and 13 the forward moving edge of piece of material 10' is shown in a one edge trailing position at 32b. In this case both sensing elements 45a and 45b remain inactive and cause power drive 42 for adjustment of the final control of the setting to be moved by means of drive shaft 43 and carriages 37 to move alignment strip 38 into friction contact with piece of material 10' for a certain distance in the direction of conveyance of pieces of material 10, 10' and so forth, until forward moving edge 32 of piece of material 10' forms a right angle with cut edge 14 and sensing element 45a is activated, while sensing element 45b remains inactive as it was before. When this state has been reached, the bottom fixtures of conveyor belts 30 of second conveyance device 27 are again lowered, in order to pick up piece of material 10' which is being held by alignment strips 38 and to carry it further. Alignment strips 38 are raised again by lifting cylinder 40 and moved back by power drive 42 into their original position shown in FIG. 1.
In the exemplary embodiment shown in FIGS. 4 and 5, alignment device 34' can be moved synchronously with first conveyance device 17 in the direction of conveyance of pieces of material 10, 10', 10" and so forth during an alignment procedure. This means that the pieces of material 10' from first conveyance device 17 can be delivered continuously to second conveyance device 27, whereupon the high production rate of the sewing station is considerably increased. In this embodiment, power drive 42 for adjustment of the final control of the setting is fastened by means of arm 41 to a carriage 47, which is mounted in turn the same as carriage 37 on guide 36 and can be moved back and forth on said carriage. Carriage 47 incorporates another arm 48, on which are mounted sensing elements 45a, 45b and 46. Arm 48 furthermore carries a pneumatically or electromagnetically operable gripper coupling, which when it is in closed state cooperates with a gripper strip 50, mounted on carriage 19 of first conveyance device 17. Another operation cylinder 51 is fastened to stationary arm 35, of which the piston rod is connected through arm 48 with carriage 47. This operation cylinder 51 serves to guide the return movement of carriages 37 and 47 to their original positions. The method of operation of alignment device 34' is as follows:
When sensing element 46 detects the edge 32 of piece of material 10' as arriving or moving forward toward arrival, then gripper coupling 49 is closed, and carriages 47 and 37 are moved synchronously with first conveyance device 17 in the direction of conveyance of pieces of material 10, 10' and so forth. Alignment strip 38 is simultaneously lowered by lifting cylinder 40 and is brought into friction contact with piece of material 10'. In the case of a one edge leading position (32a) or a one edge trailing position (32b) in the case of the forward moving edge of piece of material 10', a suitable correction is accomplished by means of alignment strip 38, as has already been described in connection with FIGS. 10, 11 and 12, 13. To be sure, in this case the alignment takes place during the synchronous movement of alignment strips 38 with first conveyance device 17. Then when front edge 32 of piece of material 10' reaches its correct position, in other words, when one sensing element 45a is activated and the other sensing element 45b is inoperable, the raised bottom fixtures of conveyor belts 30 are lowered and brought into contact with the piece of material 10' which is still being held by alignment strips 38, in order to deliver the piece of material 10' to folding devices 28 and sewing machines 29. Then alignment strips 38 are raised by lifting cylinder 40 and carriages 47 and 37 are moved to the left into their original positions by operation cylinder 51 as shown in FIGS. 4 and 5. | In a sewing station, an alignment device is provided in the delivery area from a first conveyance device to a second conveyance device and, seen from the direction of movement of the piece of material, before a processing station. The alignment device has alignment strips which may be raised and lowered and which are also horizontally adjustable. The strips are controlled by sensing elements sensing the arrangement of the front edges of the pieces of material and placed on the piece of material. In accordance with the oblique position of the forward moving edge of the piece of material, the alignment strips are moved together with the piece of material in the direction of conveyance or counter to the direction of conveyance, and this continues until the oblique position of the forward moving edge is corrected or lies within the allowable tolerance. After such alignment, the second conveyance device conveys the piece of material to the processing station. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to exercise equipment and more particularly to an improved bar for use in lifting weights.
2. Description of the Prior Art
The sport of weight lifting using barbells to lift weights is well known. In performing such lifting exercises, different bars may be used depending on which particular set of muscles are being exercised during the lifting routine. For example, straight bars are used for general lifting, equal sets of weights being removably secured near the outer ends of the bar, outboard of a gripping area. Curling bars are known which have kink or bend in the bar in each of the two hand grip areas so that the exercisor's hands will be turned slightly relative to the axis of the bar during lifting. This increases the benefical result to the biceps. A tricep bar is known which has an even more pronounced bend in each hand grip portion so that exercisor's hand are positioned at an even greater angle relative to the axis of the bar. As suggested by the name, this bar increases the benefits to the triceps during lifting exercise.
With the use of these prior and known bars, the exercisor would either have to have multiple sets of weights, each set being held on one of the respective bars for performing the various exercises serially, or else the exercisor would have to remove each set of weights from a particular bar and replace those selected weights on another one of the bars to perform the next lifting exercise. In any event, the exercisor would have to have at least three separate bars for performing the three exercises described above. For each different angle of handle grip, the exercisor would require a separate bar and, perhaps, its associated weights.
SUMMARY OF THE INVENTION
The present invention provides a weight lifting bar in which the grip area is selectively rotatable relative to the axis of the bar such that an exercisor may select one of a plurality of different angular relationships between the handle portion and the bar to exercise various sets of muscles without requiring separate bars or requiring multiple sets of weights.
The angle of the grip portion can be changed rapidly and easily without requiring the removal of the weights and can be securely held in the selected angular position for lifting.
Each hand grip area has a pair of concentric rings which are relatively rotatable, an outer ring being permanently affixed to the bar and an inner ring have a cylindrical grip permanently affixed to it. Retaining means are provided to hold the rings in a selected rotational position during the lifting exercise.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a weight bar incorporating the principles of the present invention.
FIG. 2 is an enlarged partial view of the hand grip area of the weight bar shown in FIG. 1.
FIG. 3 is a partial sectional view of the hand grip portion.
FIG. 4 is a partial cross-sectional view of the retaining means for the handle portion.
FIG. 5 is a partial cross-sectional view of an alternate embodiment of the retaining means.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 there is shown a weight lifting apparatus generally at 10 comprised of a weight lifting bar 12 which two sets of selectively removable weights 13, 13 which are secured near opposite ends 14, 15 of the bar 12. Positioned inboard of the weights 13, 13 are a pair of grip assemblies 16, 16 spaced out board of a central area 17 of the bar 12 and are shown in greater detail in FIGS. 2-4.
As shown in FIGS. 2-4 the grip assembly 16 is comprised of a grip cylinder 18 secured to an inner ring 20. The inner ring 20 is rotatably carried in an outer ring 22. The outer ring 22 is permanently affixed to the bar 12 such as by welding one peripheral side of the ring 22 to the end portion 14 and an opposite peripheral side of the ring 22 to the central portion 17.
The inner ring 20 is just slightly smaller than the outer ring so that the rings freely rotate relative to one another, but without a large degree of relative lateral movement permissable between the rings. The inner ring 20 is axially captured in the outer ring 22 by ears 24, 24 which form a part of the outer ring 22 and overlie a portion of the inner ring 20. The ears 24, 24 may be located on only one side of the outer ring 22 with the inner ring seated on an annular flange 25 (FIG. 4) on the outer ring 22 or the ears 24, 24 may be located on both sides of the outer ring 22, each ear 24 located at 90° from an ear on the opposite side and 180° from an ear on the same side. Thus, the inner ring 20 is free to rotate relative to the outer ring 22, but is held in a fixed axial and lateral position relative to the outer ring 22. Since the grip cylinder 18 is fixed to the inner ring 20, the grip cylinder 18 is rotatable relative to the bar 12.
The rotational position of the inner ring 20 relative to the outer ring 22 can be selectively fixed by means of a pair of retaining means 26, 26 shown in FIGS. 2-4 as comprising a wing 27 nut captured on a screw 29. A plurality of spaced apertures 28 are provided around the circumference of the outer ring 22 and two pairs of opposed apertures 30 are provided through the inner ring 20 for receiving the retaining means 26.
The apertures 28 formed in the outer ring 22 are preferably spaced at even intervals of, for example, 15°. The adjacent apertures 30 in the inner ring are preferably spaced at an interval different than the spacing of the outer ring, for example, 22.5°. By such an arrangement, the grip cylinder 18 may be selectively retained at a desired angular position, with the selectable positions being every 7.5°. Also, with at least two apertures 30 in the inner ring any interference due to the bar 12 is avoided.
Thus, to change the angular position of the grip cylinder 18 relative to the bar 12, the two wing nuts would be removed from the screws, the screws removed from the apertures 28, 30 and the grip cylinder 18 would then be free to rotate relative to the bar 12 several angular positions are shown in phantom in FIG. 3. Upon arrival at a desired angular position, the screws would be reinserted through two opposite apertures 30 and through the aligned apertures 28 to retain the rings 20, 22 in a fixed relationship. Thus, an exercisor could readily perform general lifting exercises, curling exercises and tricep exercises serially without having to remove the weights 14, 14 from the bar 12. The only removal or addition of the weights would be dependent on the amount of weight desired to be lifted in any particular exercise. In most cases, the majority of the weights would remain in place.
In FIG. 5 there is shown an alternate embodiment of the retaining means 26A which comprises a spring loaded button manually displaceable for selectively retaining the rings 20A, 22A in the desired rotational relationship. Specifically, the retaining means 26A comprises a button member 32 which protrudes upwardly through a bevelled opening 34 in the outer ring 22A. The opening 34 corresponds to the openings 28 identified in the first embodiment above. The button 32 has an annular shoulder 36 at a bottom end for seating against a step portion 38 of the inner ring 20A. Thus, the button 32 is prevented from moving outwardly beyond the engagement point of the shoulder 36 with the step 38.
A button housing 40 is frictionally seated in the inner ring 20A and is hollow to receive the annular shoulder 36 of the button 32 as the button 32 is depressed into the housing 40. A coil spring 42 is positioned on the interior of the housing 40 and button 32 to continuously bias the button 32 outwardly.
When the exercisor wishes to select a different rotational position of the grip cylinder 18 relative to the bar 12, he would merely depress the buttons 32, of which would there would preferably be two opposed, so that the button 32 would clear the inside of the outer ring 22A. Then, the inner ring 20A would be free to rotate within the outer ring 22A. When the desired position is reached the button 32 would align with one of the apertures 34 in the outer ring 22A and would securely hold the inner ring 20A in a fixed rotational position relative to the outer ring. Although other types of retaining devices can be used to selectively hold the two rings in a fixed relative rotational position, a retaining means of the type shown in FIG. 5 is advantageous in that it avoids the necessity of removal and replacement of any parts.
It is thus seen from the foregoing description that the present invention comprises a weight lifting bar having hand grip portions selectively rotatable relative to the longitudinal axis of the bar and which can be selectively rotated without requiring the removal of the weights on the bar, such that a plurality of different exercises may be performed using a single bar and a single set of weights. Various retaining means can be used to secure the concentric rings in the desired rotational positions.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art. | A weight lifting bar has hand grip members selectively rotatable relative to the longitudinal axis of the bar so that an exercisor can perform lifting exercises benefiting different muscle groups using a single bar and a single set of weights. A pair of concentric rotatable rings are used, the outer ring being secured to the bar and the inner ring carrying the hand grip member. The rings are securable against rotation after the desired angular relationship between the hand grip member and the bar is selected. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on, and claims priority to, GB Application No. GB1409919.6, filed on Jun. 4, 2013, the entire contents of which is fully incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method, system and computer program for managing a repository of personal data and, more particularly, a repository of authenticated personal data.
BACKGROUND TO THE INVENTION
[0003] The UK Home Office Identity Fraud Steering Committee defines identity fraud as “when a false identity or someone else's identity details are used to support unlawful activity, or when someone avoids obligation/liability by falsely claiming that he/she was the victim of identity fraud” (National Fraud Authority, Fraud Typologies and Victims of Fraud—Literature Review 2009). Identity crimes are one of the fastest growing types of fraud in the UK. The UK's Fraud prevention service found that identity fraud accounted for roughly 50% of all frauds recorded in 2012; and that there had been a 9 percent increase in identity frauds, compared with 2011 (CIFAS 2012 Fraud Trends, 17 Jan. 2013). In December 2012 the National Fraud Authority suggested that identity fraud cost UK adults approximately £3.3 billion each year (National Fraud Authority, Annual Fraud Indicator 2013). However, this does not include any losses suffered by the public, private or charity sectors. Therefore, the full cost to the UK from identity fraud each year is likely to be considerably higher. Similarly, a National Crime Victimization Survey conducted in the US found that individual financial losses due to personal identity theft totaled $24.7 billion, over $10 billion more than the losses attributed to all other property crimes measured in the survey (Victims of Identity Theft 2012).
[0004] The first step in identity theft is obtaining personal data (e.g. credit card numbers, social security numbers, driver's license numbers, ATM numbers, mortgage details, date of birth, passwords and PINs, home address, phone numbers etc. (A. Hedayati, Jnl of law and Conflict Resolution, 4(1), 2012, 1-12)) pertaining to the victim. For clarity, and borrowing from the Data Protection Act 1998, the term “personal data” will be used henceforth to refer to data which relate to a living individual who can be identified from those data alone or in combination with other information in the possession of another person.
[0005] The most common form of personal data obtained by offenders is credit card data. Offenders use this to order new credit cards and/or duplicate cards on an existing account; and to buy merchandise for their own use or to resell/return for cash (H. Copes H., and L. Vieraitis (2009) Identity Theft in J. Miller (Ed.) 21 st Century Criminology: a Reference Handbook , Thousand Oaks, SAGE Publications Inc.). Offenders may sometimes change the billing address on a victim's credit card, so that the victim will not receive bills for the illicit purchases and see the fraudulent charges; thereby allowing the thief more time to abuse the victim's identity and credit. Offenders may also use stolen identities to acquire or produce additional identity-related documents, e.g. birth certificates, driver's licenses, social security cards and state identification cards etc. To reduce the risk of their identity being stolen, individuals are recommended to carry identity documents only when they are needed; and, at all other times, to keep their identity documents in a safe place.
[0006] In a recent good practice guide (Good Practice Guide 45, December 2013 Issue No 2.2 —Identity Proofing and Verification of an Individual ) the UK Cabinet Office and the Communications Electronics Security Group (CESG) set out four levels of identity-proofing, providing increasing degrees of confidence that an applicant's claimed identity is their real identity. At level 1, the identity of the applicant need not be proved. The applicant is merely required to provide an identifier that can be used to confirm an individual as the applicant. At level 2, an applicant must claim an identity and provide evidence that supports the real world existence and activity of the identity. Level 3 requires that the provided evidence physically identifies the person to whom the identity belongs; and Level 4 requires the provision of further supporting evidence and the implementation of additional processes, including the use of biometrics to further protect an identity from impersonation or fabrication.
[0007] However, in practice, there is often a substantial imbalance between the value of guarded properties and the levels of the security checks applied thereto. For example, ATMs which often cap cash withdrawals at £300 per day, use two identifying principles (i.e. knowing a PIN and possessing a debit/credit card) to guard money. However, online banking uses only one principle, namely knowing a username and password to empower a person to transfer thousands of pounds in a matter of seconds (S. Y. K. Wang and W Huang, Internet Jnl of Criminology 2011). Similarly, notwithstanding the growing availability of high-tech identity verification tools (e.g. speech pattern analysis, fingerprint/retinal scanning etc.), a recent survey of information technology professionals revealed that low tech methods of identity verification are used more often than high-tech methods; and of the high tech methods, virtual credit cards and RFID technologies were the preferred options (J. Compomizzi, S. D'Aurora and D. P. Rota, Issues in Information Systems, 2013, 14(1), 162-168).
[0008] Growing public use of mobile communications technologies and the convergence of these technologies with sensors and online social networks has caused an exponential increase in the creation and consumption of personal data. While the Internet was conceived as a decentralized network, the most widely used web applications today tend toward centralization. To use these applications, users must consent to the collection of their personal data by the applications. For example, social networks employ a centralized model in which the creator of the social network sets all the terms for membership thereof and has access to all the personal data of the network's members. Furthermore, user privacy is essentially defined by the privacy policies of the applications creators. Thus, control increasingly rests with centralized service providers who, as a consequence, have amassed unprecedented amounts of data about the behaviours and personalities of users. This prevents users from being able to control their own data, since once they hand the data over to a corporation, it is very difficult to refute or retract the decision. Similarly, given the sheer volume of data involved, it is impracticable for an individual to consent to all of the various ways in which data is collected and used. In addition, securing personal data is increasingly difficult in a distributed network system with multiple parties involved in storage and management, since they must all take appropriate steps to secure data from accidental release, theft, unauthorized access, and misuse.
[0009] Recent years has seen the emergence of decentralized architectures as a response to the centralized services. Their underlying premise is that personal data is a personal asset, whose full potential value can only be realised if individuals are able to control what personal data they share with whom, for what purposes, under what terms and conditions; and if they can realise the benefits (including financial benefits) of doing so. These decentralized architectures reflect a paradigm shift from information as a tool in the hands of an organization to information as a tool in the hands of the individual, wherein privacy becomes a personal setting, rather than something dictated through a policy created by an organisation. These services include cloud-based personal data vault management platforms such as Personal Fill It (trade mark), My Personal Vault (trade mark), Mydex (trade mark), and Cloud IT (trade mark) recently launched by Barclays Bank (trade mark)). Open PDS enables computations on user data to be performed in a Personal Data Store (PDS) environment, under the control of the user, so that only the relevant summarized data for providing functionality to an application leaves the boundaries of the user's PDS (Y-A de Montjoye, S. S. Wang and A. Pentland, IEEE Data Engineering Bulletin, 35-4(2012)). Similarly, FreedomBox provides a software platform that connects groups of individuals who trust each other. In parallel with these developments, there has been increased discussion of distributed and federated social network structures following a number of well-publicized privacy mishaps by Facebook (trade mark) and Google (trade mark).
[0010] However, detection of fraud is difficult in an architecture without a single point of data aggregation, management and control (A. Narayanan, V. Toubiana, S. Barocas, H. Nissenbaum and D. Boneh: A Critical Look at Decentralized Personal Data Architectures . CoRR abs/1202.4503 (2012)). It should be noted that one of the challenges in identifying identity thieves is that they may operate under multiple identities including actual identities, stolen identities and cyber identities. Personal Data Management Systems and distributed social networks could potentially provide a useful hiding place for identity thieves, by enabling the relatively easy creation of multiple digital identities for an individual.
SUMMARY OF THE INVENTION
[0011] According to a first aspect of the invention there is provided a method for managing a repository of authenticated personal data, the method comprising the steps of
[0012] creating for a first user an account in the repository, to produce a first user account;
[0013] storing personal data of the first user in the first user account;
[0014] allowing the first user to configure the first user account to store therein details of one or more entities with whom the first user is willing to share their personal data; and specify which one or more elements of the personal data stored in the first user account, the first user is willing to share with the or each of the entities;
[0015] receiving a request from a second user for access to one or more elements of personal data of a third user;
[0016] determining whether the third user has an account in the repository;
[0017] in the event the third user has an account with the repository, determining whether the second user is an entity whose details are stored in the third user's account;
[0018] in the event the second user is an entity whose details are stored in the third user's account, determining whether the or each element of personal data to which the second user has requested access are stored in the account of the third user, and are specified in the third user's account as personal data that the third user is willing to share with the second user;
[0019] in the event the or each element of personal data to which the second user has requested access are stored in the account of the third user, and are specified in the third user's account as personal data that the third user is willing to share with the second user, transmitting details of the or each element of the requested personal data to the second user
[0020] characterised in that
[0021] the step of creating an account for the first client comprises the steps of:
[0022] receiving one or more items of identity evidence from the first client;
[0023] extracting one or more features from the or each item of received identity evidence;
[0024] validating the authenticity of the or each items of received identity evidence by comparing the or each extracted feature from the or each given item of received identity evidence with related one or more items of feature information acquired from an issuing source for the or each relevant item of identity evidence; and
[0025] verifying that the first client is the genuine owner of the identity being claimed by way of the received identity evidence; and
[0026] the step of storing personal data of the first user in the first user account comprises the step of storing the extracted features from the or each item of received identity evidence whose authenticity has been validated.
[0027] Preferably, the step of validating the authenticity of the or each items of received identity evidence comprises the step of cross-comparing at least some of the extracted features from the or each item of received identity evidence to assess their consistency with each other and the related one or more items of feature information acquired from an issuing source for the or each relevant item of identity evidence.
[0028] Preferably, the method comprises the step of issuing a token to the first user on creation of the account of the first user account, and storing details of the token in the repository, so that the token is usable to identify the first user as having an account with the repository.
[0029] Preferably, the step of allowing the first user to configure the first user account comprises the step of allowing the first user to reconfigure the token issued thereto.
[0030] Desirably, the method comprises the step of providing 92 a rating to the first user account according to the number of received items of identity evidence whose authenticity has been validated.
[0031] Desirably, the method comprises the step of providing 92 a rating to the first user account according to the issuing source of the or each item of received identity evidence.
[0032] Desirably,
[0033] (a) the step of creating for a first user an account in the repository, is preceded by a step of allowing an operator to establish a first threshold; and
[0034] (b) the step of validating the authenticity of the or each items of received Identity evidence comprises the step of issuing an alert message in the event one or more received items of identity evidence are found not to be authentic and the number of received items of identity evidence found not to be authentic exceeds the first threshold.
[0035] Preferably, the method comprises the step of requesting 98 the first user to present further items of identity evidence in the event the number of items of identity evidence found to be lacking in authenticity is less than the first threshold.
[0036] Preferably,
[0037] (a) the step of creating for a first user an account in the repository, is preceded by a step of allowing the operator to establish a repeat limit; and
[0038] (b) the step of requesting the first user to present further items of identity evidence is continued until a required number of items of identity evidence found to be authentic is achieved or until the number of times further items of identity evidence are requested exceeds the repeat limit.
[0039] Preferably, the step of requesting the first user to present further items of identity evidence comprises the step of issuing an alert message in the event the number of times further items of identity evidence are requested exceeds the first limit.
[0040] Desirably, the step of storing personal data of the first user in the first user account comprises a step of allowing the first user to add further personal data to the first user account.
[0041] Desirably, the step of storing personal data of the first user in the first user account comprises a step of contacting third party sources to acquire additional personal data of the first user and adding the additional personal data to the first user account.
[0042] Desirably, the step of receiving a request from the second user for access to one or more elements of personal data of the third user is preceded by the step of allowing the second user to create the request and include within the request
[0043] (a) a digital token received from the third user;
[0044] (b) an identifier of the second user; and
[0045] (c) details of the items of the third user's personal data to which the second user seeks to gain access.
[0046] Preferably, the method comprises the step of issuing an alert in the event of any one of the occurrences selected from the group comprising
[0047] the third user does not have an account with the repository;
[0048] the second user's details are not stored in the third user's account;
[0049] the or each element of personal data to which the second user has requested access are not stored in the account of the third user; and
[0050] the or each element of personal data to which the second user has requested access are not specified in the third user's account as personal data that the third user is willing to share with the second user.
[0051] Preferably, the method comprises the further step of recording the outcome of substantially every received request for access to the personal data of the third user.
[0052] Preferably, the step of recording the outcome of substantially every received request for access to the personal data of the third user comprises the step of issuing an alert message to the third user on receipt of a request for access to the personal data of the third user, the alert message comprising details of the outcome of the received request.
[0053] According to a second aspect of the invention there is provided a system for managing a repository of authenticated personal data, the system comprising
[0054] a registration module adapted to create in the repository a first user account for a first user;
[0055] a personal data store coupled with the first user account and adapted to store personal data of the first user;
[0056] a configuration module adapted to allow the first user to configure the first user account to store in the first user account
[0057] (a) details of one or more entities with whom the first user is willing to share their personal data; and
[0058] (b) details of which one or more elements of the personal data stored in the personal data store, the first user is willing to share with the or each of the entities;
[0059] an access request handler adapted to receive a request from a second user for access to one or more elements of personal data of a third user;
[0060] a token validation module adapted to determine whether the third user has an account in the repository;
[0061] an accessor identifier adapted to be activated by the token validation module on confirmation that the third user has an account in the repository, to determine whether the second user is an entity whose details are stored in the third user's account;
[0062] a comparator adapted to be activated by the accessor module on confirmation that the second user's details are stored in the third user's account, to determine whether the or each element of personal data to which the second user has requested access are among the personal data whose details are stored in the third user's account as personal data that the third user is willing to share with the second user; and
[0063] a data extractor adapted to be activated by the comparator on confirmation that the or each element of personal data to which the second user has requested access are stored in the third user's account and are among the personal data the third user is willing to share with the second user, to retrieve from the personal data store coupled with the third user's account, the or each element of personal data requested by the second user and transmit the retrieved personal data to the second user
[0064] characterised in that the registration module comprises
[0065] (a) a sampling device adapted to receive one or more items of identity evidence from the first client, to create received identity evidence;
[0066] (b) a feature extraction module adapted to extract one or more features from the or each item of received identity evidence, to create one or more extracted features; and
[0067] (c) a verification/validation module adapted to:
validate the authenticity of the or each items of received identity evidence, by comparing the or each extracted feature with related one or more items of feature information acquired from an issuing source for the or each relevant item of received identity evidence; and verify that the first client is the genuine owner of the identity being claimed by way of the received identity evidence; and
[0070] the personal data store is adapted to store the extracted features whose authenticity has been validated.
[0071] Preferably, the verification/validation module is adapted to validate the authenticity of the or each items of received identity evidence by cross-comparing at least some of the extracted features from the or each item of received identity evidence to assess their consistency with each other and the related one or more items of feature information acquired from an issuing source for the or each relevant item of identity evidence.
[0072] Preferably, the system comprises a digital token store comprising one or more client digital tokens issued to the first client and by which the first client may be subsequently recognised by the system as having a an account with the repository.
[0073] Preferably, the client digital token may be reconfigured by the first client.
[0074] Desirably, the client digital token comprises an element from the set comprising a PIN, a password, a fingerprint scan, a facial scan or an iris scan.
[0075] Desirably, the first user account comprises a rating, the value of the rating being determined by the number of items of received identity evidence whose authenticity has been validated.
[0076] Desirably, the value of the rating is determined by the issuing source of the or each item of received identity evidence.
[0077] Preferably, the system comprises a of a first threshold whose value is configurable by an operator; and the verification/validation module is adapted to issue an alert message in the event one or more items of received identity evidence are found not to be authentic; and the number of items of received identity evidence found not to be authentic exceeds the first threshold.
[0078] Preferably, the verification/validation module is adapted to request the first user to present further items of identity evidence in the event the number of items of received identity evidence found to be lacking in authenticity is less than the first threshold.
[0079] Preferably, the system comprises a repeat limit whose value is configurable by an operator and wherein the verification/validation module is adapted to continue to request the first user to present further items of identity evidence until a required number of items of identity evidence found to be authentic is achieved or until the number of times further items of identity evidence are requested exceeds the repeat limit.
[0080] Desirably, the personal data store is adapted to store further personal data provided by one selected from the group comprising the first user and one or more third party sources on request by the first user.
[0081] Desirably, the request received by the access request handler comprises
[0082] (a) a digital token received from the third user;
[0083] (b) an identifier of the second user; and
[0084] (c) details of the items of the third user's personal data to which the second user seeks to gain access.
[0085] Desirably, the system is adapted to issue an alert in the event of any one of the occurrences selected from the group comprising
[0086] the third user does not have an account with the repository;
[0087] the second user's details are not stored in the third user's account;
[0088] the or each element of personal data to which the second user has requested access are not stored in the account of the third user; and
[0089] the or each element of personal data to which the second user has requested access are not among the details of the personal data that the third user is willing to share with the second user.
[0090] Preferably, the system comprises a transaction history archive adapted to store the outcome of substantially every received request for access to the personal data of the third user.
[0091] Preferably, the system is adapted to notify the third user of every received request for access to the personal data of the third user and details of the outcome of the received request.
[0092] Preferably, the identity evidence received from the first client may comprise one selected from the group comprising documentary forms of identity evidence, biometric forms of identity evidence and biochemical forms of identity evidence.
[0093] Desirably, the sampling device comprises one selected from the group comprising a scanner, a passport reader, a fingerprint reader, a camera/face scanner and an iris scanner.
[0094] Desirably, the digital token comprises one selected from the group comprising a PIN, a password, a fingerprint scan, a facial photograph and an iris scan.
[0095] According to a third aspect of the invention there is provided an authenticated personal data repository management computer program, tangibly embodied on a computer readable medium, the computer program product including instructions for causing a computer to execute the method for managing a repository of authenticated personal data according to the first aspect of the invention.
[0096] According to a fourth aspect of the invention there is provided an adaptive social network system comprising the system for managing a repository of authenticated personal data according to the second aspect of the invention, the adaptive social network comprising
[0097] filtering means adapted to restrict membership of the social network to persons having specified personal data attributes;
[0098] selection means adapted to allow members to select which elements of their stored personal data to share with other members of the social network.
[0099] Among its many advantages, the present invention may allow a user to control access to their personal data by third parties. In particular, the present invention may allow a user to control the parties with whom their personal data is shared and customise which elements of their personal data may be shared with each such third party. Furthermore, and in recognition of the significant benefits posed by the citizen as an active contributor to the innovation process under the Open Innovation 2.0 model, the present invention may allow a user to specify a fee for sharing particular aspects of their personal data, thereby allowing the user to monetise their personal data assets and be remunerated for their contribution to an innovative process.
[0100] The present invention is a significant step forward from previous personal data systems insofar as it is significantly based on authenticated personal data. This provides a degree of assurance to a recipient of personal data from the system of the present invention that the personal data is genuine, as is the identity of the person to whom the personal data relates. The identity assurance aspect is copper-fastened by a rating system which provides a rating to a personal data record according to the number of items of personal data deemed to be authentic, the nature of the issuing source of the identity evidence (e.g. a passport is rated more highly than a driving license) or the organisation who created the personal data record (e.g. the police may be rated more highly than a local library etc.)
[0101] From the user's perspective, another advantage is that the present invention employs a digital token mechanism by which the personal data record may be conveniently accessed. This allows the user to provide personal data to entities as often as required, while allowing the original physical identity documents (on which the personal data accounts are based) to be held in safe-keeping at home or in another location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0102] Preferred embodiments of the present invention are herein described, by way of example of only, with reference to the accompanying figures in which:
[0103] FIG. 1 is a block diagram of a system for managing a repository of authenticated personal data, in accordance with a second aspect of the invention;
[0104] FIG. 2 is a flow chart of a method of managing a repository of authenticated personal data, in accordance with a first aspect of the invention:
[0105] FIG. 3 is a flow chart of a registration process in the method of managing a repository of authenticated personal data of FIG. 2 ; and
[0106] FIG. 4 is a flow chart of an enhanced security method for managing financial transactions.
DETAILED DESCRIPTION OF THE INVENTION
[0107] Referring to FIG. 1 , while certain specific features are illustrated, those skilled in the art will appreciate from the present disclosure that various other features have not been illustrated for the sake of brevity and so as not to obscure more pertinent aspects of the implementations disclosed herein. Similarly, for the sake of clarity, the term “identity” will be used henceforth to mean a collection of attributes that uniquely define a person (the fact of being what a person is). Similarly, the term “identity evidence” will be used henceforth to mean information and/or documentation provided by a user to support their claim to a specified identity. Similarly, the term “issuing source” will be used henceforth to refer to an authority that is responsible for the generation of data and/or documents that may be used as identity evidence, for example, security forces, intelligence agencies, border control/immigration agencies, welfare agencies, utility companies, banks or other financial organisations etc. Furthermore, the term “authoritative source” will be used henceforth to refer to an authority that has access to sufficient information from an issuing source that they are able to confirm the validity of an item of identity evidence.
[0108] A preferred embodiment of the system for managing a repository of authenticated personal data, may comprise a registration module 10 , a management module 12 and an accessor module 14 . The management module 12 may comprise an account handler 16 and an access request handler 18 . Both the registration module 10 and the accessor module 14 may be coupled with the management module 12 by way of one or more network and other communications interfaces (not shown) and through any combination of wired and wireless local area network (LAN) and/or wide area network (WAN), including a portion of the internet 20 . The skilled person will understand that while the access request handler 18 is shown as a separate entity to the account handler 16 , this configuration is provided for example purposes only. The preferred embodiment should in no way be construed as being limited to the depicted configuration, since the access request handler 16 may be integral with the account handler 18 .
[0109] The registration module 10 may comprise a sampling device 22 . The sampling device 22 may comprise a camera or scanner or other device suitable for capturing a one or more images (or other graphical representations) of a one or more presented documentary items of identity evidence (IDEv 1 , IDEv 2 . . . . IDEvn) presented by a first client 19 . For example, the documentary items of identity evidence might include a passport, a driving license, a military personnel card or a utility bill etc. The skilled person will understand that these are provided for illustration purposes only; and should in no way be construed as limiting the preferred embodiment to these documentary items of identity evidence. Similarly, the skilled person will understand that while FIG. 1 shows at least three items of documentary identity evidence, this is provided for illustration purposes only; and should in no way be construed as limiting the preferred embodiment. In particular, the preferred embodiment is extendable to any number and/or form of documentary identity evidence.
[0110] The sampling device 22 may also include a means of acquiring and processing biometric or biochemical forms of identity evidence of a first client 24 . For example, the sampling device 22 may be a fingerprint reader configured to acquire a fingerprint from the first client 24 . Alternatively, the sampling device 22 may be a DNA reader configured to analyse and determine the DNA sequence from an appropriate sample provided by the first client 24 . The skilled person will understand that these examples are provided for illustration purposes only, and should in no way be construed as limiting the scope or function of the preferred embodiment. In particular, the preferred embodiment is extendable to assess any biometric or biochemical forms of identity evidence as required. For brevity, the images of the one or more items of documentary forms of identity evidence and/or biometric or biochemical forms of identity evidence will henceforth be collectively known as “acquired attributes”.
[0111] The sampling device 22 may be adapted to transmit the acquired attributes to a verification/validation module 26 . The verification/validation module 26 may comprise a feature extraction module 28 adapted to receive the acquired attributes from the sampling device 22 ; and extract one or more features (“extracted features” ExFtε u ) from the acquired attributes. The extracted features may depend on the acquired attribute from which they are obtained. Subject to this, the number and nature of the extracted features obtained from a given acquired attribute may be user-configurable. For example, the feature extraction module 28 may be adapted to extract features such as date of birth or issuing office from an image of a presented passport document. Alternatively, the feature extraction module 28 may be adapted to extract ridge features from a fingerprint. The skilled person will understand that the above-mentioned extracted features and acquired attributes are provided for example purposes only; and should in no way be construed as limiting the preferred embodiment to these extracted features and/or acquired attributes. On the contrary, the preferred embodiment is adaptable to embrace any number and type of extracted features and acquired attributes.
[0112] The feature extraction module 28 may be adapted to transmit the extracted features to a one or more comparison engines (ENG 1 , ENG 2 . . . ENG m ), the or each of which may be adapted to authenticate the or each of the extracted features, by:
[0113] (a) comparing the or each extracted feature with related feature information (not shown) gathered from an issuing source (not shown); and/or
[0114] (b) cross-comparing at least some of the extracted features to assess their consistency with each other and their related feature information (not shown) gathered from an issuing source (not shown).
[0115] Alternatively, the comparison engines (ENG 1 , ENG 2 . . . . ENG m ) may be adapted to delegate the comparison or cross-comparison operations to an authoritative source (not shown). From these operations, the or each comparison engine (ENG 1 , ENG 2 . . . ENG m ) may produce an output comprising an indication of the authenticity of the or each relevant extracted feature. The outputs from the comparison engines (ENG 1 , ENG 2 . . . . ENG m ) may be aggregated in a decision module 30 which may be adapted to perform one or both of a:
[0116] (a) validation process to determine whether the or each of the presented documentary items of identity evidence (IDEv 1 , IDEv 2 . . . . IDEv n ) is authentic; and
[0117] (b) verification process (using for example, the acquired biometric and/or biochemical forms of identity evidence) to determine whether the first client 24 is the owner of the identity they are claiming through the presented items of identity evidence (IDEv 1 , IDEv 2 . . . . IDEv n ).
[0118] Based on the outcomes of the validation process and/or the verification process, the decision module 30 may be adapted to produce an output indicating:
[0119] (a) the number of presented documentary items of identity evidence (IDEv 1 , IDEv 2 . . . . IDEv n ) deemed to be authentic/lack authenticity (i.e. may be fraudulent, counterfeit or forged) by comparison with information from the issuing/authoritative source; and
[0120] (b) the first client 24 is, or is not, deemed to be the authentic owner of the claimed identity.
[0121] The registration module 10 may be adapted to:
[0122] (a) store a record of the presented items of identity evidence (IDEv 1 , IDEv 2 . . . IDEv n ) and provide an alert message to the authorities, in the event the decision module 30 produces an output indicating that the number of presented documentary items of identity evidence (IDEv 1 , IDEv 2 . . . . IDEv n ) deemed to lack authenticity exceeds a pre-defined first threshold, or that the first client 19 is not the authentic owner of the claimed identity; or
[0123] (b) issue an account activation message (Activate) to the account handler 16 in the event the decision module 30 produces an output indicating that the number of presented documentary items of identity evidence (IDEv 1 , IDEv 2 . . . IDEv n ) deemed to be authentic exceeds a pre-defined second threshold; and the first client 19 is the authentic owner of the claimed identity, wherein the account activation message (Activate) comprises the or each of the extracted features from the authenticated items of identity evidence; or
[0124] (c) issue a request to the first client 24 to provide one or more alternative items of identity evidence, in the event, the decision module 30 produces an output indicating that the number of presented documentary items of identity evidence (IDEv 1 , IDEv 2 . . . . IDEv n ) lacking authenticity is less than the first threshold; the number of presented documentary items of identity evidence (IDEv 1 , IDEv 2 . . . IDEv n ) deemed to be authentic is less than the second threshold; and the first client 24 is the authentic owner of the claimed identity.
[0125] The sampling device 22 and the verification/validation module 26 may be housed in a same computer system of a trusted intermediary body (e.g. bank, post office etc.) and remotely located from the rest of the system of the preferred embodiment. Alternatively, the verification/validation module 26 may be housed remotely of the sampling device 22 which remains within the trusted intermediary body. In this alternative embodiment, the acquired attributes are encrypted prior to their transmission to the verification/validation module 26 .
[0126] The account handler 16 may be adapted to create a client account for the first client 24 on receipt of an account activation message (Activate) from the registration module 10 . The account handler 16 may be adapted to provide a rating to the client account according to the number of presented documentary items of identity evidence (IDEv 1 , IDEv 2 . . . . IDEv n ) deemed to be authentic by the decision module 30 . The account handler 16 may also adapted to adjust the rating according to the issuing source of a presented documentary item of identity evidence (IDEv 1 , IDEv 2 . . . IDEv n ) or the authoritative source for the authentication of a presented item of identity evidence. The rating may provide an indication of confidence in the authenticity of the client (and client account) corresponding with a recognizable level of identity proofing and clearance.
[0127] The account handler 16 may be adapted, on creation of a client account, to store in a personal data store 32 associated with the client account, the or each extracted feature from the received account activation message (Activate). The personal data store 32 may be contained in a distributed computing environment (e.g. the cloud) or in a monolithic computing environment (e.g. a dedicated server). The personal data store 32 may be adapted to store further personal data ( Fdat ε v ) received by the account handler 16 from the first client 24 or one or more third party sources (not shown) on request by the first client 24 . For example, the further personal data Fdat may include credit rating information or details of recent travel (e.g. flight bookings etc.) or purchases (e.g. from vendor receipts etc.). The skilled person will understand that these examples of further personal data are provided for illustration purposes only and should in no way be construed as limiting the operation of the preferred embodiment to these examples. In particular, the preferred embodiment is adaptable to store any form of further personal data Fdat.
[0128] The account handler 16 may also be adapted to communicate the further personal data Fdat to the comparison engines (ENG 1 , ENG 2 , ENG m ) for authentication prior to the storage of the further personal data Fdat in the personal data store 32 . Thus, the personal data store 32 may include unauthenticated data (from the further personal data Fdat) and authenticated data (acquired by the registration module 10 and used to establish the client account). In the event the further personal data Fdat is not authenticated, the personal data store 32 may be adapted to store the further personal data Fdat with a flag indicating its unauthenticated status. The account handler 16 may be adapted to adjust the rating on the client account according to the number of items of further personal data Fdat stored therein; or the source of the further personal data Fdat; or the number of authenticated stored further personal data items Fdat. For brevity, the extracted features used to establish the client account and the further personal data Fdat will be collectively known henceforth as “client data” (CD) wherein CD=ExFt∪ Fdat . Thus, CDε s , where s=u+v.
[0129] The account handler 16 may comprise a configuration module 34 , which in turn, may comprise an accepted organisations module 36 . The accepted organisations module 36 may comprise an organisations list 38 associated with each client account, wherein the organisations list 38 may comprises one or more identifiers of organisations (Org 1 , Org 2 , Org p ) (i.e. Org ε p ) with whom the first client 24 is willing to share data from their personal data store 32 . The accepted organisations module 36 may also comprise an allowed data matrix 40 (Alldatε txp ) associated with each client account, wherein the allowed data matrix 40 may comprise identifiers for the elements of the client data (CD) the first client 24 is willing to share with each of the organisations Org identified in the client's organisations list 38 . Using the above nomenclature, the first client 24 may choose to allow a given organisation Org i access to personal data items Alldat i =identifiers ⊂ CD (i=1 to p) and Alldat i ε j , j≦s.
[0130] Both the organisations list 38 and the allowed data matrix 40 may be reconfigurable by the first client 24 to add or remove elements thereto/therefrom. Indeed, the allowed data matrix 40 may be reconfigurable by the first client 24 on presentation of the first client's digital token to a requesting organisation (described below) to support an engagement with the requesting organisation.
[0131] The person skilled in the art will understand that while the accepted organisations module 36 is shown in FIG. 1 as a separate entity to the personal data store 32 , this depiction is provided for ease of understanding of their different functionalities. However, the preferred embodiment is not limited to this implementation. Instead, the organisations list 38 and the allowed data matrix 40 may be storable together with the personal data store 32 . Alternatively, the organisations list 38 and the allowed data matrix 40 may be storable separately of each other and/or the personal data store 32 in other distributed or monolithic computing environments.
[0132] The configuration module 34 may further comprise a digital token store 42 comprising a one or more client digital tokens (not shown) issued to the first client and by which the first client 24 may be subsequently recognised by the system of the preferred embodiment. The or each client digital token (not shown) may be configurable by the first client 24 ; and may, for example, comprise a password or personal identification number (PIN) selected by the first client 24 which may be transmittable to and storable in a mobile computing/communications device (not shown) in the possession of the first client 24 . Alternatively, the or each client digital token (not shown) may comprise a biometric feature (e.g. fingerprint, face or iris scan etc.), in which case the first client 24 themselves contain these features (so there is no need to transmit the digital representation of these features to the mobile computing/communications device (not shown) for storage therein). It will be understood that the above examples of client digital tokens are provided for illustration purposes only; and that the preferred embodiment should in no way be construed as being limited to these examples. Instead, the preferred embodiment is extendable to any form of client digital token selected by the first client 24 .
[0133] The client digital token (not shown) may be used to allow the first client 24 to gain access to their client account (not shown) and amend details therein, for example, to add/remove organisations from the organisations list 38 or identifiers for specific elements of client data which the user is willing to share with a given organisation from the organisations list 38 . Alternatively, the client digital token (not shown) may be used to subsequently identify a person presenting it, by supporting requests from organisations for access to the stored client data of the first client 24 .
[0134] The preferred embodiment may also include an accessor module 14 which may be accessed by a requesting organisation 44 requesting access to personal data stored in the system of the preferred embodiment. The accessor module 14 may comprise a token processor 46 , a data receiver module 48 and an operator display 50 . The token processor 46 may be adapted to receive a candidate digital token 52 from a second client 54 . The candidate digital token 52 is a unique identifier of the second client 54 ; and may comprise a fingerprint, a facial scan or an iris scan from the second client 54 , or a password or PIN etc. It will be understood that the preferred embodiment is not limited to these candidate digital tokens, but is extendable to any form of candidate digital token required by the requesting organisation 44 . The accessor module 14 may construct an access request (Acc_Req) from the requesting organisation 44 for access to the stored personal data of the second client 54 (as identified by the candidate digital token 52 ). To this end, the access request (Acc_Req) comprises:
(a) the candidate digital token 52 received by the token processor 46 ; (b) an identifier (not shown) of the requesting organisation 44 ; and (c) details of which elements of the stored client data the requesting organisation 44 wishes to gain access
[0138] The accessor module 14 may be adapted to communicate the access request (Acc_Req) to the access request handler module 18 in the management module 12 .
[0139] The access request handler module 18 may comprise a token validation module 56 and an access processor 58 . The token validation module 56 may be adapted to extract a candidate digital token 52 from a received access request (Acc_Req). The token validation module 56 may also be adapted to communicate with the digital token store 42 to compare the candidate digital token 52 with the client digital tokens contained in the digital token store 42 . The token validation module 56 may be adapted to communicate a validation message (VM) to the accessor processor 58 in the event the candidate digital token 52 matches a client digital token in the digital token store 42 . The validation message (VM) comprises a confirmation that the second client 54 is a client registered with the system of the preferred embodiment. The token validation module 56 may also be adapted to communicate an alert message (AM 1 ) to the accessor module 14 in the event the received candidate digital token 52 does not match a client digital token. The alert message (AM 1 ) may comprise a notification that the second client 54 is not a client registered with the system of the preferred embodiment.
[0140] The access processor 58 may comprise an accessor identifier 60 , a comparator 61 and a data extractor 62 . The access processor 58 may be adapted to receive the validation message (VM) from the token validation module 56 and activate the accessor identifier 60 . The accessor identifier 60 may be adapted, on activation, to extract from the received access request (Acc_Req) the identifier of the requesting organisation 44 . The accessor identifier 60 may be adapted to communicate with the organisations list 38 of the client account (not shown) whose client digital token matches the candidate digital token 52 ; and compare the identifier of the requesting organisation 44 with those in the organisations list 38 . The accessor identifier 60 may be adapted to activate the comparator 61 in the event the identifier of the requesting organisation 44 matches an identifier in the organisations list 38 (i.e. the requesting organisation is an organisation with whom the second client 54 is willing to share their data). The accessor identifier 60 may also be adapted to transmit a secondary alert message (AM 2 ) to the accessor module 14 in the event the identifier of the requesting organisation 44 does not match an identifier in the organisations list 38 . The secondary alert message (AM 2 ) may comprise a notification that the second client 54 is unwilling to share their data with the requesting organisation 44 or is only willing to share their data with the requesting organisation on payment to the second client of a specified fee.
[0141] The comparator 61 may be adapted, on activation to extract from the received access request (Acc_Req) details of the elements of the stored client data the requesting organisation 44 wishes to gain access. The comparator 61 may also be adapted to communicate with the allowed data matrix 40 of the client account (not shown) whose client digital token matches the candidate digital token 5 and determine whether the data to which the requesting organisation 44 has requested access matches the identifiers of the elements of the second client's data (in the associated personal data store 32 ) the second client 54 is willing to share with the requesting organisation 44 . The comparator 61 may be adapted to activate the data extractor 62 on confirmation of a match. The comparator 61 may also be adapted to transmit an alert message to the accessor module 14 in the event the data to which the requesting organisation 44 has requested access does not match the identifiers of the elements of the second client's data (in the associated personal data store 32 ) the second client 54 is willing to share with the requesting organisation 44 . The alert message may comprise a notification that the second client is unwilling to share the requested personal data with the requesting organisation, or is only willing to share the requested personal data with the requesting organisation on payment to the second client of a specified fee.
[0142] The data extractor 62 may be adapted, on activation, to communicate with the allowed data matrix 40 of the client account (not shown) whose client digital token matches the candidate digital token 5 , to retrieve therefrom the identifiers of the elements of the second client's data (in the associated personal data store 32 ) requested by the requesting organisation 44 . The data extractor 62 may be adapted to communicate the identifiers to the personal data store 32 and retrieve therefrom the relevant client data elements (CD). The data extractor 62 may be adapted to communicate the retrieved client data elements (CD) to the data receiver module 48 in the accessor module 14 . The data receiver module 48 may be adapted to process the retrieved client data elements (CD) and display a result thereof on the operator display 50 . The access request handler 18 may also be adapted to store in a transaction history archive 64 , a record of one or more of the received access requests (Acc_Req), including the date and time of receipt and the outcomes thereof (including alert messages (AM 1 , AM 2 ), personal data transmission etc.). The access request handler 18 may also be adapted to adjust the rating on the client account (not shown) according to the number and/or frequency of successful received access requests (Acc_Req).
[0143] Referring to FIG. 2 together with FIG. 1 , the method of the preferred embodiment may comprise a registration process 70 adapted for registering a first client 24 with the system of the preferred embodiment. The registration process 70 may be implemented by a trusted third party intermediary (for example, the police, a bank, post office etc.) who may provide a recognized level of confidence in the authenticity of a created client account. Referring to FIG. 3 , the first step of the registration process 70 may comprise the step of acquiring 72 attributes (e.g. date of birth, expiry date, issuing office etc. attributes from a presented passport document) from one or more pieces of identity evidence presented by the first client 24 . The step of acquiring attributes 72 may comprise the step of
[0144] (a) capturing with a camera or scanner (or other suitable device) one or more images (or other graphical representations) of one or more pieces of documentary identity evidence (IDEv 1 , IDEv 2 , . . . IDEv n ); or
[0145] (b) acquiring with a biometric reader or biochemical analysing device one or more biometric or biochemical forms of identity evidence of the first client 24 .
[0146] The registration process 70 may comprise a next step of validating 74 the acquired attributes by extracting one or more identifying features therefrom and
[0147] (a) comparing the or each extracted feature with related feature information (not shown) gathered from an issuing source (not shown); and/or
[0148] (b) cross-comparing at least some of the extracted features, to assess their consistency with each other and their related feature information (not shown) gathered from an issuing source (not shown).
[0149] In the event the registration process 70 determines that the presented identity evidence is authentic 76 , the registration process 70 may implement a step comprising verifying 78 that the first client 24 is the genuine owner of the claimed identity. In the event the registration process 70 determines 80 that the first client 24 is the genuine owner of the claimed identity, the registration process 70 may comprise the steps of establishing 82 a client account for the first client 24 ; populating 84 the client account with the or each extracted features; and storing 86 the or each extracted features in the personal data store 32 associated with the client account. The registration process 70 may also comprise the steps of
[0150] (a) issuing 88 the first client 24 with a client digital token by which the first client 24 may be subsequently recognised by the system of the preferred embodiment;
[0151] (b) storing 90 in the digital token store 42 , the details of the issued client digital token; and
[0152] (c) linking 91 the stored client digital token with the client account, so that the digital token can act as an identifier therefor and enable the subsequent retrieval therefrom of client data.
[0153] The registration process 70 may comprise a further step of providing a rating 92 to the client account according to the number of presented items of identity evidence deemed to be authentic or the issuing source of a presented item of identity evidence or the authoritative source for the authentication of a presented item of identity evidence. However, in the event the registration process 70 determines 80 that the first client 24 is not the genuine owner of the claimed identity, the registration process 70 may comprise the step of issuing 94 an alert message to the authorities.
[0154] In the event the registration process 70 determines that at least some of the pieces of presented identity evidence lack authenticity, the registration process 70 may comprise a step of determining 96 whether the number of items of identity evidence lacking authenticity exceeds a predefined threshold. In the event the threshold is exceeded, the registration process 70 may comprise the step of issuing 94 an alert message to the authorities. However, in the event the threshold is not exceeded, the registration process 70 may comprise a step of requesting 98 the first client 24 to provide more pieces of identity evidence for validation until a required target number of authentic pieces of identity evidence is achieved. Alternatively, failure by the first client 24 to provide the required number of authentic pieces of identity evidence within a defined number of iterations may cause the registration process 70 to implement a step of issuing 94 an alert message to the authorities.
[0155] Returning to FIG. 2 together with FIG. 1 , on completion of the registration process 70 , the method of the preferred embodiment may comprise the step of allowing the first client 24 to add 100 further data to their client account/personal data store 32 . The method may also comprise the step (not shown) of contacting third party sources (e.g. credit rating agencies) to acquire further personal data for inclusion in the client account/personal data store 32 . Similarly, the method may also comprise the step of allowing the first client 24 to con figure 102 their client account by:
[0156] (a) specifying organisations with whom the first client 24 is willing to share at least some of the data contained in their client account;
[0157] (b) specifying which elements of the data contained in their client account/personal data store 32 , the first client 24 is willing to share with each organisation they specified as being organisations with whom they are willing to share their data; and
[0158] (c) reconfiguring their client digital token (e.g. allowing first client 24 to pick their own password or PIN etc.).
[0159] For example, a client may specify that they are willing to share their personal data with a local nightclub (e.g. to indicate they are of sufficient age to gain entry to the club) and their financial advisor. However, the client may not be willing to share the same personal data (e.g. personal finances information) with the nightclub as they do with their financial advisor. The method of the preferred embodiment allows the first client 24 to specify the parties with whom they are willing to share their personal data; and the elements of their personal data they are willing to share with each such party. The skilled person will understand that the above-described scenarios are provided for illustration purposes only and should in no way be construed as limiting the use of the preferred embodiment to the described night-club or financial advisor example. Similarly, the preferred embodiment is not limited to the provision of financial information. On the contrary, the preferred embodiment is adaptable for use across a wide variety of domains and information types.
[0160] The method of the preferred embodiment may comprises the further step of receiving 104 a candidate digital token 52 from a second client 54 . This further step may be implemented by a requesting organisation 44 seeking to gain access to at least some of the personal data of the second client 54 . The method of the preferred embodiment may further comprise the step of allowing the requesting organisation 44 to create 106 an access request (Acc_Req) comprising:
[0161] (a) the candidate digital token 52 ;
[0162] (b) an identifier of the requesting organisation 44 ; and
[0163] (c) details of the items of the second client's personal data to which the requesting organisation 44 seeks to gain access.
[0164] Using the previous nightclub example, the nightclub is the requesting organisation and the second client is a person seeking to prove their age and thereby gain entry to the nightclub. In this case, the nightclub might possess a fingerprint scanner or iris scanner; and the person might present a finger or iris for scanning by the nightclub. Alternatively, the person might send the nightclub with an SMS or other message (comprising a PIN or password etc,) from a mobile computing/communications device on their person. These may be used as the candidate digital token for the person. Using the received candidate digital token the nightclub creates an access request (Acc_Req) for the date of birth/age, photo etc. of the person, so as to determine whether to grant the person entry to the nightclub. For example, using near field technology, the person may tap their mobile phone against a reading device at the nightclub and a relevant password, tag or other message is transmitted to the reading device, to enable the person to be identified by the nightclub without needing to present their original identity documents. The skilled person will understand that the above-described scenario and mentioned types of candidate digital tokens are provided for illustration purposes only and should in no way be construed as limiting the use of the preferred embodiment or the types of candidate digital tokens usable therein. In particular, the method of the preferred embodiment is adaptable to any form of candidate digital token, both embodied within the person of a candidate user and in devices in the possession of the candidate user.
[0165] The method of the preferred embodiment may comprise the step of receiving 108 the access request (Acc_Req) from the requesting organisation 44 ; and checking 110 the received access request (Acc_Req) to determine the identity of the subject thereof (i.e. the person about who information is requested in the received access request (Acc_Req)). In the event the method of the preferred embodiment determines 112 that the candidate digital token 52 in the received access request (Acc_Req) does not match a client digital token (not shown) in the digital token store 42 of the system of the preferred embodiment, the method of the preferred embodiment may comprise the step of issuing 114 an alert message stating that the second client 54 is not registered with the system of the preferred embodiment. However, in the event the method of the preferred embodiment determines 112 that the candidate digital token 52 matches a client digital token (not shown) in the digital token store 42 (i.e. the second client 54 is a person registered with the system of the preferred embodiment), the method may comprise the step of using the candidate digital token 52 /matching client digital token to access the relevant client account and check 116 whether the requesting organisation in the received access request (Acc_Req) is entitled to access any of the stored personal data in the client account of the second client 54 .
[0166] In the event the method of the preferred embodiment determines 116 that the identifier of the requesting organisation 44 in the received access request (Acc_Req) does not match an identifier (in the organisations list 38 of the client account (not shown)) of an organisation with whom the second client 54 is willing to share their personal data, the method may comprise the step of issuing 118 an alert message stating that the second client 54 is unwilling to share any of their personal data with the requesting organisation 44 . Alternatively, the alert message may state that the second client 54 is willing to share personal data with the requesting organisation on payment of a specified fee by the requesting organisation to the second client. The fee may have been specified by the second client 54 while configuring their client account. However, in the event the method of the preferred embodiment determines 116 that the identifier of the requesting organisation 44 matches an identifier of an organisation with whom the second client 54 is willing to share their personal data, the method may comprise the step of checking 120 whether the requesting organisation 44 is entitled to access the specific items of personal data requested in the received access request (Acc_Req). This comprises the step of checking whether the details of the personal information in the received access request (Acc_Req) match the elements of the second client's 54 personal data (contained in the client account/personal data store 32 ) which the second client 54 indicated as being willing to share with the requesting organisation 44 .
[0167] In the event the method of the preferred embodiment determines 120 that a match is not present, the method may comprise the step of issuing 118 an alert message indicating that the second client 54 is unwilling to share the requested personal information with the requesting organisation 54 . Alternatively, the alert message may state that the second client 54 is willing to share the requested personal data with the requesting organisation on payment of a specified fee by the requesting organisation to the second client. The fee may have been specified by the second client 54 while configuring their client account.
[0168] However, in the event the method of the preferred embodiment determines 120 that the personal information requested by the requesting organisation 44 matches the elements of the second client's 54 personal data which the second client 54 indicated as being willing to share with the requesting organisation 44 , the method of the preferred embodiment may comprise the step of retrieving 122 from the personal data store 32 , the requested items of personal data and delivering 124 them to the requesting organisation 44 . The method of the preferred embodiment may also comprise the step of displaying (not shown) the retrieved items of personal data. Similarly, the method of the preferred embodiment may also comprise the step of recording 120 received access requests (Acc_Req) and the outcomes thereof (i.e. alert messages or details (date/time etc.) of data retrieval.
[0169] The method of the preferred embodiment may also comprise the step of transmitting 128 (by email or SMS (or other suitable messaging protocol)) details of received access requests to the person identified in the access request (as owner of the requested data). Thus, registrants with the system of the preferred embodiment are updated every time their client digital token is used; and informed of authorised and unauthorised requests for their personal data. With this information, registrants can keep track of requests for their personal information; and in response, amend their client accounts to include new organisations with whom they might wish to share their personal information; or further configure their client account to address broader changing trends in requested information. Similarly, registrants may be equipped to detect potential identity theft instances. In addition, registrants may be allowed to configure alert messages to be sent to them by the system/method of the preferred embodiment in the event of particular organisations making requests for the registrants' personal information, or changes in the number/frequency of access requests or changes in the number/frequency of requests for particular elements of the registrant's personal data or requests from particular organisations etc.
[0170] In another embodiment, the method and system for managing a repository of authenticated personal data may form the basis of an enhanced security system and method for managing financial transactions (henceforth know for brevity as the “enhanced security system” and the “enhanced security method” respectively). The architecture of the enhanced security system may be substantially similar to the architecture of the system for managing a repository of personal data as shown in FIG. 1 .
[0171] Referring to FIG. 4 , in the enhanced security method, a first client 224 is registered 200 with the enhanced security system (not shown) for managing financial transactions. The first client 224 is registered 200 using the registration process shown in FIG. 3 , wherein the registration process may be implemented by a trusted third party intermediary (e.g. a bank). On registering the first client 224 , the method may comprise a next step of contacting one or more credit rating agencies or other financial reporting organisations (e.g. Equifax (trade mark), Experian (trade mark) and Trans Union (trade mark)) to perform 202 a credit or other check on the financial health of the first client 224 . In a next step, the client account rating is scored 204 according to the financial health of the first client 224 (in addition to, or in place of the rating accorded to the client account during the registration process). In an optional additional step, a photograph of the first client 224 may be taken and appended to the first client's client account.
[0172] The first client 224 may be allowed to con figure 206 their client account to specify:
[0173] (a) banking or other financial organisations with whom the first client 224 is willing to transact;
[0174] (b) a maximum or minimum cap on the value of the transactions the first client 224 is willing to undertake with a given banking or other financial organisation; and optionally
[0175] (c) the elements of authenticated personal data the first client 224 is willing to share with the or each banking/financial organisation, to enable the or each banking/financial organisation to verify the identity of persons subsequently undertaking financial transactions therewith.
[0176] In configuring their client account, the first client 224 may also be allowed to reconfigure their client digital token (e.g. to pick a PIN or password of their choice). The reconfigured elements of the client account are stored in the organisations module, the digital token store and the personal data store of the enhanced security system, substantially as shown in FIG. 1 .
[0177] On receipt 208 of a candidate digital token by a banking/financial organisation 244 from a second client 254 , the banking/financial organisation 244 may be allowed to create 210 an access request comprising:
[0178] (a) the candidate digital token;
[0179] (b) an identifier of the banking/financial organisation 244 ; and
[0180] (c) details of the transaction (including the value thereof) which the second client 254 wishes to undertake with the banking/financial organisation 244 .
[0181] The enhanced security method may comprise the step of receiving 214 (by the management module 212 ) the access request from the banking/financial organisation 244 ; and may further comprise the step of checking 216 the received access request to determine the identity of the subject thereof (i.e. the person who wishes to conduct a transaction with the banking/financial organisation 244 ).
[0182] In the event the enhanced security method determines 218 that candidate digital token in the received access request does not match a client digital token in the digital token store, the enhanced security method may comprise the step of issuing 220 an alert message to the banking/financial organisation 244 . The alert message may state that the second client 254 is not registered with the enhanced security system; and consequently, the banking/financial organisation 244 will be unable to verify the identity of the second client 254 using the enhanced security system. However, in the event the enhanced security method determines 218 that the candidate digital token matches a client digital token in the digital token store (i.e. the second client 254 is a person registered with the enhanced security system), the enhanced security method may comprise the step of checking 222 the identity of the banking/financial organisation 244 requesting information about the second client 254 in the received access request.
[0183] In the event the enhanced security method determines 222 that the identifier of the banking/financial organisation 244 in the received access request does not match an identifier (in the organisations list) of a banking or other financial organisation with whom the second client 254 is willing to transact, the enhanced security method may comprise the step of issuing 226 an alert message to the banking/financial organisation 244 , stating that the second client 254 was unwilling to transact with banking/financial organisation 244 . However, in the event the enhanced security method determines 222 that the identifier of the banking/financial organisation 244 matches that of a banking or other financial organisation with whom the second client 254 is willing to transact, the enhanced security method may comprise the step of comparing 228 the value of the value of the transaction (specified in the received access request) which the second client 254 wishes to undertake with the banking/financial organisation 244 against the maximum or minimum cap on the value of the transactions the second client 254 specified (in the organisations module) they were willing to undertake with the banking/financial organisation 244 .
[0184] The enhanced security method may optionally include an intervening step between determining that the identifier of the banking/financial organisation 244 matches that of an organisation with whom the second client 254 is willing to transact, and comparing the value of the transaction which the second client 254 wishes to undertake with the banking/financial organisation 244 against the maximum or minimum cap on the value of the transactions previously specified by the second client 254 . The optional intervening step may provide an additional level of security to the enhanced security method, by providing (not shown) the banking/financial organisation 244 with the elements of authenticated personal data (from the client account) the second client 224 was willing to share with the banking/financial organisation 244 to enable the banking/financial organisation 244 to verify the identity of persons subsequently undertaking financial transactions therewith. The banking/financial organisation 244 may be allowed to request the person attempting the transaction to answer questions based on the provided elements of authenticated personal data. Further optionally, the banking/financial organisation 244 may be provided with a photograph of the face of the first client 224 which they may compare with the face of the person attempting the transaction. In the event the person attempting the transaction was unable to provide the correct answers to the questions (or the face of the person did not match that in the photo of the second client), the enhanced security method may comprise an additional step of issuing an alert message to the banking/financial organisation 244 and/or the first client advising them of the same.
[0185] Returning to FIG. 4 , in the event the enhanced security method determines 228 that the value of the transaction is within the maximum and minimum limits specified in the client account; and complies with the banking/financial organisation's own rules or limits on the value of transactions therewith, the enhanced security method comprises the step of allowing the banking/financial organisation 244 to conduct 230 the transaction with the second client 254 . This step will be performed by a transaction conductor module (not shown in FIG. 1 ) in the access request handler 18 .
[0186] However, in the event the enhanced security method determines 228 that the value of the transaction is greater than the maximum limit or less than the minimum limit specified in the client account; and/or fails to complies with the banking/financial organisation's own rules or limits on the value of transactions therewith, the enhanced security method comprises the step of issuing 232 an alert message to the banking/financial organisation 244 . In this eventuality, the enhanced security method may comprise an additional step of allowing the banking/financial organisation 244 to
[0187] (a) terminate the transaction; or
[0188] (b) amend the transaction so that its value is within the above-mentioned limits, and/or complies with the banking/financial organisation's rules; and allow the second client 254 to re-attempt the transaction with the banking/financial organisation 244 .
[0189] Similarly, the enhanced security method may also comprise the step of recording 234 received requests for transactions from banking/financial organisations and the outcomes thereof (i.e. alert messages or details (date/time etc.) of transaction; and transmitting 236 the record to the second client 254 .
[0190] In a further embodiment, the method/system for managing a store of authenticated personal data may provide a method or system for managing an adaptive secure social network, whose members provide authenticated personal data and choose which elements of that personal data to share with other members of the social network. Membership of the network may be restricted to those persons possessing pre-defined authenticated personal information attributes (e.g. age or gender etc.). This for example, could be used to establish and manage social networks amongst children or other vulnerable members of society (by ensuring undesirable persons might not gain access to the members of the social network). Alternatively, membership of the social network could be according to personal taste attributes (e.g. nightclubs visited, sports club membership, restaurants frequented etc.)
[0191] Modifications and alterations may be made to the above without departing from the scope of the invention. | The present invention relates to a method, system and computer program for managing a repository of personal data and, more particularly, a repository of authenticated personal data. Among its many advantages, the present invention allows a user to control access to their personal data by third parties. In particular, the present invention may allow a user to control the parties with whom their personal data is shared and customise which elements of their personal data may be shared with each such third party. Furthermore, the present invention allows a user to specify a fee for sharing particular aspects of their personal data, thereby allowing the user to monetise their personal data assets and be remunerated for their contribution. | 7 |
FIELD OF INVENTION
[0001] The present invention relates to improved, industrially acceptable processes for the preparation of pharmaceutical grade cis-2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine.
BACKGROUND OF INVENTION
[0002] Cis-2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine (C-MSOQ), also known as cevimeline, is a pharmaceutical compound useful for the treatment of diseases of the central nervous system in mammals, particularly for the treatment of diseases due to disturbances of central cholinergic function and autoimmune disease such as Sjögren's syndrome.
[0003] U.S. Pat. No. 4,855,290 describes a process of making the intermediate 3-hydroxy-3-mercaptomethylene quinuclidine using a sodium hydroxide/dichloromethane system and hydrogen sulfide at 40° C. with 33 to 40% yield. Drawbacks of this process include providing the intermediate in very low yields due to the decomposition of the intermediate in the given reaction conditions, side product “diol” formation due to the susceptibility of the epoxide moiety to form diol with the sodium hydroxide solution at the recommended temperature, and the requirement of a continuous stream of hydrogen sulfide gas.
[0004] U.S. Pat. No. 5,571,918 describes the preparation of the intermediate 3-hydroxy-3-mercaptomethylene quinuclidine by a process of passing hydrogen sulfide gas continuously with a special type of catalyst, p-toluene sulfonic anhydride. Drawbacks of this process include an excess use of hydrogen sulfide gas by passing the hydrogen sulfide gas continuously for more than 6 hours and the requirement of an additional catalyst to complete the reaction. The amount of hydrogen sulfide used for the process is quite high—18 grams/per minute flow for 6 hours, therefore for a 13.9 gm batch of product the required quantity of hydrogen sulfide gas is 6.5 kg.
[0005] U.S. Published Patent Application No. 2008/0249312 describes a two way process of making the aforementioned intermediate using thiol-acetic acid, an industrially toxic chemical with a highly unpleasant odor, with a yield of approximately 60 to 70%. This process requires first making the salt and then isolating the salt to obtain the salt of the intermediate, which is then used for the subsequent reaction.
[0006] For the preparation of the cis isomer of cevimeline, U.S. Pat. No. 4,855,290 describes a process employing multiple recrystallization of the racemic 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine. Drawbacks of this process include lack of scalability due to multiple recrystallization steps and the requirement of enrichment of the cis-isomer from mother liquor involving chromatographic purification and isolation. In addition to unsuitability for commercialization, the resultant yield after several steps of purification is less than 10%.
[0007] U.S. Pat. No. 4,981,858 involves a resolution of enantiomers of cis and trans isomers of 2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine individually by a tartaric acid resolution technique. There is no discussion regarding preparation and purification of the cis isomer from a racemic 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine.
[0008] U.S. Pat. No. 4,861,886 describes the conversion of pure trans 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine to the cis isomer under different conditions. However, no method is taught or disclosed for complete conversion of the trans isomer to the cis isomer. None of the techniques describe how to obtain pharmaceutical quality cis-2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine.
[0009] U.S. Pat. No. 5,571,918 describes the conversion of racemic 2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine to the cis isomer using stannic chloride as a catalyst. There is no teaching of any process or technique to obtain the cis isomer with greater than 98.5% purity when analyzed by HPLC.
[0010] Therefore, there is a need for an industrially viable process that achieves better yields of cis-form-2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine and employs less expensive reagents and solvents, resulting in lower production costs. Furthermore, there is further a need for a process which can generate cis-form-2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine of a pharmaceutically acceptable isomeric purity, i.e., at least 99.0% purity or greater, without the need for multiple tedious isolation, purification and/or separation steps.
SUMMARY OF THE INVENTION
[0011] Industrially advantageous methods are provided for making pharmaceutical grade cis-2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine (sometimes referred to herein as C-MSOQ) and pharmaceutically acceptable salts thereof. The disclosed methods provide surprisingly high yields and purity of C-MSOQ, cevimeline hydrochloride and hydrate forms thereof through the control of intermediates using novel solvent systems and reactions.
[0012] In one embodiment the disclosed method provides cis-2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine by isomerizing racemic 2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine to cis-2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine and subsequent purification of the C-MSOQ by salt formation with inexpensive and commercially available material such as sulfuric acid. This salt is purified by a novel purification method which employs an organic solvent/water system and recrystallization with an organic solvent such as acetone.
[0013] In one embodiment, the method involves preparing 3-hydroxy-3-methyl-quinuclidine, isomerizing racemic 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine (65:35 trans:cis isomer) to initially about 90% cis isomer with a Lewis acid such as titanium tetrachloride and subsequent purification by acid addition salt formation with an inorganic acid such as sulfuric acid. The resulting sulfate salt is further purified with an organic solvent/water acetone medium to produce pharmaceutical-grade cis-2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine wherein the cis isomer purity is greater than or equal to 99.5% by HPLC.
[0014] In another embodiment, a novel simple, single-step method is disclosed in which the intermediate 3-hydroxy-3-mercaptomethylene quinuclidine is prepared from the epoxide of 3-methylene quinuclidine using hydrogen sulfide in molar quantity in a solvent medium of methanol. This method is industrially more acceptable and inexpensive, and achieves much higher yields, compared to prior art processes referenced above. Employing hydrogen sulfide in a molar ratio avoids any excess quantity of hydrogen sulfide. The disclosed processes do not require any catalyst. The reaction time is much shorter than prior art processes, which helps greatly to stabilize the 3-hydroxy-3-mercapto methyl quinuclidine—and reduces plant utilization time and equipment usage.
[0015] In one embodiment, in situ reaction of the 3-hydroxy-3-mercaptomethyl quinuclidine with acetaldehyde and boron trifluoride etherate is employed to obtain racemic 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine. The racemic 2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine is isomerized to cis-2-methylspiro(1,3-oxathiolane 5,3′)quinuclidine using titanium tetrachloride and further purified by salt formation and recrystallisation with concentrated sulfuric acid and an organic solvent to obtain pharmaceutically acceptable quality cis-2-methylspiro(1,3-oxathiolane 5,3′)quinuclidine of >99.5% purity by HPLC.
[0016] These and other aspects of the invention will be apparent to those skilled in the art.
DETAILED DESCRIPTION
[0017] In the following description, for purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one having ordinary skill in the art that the invention may be practiced without these specific details. In some instances, well-known features may be omitted or simplified so as not to obscure the present invention. Furthermore, reference in the specification to phrases such as “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of phrases such as “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
[0018] In accordance with one embodiment a method is disclosed for the preparation of the key intermediate 3-hydroxy-3-mercaptomethyl quinuclidine by passing a fixed quantity of hydrogen sulfide gas to the epoxide of 3-methylene quinuclidine in a novel solvent medium of methanol.
[0019] Scheme 1 below shows a method of preparing the epoxide of 3-methylene quinuclidine, which method is known in the art.
[0000]
[0020] As shown in Scheme II below, the epoxide of 3-methylene quinuclidine is dissolved in a medium of dichloromethane/methanol and a fixed quantity of hydrogen sulfide is introduced to the solution for a period of 1 to 3 hours at a temperature range of −10 to 5° C. The gas flow is stopped and the reaction mixture is stirred for another 1 to 3 hours to convert 3-methylene quinuclidine to 3-hydroxy-3-methyl quinuclidine. In a preferred embodiment, as shown in Stage I of Scheme II, the amount of hydrogen sulfide used is either exactly what is required or slightly in excess of the mole ratio, to avoid excessive usage of this toxic gas. Excess hydrogen sulfide may be removed by passing nitrogen gas through the reaction mixture.
[0021] As shown in Stage II below, the resulting thiol derivative is converted in situ to 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine. The disclosed one-pot conversion of the epoxide of 3-hydroxy-3-mercaptomethyl quinuclidine to 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine is simple, achieves high yields and is easily scalable, all with inexpensive reagents/chemicals in a short reaction time. Surprisingly, it was found that methanol can be used as a good solvent medium for this reaction. This finding is contrary to the usage of methanol for these type of reactions, as it is well known methanol can compete as a nucleopile with hydrogen sulfide.
[0022] The compound 3-hydroxy-3-mercaptomethylquinuclidine is very unstable. The disclosed methods of preparation allow for the next step without any serious difficulties and result in very high yield of 2-methylspiro(1,3-oxathiolane 5,3′)quinuclidine. Two-way addition of 3-hydroxy 3-methylquinuclidine and boron trifluoride to an acetaldehyde solution at low temperature minimizes impurity formation and maximizes the yield.
[0000]
[0023] Stage I of Scheme III shown below involves the isomerization of the racemic 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine. Stage II illustrates the purification process to obtain the cis isomer with >99.5% purity by HPLC.
[0024] In a preferred embodiment a mixture of racemic 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine with an isomer ratio of about 65:35 cis:trans respectively is isomerized initially to 90% cis 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine with the Lewis acid catalyst titanium tetrachloride in an organic solvent such as acetone, dichlororomethane, dimethyl sulfoxide, methyl isobutyl ketone or a mixture thereof. A suitable quantity of titanium tetrachloride preferably, 0.5 to 5 moles, is added to the racemic 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine in a solvent system as described above. The reaction mixture is stirred for 1 to 48 hours at a temperature range of −5 to 50° C. After the completion of the isomerization, the reaction mass is worked up to generate the free base of cis-2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine having nearly 90% purity of cis isomer by HPLC.
[0025] The above-generated cis isomer is further converted to greater than or equal to 99.5% cis isomer (HPLC purity) by salt formation with sulfuric acid, purification and finally to hydrochloride salt. A suitable amount of sulfuric acid, preferably 1.0 to 3.0 equivalents relative to the input quantity, is added to the above-described nearly 90% pure cis 2-methylspiro (1,3-oxathiolane-5,3′)quinuclidine base at a temperature range of 0 to 30° C. After addition, the reaction mass is stirred for 2 to 24 hours at a temperature range of 0 to 115° C., preferably 20 to 40° C., and filtered to isolate the sulfate salt. The above prepared salt can be recrystallized in a solvent such as acetone, ethyl methyl ketone, methyl isobutyl ketone or a mixture thereof at different temperature ranges to obtain the desired pharmaceutically acceptable grade cis-2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine having a purity of 99.5% of cis-isomer by HPLC.
[0000]
EXAMPLES
Example I
Preparation of 3-hydroxy 3-mercapto methylquinuclidine
[0026] A solution of the epoxide of 3-methylene quinuclidine (100 g, 0.719 moles) in dichloromethane was cooled to a temperature between about 0 to 5° C. The solution was charged with methanol (100 ml). The mass was stirred for 10 to 15 minutes at this temperature range. To this cold solution hydrogen sulfide gas (50 g, 1.4 mol) was passed and after the passing was complete, the reaction was continued at this temperature for 2 to 3 hours, monitored by gas chromatography, whereupon the peak of epoxide of 3-methylene quinuclidine disappeared. After completion of the reaction, a dichloromethane solution of 3-hydroxy 3-mecapto methylquinuclidine in methanol was obtained. This solution was used for the next step.
Example II
[0027] A solution of acetaldehyde (250 ml) in dichloromethane (1000 ml) was cooled to 0 to 5° C. To this solution was charged the 3-hydroxy-3-mecapto methylquinuclidine solution (100 g epoxide equivalent) prepared in Example I. Boron trifluoride etherate (320 ml) was added simultaneously drop wise over 2 to 3 hours. After completion of the addition, the reaction mass was stirred at 20 to 25° C. for an additional 3 hours. The reaction mass was cooled to 0 to 5° C. A solution of sodium hydroxide (150 g dissolved in 150 ml water) was charged to the solution and the pH of the mixture was adjusted to 12 to 14. The layers were separated. The dichloromethane layer was washed with 5% sulfuric acid solution (500 ml). The product was extracted again in di-isoproyl ether with basification of the aqueous layer to pH 10 to 12. The organic layer containing the product was separated and the base converted to a hydrochloride salt by acidification with IPA/HCl solution to yield 65 g of the racemic cevimeline hydrochloride with 65:35 ratio of cis:trans isomer by HPLC.
Example III
[0028] Dichloromethane (200 ml) was charged in a vessel. To this was charged (10.0 g) of racemic mixture of cis/trans cevimeline having a 65:35 ratio of cis:trans isomer. The reaction mass was stirred for 10 to 15 minutes at 20 to 25° C. 1.0 ml of IPA was charged to the reaction mass. The reaction mass was cooled to −5 to 0° C. Anhydrous titanium tetrachloride (7.0 ml) was charged to the reaction mass over 5 to 10 minutes. After addition, stirring was continued for 18 to 24 hours at 20 to 30° C. After completion of the reaction, the reaction mass was cooled to 0 to 5° C. Process water (100 ml) was added and the mass was stirred for 10 to 15 minutes. The layers were separated. The dichloromethane layer was washed with 5% sulfuric acid (2×50 ml) and the layers separated. To the combined aqueous layer, di-isopropyl ether (100 ml) was charged and the pH of the solution adjusted 10 to 12. The layers were separated and the aqueous portion re-extracted with di-isopropyl ether (50 ml). The combined organic layer was dried with anhydrous sodium sulfate. To the dried solution was charged IPA/HCl solution to acidic. The separated solid was stirred and filtered at 0 to 5° C. for 30 to 45 minutes. The solid was washed with chilled di-isopropyl ether (2×10 ml). The solid was suction dried at 50 to 60° C. under vacuum to yield 6.5 g of the product with cis isomer of cevimeline hydrochloride >90% purity by HPLC.
Example IV
[0029] Dichloromethane (200 ml) was charged to a vessel and to this was added (10.0 g) of racemic mixture of cis/trans cevimeline with a ratio of about 65:35 cis:trans isomer as prepared in Example III. The reaction mass was stirred for 10 to 15 minutes at 20 to 25° C. 1.0 ml IPA was charged to the vessel and the reaction mass cooled to −5 to 0° C. 1.0 ml DMSO was charged to the mass. Anhydrous titanium tetrachloride (7.5 ml) was added drop wise over 5 to 10 minutes. After this addition, stirring was continued for 6 hours at 20 to 30° C. The reaction mass was then cooled and processed as in Example III to yield 6.0 g of the product of cis isomer of cevimeline hydrochloride with >90% purity by HPLC.
Example V
[0030] Charged chloroform (35 ml) to a vessel and to this charged (5.0 g) of a racemic mixture of cis/trans cevimeline with about 65:35 ratio of cis:trans isomer. Stirred the reaction mass for 10 to 15 minutes at 20 to 25° C. Cooled the reaction mass to −5 to 0° C. Charged anhydrous titanium tetrachloride (3.5 ml) drop wise over 10 to 15 minutes. After addition, continued stirring for 24 hours at 20 to 30° C. The reaction mass was then cooled and processed as in Example III to yield 3.0 g of the product of cis isomer of cevimeline hydrochloride with >90% purity by HPLC.
Example VI
[0031] Charged di-isopropyl ether (DIPE) (100 ml) in a vessel and to this charged cevimeline hydrochloride (10.0 g with cis isomer>90% purity and prepared by any one of the above methods). Cooled to 0 to 10° C. Charged concentrated sodium hydroxide solution drop wise to adjust the solution to pH above 12 (pH around 12 to 14). Stirred for 15 to 20 minutes and separated the DIPE layer. Reextracted the aqueous layer with DIPE and distilled off the organic layer, leaving a thick residue. To this residue, charged acetone (10 ml) and continued the distillation to remove the traces of DIPE. Charged acetone (100 ml) to the residue and stirred for 10 to 15 minutes. Cooled the solution to 0 to 5° C. Charged concentrated sulfuric acid (2.5 ml) slowly at the above temperature range. Stirred the separated solid for 30 minutes at 0 to 5° C. Raised the reaction mass temperature to 55 to 60° C. Stirred for 2 hrs and then cooled to 0 to 10° C. Stirred for 30 minutes. Filtered the solid and washed it with chilled acetone (10 ml). Suction dried the solid well and dried the solid at 50 to 60° C. to obtain 9.0 g of the product of cis isomer of cevimeline sulfate with >97% purity HPLC.
[0032] Charged cevimeline sulfate to a solution of di-isopropyl ether (100 ml) and cooled the solution to 0 to 10° C. Charged concentrated sodium hydroxide solution drop wise to adjust the pH of the solution to above 12. Stirred for 15 to 20 minutes and separated the DIPE layer. Re-extracted the aqueous layer with DIPE and dried the total DIPE layer with anhydrous sodium sulfate. Cooled the dried DIPE layer to 0 to 10° C. and charged IPA/HCl solution to acidic. Stirred the separated solid at this temperature for 30 to 45 minutes. Filtered the solid and washed it with chilled DIPE (10.0 ml). Suction dried the solid well and dried the solid at 50 to 60° C. to obtain 6.0 g of the cevimeline hydrochloride with cis isomer >97% by HPLC.
Example VII
[0033] Charged DIPE (60 ml) to a vessel and to this charged cevimeline hydrochloride (prepared from Example VI) (6.0 g with 97% cis isomer). Cooled the solution to 0 to 10° C. Charged concentrated sodium hydroxide solution drop wise to adjust pH of the solution to above 12. Stirred for 15 to 20 minutes and separated the DIPE layer. Re-extracted the aqueous layer with DIPE and distilled off the organic layer, leaving a thick residue. To this residue, charged acetone (6.0 ml) and continued the distillation to remove traces of DIPE. Charged acetone (60 ml) to the residue and stirred for 10 to 15 minutes. Cooled the solution to 0 to 5° C. Charged sulfuric acid (3.0 ml) slowly at the above temperature range. Raised the reaction mass temperature to 55 to 60° C. Charged sulfuric acid (0.6 ml). Stirred for 2 hrs and then cooled to 0 to 10° C. Stirred for 30 minutes. Filtered the solid and washed it with chilled acetone (10 ml). Suction dried the solid well and dried the solid at 50 to 60° C. to obtain 6.0 g of the product as cevimeline sulfate with cis isomer purity >99.5% by HPLC.
[0034] Charged DIPE (60 ml) to a vessel and to this charged the above cevimeline sulfate (99.5% cis isomer). Cooled the solution to 0 to 10° C. Charged concentrated sodium hydroxide solution drop wise to adjust the pH of the solution to above 12. Stirred for 15 to 20 minutes and separated the DIPE layer. Re-extracted the aqueous layer with DIPE and dried the total DIPE layer with anhydrous sodium sulfate. Cooled the dried DIPE layer to 0 to 10° C. and charged IPA/HCl solution to acidic. Stirred the separated solid at this temp for 30 to 45 minutes. Filtered the solid and washed it with chilled DIPE (9.0 ml). Suction dried the solid well and dried the solid at 50 to 60° C. to obtain 3.6 g of the cevimeline hydrochloride with cis isomer >99.5% with individual impurities below 0.10% by HPLC.
Example VIII
[0035] Charged ethyl methyl ketone (40 ml) to a vessel and to this charged cevimeline free base with cis isomer >90% by HPLC (4.0 g) (prepared by any one of the above methods given in Examples III to V). Stirred for 10 to 15 minutes to obtain a clear solution. Cooled the solution to 0 to 5° C. Charged concentrated sulfuric acid (1.3 ml) drop wise over 30 minutes and stirred the resultant liberated sulfate salt for 30 minutes at 0 to 5° C. Then slowly raised the temperature to reflux temperature and continued the reflux for 60 to 90 minutes. The reaction mass was then cooled and processed as in Example VI to yield 4.0 g of the product cevimeline sulfate with cis isomer >97% purity by HPLC.
[0036] Charged DIPE (260 ml) to a vessel and to this charged the above cevimeline sulfate (4.0 g with 97% cis isomer). Cooled the solution to 0 to 10° C. and proceeded as in Example VI to obtain 2.5 g of cevimeline hydrochloride with cis isomer >97% purity by HPLC.
Example IX
[0037] Charged DIPE (26 ml) to a vessel and to this charged cevimeline hydrochloride (2.6 g with 97% cis isomer as prepared in Example VIII). Cooled the solution to 0 to 10° C. Charged concentrated sodium hydroxide solution drop wise to adjust pH of the solution to above 12. Stirred for 15 to 20 minutes and separated the DIPE layer. Re-extracted the aqueous layer with DIPE and distilled off the organic layer, leaving a thick residue. To this residue, charged acetone (6.0 ml) and continued the distillation to remove traces of DIPE. Charged acetone (60 ml) to the residue and stirred for 10 to 15 minutes. Cooled the solution to 0 to 5° C. Charged sulfuric acid (1.3 ml) slowly at the above temperature range. Raised the reaction mass temperature to 55 to 60° C. Charged sulfuric acid (0.26 ml) and proceeded as in Example VII to yield 2.6 g of cevimeline sulfate with >99.5% cis isomer by HPLC.
[0038] Charged DIPE (60 ml) to a vessel and to this charged the above cevimeline sulfate (2.6 g, 99.5% cis isomer). Cooled the solution to 0 to 10° C. and proceeded as in Example VII to yield 1.7 g of the cevimeline hydrochloride with cis isomer >99.5% with individual impurities below 0.10% by HPLC.
Example X
[0039] Charged methyl isobutyl ketone (60 ml) and to this charged cevimeline free base with cis isomer >90% by HPLC (5.0 g) (prepared by any one of the above methods given in Examples III to V). Stirred for 10 to 15 minutes to obtain a clear solution. Cooled the solution to 0 to 5° C. Charged concentrated sulfuric acid (1.6 ml) drop wise over 30 minutes and stirred the resultant liberated sulfate salt for 30 minutes at 0 to 5° C. Then slowly raised the temperature to reflux temperature and continued the reflux for 60 to 90 minutes. The reaction mass was then cooled and processed as in Example VI to yield 3.0 g of the cevimeline sulfate with cis isomer >97% purity by HPLC.
[0040] Charged DIPE (26 ml) to a vessel and to this charged the above cevimeline sulfate (3.0 g with 97% cis isomer). Cooled the solution to 0 to 10° C. and proceeded as in Example VI to obtain 2.0 g of cevimeline hydrochloride with cis isomer >97% purity by HPLC.
Example XI
[0041] Charged DIPE (20 ml) to a vessel and to this charged cevimeline hydrochloride prepared from Example X (2.0 g with 97% cis isomer). Cooled the solution to 0 to 10° C. Charged concentrated sodium hydroxide solution drop wise to adjust pH of the solution to above 12. Stirred for 15 to 20 minutes and separated the DIPE layer. Re-extracted the aqueous layer with DIPE and distilled off the organic layer, leaving a thick residue. To this residue, charged acetone (2.0 ml) and continued the distillation to remove traces of DIPE. Charged acetone (20 ml) to the residue and stirred for 10 to 15 minutes. Cooled the solution to 0 to 5° C. Charged sulfuric acid (1.0 ml) slowly at the above temperature range and raised the reaction mass temperature to 55 to 60° C. Charge sulfuric acid (0.2 ml) and proceeded as in Example VII to yield 2.0 g of cevimeline sulfate with >99.5% cis isomer by HPLC.
[0042] Charged DIPE (20 ml) to a vessel and to this charged the above cevimeline sulfate (99.5% cis isomer). Cooled the solution to 0 to 10° C. and proceeded as in Example VII to yield 1.7 g of the cevimeline hydrochloride with cis isomer >99.5% with individual impurities below 0.10% by HPLC.
Example XII
[0043] Charged toluene (50 ml) and to this charged cevimeline free base with cis isomer >90% (5.0 g) (prepared by any one of the above methods given in examples III to V). Stirred for 10 to 15 minutes to obtain a clear solution. Cooled the solution to 0 to 5° C. Charged concentrated sulfuric acid (1.3 ml) drop wise over 30 minutes and stir the resultant liberated sulfate salt for 30 minutes at 0 to 5° C. Then slowly raised the temperature to reflux temperature (100 to 115° C.) and continued the reflux for 60 to 90 minutes. The reaction mass was then cooled and processed as in Example VI to yield 3.5 g of cevimeline sulfate with cis isomer >97% purity by HPLC.
[0044] Charged DIPE (35 ml) to a vessel and to this charged the above cevimeline sulfate (3.5 g with 97% cis isomer). Cooled the solution to 0 to 10° C. and proceeded as in Example VI to obtain 2.0 g of cevimeline hydrochloride with cis isomer >97% purity by HPLC.
[0045] Charged DIPE (20 ml) to a vessel and to this charged cevimeline hydrochloride (prepared from Example XII) (2.0 g with 97% cis isomer). Cooled the solution to 0 to 10° C. Charged concentrated sodium hydroxide solution drop wise to adjust pH of the solution to above 12. Stirred for 15 to 20 minutes and separated the DIPE layer. Re-extracted the aqueous layer with DIPE and distilled off the organic layer, leaving a thick residue. To this residue, charged acetone (2.0 ml) and continued the distillation to remove traces of DIPE. Charged acetone (20 ml) to the residue and stirred for 10 to 15 minutes. Cooled the solution to 0 to 5° C. Charged sulfuric acid (1.0 ml) slowly at the above temperature range and raised the reaction mass temperature to 55 to 60° C. Charged sulfuric acid (0.2 ml) and proceeded as in Example VII to yield 2.0 g of cevimeline sulfate with >99.5% cis isomer by HPLC.
[0046] Charged DIPE (20 ml) to a vessel and to this charged the above cevimeline sulfate (99.5% cis isomer). Cooled the solution to 0 to 10° C. and proceeded as in Example VII to yield 1.8 g of the cevimeline hydrochloride with cis isomer >99.5% with individual impurities below 0.10% by HPLC.
[0047] While the preferred embodiments have been described and illustrated it will be understood that changes in details and obvious undisclosed variations might be made without departing from the spirit and principle of the invention and therefore the scope of the invention is not to be construed as limited to the preferred embodiment. | Methods are provided for making pharmaceutical-grade cis-2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine and pharmaceutically acceptable salts thereof by isomerizing racemic 2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine to cis-2-methylspiro(1,3-oxathiolane-5,3′)quinuclidine and subsequent purification of the C-MSOQ by salt formation with inexpensive and commercially available material such as sulfuric acid. Purification methods are disclosed which employ an organic solvent/water system and recrystallization with an organic solvent such as acetone. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to telephone circuit distribution systems, and more particularly to a telephone distribution frame connector assembly having overload protector modules and a test field.
Distribution frame connectors of the type having plug-in modules are generally known in the telephone art. Such arrangements are typically shown in patents to Shores, Jr. U.S. Pat. No. 3,518,611 and Georgopulos U.S. Pat. No. 3,760,328. In such arrangements outside lines are connected on connector blocks to central office equipment through protector modules which protect the inside equipment from overvoltage or overcurrent faults. These connector blocks are mounted on distribution frames, for instance those having uprights. The connector block also includes some type of test field wherein a test shoe can be used to test a number of lines simultaneously. In arrangements of the foregoing type it is desirable to package the various components in a minimum of space and yet provide for ready servicing in terms of making line tests and replacing plug-in protector modules.
OBJECTS AND SUMMARY OF THE INVENTION
An object of this invention is to provide a telephone distribution frame connector assembly which is economical in terms of its "packaging" of the components, but which is nevertheless accessible for servicing when mounted on a distribution frame. Of primary importance, is the fact that this packaging approach increases by approximately 50 to 67 percent on an 8 foot vertical, even more on taller verticals, the number of protected pairs that can be mounted in the same vertical space used by the present generation of telephone distribution frame connectors.
A further object of this invention is to provide a connector of the type stated in which the test field is uniquely positioned for ready access by service personnel.
In accordance with the foregoing objects the connector assembly comprises an insulating connector block having a front face, a rear face and opposed side faces. Means are provided for mounting the block on a distribution frame such that the rear face is adjacent to the frame and the front face is remote from the frame. A plurality of such blocks are mounted on a distribution frame, preferably about eight inches on center, and with the blocks being side by side and parallel with a side face of one block being presented to a side face of an adjacent block. The block has a group of socket type electrical terminals for receiving a plurality of plug-in overload protector modules. Terminals are provided for connection of wires to inside central office equipment. There is a cable stub adjacent to the rear face of the block. The cable stub has pairs of wires (typically 100 pair) in electrical connection with the socket type terminals so that subscriber circuits are completed from the cable stub to the central office equipment through the overload protector modules. In one form of the invention the test field is at the front face of the connector assembly so that it is accessible to service personnel. The test field may be divided up into two sections offset from one another and in various configurations, as will be hereinafter more fully described. In another form of the invention the test field comprises elongated plug-in receptacles at one side of the block but near the forward face thereof.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a sectional view looking downwardly of the frame assembly in accordance with the present invention;
FIG. 2 is a side elevational view of the structure of FIG. 1;
FIG. 3 is a front elevational view of the assembly;
FIG. 4 is a sectional view smilar to FIG. 1 but of a modified form of the invention;
FIG. 5 is a side elevational view of the structure of FIG. 4;
FIG. 6 is a perspective view of another form of the invention; and
FIG. 7 is a perspective view of still another form of the present invention.
DETAILED DESCRIPTION
Referring now in more detail to the drawing, and in particular to FIGS. 1 - 3, there is shown a telephone distribution frame connector assembly 2 that includes a connector block structure 4 of insulating material. The block 4 has a panel 6 with an outer surface 8 that provides a side face for the block 4. At one end the panel 6 has a lateral flange 10 and a forward flange portion 12 to provide a somewhat widened front for the block 4.
The block 4 also comprises a plate 14 spaced from the panel 6. The plate 14 has an outer surface 16 that constitutes another side face of the panel 4 that is opposite to the side face 8. At the rear of the block 4 is a portion 18 that is integral with and transverse to the panel 6 and joined to the plate 14. This portion 18 provides a rear structure for the panel 6, this rear structure having a rear face 20.
At the front face of the block 4 are two test field panel segments 22,24 which are of plastic and are side-by-side. They are integrally bonded or otherwise joined to the back of plate 14 and to the flange section 12. As will be seen best in FIG. 3 the test field panel segments 22,24 are vertically offset from one another, but having some overlap at the central region of the front face of the block 4. There is also provided a transparent cover 26 that overlies the side plate 14. This cover 26 is removable and may have a sliding fit at tracks 28,28 (FIG. 3). Adjacent to the cover 26 and at the rear of the side plate 16 is a fanning strip 30 which runs substantially the full vertical length of the block 4. The fanning strip 30 has a series of slots 31, as best shown in FIGS. 6 and 7, for sorting wires going to central office equipment.
Mounted on the rear face 20 by screws 32 is a bracket 34 by which block 4 may be secured to an upstanding frame member 36 that is a vertical structural member of a telephone distribution frame. A number of such members 36 support a series of assemblies 2, each member having a plurality of assemblies 2 one above the other. Thus, a side face of one block will be presented to a side face of an adjacent block on the adjacent upright member 36. The bracket 34 may fit against the frame member 36 and be secured thereto by any suitable bolt and nut assemblies 38,38. Also secured to the bracket 34 is a cable stub 40. Clamps 42,42 encircle the cable stub 40 and the clamps 42,42 are attached to the bracket 34. The cable stub 40 typically has one hundred pairs of wires, each pair being made up of a "tip" wire and a "ring" wire. The lower ends (not shown) of these hundred pairs are spliced to outside subscriber lines which are external to the situs of the distribution frame.
The assembly 2 is intended to be an interface between the outside lines and the central office or in-plant equipment. The interfacing is carried out through line overload protector modules 46 which may be of any known type, for instance that shown in U.S. Pat. No. 3,587,021 to Baumbach.
These modules provide overvoltage protection in the event of lightning or power line faults. Usually also the modules provide overcurrent protection. The modules are typically of the plug-in type having a number of conductive pin terminals 48 that are adapted to be plugged into socket type electrical terminals 50 conventionally mounted in the panel 6. In the form of the invention herein illustrated, each protector has a five-pin arrangement which provides for an input and an output for each of the tip and ring lines, plus a ground pin. The ground pins are conventionally grounded. The pin terminal pattern in the modules 46 is shown in the present application by way of illustration only, and not by way of limitation. In the present invention there are one hundred modules in a ten by ten array, designated by the crosses shown in FIG. 2 on the face 8, four modules 46 at the corners of the array being actually shown.
Some of the socket terminals 50 have extensions running rearwardly and through the plate 16 to provide bent pin portions 52. The bent pin portions 52 form an array of wire wrap terminals at which wires may be connected to central office equipment. Thus, the bent pin portions 52 are extensions of those socket terminals 50 that receive the socalled central office pins 48 of the protectors 46.
The test strip segments 22,24 also have terminals 54 which have rearwardly extending wire wrap sections 54a. As best seen in FIGS. 1 and 2, test field wires 56,58 are wire wrapped to the rearward wire wrap portions 50a of those socket terminals 50 that do not provide the bent pin portions 52. Likewise, a pair of wires 56a, (tip) 58a, (ring) running from the cable stub 40, are wire wrapped to the pin portions 50a,50a so as to electrically connect those pin portions 50a,50a, the wires 56,56a and the wires 58,58a. The wiring of the wires 56,56a,58,58a onto the wire wrap portions 50a,54a constitute internal wiring that is made as part of the procedure for constructing the assembly 2. Only one pair of wires 56,58 is shown, it being understood that the other ninety-nine pairs of wires are wrapped in like manner.
Wrapped around the bent pin wire wrap pin portions 52 are wires 56b,58b which pass through the fanning strip 30 to central office equipment of known type, for instance, switching equipment. This side of the interface is frequently called the "switchboard side". Thus, each line of a pair coming from the outside of the plant is in a circuit that runs through the module and to the central office equipment. At the same time there is a jumper wire that joins each line pair to the test field. The cover 26 may be removed for wire wrapping operations at bent pins 52.
The assemblies 2 are mounted with the modules 46 extending perpendicular out to one side and with the test field presented forwardly. This results in a saving of space and yet makes the test field convenient for operation because test field shoes do not have to be inserted between assemblies 2 on adjacent members 36. Each test field 22,24 may receive the shoe or adapter whereby fifty line pairs can be tested at one time. Also, by offsetting the test fields 22,24 the wires 56,58 tend to be spread out over a larger region and are, therefore, less crowded. This facilitates manufacture of the assembly 2.
FIGS. 4 and 5 show a modification of the invention in which like reference numerals indicate like or corresponding parts as compared to the form shown in FIGS. 1 - 3. In the forms shown in FIGS. 4 and 5, the panel 6 has flange portions 10a,12a forming the front portion of one side of the block. The portions 10a,12a are offset from the part of the panel 6 that receives the modules 46. This offset portion supports four elongated socket type test shoe receptacles 60,60,60,60. The configuration of the structures 60 is known and need not be described. Suffice it to say, however, that these receptacles 60 each are adapted for plug-in reception of a tester capable of testing fifty pairs at one time.
The plate 14a is somewhat thinner and of somewhat different configuration than plate 14. The bent pin terminals 52 are not used, but are replaced by socket terminals 50. The forward edge of plate 14a has a fanning strip 61 for sorting and holding wires 56b,58b. The circuit through the protector module 46 for each line is the same as previously described. There are, however, jumper wires 56c,58c which are wire wrapped around the rear portions of pin terminals 62 and wire wrapped to 50b,50b. The pin terminals 62 are secured to a front panel 64 at which the wires 56b,58b to the central office equipment are wrapped. Thus, in this form of the invention the test receptacles 60,60,60,60 are at one side while the array of central office pins 62 are forwardly presented, i.e. at the front face of the block.
In FIG. 6 a further modified form of the invention is shown in which the forward face of the block assembly 4 includes the central office equipment pin array 62r consisting of two hundred pins of the type shown generally as 62 in FIG. 4. At one side edge of the front face is a front fanning strip 64 at which the wire pairs 56b,58b pass for connection to the central office equipment. Each pair 56b,58b also pass through the rear fanning strip 30 which is like the fanning strip 30 shown in the previous figures. The protector modules 46 project to one side of the block while the forwardly presented test strips or panels are made up of sections 22a,24a (each for testing fifty pair) which are on opposite sides of the pin terminal array 62r. Each test strip 22a,24a contains terminals with rear wire wrap portions (like at 54 and 54a) and are for substantially the same purpose as previously described with respect to FIGS. 1 - 3. In this form of the invention there is convenience to construction and maintenance personnel in the fact that the test strips 22a,24a are both forwardly facing and the same is true for the pin terminals 62 for wire wrap connections to the central office equipment. The internal wiring is not shown in FIG. 6 as it involves the same circuit arrangement, previously described with respect to wires 56,58,56a,58a,56b,58b,56c,58c (FIG. 4).
FIG. 7 shows a further modified form of the invention which is in many respects similar to FIG. 6 (the cable stub 40 being omitted). The essential difference between FIG. 6 and FIG. 7 lies in the fact that in FIG. 7 the test field is in the form of four elongated receptacles 60a of the type shown in FIGS. 4 and 5. Also the receptacles 60a are on the same face (i.e. the forward face) as is the pin terminal array 62r.
In both FIGS. 6 and 7, like in FIGS. 1 - 3, the test field structure is accessible without interference from adjacent blocks or modules thereon or from frame members. | A telephone distribution frame connector assembly comprises a connector block with terminals for receiving plug-in type overload protector modules. Incoming line pairs are connected through a cable stub to terminals on the block. Furthermore, terminals on the block are connected to inside central office equipment, the connections being through the overload protector modules. A test field is provided for testing the lines. The test field and the terminals for central office connection are mounted in various novel ways to effect a compact arrangement. | 8 |
FIELD OF THE INVENTION
It was discovered that blending small amounts of polyethylene into clear transparent polystyrene accelerated the degradation of polystyrene on exposure to UV light.
BACKGROUND OF THE INVENTION
Polystyrene is used in packaging and disposable service ware associated with the food packaging and fast-food service markets. In these applications, it can be desirable to provide the polystyrene as a composition which is photodegradable on exposure to UV light.
The current emphasis on ecology, and in particular, the disposal of bulk rubbish, is in part directed to coping with the tremendous increase in the use of plastic containers and plastic films for packaging foodstuffs, and garbage wraps and the like which not only present a serious disposal problem but increase unsightly litter in picnic areas, on roadside and the like.
The actual decomposition of polystyrenes is relatively slow and hence despite some discoloration and/or embrittlement when exposed to sunlight these plastic materials tend to remain substantially intact for relatively long periods of time.
SUMMARY OF THE INVENTION
The present invention relates to a polystyrene composition in film or package form, foamed or unfoamed, which has been modified to render it more readily decomposable on exposure to ultraviolet light.
The invention relates to a composition of matter comprising ultraviolet degradable polyethylene modified polystyrene and to method for accelerating the degradation of polystyrene on exposure to ultraviolet light.
The present invention also includes food wrapped or contained in films or packaging materials, foamed or unfoamed, from polystyrene modified in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to a composition of a crystal polystyrene and an amount of polyethylene polymer effective to accelerate the degradation of the styrene polymer on exposure to light.
The amounts of the ethylene polymer can range from 0.1 to 10 weight percent of the composition. The ethylene polymer can be introduced into the composition in any convenient manner, such as by direct addition or by introduction with a master batch containing ethylene polymer and a styrene polymer and a higher concentration of the polyethylene than necessary. The master batches than can be diluted with additional virgin polystyrene to achieve the necessary concentration in the composition as disclosed herein.
The ethylene polymer can be a high density polymer of ethylene or a linear low density polymer of ethylene. Linear low density ethylene polymers are copolymers of ethylene and a higher olefin and contain a sufficient amount of the higher olefin so that the copolymer has a density in the range of about 0.90 to about 0.94, preferably 0.91 to 0.93. The higher olefin is commonly 1-butene, 1-hexane, 4-methyl-1-pentene or 1-octene. Such materials are disclosed in U.S. Pat. No. 4,076,698 which is incorporated herein by reference in its entirety, and are widely available.
The composition of the invention can also contain conventional ingredients, such as fillers, antioxidants, stabilizers and the like.
These compositions can be used as films, as skins on other biodegradable or photodegradabel substrates or as packages per se in unfoamed or foamed conditions.
The invention will be illustrated by the following examples.
EXAMPLES
Polystyrene 1800 was blended via Brabender with two weight percent of the following polyethylenes;
Blended (via Brabender) two weight percent of the following polyethylenes into Polystyrene 1800:
Union Carbide 1137--very low density PE (VLDPE)
Mobil MJA042 --linear low density PE (LLPDE)
Mobil 5340D --high density polethylene (HDPE)
The composition were exposed to ultraviolet radiation in QUV Weather-O-Meter for 200 hours. Loss of molecular weight as function of exposure time was measured.
______________________________________Time, Hrs PS1800 VLDPE LLDPE HDPE______________________________________ 0 100 100 100 100 50 100 91 92 90100 97 80 78 81150 91 71 64 73200 90 63 55 56______________________________________ % molecular weight retained.
The surprising outcome of the study was that the polyethylene, when exposed to UV radiation, caused the degradation of the polystyrene matrix.
Although the present invention has been described with respect to preferred embodiments, it is to be understood that modifications and variations may be restored to, without departing from the spirit and scope of this invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims. | Linear polyethylenes are added to crystal, clear transparent polystyrene to accelerate the degradation of polystyrene on exposure to ultraviolet light. | 2 |
BACKGROUND OF THE INVENTION
The invention relates broadly to an apparatus and method for cementing of a well casing in a bore hole. More specifically, the invention covers a cementing head for injecting a cementing plug into the well casing. The cementing head described herein is particularly suited for injecting cementing plugs of an omega design into a well casing.
In a typical well cementing operating, a bottom cementing plug is introduced into the well casing ahead of the cement slurry. After the desired amount of cement slurry has been injected, another plug, usually called a top plug, follows immediately behind the slurry column as it travels down the well casing. The function of the top and bottom plugs is to separate the cement slurry column from drilling muds and other fluids which can contaminate the slurry. A fluid, such as drilling mud, is then pumped into the casing behind the top plug to push the cement slurry through the casing and up into the annulus between the casing and the bore hole.
The cementing heads presently in use for injecting cementing plugs into a well casing are not entirely satisfactory. One reason is that most of the cementing heads now in use require the presence of an operator on the rig floor to inject the plug into the well casing, at the appropriate time, using a manual procedure. Because these cementing heads do not have a positive means for indicating that the plug has been injected into the casing, it can create a very hazardous situation for the operator if the plug should hang up in the head itself, or inside the casing. In addition to being unsafe, the situation described above can result in the waste of a substantial amount of material (cement slurry), and a waste of time required to shut down the operation and clean up the equipment.
SUMMARY OF THE INVENTION
The cementing head of this invention includes a fluid chamber adapted for receiving an operating fluid. The operating fluid is carried into the fluid chamber through an inlet which communicates with the inside of the chamber and also with a source for the operating fluid. A plug housing is coupled into the bottom end of the fluid chamber. This housing acts as a retainer for holding the cementing plug in the head apparatus prior to injection into the well casing. Another component of the cementing head is a plunger, which is positioned inside the fluid chamber and it is movable, by the action of the operating fluid, between a rest position and an extended position.
At its bottom end the plug housing is coupled into a valve housing and the valve housing, in turn, connects into the well casing. A control valve is installed inside the valve housing. The control valve has a lengthwise bore through the body of the valve and the valve itself can be moved between a closed position and an open position. An inlet for cement is mounted on the valve housing below the control valve. During the cementing operation, a cement slurry is carried into the well casing through the cement inlet. Following discharge of the cement slurry into the casing, the control valve is opened and the plunger is moved by the action of the operating fluid to its extended position. As the plunger moves to the extended position, it pushes the cementing plug through the bore in the open valve, such that the plug comes to rest below the cement inlet.
DESCRIPTION OF THE DRAWINGS
FIGS. 1A, 1B, and 1C, taken together, comprise an elevation view, mostly in section, of the cementing head apparatus of this invention. In this view, the cementing plug is in its "retained" position within the cementing head, which is the normal position of the plug prior to injecting the cement slurry into the well casing.
FIGS. 2A and 2B, taken together, comprise a partial elevation view, mostly in section, of the apparatus shown in FIG. 1. In this view, which is after the cement slurry has been delivered into the well casing, the cementing plug is in its normal position below the cement inlet, after having been pushed through the open control valve by the extended plunger.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, the cementing head of this invention is indicated generally by the letter "H". The basic structure of the cementing head is made up of a fluid chamber, a plug housing, a plunger, and a control valve. The fluid chamber 10 provides means for receiving the operating fluid to operate the plunger. A flange 11, of a generally rectangular shape, is fastened on to the fluid chamber 10 at the top end of the chamber. A right angle bore 12 is drilled through the flange 11 to provide a passage for carrying the operating fluid into the chamber 10. The upper end of bore 12 opens into the fluid chamber 10 and the lower end of the bore is connected into a fluid inlet line 13. The opposite end of line 13 is connected into a source for the operating fluid. The operating fluid and its source are not shown in the drawings.
A lift sub 14 is coupled into the top end of the fluid chamber 10. The sub provides a means for lifting the cementing head "H" into its operating position on the well casing, and for removing the head from the casing. The plunger is defined by a head member 15 and a rod 16, which depends from the head. As shown in the drawing, the plunger fits inside the fluid chamber 10 and it is movable up and down within the chamber. The plug housing 17 is positioned below the fluid chamber 10. The bottom end of chamber 10 is threaded into an adapter coupling 18, which, in turn, is threaded into the top end of a valve housing 19.
At the bottom end of the fluid chamber 10 are mounted two flag members 20 and 21. Each flag is fastened into the chamber 10 by a roll pin, such that the flags are on the opposite sides of the plunger rod 16. The purpose of these flags is to provide a visible signal means to indicate that the cementing plug is in position to follow the cement slurry into the well casing. This function is explained in greater detail in this description. Prior to its injection into the well casing, the cementing plug 22 is retained in the plug housing 17.
A control valve installed in the valve housing 19 provides a positive means for controlling injection of the plug 22 into the well casing at the appropriate time. The basic structure of the control valve consists of a ball 23, with a central bore 23a, which extends lengthwise through the ball. Also, on one side of ball 23, is a flat surface which defines a side face 23b. Means for operating the valve is provided by a control shaft 24. The inner end of shaft 24 fits into a crosswise slot (not numbered) in the side face 23b of the ball. The outer end of the control shaft is keyed to a hub 25, and the hub is, in turn, mounted flush to the outside of the valve housing and held in place by a hex socket bolt 26.
An ear member 28 is mounted on the outside of the valve housing 19 just above the hub 25. A control handle 27 threads into a hole (not shown) on the top side of hub 25. When the control valve 23 is in its closed position, as shown in FIG. 1C, the handle 27 extends through an opening indicated by numeral 28a in FIG. 2B, in the ear member 28. With handle 27 in this position, the valve is locked into its closed position. To unlock the valve 23, the handle 27 is unscrewed from the top hole in hub 25 and pulled through the hole 28a in the ear member. The handle is then rethreaded into a second hole (not shown) in the hub 25.
With the handle 27 in the second hole in the hub, the handle can be used to rotate the hub 25 a quarter turn, to move the valve 23 to its open position, as shown in FIG. 2B. Along the bottom of the hub 25 is a slot with a quarter circle configuration (not numbered). This slot encloses a fixed pin 29, which is mounted on the outside of the valve housing 19. Opposite ends of this slot thus provide a travel limit for the hub 25, to insure that the valve 23 will not rotate beyond its fully closed position, as shown in FIG. 1C, or its fully open position, as shown in FIG. 2B.
The ball valve 23 also includes four "pressure relief" holes, as indicated by numeral 30. As best shown in FIG. 1C, two of the pressure relief holes are drilled through the wall of the valve, at an angle from the centerline on one side of the ball 23. The other two pressure relief holes are drilled through the valve wall on the opposite side of ball 23. The purpose of these holes is to allow fluid to pass through the valve 23, when it is in closed position, to prevent pressure build up and possible seizure of the valve in its seat.
A nipple section 31 threads into the bottom end of the valve housing 19. This nipple is, in turn, connected by a coupling 32 into the well casing 33. A cement inlet line 34 is connected into the valve housing 19 below the valve 23. The opposite end of line 34 is coupled into a cement pump or some other apparatus suitable for delivering a cement slurry into the well casing 33. The cement pumper is not illustrated in the drawing.
OPERATION
The invention can be illustrated by describing a typical cementing operation using the cementing head apparatus described herein. The cementing pump 22, which is a wiper plug of the omega design, is first loaded into the plug housing 17 and the valve 23 is locked into its closed position, as shown in FIG. 1C. Although the cementing head apparatus described herein is particularly designed for injecting an omega plug into a well casing, it can also be used to inject various other types of wiper plugs now in common use. A tubing insert (not shown), which the cementing plug can latch into, is dropped into the well casing 33 prior to mounting the cementing head. The head apparatus "H" is then coupled into the casing and the cement slurry charge is pumped into the well.
After the desired amount of slurry is pumped down the casing 33, the operator cuts off the slurry flow from the pumper. The next step is to remove the valve handle 27 from the top hole in hub 25, pull it out of the ear 28, and thread it into the second hole in the hub. The operator then rotates the hub a quarter turn to open the valve 23, as shown in FIG. 2B. An operating fluid, such as hydraulic fluid, is then directed into the fluid chamber 10 through the bore 12 in flange 11. At this point, as illustrated in FIGS. 1A and 1B, the plunger is in its rest position. When the plunger is in the rest position, there is a small space 35 defined between the top face of the plunger head 15 and the bottom face of the lift sub 14. The space 35 thus provides a relief groove for entry of the operating fluid. The groove 35 is actually defined by the fact that the center part 36, on the top face of plunger head 15, projects above the surrounding surface. This is best shown in the illustration of the head member 15 in FIG. 2A of the drawing.
As the hydraulic fluid flows into chamber 10, and pushes its way into the relief groove 35, it exerts enough pressure to move the plunger downwardly. The downward travel of the plunger rod 16 drives the cementing plug 22 through the opening in the control valve 23. When the rod 16 reaches the bottom of its stroke, the plunger is in its fully extended position, and the plug 22 is resting in the nipple 31 just below the cementing inlet 34. During the downward travel of the plunger, the bottom face of the head member 15 of the plunger hits both of the flag members 20 and 21. This causes each flag to swing outwardly, as noted in FIG. 2A. Each flag thus provides a visual signal that gives the operator a positive indication that the plug 22 is in the desired position below the cementing inlet 34.
The next step is to retract the plunger to its rest position and then force the plug 22 down the well casing behind the cement slurry. The plug is moved down into the casing by flowing water, or some other suitable fluid, under pressure, through the inlet 34. The force of the fluid moves the plug and the slurry column down the casing until the plug latches into the tubing insert positioned in the casing. After a cementing operation is completed, the head "H" can be removed from the casing 33 and re-loaded with another cementing plug to prepare for another cementing operation. | A cementing head is disclosed, which is particularly designed for injecting an omega-type cementing plug into a well casing. Prior to cementing, the plug is retained in a housing. Located above the plug is a movable plunger, actuated by an operating fluid, such as hydraulic fluid. Below the plug is a control valve. When the valve is closed, it prevents any accidental downward movement of the plug into the well casing. Following injection of the cement slurry into the casing, the valve is opened, and the plunger is moved down to push the plug through the valve and beyond the cement inlet. A fluid such as water is passed through the cement inlet, under pressure, to push the plug down the casing behind the cement slurry. | 4 |
This is a division of application Ser. No. 742,788, filed Aug. 8, 1991, now U.S. Pat. No. 5,134,155 which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
Compounds which inhibit HMG-CoA reductase, the enzyme controlling the rate-limiting step in cholesterol biosynthesis, are assuming an important role in the management of certain forms of hyperlipidemia. Lovastatin, disclosed in U.S. Pat. No. 4,231,938, has been approved for use in the treatment of primary hypercholesterolemia, a disease characterized by normal serum triglyceride levels and elevated serum levels of low density lipoprotein (LDL) cholesterol and total cholesterol. In several large clinical studies, lovastatin was found to decrease plasma LDL and total cholesterol concentrations 25% to 40% while causing small but significant increases (up to 10%) in high density lipoprotein (HDL) cholesterol concentration. When compared with cholestyramine and probucol, two drugs used in the treatment of primary hypercholesterolemia, lovastatin reduced LDL cholesterol levels to a significantly greater extent. In addition, combined administration of lovastatin with other hypolipidemic agents was found to potentiate their effects on LDL and total cholesterol concentrations.
The biochemical target for lovastatin is HMG-CoA reductase, the enzyme which catalyzes the reduction of HMG-CoA to mevalonic acid. Lovastatin, in its open dihydroxy acid form, is a reversible, competitive inhibitor of the enzyme. A number of compounds structurally related to lovastatin have been shown to be inhibitors of HMG-CoA reductase. These include simvastatin (U.S. Pat. No. 4,444,784 and related compounds disclosed in U.S. Pat. No. 4,444,784). Sankyo has reported a related compound, pravastatin (U.S. Pat. No. 4,346,227). Sandoz has reported a number of HMG-CoA reductase inhibitors: indoles (U.S. Pat. No. 4,739,073), pyrazoles (U.S. Pat. No. 4,613,610), imidazoles (U.S. Pat. No. 4,808,607), and pyrazolopyridines (U.S. Pat. No. 4,822,799). Merck disclosed biphenyl-containing inhibitors in U.S. Pat. No. 4,375,475. Hoechst, A. G. disclosed non-heterocyclic HMG-CoA reductase inhibitors in Tetrahedron Letters, 1988, 29, 929. Bristol-Myers reported tetrazole-containing compounds in UK Patent 2,202,846. Acylpyrroles are reported in U.S. Pat. No. 4,681,893 by Warner-Lambert. Warner-Lambert also disclosed pyrimidines in U.S. Pat. No. 4,868,185 and quinolines in U.S. Pat. No. 4,761,419. Bayer, A. G. reported tri-arylpyrroles in European Patent 287,890. Rorer reported aryl-cycloalkene and aryl-cycloalkadiene inhibitors in U.S. Pat. Nos. 4,892,884 and 4,900,754. Squibb reported a number of potent compounds based on a variety of heterocycles in Journal of Medicinal Chemistry, 1990, 33, 2852. Finally, Upjohn disclosed in WO 867,357 an anti-inflammatory, anti-allergic compound generically described as cyclopentapyrazole.
The compounds of the present invention are structurally different from the known compounds and have been shown to be potent inhibitors of HMG-CoA reductase and cholesterol biosynthesis.
SUMMARY OF THE INVENTION
Novel tetrahydroindazole, tetrahydrocyclopentapyrazole, and hexahydrocycloheptapyrazole compounds of the general formula I: ##STR2## wherein R 1 , R 2 , R 3 , Y, Z, n, and p are defined hereinafter have been found to be potent compounds for inhibiting HMG-CoA reductase and cholesterol biosynthesis and are thus useful in the treatment or prevention of hypercholesterolemia, hyperlipoproteinemia, and atherosclerosis.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to compounds of the following general formula I: ##STR3##
R 1 is selected from any one of H, C 1 -C 8 alkyl, aryl, or substituted aryl. The R 1 substituent may be attached either directly or indirectly to either of the ring nitrogens but not both at the same time. Two double bonds represented by the dotted line in the nitrogen containing ring are positioned accordingly depending upon the position of the R 1 substituent. Examples of suitable R 1 substituents include 4-fluorophenyl and 4-chlorophenyl.
R 2 is selected from any one of H, C 1 -C 8 alkyl, aryl, substituted aryl, aralkyl wherein the alkyl portion is C 1 -C 4 , substituted aralkyl wherein the alkyl portion is C 1 -C 4 , aralkenyl wherein the alkenyl portion is C 1 -C 4 , or C 3 -C 8 cycloalkyl such as cyclopropyl, cyclobutyl, cyclopentyl and the like. Examples of suitable R 2 groups include H, 4-fluorobenzyl, 3-phenyl-2-propenyl, cyclohexyl, ethyl, methyl, 1-naphthylmethyl, 2-naphthylmethyl, 4-phenylbenzyl, benzyl, 4-chlorobenzyl, 4-isopropylbenzyl, 4-methoxybenzyl and 4-t-butylbenzyl.
R 3 is H.
R 2 and R 3 may be taken together to form a benzo or naphtho ring system.
Y is C 1 -C 8 alkyl or C 1 -C 8 alkenyl such as CH═CH and CH═C(CH 3 ).
Z is selected from any one of: ##STR4## wherein R 4 is H, C 1 -C 8 alkyl, a protonated amine of the formula HN(R 5 ) 3 + wherein R 5 is H or C 1 -C 8 alkyl, or a cation such as Na + , K + , Li + , Ca 2+ , or Mg 2+ .
The values for n are 0 to 3 and the values for p are 0 to 3.
The compounds of formula I can be generally represented by three sub-groups of compounds represented by formulas I(a), I(b), and I(c) which are set forth as follows: ##STR5## wherein R 4 is any of C 1 -C 8 alkyl, and R 1 , R 2 , R 3 , Y, n, and p are as defined above; or ##STR6## wherein R 4 is H, a cation such as Na + , K + , Li + , or a protonated amine of the formula HN(R 5 ) 3 + , wherein R 5 is H or C 1 -C 8 alkyl, and R 1 , R 2 , R 3 , Y, n, and p are as defined above; or ##STR7## wherein R 1 , R 2 , R 3 , Y, n, and p are as defined above.
Also within the scope of this invention are intermediate compounds which are useful in making the compounds of formula I. The intermediate compounds are represented by the general formula X: ##STR8## wherein R 1 , n, and p are as defined above.
R 2 is selected from any one of H, C 1 -C 8 alkyl, aryl, substituted aryl, aralkyl wherein the alkyl portion is C 1 -C 4 , substituted aralkyl wherein the alkyl portion is C 1 -C 4 , aralkenyl wherein the alkenyl portion is C 1 -C 4 , or C 3 -C 8 cycloalkyl such as cyclopropyl, cyclobutyl, cyclopentyl and the like.
R 3 is H.
R 2 and R 3 may be taken together to form a benzo or naphtho ring system.
The term "aryl," as used herein alone or in combination with other terms, indicates aromatic hydrocarbon groups such as a phenyl or naphthyl group. The term "aralkyl" indicates a radical containing a lower C 1 -C 8 alkyl group substituted with an aryl radical or substituted aryl radical as defined above.
The aryl groups and the ring formed by R 2 and R 3 may be independently substituted with any of C 1 -C 8 alkyl, such as methyl, ethyl, propyl, isopropyl, t-butyl, and sec-butyl; alkoxy such as methoxy and t-butoxy; halo such as fluoro, chloro, bromo, and iodo; or nitro.
As used herein alkyl and alkoxy include straight and branched chains. For example, alkyl radicals include methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl, sec-butyl, t-butyl, n-pentyl, 2-methyl-3-butyl, 1-methylbutyl, 2-methylbutyl, neopentyl, n-hexyl, 1-methylpentyl, 3-methylpentyl. Alkoxy radicals are oxygen ethers formed from the previously described straight or branched chain alkyl groups. The term "independently" is used with respect to aryl and ring substituents to indicate that when more than one of such substituents is possible such substituents may be the same or different from each other. Position 1 in the N-containing ring is the N atom adjacent to the ring fusion.
The compounds produced according to the invention include the various individual isomers as well as the racemates thereof, e.g. the isomers arising from the various attachments on the side chain Z as well as the substituents R 2 and R 3 .
The compounds of formula I and intermediates of formula X may be prepared according to the following general reaction scheme, which as is apparent contains a plurality of alternative routes depending upon starting materials and the reactions carried out. ##STR9##
If desired, the substituted cyclic ketone VI may be obtained from commercial suppliers (Aldrich Chemical Co., Lancaster Synthesis Ltd., or Wiley Organics). Alternatively, compound VI may be prepared as shown in the reaction scheme by treatment of imine IV (Stork, G., Dowd, S. R. J. Am. Chem. Soc., 1963, 85, 2178-80) in an inert solvent such as THF with an appropriate base such as s-BuLi or LiN(i-Pr) 2 (LDA) at -78° to 0° C. for 15 to 45 min under N 2 , followed by alkylation at 0° C. to RT (room temperature) for 16 h, followed by hydrolysis of the resulting imine with 2N HCl at RT for 5 h. Alternatively, compound VI may be prepared by treatment of the 2-carboethoxy cyclic ketone V (commercially available from Aldrich Chemical Co.) in an inert solvent such as benzene or DMF with an appropriate base such as NaH at 0° to 25° C. for 30 to 60 min under N 2 , followed by alkylation at 0° C. to RT for 2 to 3 days, followed by hydrolysis of the ester and decarboxylation of the resulting acid with 6N HCl at reflux for 2 to 3 days.
Compound VI can be treated with an appropriate base, such as LDA or LiN(SiMe 3 ) 2 , in an inert solvent, such as THF, at -78° C. to 0° C. and acylated with methyl dimethoxyacetate at 0° C. to RT for 16 h to give the diketone VII. Compound VII is dissolved in an appropriate solvent, such as EtOH, and treated with a substituted hydrazine for 16 h at RT. The resulting acetal is hydrolyzed with 1N HCl at reflux to give the aldehyde X as a separable mixture of regioisomers.
Compound X can also be prepared from compound VI by several alternate routes. Thus, compound VI is treated with pyrrolidine and acetoxyacetyl chloride to give the acetoxy methyl diketone VIII (R=Ac: Dolmazon, R. J. Heterocyclic Chem., 1982, 19, 117-121). Reaction of VIII with a substituted hydrazine in a suitable solvent, such as EtOH, from RT to reflux for 4 to 10 h gives the regioisomeric mixture of acetoxy compounds XI, which is dissolved in an alcoholic solvent such as MeOH and hydrolyzed with 1N NaOH at RT to provide the separable mixture of alcohols XII. Alternatively, the THP derivative of compound VIII (R=THP), prepared by the treatment of compound VI and ethyl (tetrahydropyranyloxy)acetate (Ireland, R. Tetrahedron Lett., 1989, 30, 919-922) in ether with a suitable base, such as NaH or NaOEt, from 0° C. to RT for 16 h, can be treated with a substituted hydrazine at reflux for 4 h, followed by hydrolysis of the THP group with 1N HCl to give the separable mixture of alcohols XII.
Alternatively, compound VI is treated with NaH and diethyl oxalate to give the 2-substituted dioxoacetate IX (Tsuboi, S. J. Org. Chem, 1987, 52, 1359-62). Treatment of compound IX in MeOH with hydrazine hydrate at RT to 60° C. for 16 h gives the 3-carboethoxy compound XIII. The separable regioisomeric mixture of esters XIV is prepared by treating compound XIII with a suitable base, such as NaH, in an inert solvent, such as DMF, at 140° C. for 15 min under N 2 , followed by the addition of the alkylating agent at 140° C. The alcohol XII is prepared by reduction of the corresponding 3-carboxylate XIV with a suitable reducing agent, such as LiAlH 4 , in an inert solvent, such as THF, at 0° C. to RT for 2 to 3 h under N 2 . Oxidation of compound XII with either MnO 2 in an appropriate solvent, such as benzene, or pyridinium chlorochromate in an appropriate solvent, such as methylene chloride, gives the corresponding aldehyde X.
Treatment of compound X with NaH and triethyl phosphonoacetate or triethyl phosphonopropionate in an inert solvent such as THF at 0° to RT for 16 h gives the corresponding ester XV. Reduction of the ester is accomplished by treatment of XV with (i-Bu) 2 AlH in an inert solvent, such as toluene or THF, for 1 to 2 h at 0° C. under N 2 to give the alcohol XVI. Alternatively, compound XVI can be prepared from the appropriately substituted cyclic ketone VI by treatment of said ketone with a substituted hydrazine and an appropriate base, such as NaOAc, in EtOH at reflux for 3 h to give the hydrazone. The hydrazone is then treated with a suitable base, such as LDA, at -10° C. and acylated with methyl 4-tetrahydropyranyloxy-2-butenoate (Harnish, W.; Morera, E.; Ortar, G. J. Org. Chem., 1985, 50, 1990-2); the resulting intermediate is treated with 3N HCl at reflux for 15 min, followed by reaction with pyridinium p-toluenesulfonate at reflux for 8 h under N 2 to give the substituted alcohol XVI. Oxidation of alcohol XVI by treatment with MnO 2 in an appropriate solvent, such as benzene, at reflux for 3 h or with CrO 3 and pyridine in an appropriate solvent, such as methylene chloride, gives aldehyde XVII. Ethyl acetoacetate is treated with an appropriate base, such as LDA, or mixture of bases, such as NaH and n-BuLi, and reacted with compound XVII at 0° to -10° C. for 1 to 2 h in an inert solvent such as THF. Reaction of the intermediate ester with Et 3 B in a solvent mixture such as 1:4 MeOH:THF at 0° C., followed by treatment with NaBH 4 at -78° C. to RT for 16 h, gives the dihydroxyheptenoate I(a).
Alternatively, compound I(a) can be prepared by the reaction of compound X with methyl 3-[(t-butyldimethylsilyl)oxy-6-(dimethoxyphosphinyl)-5-oxohexanoate XVIII (Theisen, P. D.; Heathcock, C. H. J. Org. Chem., 1988, 53, 2374-81), LiCl, and DBU in an appropriate solvent, such as acetonitrile, at RT under N 2 for 6 h to give 3-hydroxy-5-oxoheptenoate XIX. Treatment of ester XIX with Et 3 B in a solvent mixture such as 1:4 MeOH:THF at 0° to -78° C., followed by reaction with NaBH 4 at -78° C. to RT for 16 h gives the dihydroxyheptenoate I(a). Compound I(a) can be hydrolyzed with aqueous NaOH or KOH and a suitable alcoholic solvent, followed optionally by neutralization with dilute aqueous HCl and treatment with an amine base, to give the dihydroxyheptenoic acid derivative I(b). Hydrolysis of compound I(a) as described above to the crude acid, followed by treatment of said acid with an appropriate carbodiimide, such as 1-cyclohexyl-3-(2-morpholinoethyl) carbodiimide metho-p-toluenesulfonate, in an inert solvent, such as methylene chloride, at 0° C. to RT for 16 h, gives the tetrahydropyranyl compound I(c).
The compounds of this invention are useful as hypocholesterolimic or hypolipidemic agents by virtue of their ability to inhibit the biosynthesis of cholesterol through the inhibition of the enzyme 3-hydroxy-3-methylglutaryl coenzyme A reductase (HMG-CoA reductase). The ability of the compounds of the present invention to inhibit the biosynthesis of cholesterol was measured by two different tests.
HMG-CoA Reductase Isolation And Assay
Livers were harvested from male Wistar rats (250 g) following a five day feeding with powdered chow containing 2% cholestyramine. Ammonium sulfate precipitated HMG-CoA reductase was prepared from these livers according to the method of Heller, et. al. (Heller, R. A. Shrewsbury, M. A. Journal of Biological Chemistry, 251, 1976, 3815-3822). HMG-CoA reductase activity was measured using a modification of the procedure of Edwards, et. al. (Edwards, P. A., Lemongello, D., Fogelman, A. M. Journal of Lipid Research, 20, 1979, 40-46). The effects of compounds on HMG-CoA reductase activity were determined by combining the compound with the enzyme and preincubating for 10 minutes prior to addition of the substrate HMG-CoA reductase.
Cell Culture Cholesterol Biosynthesis Assay
Hep-G2 cells obtained from the American Type Culture Collection were maintained in MEM (minimal essential medium) obtained from GIBCO containing Earles salts and supplemented with 10% HI-FBS. For cholesterol biosynthesis experiments, cells were plated into T25 flasks. When the cells were 2/3 confluent, they were fed MEM containing Earles salts and delipidated serum protein (DLP) at 5 mg/mL and then incubated for a period of 24 h. DLP was prepared according to the procedure of Rothblat, et. al. (Rothblat, G. H. Arrbogast, L. Y., Ouellette, L., Howard, B. V. In Vitro (Rockville), 12, 1976, 554-557). The DLP medium was then removed and 3.3 mL of media containing the drug indicated was added. Monolayers were incubated with drug for 2.5 h at which time 14 C-acetate (0.2 mCi/12 mmol) was added and cells incubated for an additional 3 h. The reaction was stopped by the addition of 0.2 mL of 12N H 2 SO 4 ; 3 H-cholesterol and 3 H-oleic acid were added as internal recovery standards, and samples were saponified. Fatty acids were extracted and digitonin precipitable sterols were recovered according the procedure of Kanduch and Saucier (Kandutch, A. A., Saucier, S. E. Journal of Biological Chemistry, 244, 1969, 2299-2305). To adjust for cell number per flask, the cholesterol synthesized was normalized to the fatty acids synthesized and results were expressed as percent inhibition vs. control.
The activities of certain representative examples are shown in Tables I-V. In the Tables, Me means methyl, Et is ethyl, Pr is propyl, Bu is butyl, c-Hex is cyclohexyl, Ph is phenyl, Nap is naphthyl, MeO is methoxy, and Biphenyl is (1,1'-biphenyl)-4-yl. Each of the compounds was tested in the form of a racemic mixture.
Each of the compounds in Tables I-V was tested in one or both of the biological assays. The symbol "nt" indicates that a particular compound was not tested.
TABLE I______________________________________ ##STR10## Cell Culture CholesterolCompound BiosynthesisNumber R.sub.2 IC.sub.50 (μM)______________________________________42 (2-Nap)-CH.sub.2 0.36543 (4-i-PrPh)CH.sub.2 0.12______________________________________
TABLE II__________________________________________________________________________ ##STR11## Cell Culture HMG-CoA CholesterolCompound Reductase BiosynthesisNumber n R.sub.1 R.sub.2 IC.sub.50 (μM) IC.sub.50 (μM)__________________________________________________________________________2 0 4-FPh H 100,000 nt3 1 4-FPh (4-FPh)CH.sub.2 31,000 274 1 4-FPh c-Hex 47,000 nt5 1 4-FPh Et 35,000 nt6 1 4-FPh Me 100,000 nt7 1 4-FPh Ph(CH.sub.2).sub.2 nt >108 1 4-FPh PhCHCHCH.sub.2 3,000 nt9 2 (4-FPh)CH.sub.2 H 100,000 nt__________________________________________________________________________
TABLE III__________________________________________________________________________ ##STR12## Cell Culture HMG-CoA CholesterolCompound Reductase BiosynthesisNumber n R.sub.1 R.sub.2 R.sub.3 Y IC.sub.50 (μM) IC.sub.50 (μM)__________________________________________________________________________1 1 4-FPh (Biphenyl)-CH.sub.2 H CHCH 2.7 0.2410 0 4-FPh H H CHCH 5,100 nt11 1 4-FPh (1-Nap)-CH.sub.2 H CHCH 26 0.3712 1 4-FPh (2-ClPh)CH.sub.2 H CHCH 100 1.313 1 4-FPh (2-Nap)-CH.sub.2 H CHCH 5.6 0.3314 1 4-FPh (3-MeOPh)CH.sub.2 H CHCH 48 1.0915 1 4-FPh (3,4-di-MeOPh)CH.sub.2 H CHCH 168 3.916 1 4-FPh (4-ClPh)CH.sub.2 H CHCH 58 0.3617 1 4-FPh (4-FPh)CH.sub.2 H CHCH 150 0.7018 1 4-FPh (4-i-PrPh)CH.sub.2 H CHCH 14 0.2619 1 4-FPh (4-MePh)CH.sub.2 H CHCH 19 0.1320 1 4-FPh (4-MeOPh)CH.sub.2 H CHCH 14 0.4621 1 4-FPh (4-t-BuPh)CH.sub.2 H CHCH 16 0.13522 1 4-FPh 6,7-Benzo CHCH 13,000 nt23 1 4-FPh c-Hex H CHCH 7,700 nt24 1 4-FPh Et H CHCH 1,000 nt25 1 4-FPh H H CHCH 2,500 nt26 1 4-ClPh H H CHCH 8,800 nt27 1 4-FPh H H CHC(Me) 2,700 nt28 1 4-FPh Me H CHCH 1,100 nt29 1 4-FPh n-Pr H CHCH 1,300 nt30 1 4-FPh Ph H CHCH 3,100 nt31 1 4-FPh PhCH.sub.2 H CHCH 85 0.2232 1 4-FPh Ph(CH.sub.2).sub.2 H CHCH 334 1.7533 1 4-FPh Ph(CH.sub.2).sub.3 H CHCH 160 1.134 1 4-FPh PhCHCHCH.sub.2 H CHCH 32 1.335 1 4-FPh s-Bu H CHCH 1,000 nt36 2 4-FPh 7,8-Benzo CHCH 2,100 nt37 2 4-FPh H H CHCH 3,800 nt38 2 (4-FPh)CH.sub.2) H H CHCH 23,000 nt__________________________________________________________________________
TABLE IV______________________________________ ##STR13## Cell Culture HMG-CoA CholesterolCompound Reductase BiosynthesisNumber R.sub.2 IC.sub.50 (nM) IC.sub.50 (μM)______________________________________47 PhCH.sub.2 120 0.2958 (3-MeOPh)CH.sub.2 210 0.8060 (4-ClPh)CH.sub.2 nt 0.4662 (4-MePh)CH.sub.2 70 0.2064 (4-t-BuPh)CH.sub.2 30 nt______________________________________
TABLE V______________________________________ ##STR14## Cell Culture HMG-CoA CholesterolCompound Reductase BiosynthesisNumber R.sub.2 IC.sub.50 (nM) IC.sub.50 (μM)______________________________________79 PhCH.sub.2 750 0.2680 (2-Et)Bu 29,000 nt81 (2-Nap)-CH.sub.2 nt 0.3982 (4-t-BuPh)CH.sub.2 70 0.2383 H 9,000 nt______________________________________
The pharmaceutical compositions containing compounds of the present invention are comprised of the compounds of the present invention and a pharmaceutically acceptable carrier in either solid or liquid form. Solid form preparations include powders, tablets, dispersible granules, capsules, etc. The carrier may also be one or more substances which act as diluents, flavoring agents, solublizers, lubricants, suspending agents, binders, or tablet disintegrating agents and they may also be encapsulating materials. Suitable carriers are magnesium carbonate, magnesium stearate, talc, lactose, sugar, peptin, dextrin, starch, methyl cellulose, sodium carboxyl methyl cellulose, and the like. Liquid form preparations include solutions which are suitable for oral or parenteral administration, or suspensions and emulsions suitable for oral administration. Sterile water solutions of the active component or sterile solutions of the active components in solvents comprising water, ethanol, or propylene glycol are examples of liquid preparations suitable for parenteral administration. Sterile solutions may be prepared by dissolving the active component in the desired solvent system, then passing the resulting solution through a membrane filter to sterilize it, or alternatively, by dissolving the sterile compound in a previously sterilized solvent under sterile conditions. Aqueous solutions for oral administration can be prepared by dissolving the active compound in water and adding suitable flavorants, coloring agents, stabilizers and thickening agents as required. Aqueous suspensions for oral use can be made by dispersing the finely divided active component in water together with a viscous material such as a natural or synthetic gum, resin methyl cellulose, sodium carboxy methyl cellulose, and other suspending agents known to the pharmaceutical formulation art.
It is especially advantageous to formulate the aforementioned pharmaceutical compositions in unit dosage form for ease of administration and uniformity of dosage. The term "unit dosage form" as used in the specification and claims herein refers to physically discrete units suitable as unit dosages, each unit containing a predetermined quantity of active ingredient calculated to produce the desired therapeutic effect in association with the required pharmaceutical carrier.
In therapeutic use as hypolipidemic or hypocholesterolemic agents, the compounds utilized in the pharmaceutical method of this invention are administered to the patient at dosage levels of from about 0.01-100 mg/kg per day. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of optimum dosages for a particular situation is within the skill of the art.
In the following examples, Examples 13, 14, 20 and 21, Tables 8, 9A, 9B, 13A, 13B, and 14, illustrate the preparation of the final compounds I(a-c) according to the present invention. Examples 3 and 11, Tables 3A, 3B, and 6, illustrate the preparation of the novel intermediate of the compound of formula X. The remainder of the examples illustrate the preparations of the various intermediates according to the reaction scheme set forth previously that are made to produce the compounds of the present invention. For ease of reference, each example is keyed to a particular step in the reaction scheme. Moreover, there are specific examples of one compound for each step in the sequence and a general procedure for making the other compounds which are listed in the table at the end of each example.
Unless otherwise noted, materials used in the examples were obtained from commercial suppliers and were used without further purification. Tetrahydrofuran (THF) was distilled from Na/benzophenone immediately prior to use. The following chemicals were obtained from Sigma Chemical Co: digitonin, 3-hydroxy-3-methylglutaryl coenzyme A (HMG-CoA), and β-nicotinamide adenine dinucleotide phosphate, reduced form (NADPH). The (1- 14 C)-acetate was obtained from both Research Biochemicals, Inc. (RBI) and New England Nuclear-Dupont (NEN). The (3- 14 C)-HMG-CoA was obtained from NEN, and (7- 3 H)-cholesterol and (7- 3 H)-cholesteryl oleate were obtained from Amersham. HI-FBS (heat-inactivated fetal bovine serum) and calf serum were obtained from Grand Island Biological Co. (GIBCO). Lovastatin was obtained from Merck. Lovastatin-Na was prepared from Lovastatin by reaction with sodium hydroxide. Pravastatin was obtained from Sigma, and XU-62320 was obtained from Sandoz. Diisopropylamine was distilled from CaH 2 and was stored over 4 A molecular sieves. 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU) was used without purification. Dimethylformamide (DMF) was dried over 4 A sieves prior to use. Melting points were determined on a Thomas-Hoover apparatus and are uncorrected. Nuclear magnetic resonance (NMR) spectra were measured in the indicated solvent with tetramethylsilane (TMS) as the internal standard using the following spectrometers: Bruker WP-100SY (100 MHz 1 H, 25 MHz 13 C), General Electric QE-300 (300 MHz 1 H, 75 MHz 13 C), Varian XL-400 (400 MHz 1 H, 100 MHz 13 C). NMR chemical shifts are expressed in parts per million (ppm) downfield from internal TMS using the δ scale. 1 H Hertz). 13 C NMR data are reported for proton-decoupled spectra and are tabulated in order. Infrared (IR) spectra were determined on a Nicolet 5DXB FT-IR spectrophotometer. Chemical ionization (DCI), electron impact (EI), and fast atom bombardment (FAB) mass spectra (MS) were determined on a Finnegan MAT 8230 spectrometer. Elemental analyses were carried out on a Perkin Elmer 240C analyzer. Analytical thin layer chromatography (TLC) was done with Merck Silica Gel 60 F 254 plates (250 micron). Flash chromatography and medium pressure liquid chromatography (MPLC) were done with Merck Silica Gel 60 (230-400 mesh).
EXAMPLE 1
2-[(1,1'-Biphenyl)-4-ylmethyl]cyclohexanone (Compound (hereinafter CP) 84, Reaction Scheme (hereinafter RS) Step a)
A 1.3M solution of s-BuLi in hexanes (51.8 mmol, 39.8 mL) was added over a 15 min period to a -78° C. solution containing 9.29 g (51.8 mmol) of N-cyclohexylidine cyclohexylamine (Stork, G., Dowd, S. R. J. Am. Chem. Soc., 1963, 85, 2178-80) in 75 mL of THF under N 2 . After 30 min, the cooling bath was removed and the cloudy solution was allowed to warm to 0° C. A solution of 10.0 g (49.3 mmol) of 4-(chloromethyl)biphenyl in 30 mL of THF was added and the resulting mixture was stirred at room temperature overnight. A 40 mL portion of 2N aqueous HCl was added and the mixture was stirred for 5 h. Et 2 O (200 mL) was added and the organic solution was washed successively with water, saturated NaHCO 3 , and brine. The organic layer was dried over Na 2 SO 4 and concentrated to give 13.1 g of an off-white solid. Recrystallization from EtOAc:hexanes afforded 9.22 g (71%) of the title compound as a white solid, m.p. 78°-79° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.40 (m, 1), 1.65 (m, 2), 1.83 (m, 1), 2.10 (m, 2), 2.35 (m, 1), 2.52 (m, 2), 2.60 (m, 1), 3.27 (dd, 1, J=5, 13.5 Hz), 7.2-7.6 (complex); IR (KBr) 1695 cm -1 ; MS (DCI) m/z 265 (base). Anal. Calcd. for C 19 H 20 O: C, 86.32; H, 7.63. Found: C, 86.66; H, 7.98.
General procedure for the preparation of 2-substituted cyclohexanones shown in Table 1
Method A (RS step a): s-BuLi (50 mmol) was added under N 2 to a solution of 50 mmol of the cyclohexylimine of N-cyclohexylidine cyclohexylamine in 75 mL of THF at -78° C. The resulting cloudy solution was stirred for 30 min and was allowed to warm to 0° C. A solution of 48 mmol of the appropriate alkyl or aralkyl halide in a minimum volume of THF was added dropwise and the solution was allowed to warm to room temperature and was stirred overnight. A 50 mL portion of 2N aqueous HCl (100 mmol) was added and the two phase mixture was stirred vigorously until TLC analysis showed that hydrolysis of the imine was complete (2-8 h). The mixture was extracted with Et 2 O or EtOAc and the organic layer was washed with water, saturated aqueous NaHCO 3 , and brine. After drying over Na 2 SO 4 and concentration, the crude product was purified by either MPLC or vacuum distillation using a short path still.
Alternatively, a solution of 50 mmol of the appropriate cyclohexylimine in a minimum volume of THF was added dropwise under N 2 to an ice-cold stirring solution of 52.5 mmol of lithium diisopropylamide (LDA, generated by the addition of 55 mmol of diisopropylamine in 35 mL of THF to 52.5 mmol of a 1.6M hexanes solution of n-BuLi at 0° C.). After 30-45 min, a solution of 48 mmol of the appropriate alkyl or aralkyl halide in a minimum volume of THF was added dropwise and the mixture was allowed to warm to room temperature and was stirred overnight. A 75 mL portion of 2N aqueous HCl (150 mmol) was added and the two phase mixture was stirred vigorously until TLC analysis showed that hydrolysis of the imine was complete (4-24 h). The reaction mixture was worked up as described above.
Method B (RS step b): An ice-cold suspension of oil-free NaH (150 mmol) in 120 mL of a 1:1 mixture of benzene and DMF was treated, dropwise, with ethyl 2-cyclohexanonecarboxylate (145 mmol) in 60 mL of the same solvent mixture over a 30 min period. The mixture was stirred an additional 30 min and 140 mmol of the appropriate alkyl or aralkyl halide in a minimum amount of benzene was added dropwise. After stirring at room temperature for 2-3 days, 250 mL of Et 2 O was added and the organic solution was washed with water (3×100 mL) and brine. Drying (Na 2 SO 4 ) and concentration gave the crude alkylated keto ester which was dissolved in 100 mL each of HOAc and 6N aqueous HCl and refluxed until TLC analysis showed that the hydrolysis/decarboxylation was complete (2-3 days). Most of the solvent was removed by rotary evaporation and the residue was partitioned between water (100 mL) and Et 2 O (300 mL). The Et 2 O layer was washed with brine, dried over Na 2 SO 4 , and concentrated to give the crude product which was purified as described in Method A above.
TABLE 1__________________________________________________________________________ ##STR15##Compound Mass spectrumNumber Method R.sub.2 bp (°C.) m/z [M + H].sup.+__________________________________________________________________________85 A (1-Nap)-CH.sub.2 oil 23986 B (2-ClPh)CH.sub.2 129-135 (0.4 Torr) 22387 A (2-Nap)-CH.sub.2 180-190 (0.6 Torr) 23988 A (3-MeOPh)CH.sub.2 190-195 (4 Torr) 21989 A (3,4-di-MeOPh)CH.sub.2 180-187 (1 Torr) 24990 A (4-ClPh)CH.sub.2 150-170 (0.1 Torr) 22391 B (4-FPh)CH.sub.2 110-125 (0.5 Torr) 20792 A (4-i-PrPh)CH.sub.2 90-160 (0.1 Torr) 23193 A (4-MePh)CH.sub.2 oil 20394 B (4-MeOPh)CH.sub.2 155-170 (0.6 Torr) 21995 A (4-t-BuPh)CH.sub.2 136-148 (0.5 Torr) 24596 A Ph(CH.sub.2).sub.2 124-130 (0.5 Torr) 20397 A Ph(CH.sub.2).sub.3 100-200 (0.8 Torr) 21798 A PhCHCHCH.sub.2 160-170 (0.8 Torr) 215__________________________________________________________________________
EXAMPLE 2
6-[(1,1'-Biphenyl-4-yl)methyl]-2-(2,2-dimethoxy-1-oxoethyl)cyclohexanone (CP 99, RS step c)
Diisopropylamine (38.8 mmol, 3.93 g, 5.4 mL) was added under N 2 to a -20° C. solution of 1.6M n-BuLi in hexanes (35.3 mmol, 22.0 mL) and 30 mL of THF. After 15 min, the solution was cooled to -78° C. and 8.88 g (33.6 mmol) of Compound 84 in 50 mL of THF was added. After 45 min, 2.26 mL (18.5 mmol, 2.48 g) of methyl dimethoxyacetate was added and the mixture was allowed to warm slowly to room temperature and was stirred overnight. The resulting solution was cooled to 0° C. and acidified to pH 3-4 with 2N aqueous HCl. The mixture was diluted with Et 2 O (200 mL) and washed with water and brine. After drying over Na 2 SO 4 , the solution was concentrated to give 11.5 g of a yellow oil. The crude product was purified by MPLC using a solvent gradient ranging from 1:6 to 1:5 EtOAc:hexanes to afford 5.94 g (96%) of the title compound as a waxy, white solid; 1 H NMR (CDCl 3 , 300 MHz) 1.4-2.8 (complex, 9), 3.33 (s, 3, minor tautomer), 3.37 (s, 3, minor tautomer), 3.42 (s, 6, major tautomer), 4.63 (s, 1, minor tautomer), 4.96 (s, 1, major tautomer), 7.2-7.6 (complex, 9); IR (KBr) 1739, 1704, 1601, 1584, 1488, 1444 cm -1 ; MS (DCI) m/z 335 (base), 303. Anal. Calcd. for C 23 H 26 O 4 : C, 75.38; H, 7.15. Found: C, 75.64; H, 7.39.
General procedure for the preparation of 6-substituted diketones shown in Table 2 (RS step c)
Diisopropylamine (57.8 mmol) was added under N 2 to a -20° C. solution of 52.5 mmol of a 1.6M hexanes solution of η-BuLi and 45 mL of THF. (Alternatively, 52.5 mmol of a 1.0M solution of LiN(SiMe 3 ) 2 in THF/cyclohexane was added to 25 mL of THF under N 2 at -20° C.) After 15 min, the solution was cooled to -78° C. and 50.0 mmol of the appropriately substituted cyclohexanone (from Table 1, or commercially available) in 50 mL of THF was added. After 45 min, 27.5 mmol of methyl dimethoxyacetate was added and the mixture was allowed to warm slowly to room temperature. After stirring overnight, the resulting solution was cooled to 0° C. and acidified to pH 3-4 with 2N aqueous HCl. The mixture was diluted with Et 2 O (200 mL) and washed with water and brine. After drying over Na.sub. 2 SO 4 , the solution was concentrated to give the crude product, which was purified by MPLC.
TABLE 2______________________________________ ##STR16##Com- Mass spectrumpound mp m/zNumber R.sub.2 (°C.) [MHMeOH].sup.+______________________________________100 (1-Nap)CH.sub.2 oil 309101 (2-ClPh)CH.sub.2 oil 293102 (2-Et)Bu oil 225103 (2-Nap)CH.sub.2 oil 309104 (3-MeOPh)CH.sub.2 oil 289105 (3,4-di-MeOPh)CH.sub.2 oil 319106 (4-ClPh)CH.sub.2 oil 293107 (4-FPh)CH.sub.2 oil 277108 (4-i-PrPh)CH.sub.2 oil 301109 (4-MePh)CH.sub.2 oil 273110 (4-MeOPh)CH.sub.2 oil 289111 (4-t-BuPh)CH.sub.2 oil 315112 c-Hex oil 251113 Et oil 197114 Me oil 183115 n-Pr oil 211116 Ph oil 245117 PhCH.sub.2 oil 259118 Ph(CH.sub.2).sub.2 oil 273119 Ph(CH.sub.2).sub.3 oil 287120 PhCHCHCH.sub.2 oil 285121 s-Bu oil 225______________________________________
EXAMPLE 3
7-[(1,1'-Biphenyl-4-yl)methyl]-2-(4-fluorophenyl)-4,5,6,7-tetrahydro-2H-indazole-3-carboxaldehyde (CP 122, RS step g) and 7-[(1,1'-Biphenyl-4-yl)methyl]-1-(4-fluorophenyl)-4,5,6,7-tetrahydro-1H-indazole-3-carboxaldehyde (CP 123 RS step g)
A solution of Compound 99 (20.2 mmol, 5.35 g) in 100 mL of absolute EtOH was treated with 1.91 g (23.3 mmol) of NaOAc and 3.45 g (21.2 mmol) of 4-fluorophenylhydrazine.HCl. After stirring overnight under N 2 , the solvent was removed by rotary evaporation and the orange residue was dissolved in 100 mL of THF. A 50 mL portion of 1N aqueous HCl was added and the mixture was stirred and refluxed gently for 4 h. Et 2 O (150 mL) was added after cooling and the organic layer was washed sequentially with water, saturated aqueous NaHCO 3 , and brine. Drying over Na 2 SO 4 and concentration afforded 6.74 g of an orange foam. The crude product was purified by MPLC using 1:9 EtOAc:hexanes to give 1.90 g (23%) of the 2-(4-fluorophenyl) isomer and 1.15 g (14%) of the 1-(4-fluorophenyl) isomer, each as an orange solid. The 2-(4-fluorophenyl) isomer was recrystallized from EtOAc:Et 2 O to afford Compound 122 as a pale orange solid, m.p. 148°-150° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.6-2.0 (complex, 4), 2.72 (dd, 1, J=10.5, 13.5 Hz), 2.75-3.0 (complex), 3.15 (m, 1), 3.56 (dd, 1, J=4, 13.5 Hz), 7.2-7.7 (complex, 13), 9.87 (s, 1); IR (KBr) 1510, 1222 cm -1 ; MS (DCI) m/z 411 (base). HRMS (EI) Cacld for C 27 H 23 FN 2 O: 410.179428. Found: 410.175457.
The 1-(4-fluorophenyl) isomer was recrystallized from EtOAc:hexanes to provide analytically pure Compound 123 as an orange solid, m.p. 155-156; 1 H NMR (CDCl 3 , 300 MHz) 1.7-1.9 (complex, 4), 2.46 (dd, 1, J=10.5, 13.5 Hz), 2.61 (dd, 1, J=4, 13.5 Hz), 2.73 (dt, 1, J=16.5, 8 Hz), 3.02 (dt, 1, J=16.5, 4 Hz), 3.30 (m, 1), 6.89 (d, 2, J=8 Hz), 7.2-7.6 (complex, 11), 10.08 (s, 1); IR (KBr) 1691, 1512 cm -1 ; MS (DCI) m/z 411 (base). Anal. Calcd. for C 27 H 23 FN 2 O: C, 79.00; H, 5.65; N, 6.82. Found: C, 79.22; H, 5.54; N, 6.61.
General procedure for the preparation of 7-substituted 4,5,6,7-tetrahydroindazole-3-carboxaldehydes shown in Tables 3A and 3B (RS step g)
A solution of 10 mmol of the appropriately substituted diketone from Table 2 in 100 mL of absolute EtOH or MeOH was treated with 11.5 mmol of a base (NaOAc, Et 3 N, or pyridine) and 10.5 mmol of the appropriately substituted hydrazine hydrochloride. After stirring overnight under N 2 , the solvent was removed by rotary evaporation and the residue was dissolved in 50 mL of THF. A 25 mL portion of 1N aqueous HCl was added and the mixture was stirred and refluxed gently for 4 h. After cooling, 100 mL of Et 2 O was added and the organic layer was washed sequentially with water, saturated aqueous NaHCO 3 , and brine. Drying over Na 2 SO 4 and concentration afforded the crude product as a mixture of 2-aryl and 1-aryl isomers in ratios ranging from 1:1 to 1:3. The crude mixture was purified by recrystallization and/or MPLC; the 2-aryl isomer eluted before the 1-aryl isomer in all cases.
TABLE 3A__________________________________________________________________________ ##STR17## MassCompound SpectrumNumber R.sub.1 R.sub.2 mp (°C.) [M + H].sup.+__________________________________________________________________________124 4-FPh (1-Nap)CH.sub.2 183-184 385125 4-FPh (2-ClPh)CH.sub.2 137-138 369126 4-FPh (2-Et)Bu 121-122 329127 4-FPh (2-Nap)CH.sub.2 foam 385128 4-FPh (3-MeOPh)CH.sub.2 93-94 365129 4-FPh (3,4-di-MeOPh)CH.sub.2 117-119 395130 4-FPh (4-ClPh)CH.sub.2 134-135 369131 4-FPh (4-FPh)CH.sub.2 128-131 353132 4-FPh (4-i-PrPh)CH.sub.2 112-113 377133 4-FPh (4-MePh)CH.sub.2 117-118 349134 4-FPh (4-MeOPh)CH.sub.2 104-107 365135 4-FPh (4-t-BuPh)CH.sub.2 139-140 391136 4-FPh c-Hex 119-121 327137 4-FPh Et 95-97 273138 4-FPh Me 124-125 259139 4-FPh n-Pr oil 287140 4-FPh Ph 71-73 321141 4-FPh PhCH.sub.2 144-145 335142 4-FPh Ph(CH.sub.2).sub.2 97-99 349143 4-FPh Ph(CH.sub.2).sub.3 oil 363144 4-FPh PhCHCHCH.sub.2 106-108 361145 4-FPh s-Bu 86-89 301296 t-Bu (1-Nap)CH.sub.2 119-120 347__________________________________________________________________________
TABLE 3B__________________________________________________________________________ ##STR18##Compound Mass SpectrumNumber R.sub.1 R.sub.2 mp (°C.) [M + H].sup.+__________________________________________________________________________146 4-FPh (1-Nap)CH.sub.2 116-117 385147 4-FPh (2-ClPh)CH.sub.2 glass 369297 4-FPh (2-Et)Bu foam 329148 4-FPh (2-Nap)CH.sub.2 122-123 385149 4-FPh (3-MeOPh)CH.sub.2 foam 365150 4-FPh (3,4-di-MeOPh)CH.sub.2 109-110 395151 4-FPh (4-ClPh)CH.sub.2 126-128 369152 4-FPh (4-FPh)CH.sub.2 oil 353153 4-FPh (4-i-PrPh)CH.sub.2 oil 377154 4-FPh (4-MePh)CH.sub.2 foam 349155 4-FPh (4-MeOPh)CH.sub.2 oil 365156 4-FPh (4-t-BuPh)CH.sub.2 124-125 391157 4-FPh c-Hex oil 327158 4-FPh Et 72-74 273159 4-FPh Me 79-80 259160 4-FPh n-Pr 50-53 287161 4-FPh Ph 139-140 321162 4-FPh PhCH.sub.2 99-100 335163 4-FPh Ph(CH.sub.2).sub.2 89-90 349164 4-FPh Ph(CH.sub.2).sub.3 100-102 363165 4-FPh PhCHCHCH.sub.2 104-105 361166 4-FPh s-Bu oil 301298 t-Bu (1-Nap)CH.sub.2 142-143 347__________________________________________________________________________
EXAMPLE 4
3-Acetoxymethyl-2-(4-fluorophenyl)-4,5,6,7-tetrahydro-2H-indazole (CP 167, RS step h)
Et 3 N (0.717 mL, 0.520 g, 5.14 mmol) was added to a stirring suspension of 1.00 g (5.04 mmol) of 2-acetoxyacetylcyclohexanone (Dolmazon, R.; Gelin, S. J. Heterocyclic Chem., 1982, 19, 117-121) and 0.820 g (5.04 mmol) of 4-fluorophenylhydrazine.HCl in 20 mL of absolute EtOH. The resulting solution was stirred under N 2 for 4 h at room temperature and refluxed for 6 h. The mixture was concentrated and the residue was partitioned between 100 mL of Et 2 O and 50 mL of dilute aqueous HCl. The Et 2 O layer was washed with water, saturated aqueous NaHCO 3 , and brine. After drying over Na 2 SO 4 , the solution was concentrated to give 1.43 g of light brown solid. Recrystallization from EtOAc:hexanes afforded 0.753 g (52%) of the title compound as a white solid, m.p. 128.5°-129.5° C.; 1 H NMR (CDCl 3 , 400 MHz) 1.85 (m, 4), 2.07 (s, 3), 2.60 (t, 2, J=6 Hz), 2.73 (t, 2, J=6 Hz), 5.00 (s, 2), 7.15 (t, 2, J=9 Hz), 7.45 (dd, 2, J=5, 9 Hz); IR (KBr) 1740, 1220 cm -1 ; MS (DCI) m/z 289 (base), 228 . Anal. Calcd. for C 16 H 17 FN 2 O 2 : C, 66.65; H, 5.94; N, 9.72. Found: C, 66.74; H, 5.89; N, 9.61.
General procedure for the preparation of acetates shown in Table 4 RS step h)
A mixture of 10 mmol of the appropriate 2-acetoxyacetylcycloalkanone (2-acetoxyacetylcyclopentanone, Dolmazon, R. J. Heterocyclic Chem., 1988, 25, 751-7; 2-acetoxyacetylcyclohexanone, Dolmazon, R.; Gelin, S. J. Heterocyclic Chem., 1982, 19, 117-21), 10.5 mmol of Et 3 N, and 10 mmol of appropriately substituted hydrazine in 40 mL of absolute EtOH was stirred under N 2 for 4-5 h and refluxed for 6-8 h. The solvent was evaporated and the resulting residue was partitioned between Et 2 O and 0.1N HCl. The Et 2 O layer was washed with water, saturated aqueous NaHCO 3 , and brine. After drying over Na 2 SO 4 , the solution was concentrated and the crude product was purified by recrystallization and/or MPLC. The 2-acetoxyacetylcyclopentanone reaction afforded a 9:1 mixture of 1-aryl:2-aryl isomers, while the 2-acetoxyacetylcyclohexanone reaction gave only the 2-aryl isomer.
TABLE 4______________________________________ ##STR19##Compound Mass SpectrumNumber n R.sub.1 mp (°C.) [M + H].sup.+______________________________________168 0 1-(4-FPh) 85-88 275169 0 2-(4-FPh) 87-88 275170 1 2-(4-ClPh) oil 305______________________________________
EXAMPLE 5
2-(4-Fluorophenyl)-4,5,6,7-tetrahydro-2H-indazole-3-methanol (CP 171, RS step i)
Compound 167 (24.3 mmol, 7.00 g) was dissolved in 125 mL of MeOH and stirred while 26.7 mL of 1N aqueous NaOH was added. After 30 min the resulting cloudy suspension was concentrated and partitioned between 200 mL of EtOAc and 100 mL of water. The organic layer was washed with water and brine and was dried over Na 2 SO 4 . The solution was concentrated to give 5.85 g of orange solid. Recrystallization from EtOAc gave 4.08 g (68%) of the title compound as off-white crystals, m.p. 163°-164° C.; 1 H NMR (CDCl 3 , 400 MHz) 1.80 (m, 4), 2.52 (t, 1, J=5 Hz), 2.86 (t, 2, J=6 Hz), 2.71 (t, 2, J=6 Hz), 4.52 (d, 2, J=5 Hz), 7.12 (2, t, J=9 Hz), 7.58 (dd, 2, J=5, 9 Hz); 13 C NMR (DMSO-d 6 , 25 MHz) 19.8, 23.0 (triple), 52.1, 115.7 (d, J C-F =23 Hz), 116.6, 125.2 (d, J C-F =8 Hz), 136.5, 137.9, 148.8, 160.6 (d, J C-F =244 Hz); IR (HBr) 3200 (broad), 1510 cm -1 ; MS (DCI) m/z 247 (base). Anal. Calcd. for C 14 H 15 FN 2 O: C, 68.28; H, 6.14; N, 11.37. Found: C, 68.47; H, 6.02; N, 11.35.
General procedure for the preparation of alcohols shown in Table 5 RS step i)
The appropriate acetate from Table 4 (10 mmol) was dissolved in 50 mL of MeOH and stirred while 11 mmol of 1N aqueous NaOH was added. The resulting suspension was stirred 0.5-24 h and worked up by one of two methods. In the first method, the mixture was concentrated and partitioned between water and solvent. The organic phase was wasjed with water and brine, dried over Na 2 SO 4 , and concentrated. Alternatively, the reaction mixture was filtered to remove the solids and the filtrate was treated with water to precipitate the remaining product. The combined solids were dissolved in CHCl 3 , washed with brine, and concentrated. The crude product was purified by recrystallization or a combination of recrystallization and MPLC.
TABLE 5______________________________________ ##STR20##Compound Mass SpectrumNumber n R.sub.1 mp (°C.) [M + H].sup.+______________________________________172 0 1-(4-FPh) 85-86 233173 0 2-(4-FPh) 170-171 233174 1 2-(4-ClPh) 184.5-185 263______________________________________
EXAMPLE 6
2-(4-Fluorophenyl)-2,4,5,6,7,8-hexahydrocycloheptapyrazole-3-methanol (CP 175, RS step e, followed by RS step k)
A solution of 2.80 g (25 mmol) of cycloheptanone and 4.71 g (25 mmol) of ethyl (tetrahydropyranyloxy)acetate (Ireland, R. E.; Wipf, P. Tetrahedron Lett., 1989, 30, 919-22) in 20 mL of Et 2 O was added over the course of 1 h to an ice-cold, stirring mixture of hexane-washed NaH and 0.12 mL (2 mmol, 0.092 g) of absolute EtOH in 10 mL of Et 2 O under N 2 . The light brown mixture was allowed to warm to room temperature and was stirred overnight. MeOH (5 mL) was added and the solution was poured onto 200 mL of saturated aqueous NH 4 Cl. After acidification to pH 2 with 1N aqueous HCl, the mixture was extracted with Et 2 O. The organic layer was washed with brine, dried over Na 2 SO 4 , and concentrated to give 5.61 g of crude 2-[(tetrahydropyranyloxy)acetyl]cycloheptanone as a light brown oil.
The crude diketone was dissolved in 60 mL of absolute EtOH and combined with 3.07 mL (22 mmol, 2.23 g) of Et 3 N and 3.45 g (21.1 mmol) of 4-fluorophenylhydrazine.HCl. The resulting solution was stirred under N 2 overnight and refluxed for 4 h. A 30 mL portion of 1N aqueous HCl was added and the mixture was refluxed for an additional hour. The mixture was cooled and extracted with 200 mL of Et 2 O. The organic phase was washed with water, saturated aqueous NaHCO 3 , and brine and dried over Na 2 SO 4 . The solution was concentrated to give 5.50 g of a 1.2:1 mixture of 1-(4-fluorophenyl)-1,4,5,6,7,8-hexahydrocycloheptapyrazole-3-methanol and the title compound as a brown oil. The crude product was crystallized from EtOAc:Et 2 O to afford 0.97 g (18%) of the title compound as an off-white solid, m.p. 177°-178° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.72 (m, 4), 1.85 (m, 2), 2.60 (m, 2), 2.80 (m, 2), 4.51 (d, 2, J=5 Hz), 7.15 (m, 2), 7.60 (m, 2); IR (KBr) 3240 (broad), 1513, 1223 cm -1 ; MS (DCI) m/z 261 (base). Anal. Calcd. for C 15 H 17 FN 2 O: C, 69.21; H, 6.58; N, 1076. Found C, 69.15; H, 6.77; N, 10.63.
EXAMPLE 7
Ethyl 2,4,5,6,7,8-hexahydrocycloheptapyrazole-3-carboxylate (CP 176, RS step f, followed by RS step l)
Hydrazine hydrate (30.3 mmol, 1.52 g, 1.47 mL) was added dropwise under N 2 to a stirring solution of ethyl α,2-dioxocycloheptaneacetate (Tsuboi, S.; Nishiyama, E.; Furutani, H.; Utaka, M.; Takeda, A. J. Org. Chem., 1987, 52, 1359-62) in 60 mL of MeOH. The reaction mixture, which had become warm during the addition, was allowed to cool to room temperature and was stirred overnight. The solvent was evaporated and the resulting oil was dissolved in CH 2 Cl 2 and washed with water and brine. After drying over Na 2 SO 4 , the solution was concentrated to give 6.36 g of pale yellow solid. Recrystallization from EtOAc:hexanes afforded 3.44 g (52%) of the title compound as a white solid, m.p. 90°-92° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.38 (t, 3, J=7 Hz), 1.67 (m, 4), 1.84 (m, 2), 2.80 (m, 2), 2.93 (m, 2 ), 4.37 (q, 2, J=7 Hz), 7.0 (broad s, 1); IR (KBr) 1719 cm -1 ; MS (DCI) m/z 209 (base). Anal. Calcd. for C 11 H 16 N 2 O 2 : C, 63.44; H, 7.74; N, 13.45. Found: C, 63.48; H, 7.76; N, 13.64.
EXAMPLE 8
Ethyl 2-(4-fluorobenzyl)-2,4,5,6,7,8-hexahydrocycloheptapyrazole-3-carboxylate (CP 177, RS step m) and ethyl 1-(4-fluorobenzyl)-1,4,5,6,7,8-hexahydrocycloheptapyrazole-3-carboxylate (CP 178, RS step m)
A solution of 7.90 g (37.9 mmol) of Compound 176 in 35 mL of DMF was added dropwise under N 2 to a suspension of hexane-washed NaH (41.7 mol, 1.67 g of a 60% oil suspension) in 20 mL of DMF. When the addition was complete, the mixture was heated at 140° C. with an oil bath for 15 min. A solution of 5.00 mL (41.7 mmol, 6.03 g) of 4-fluorobenzyl chloride in 5 mL of DMF was added and the mixture was heated for an additional 30 min. After cooling, 400 mL of Et 2 O was added and the solution was poured onto 250 mL of saturated aqueous NH 4 Cl. The aqueous layer was extracted with two 50 mL portions of Et 2 O and the combined organic phases were washed with three 100 mL portions of water and once with brine. The organic solution was dried over Na 2 SO 4 and concentrated to give 11.9 g of a 1:1 mixture of the title compounds as a yellow oil. Purification by MPLC afforded, in the earlier fractions, 3.85 g (32%) of pure 2-(4-fluorobenzyl) isomer as a colorless oil; 1 H NMR (CDCl 3 , 100 MHz) 1.31 (t, 3, J=7 Hz), 1.70 (m, 6), 2.83 (m, 4), 4.29 (q, 2, J=7 Hz), 5.58 (s, 2), 6.9-7.4 (complex, 4). The later-eluting fractions contained 4.94 g (42%) of the 1-(4-fluorobenzyl) isomer as a colorless oil; 1 H NMR (CDCl 3 , 100 MHZ) 1.40 (t, 3, J=7 Hz), 1.4-2.0 (complex, 6), 2.55 (m, 2), 2.95 (m, 2), 4.41 (q, 2, J=7 Hz), 5.35 (s, 2), 7.00 (m, 4).
EXAMPLE 9
2-(4-Fluorobenzyl)-2,4,5,6,7,8-hexahydrocycloheptapyrazole-3-methanol (CP 179, RS step n)
A solution of 1.43 g (4.52 mmol) of Compound 177 in 13 mL of THF under N 2 was added dropwise over a 10 min period to an ice cold suspension of 0.113 g (2.83 mmol) of LiAlH 4 in 7 mL of THF. After 30 min in the cold, the suspension was allowed to warm to room temperature and was stirred for 2 h. Et 2 O (50 mL) was added, followed sequentially by 0.12 mL of water, 0.12 mL of 15% aqueous NaOH, and 0.36 mL of water, dropwise over a 1 h period. The white suspension was stirred overnight, treated with MgSO 4 , and stirred 30 min more. The solids were removed by filtration and were washed with CH 2 Cl 2 . The combined filtrates were concentrated to afford 1.24 g of a white solid, which was recrystallized to give 0.998 g (80%) of the title compound as white needles, m.p. 156°-157° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.55-1.70 (complex, 7), 1.82 (m, 2), 2.47 (m, 2), 2.74 (m, 2), 4.48 (d, 2, J=6 Hz), 5.27 (s, 2), 6.98 (t, 2, J=7 Hz), 7.12 (m, 2); IR (KBr) 3170 (broad), 1517, 1231, 1016 cm -1 ; MS (DCI) m/z 275 (base), 257. Anal. Calcd. for C 16 H 19 FN 2 O: C, 70.05; H, 6.98; N, 10.21. Found: C, 69.98; H, 6.98; N, 10.28.
EXAMPLE 10
1-(4-Fluorobenzyl)-1,4,5,6,7,8-hexahydrocycloheptapyrazole-3-methanol (CP 180, RS step n)
Following the procedure described above, 4.82 mmol (15.23 g) of Compound 178 gave 4.12 g (98%) of the title compound as an amber oil, which was used without purification; 1 H NMR (CDCl 3 , 100 MHz) 1.70 (m, 6), 2.57 (m, 4), 3.0 (broad s, 1), 4.59 (d, 2, J=6 Hz), 5.20 (s, 2), 7.00 (m, 4).
EXAMPLE 11
2-(4-Fluorophenyl)-4,5,6,7-tetrahydro-2H-indazole-3-carboxaldehyde (CP 181, RS step j)
Pyridinium chlorochromate (22.0 mmol, 4.74 g) was suspended in 50 ml of CH 2 Cl 2 . Compound 171 (14.8 mmol, 3.64 g) was added in small portions over a 5 min period and the resulting suspension was stirred at room temperature for 4 h. A 300 mL portion of Et 2 O was added and the mixture was filtered through a pad of Florisil. The tarry residue remaining in the flask was sonicated twice with 100 mL of Et 2 O and the organic solutions were also filtered through Florisil. The Florisil pad was washed thoroughly with Et 2 O and the combined organic solutions were dried over Na 2 SO 4 and concentrated to give 3.57 g of an off-white solid. The crude product was recrystallized from Et 2 O:hexanes to give 1.71 g (42%) of white crystals, m.p. 80°-81° C. (the mother liquors were concentrated to give 1.67 g (47%) of a white solid which was judged to be pure enough to carry on); 1 H NMR (CDCl 3 , 400 MHz) 1.85 (m, 4), 2.77 (t, 2, J=6 Hz), 2.88 (t, 2, J=6 Hz), 7.20 (m, 2), 7.45 (m, 2), 9.86 (s, 1); IR (KBr) 1670, 1575 cm -1 ; MS (DCI) m/z 245 (base). Anal. Calcd. for C 14 H 13 FN 2 O: C, 68.84; H, 5.36; N, 11.47. Found: C, 68.79; H, 5.40; N, 11.39.
General procedure for the preparation of aldehydes shown in Table 6 (RS step j)
Method A: MnO 2 (100-120 mmol) was added in one portion to a stirring suspension of 10 mmol of the alcohol from Example 10 in 60 mL of benzene. The mixture was refluxed gently under N 2 until TLC analysis indicated that the starting material was completely consumed. After cooling, the slurry was filtered through a Celite pad and the black solids were washed with 250 mL of CH 2 Cl 2 . The filtrate was concentrated and the crude product was purified by MPLC or recrystallization.
Method B: To a stirring suspension of pyridinium chlorochromate (10 mmol) in 25 mL of CH 2 Cl 2 was added, in approximately five portions, the appropriately substituted alcohol from Table 5 or Examples 5, 6, or 9, as a solid. The resulting suspension was stirred for 2-4 h at room temperature. Et 2 O (150 mL) was added and the mixture was sonicated for 5-10 min. The supernatant was decanted through a pad of Florisil and the remaining solids were sonicated twice with 50 mL portions of Et 2 O, which in turn were filtered. The Florisil pad was washed thoroughly with Et 2 O and the combined filtrates were concentrated to give the crude product, which was purified by recrystallization.
TABLE 6______________________________________ ##STR21## MassCom- spectrumpound Me- m/zNumber thod n R.sub.1 mp (°C.) [M + H].sup.+______________________________________182 B 0 1-(4-FPh) 122-123 231183 B 0 2-(4-FPh) 79-80 231184 B 1 2-(4-ClPh) 93-94 261185 B 2 2-(4-FPh) oil 259186 A 2 1-(4-FPhCH.sub.2) oil 273187 B 2 2-(4-FPhCH.sub.2) oil 273______________________________________
EXAMPLE 12
Methyl (E)-7-[7-[(1,1'-Biphenyl-4-yl)methyl]-2-(4-fluorophenyl)-4,5,6,7-tetrahydro-2H-indazol-3-yl]-3-hydroxy-5-oxo-6-heptenoate (CP 188, RS step t)
Compound 122 (2.68 mmol, 1.10 g), LiCl (3.08 mmol, 0.131 g), and 1.18 g (3.08 mmol) of methyl 3-[(t-butyldimethylsilyl)oxy]-6-(dimethoxyphosphinyl)-5-oxohexanoate (Theisen, P. D.; Heathcock, C. H. J. Org. Chem., 1988, 53, 2374-81) were combined in 15 mL of CH 3 CN. DBU (2.95 mmol, 0.449 g, 0.441 mL) was added and the resulting clear, orange solution was stirred under N 2 for 6 h. The mixture was diluted with 100 mL of Et 2 O and washed successively with 50 mL of 5% aqueous NaHSO 4 , water, and brine. After drying over Na 2 SO 4 , the solution was concentrated to give 2.00 g of orange oil. The crude mixture was dissolved in 25 mL of CH 3 CN, treated with 2.5 mL of 48% aqueous HF, and stirred for 5 h. Et 2 O (100 mL) was added and the acid was quenched by careful addition of saturated aqueous NaHCO 3 . The ethereal solution was washed with brine, dried over Na 2 SO 4 , and concentrated to give 1.54 g of orange foam. The crude product was purified by MPLC using 1:2 EtOAc:hexanes to afford 0.22 g (15%) of the title compound as a yellow solid and an additional 0.50 g (34%) as a pale yellow solid which crystallized directly from the chromatography fractions. m.p. 137°-138° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.4-2.1 (complex, 4), 2.56 (d, 2, J=6 Hz), 2.71 (m, 3), 2.80 (d, 2, J=6 Hz), 3.15 (m, 1), 3.47 (d, 1, J=4 Hz), 3.56 (dd, 1, J=4, 13.5 Hz), 3.71 (s, 3), 4.52 (m, 1), 6.51 (d, 1, J=16 Hz), 7.1-7.7 (complex, 14); IR (KBr) 3450 (broad), 1734, 1603, 1512 cm -1 ; MS (DCI) m/z 553, 451 (base). Anal. Calcd. for C 34 H 33 FN 2 O 4 : C, 73.89; H, 6.02; N, 5.07. Found: C, 73.94; H, 6.01; N, 5.03.
General procedure for the preparation of 7-substituted (E)-3-hydroxy-5-oxo-6-heptenoates shown in Table 7 (RS step t)
The appropriately substituted aldehyde (10 mmol) from Table 3A or 3B was combined with 11.5 mmol of LiCl and 11.5 mmol of methyl 3-[(t-butyldimethylsilyl)oxy]-6-(dimethoxyphosphinyl)-5-oxohexanoate in 25 mL of CH 3 CN. DBU (11 mmol) was added and the resulting clear solution was stirred for 4-6 h, becoming slightly cloudy during that time. The mixture was diluted with 100 mL of Et 2 O and washed successively with 100 mL of 5% aqueous NaHSO 4 , water, and brine. After drying over Na 2 SO 4 , the solution was concentrated to give the crude silyloxy keto ester. The crude residue was dissolved in 100 mL of CH 3 CN and was treated with 10 mL of 48% aqueous HF. After TLC analysis indicated complete consumption of silyloxy keto ester, 200 mL of Et 2 O was added and the HF was quenched by careful addition of saturated aqueous NaHCO 3 . The ethereal solution was washed with brine, dried over Na 2 SO 4 , and concentrated to give the crude product, which was purified by MPLC.
TABLE 7__________________________________________________________________________ ##STR22##Compound Mass SpectrumNumber R.sub.1 R.sub.2 mp (°C.) m/z [M + H].sup.+__________________________________________________________________________189 1-(4-FPh) Ph(CH.sub.2).sub.2 oil 491190 2-(4-FPh) (1-Nap)CH.sub.2 foam 527191 2-(4-FPh) (2-Nap)CH.sub.2 foam 527192 2-(4-FPh) (4-i-PrPh)CH.sub.2 oil 519193 2-(4-FPh) (4-t-BuPh)CH.sub.2 foam 533194 2-(4-FPh) Ph foam 463195 2-(4-FPh) PhCHCHCH.sub.2 oil 503__________________________________________________________________________
EXAMPLE 13
Methyl (E)-(3RS,5SR)-7-[7-[(1,1'-Biphenyl-4-yl)methyl]-2-(4-fluorophenyl)-4,5,6,7-tetrahydro-2H-indazol-3-yl]-3,5-dihydroxy-6-heptenoate (CP 39, RS step u)
Compound 188 (1.21 mmol, 0.67 g) was dissolved in 1.5 mL of MeOH and 5 mL of THF and treated, dropwise, with 1.33 mL (1.33 mmol) of a 1.0M solution of Et 3 B in THF. Air (5 mL) was bubbled into the solution via syringe and the resulting solution was stirred under N 2 for 2 h and then cooled to -78° C. After addition of solid NaBH 4 in one portion, the mixture was allowed to warm slowly to room temperature and was stirred overnight. Et 2 O (100 mL) and saturated aqueous NH 4 Cl (50 mL) were added. The ethereal solution was washed with brine, dried over Na 2 SO 4 , and concentrated to give a yellow oil. The oil was dissolved in MeOH, stirred under air overnight, and concentrated to provide 0.74 g of pale yellow foam. Purification by MPLC using 45:55 EtOAc:hexanes afforded a white foam which crystallized upon addition of Et 2 O, giving 281 mg (42%) of the title compound as a white solid, m.p. 118°-119° C. (the mother liquors gave 77 mg (12%) of additional product as a white foam); 1 H NMR (CDCl 3 , 300 MHz) 1.4-2.0 (complex, 6), 2.49 (d, 2, J=6 Hz), 2.6-2.8 (complex, 3), 3.10 (m, 1), 3.56 (dt, 1, J=13.5, 3.5 Hz), 3.62 (s, 1), 3.71 (s, 3), 3.78 (s, 1), 4.28 (m, 1), 4.48 (m, 1), 6.01 (dd, 1, J=6, 16 Hz), 6.45 (d, 1, J=16 Hz); 13 C NMR (CDCl 3 , 75 MHz) 21.6, 22.8, 27.9, 36.2, 40.3, 41.3, 42.7, 51.9, 68.3, 72.5, 115.7, 116.0 (J C-F =23 Hz), 118.0, 127.0, 127.3 (J C-F =8 Hz), 128.7, 129.8, 135.0, 135.3, 136.1, 138.8, 139.8, 141.1, 153.3, 161.7 (J C-F =247 Hz), 172.9; IR (KBr) 3400 (broad), 1734, 1513 cm -1 ; MS (DCI) m/z 555 (base), 537, 523. Anal. Calcd. for C 34 H 35 FN 2 O 4 : C, 73.63; H, 6.36; N, 5.05. Found: C, 73.33; H, 6.60; N, 5.06.
General procedure for the preparation of 7-substituted (E)-(3RS,5SR)-3,5-dihydroxy-6-heptenoates shown in Table 8 (RS step u)
The appropriately substituted hydroxy keto ester from Table 7 (10 mmol), dissolved in 10 mL of MeOH and 30 mL of THF, was treated with 11 mmol of a 1.0M THF solution of Et 3 B. Air (about 20 mL) was bubbled into the solution via syringe and the resulting solution was stirred under N 2 for 2 h. After cooling to -78° C., the solution was treated with 11 mmol of solid NaBH 4 in one portion, causing some gas evolution. The mixture was allowed to warm slowly to room temperature and was stirred overnight. Saturated aqueous NH 4 Cl was added and the mixture was extracted with Et 2 O. The organic extracts were washed with brine, dried over Na 2 SO 4 , and concentrated to dryness. The residue, which smelled of excess Et 3 B, was then dissolved in MeOH and stirred vigorously under air until TLC analysis showed complete conversion of the boron intermediates to the desired product (4-24 h). The MeOH was removed by rotary evaporation and the crude material was purified by MPLC.
TABLE 8__________________________________________________________________________ ##STR23##Compound Mass SpectrumNumber R.sub.1 R.sub.2 mp (°C.) m/z [M + H].sup.+__________________________________________________________________________40 1-(4-FPh) Ph(CH.sub.2).sub.2 foam 49341 2-(4-FPh) (1-Nap)CH.sub.2 foam 52942 2-(4-FPh) (2-Nap)CH.sub.2 foam 52943 2-(4-FPh) (4-i-PrPh)CH.sub.2 foam 52144 2-(4-FPh) (4-t-BuPh)CH.sub.2 foam 53545 2-(4-FPh) Ph foam 46546 2-(4-FPh) PhCHCHCH.sub.2 oil 505__________________________________________________________________________
EXAMPLE 14
(E)-(3RS,5SR)-7-[7-[(1,1'-Biphenyl-4-yl)methyl]-2-(4-fluorophenyl)-4,5,6,7-tetrahydro-2H-indazol-3-yl]-3,5-dihydroxy-6-heptenoic acid.Sodium salt.Dihydrate (CP 1, RS step v)
Aqueous NaOH (0.25N, 0.392 mmol, 1.57 mL) was added slowly to an ice-cold solution of Compound 39 (0.400 mmol, 222 mg) in 10 mL of MeOH. When the addition was complete, the solution was allowed to warm to room temperature and stirred for 2 h. The solution was concentrated to dryness using a rotary evaporator and the residue was dissolved in 40 mL of water. The slightly cloudy solution was suction filtered through a coarse frit, frozen in a -78° C. bath, and lyophilized. The product was dried in a vacuum oven over Drierite to provide 219 mg (93%) of the title compound as a fluffy, white solid; 1 H NMR (DMSO-d 6 , 400 MHz) 1.3-2.0 (complex, 7), 2.05 (dd, 1, J=4, 15 Hz), 2.4-2.7 (complex, 4), 3.01 (m, 1), 3.40 (m, 1), 3.75 (m, 1), 4.26 (m, 1), 5.13 (broad s, 1), 6.07 (dd, 1, J=5, 16 Hz), 6.36 (d, 1, J=16 Hz), 7.2-7.7 (complex, 13); IR (KBr) 3400 (broad), 1577, 1513 cm -1 ; MS (FAB+) m/z 535, 563, 541, 167, 115 (base). Anal. Calcd. for C 33 H 32 FN 2 NaO 4 .2H 2 O: C, 66.21; H, 6.06; N, 4.68. Found: C, 66.39; H, 5.67; N, 4.62.
General procedure for the preparation of 7-substituted (E)-(3RS,5SR)-3,5-dihydroxy-6-heptenoic acid sodium salts shown in Tables 9A and 9B (RS step v)
Aqueous NaOH (0.25N, 0.98 mmol) was added slowly to an ice-cold methanolic solution (15 mL) of 1.0 mmol of the appropriately substituted dihydroxy ester of Table 8, 13A, or 13B or Example 20. When the addition was complete, the solution was allowed to warm to room temperature and stir for 2 h until TLC analysis indicated that nearly all starting material had been consumed. The solution was concentrated to dryness using a rotary evaporator and the residue was dissolved in 40 mL of water. The slightly cloudy solution was suction filtered through a coarse frit, frozen in a -78° C. bath, and lyophilized. The product was dried in a vacuum oven over Drierite to provide the desired sodium salt as a white, fluffy powder.
TABLE 9A______________________________________ ##STR24## MassCom- Spectrumpound m/zNumber n R.sub.1 R.sub.2 [M + H].sup.+______________________________________2 0 4-FPh H 3833 1 4-FPh (4-FPh)CH.sub.2 5054 1 4-FPh c-Hex 4975 1 4-FPh Et 4256 1 4-FPh Me 4117 1 4-FPh Ph(CH.sub.2).sub.2 5018 1 4-FPh PhCHCHCH.sub.2 5139 2 4-FPhCH.sub.2 H 425______________________________________
TABLE 9B__________________________________________________________________________ ##STR25##Compound Mass SpectrumNumber n R.sub.1 R.sub.2 R.sub.3 Y m/z [M + H].sup.+__________________________________________________________________________10 0 4-FPh H H CHCH 38311 1 4-FPh (1-Nap)CH.sub.2 H CHCH 53712 1 4-FPh (2-ClPh)CH.sub.2 H CHCH 52113 1 4-FPh (2-Nap)CH.sub.2 H CHCH 53714 1 4-FPh (3-MeOPh)CH.sub.2 H CHCH 51715 1 4-FPh (3,4-di-MeOPh)CH.sub.2 H CHCH 54716 1 4-FPh (4-ClPh)CH.sub.2 H CHCH 52017 1 4-FPh (4-FPh)CH.sub.2 H CHCH 50518 1 4-F Ph (4-i-PrPh)CH.sub.2 H CHCH 52919 1 4-FPh (4-MePh)CH.sub.2 H CHCH 50120 1 4-FPh (4-MeOPh)CH.sub.2 H CHCH 51721 1 4-FPh (4-t-BuPh)CH.sub.2 H CHCH 54322 1 4-FPh 6,7-Benzo CHCH 44523 1 4-FPh c-Hex H CHCH 47924 1 4-FPh Et H CHCH 42525 1 4-FPh H H CHCH 39726 1 4-ClPh H H CHCH 41327 1 4-FPh H H CHCMe 41128 1 4-FPh Me H CHCH 41129 1 4-FPh n-Pr H CHCH 43930 1 4-FPh Ph H CHCH 47331 1 4-FPh PhCH.sub.2 H CHCH 48732 1 4-FPh Ph(CH.sub.2).sub.2 H CHCH 50133 1 4-FPh Ph(CH.sub.2).sub.3 H CHCH 51534 1 4-FPh PhCHCHCH.sub.2 H CHCH 51335 1 4-FPh s-Bu H CHCH 45336 2 4-FPh 7,8-Benzo CHCH 45937 2 4-FPh H H CHCH 41138 2 4-FPhCH.sub.2 H H CHCH 425__________________________________________________________________________
EXAMPLE 15
Ethyl (E)-3-[2-(4-fluorophenyl)-7-benzyl-4,5,6,7-tetrahydro-2H-indazol-3-yl]-2-propenoate (CP 196, RS step o)
Triethylphosphonoacetate (3.03 mmol, 0.706 g, 0.625 mL) in 2.5 mL of THF was added slowly under N 2 to a stirring suspension of oil-free NaH (3.09 mmol, 0.074 g) in 5 mL of THF. After 45 min, the solution was cooled in an ice bath and Compound 162 (2.75 mmol, 0.92 g) in 10 mL of THF was added dropwise. The mixture was allowed to warm to room temperature and was stirred overnight. Saturated aqueous NH 4 Cl (50 mL) was added and the mixture was extracted with 100 mL of Et 2 O. The organic phase was washed with brine, dried over Na 2 SO 4 , and concentrated to give 1.29 g of amber oil. The crude product was crystallized from Et 2 O:hexanes to give 0.598 g (54%) of the title compound as an off-white solid, m.p. 117°-118° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.30 (t, 3, J=7 Hz), 1.4-2.1 (complex, 4), 1.6-1.8 (complex, 3), 3.10 (m, 1), 3.54 (dd, 1 , J=4, 13.5 Hz), 4.22 (q, 2, J=7 Hz), 6.20 (d, 1, J=16 Hz), 7.1-7.4 (complex, 9), 7.48 (d, 1, J=16 Hz); IR (KBr) 1705 cm -1 ; MS (DCI) m/z 405 (base). Anal. Calcd. for C 25 H 25 FN 2 O 2 : C, 74.24; H, 6.23; N, 6.93. Found: C, 74.31; H, 6.09; N, 6.91.
General procedure for the preparation of 3-substituted 2-propenoates shown in Tables 10A and 10B (RS step o)
A solution of 11 mmol of triethylphosphonoacetate or triethyl phosphonopropionate in 10 mL of THF was added slowly under N 2 to a stirring suspension of 11.5 mmol of NaH in 15 mL of THF. After 45 min, the solution was cooled in an ice bath and the appropriately substituted aldehyde (10 mmol) from Table 3A, 3B, or 6 in THF (25 mL) was added dropwise. The mixture was allowed to warm to room temperature and was stirred overnight. Saturated aqueous NH 4 Cl (100 mL) was added and the mixture was extracted with Et 2 O. The organic phase was washed with brine, dried over Na 2 SO 4 , and concentrated. The crude product was crystallized or was carried on without purification.
TABLE 10A__________________________________________________________________________ ##STR26##Compound Mass SpectrumNumber n R.sub.1 R.sub.2 mp (°C.) m/z [M + H].sup.+__________________________________________________________________________197 0 4-FPh H 113-114 301198 1 4-FPh (4-FPh)CH.sub.2 foam 411199 1 4-FPh c-Hex oil 397200 1 4-FPh Et 99-100 343201 1 4-FPh Me oil 329202 1 4-FPh PhCHCHCH.sub.2 foam 431203 2 (4-FPh)CH.sub.2 H 75-76 343__________________________________________________________________________
TABLE 10B__________________________________________________________________________ ##STR27##Compound Mass SpectrumNumber n R.sub.1 R.sub.2 Y mp (°C.) m/z [M + H].sup.+__________________________________________________________________________204 0 4-FPh H CHCH 94-95 301205 1 4-FPh (2-ClPh)CH.sub.2 CHCH oil 439206 1 4-FPh (2-Et)Bu CHCH oil 399207 1 4-FPh (2-Nap)CH.sub.2 CHCH 154-155 455208 1 4-FPh (3-MeOPh)CH.sub.2 CHCH 135-137 435209 1 4-FPh (3,4-di-MeOPh)CH.sub.2 CHCH foam 465210 1 4-FPh (4-ClPh)CH.sub.2 CHCH oil 439211 1 4-FPh (4-FPh)CH.sub.2 CHCH oil 411212 1 4-FPh (4-MePh)CH.sub.2 CHCH 135-136 419213 1 4-FPh (4-MeOPh)CH.sub.2 CHCH oil 435214 1 4-FPh (4-t-BuPh)CH.sub.2 CHCH oil 461215 1 4-FPh c-Hex CHCH oil 419216 1 4-FPh Et CHCH oil 343217 1 4-ClPh H CHCH oil 331218 1 4-FPh H CHCH 76-77.5 315219 1 4-FPh H CHC(Me) 134-135 329220 1 4-FPh Me CHCH oil 329221 1 4-FPh n-Pr CHCH oil 357222 1 4-FPh Ph(CH.sub.2).sub.2 CHCH oil 419223 1 4-FPh Ph(CH.sub.2).sub.3 CHCH oil 433224 1 4-FPh PhCHCHCH.sub.2 CHCH oil 431225 1 4-FPh s-Bu CHCH oil 371226 2 4-FPh H CHCH 53-55 329227 2 4-FPhCH.sub.2 H CHCH oil 343__________________________________________________________________________
EXAMPLE 16
(E)-3-[2-(4-Fluorophenyl)-7-benzyl-4,5,6,7-tetrahydro-2H-indazol-3-yl]2-propen-1-ol (CP 228, RS step p)
A 1.5M solution of (i-Bu) 2 AlH in toluene (6.53 mmol, 4.35 mL) was added under N 2 to an ice cold solution of 1.10 g (6.53 mmol) of Compound 196 in 11 mL of THF. The solution was stirred for 1.5 h and was quenched with 0.5 mL of MeOH. When the initial bubbling had ceased, 35 mL of 1N aqueous HCl was added and the mixture was extracted with 150 mL of ether. The organic phase was washed sequentially with water, saturated aqueous NaHCO 3 , and brine. After drying over Na 2 SO 4 , the solvent was evaporated to give 0.89 g of an off-white solid. Recrystallization from EtOAc:hexanes afforded 0.62 g (63%) of the title compound as a white solid, m.p. 185°-186° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.4-2.0 (complex, 5), 2.62 (m, 3), 3.05 (m, 1), 3.54 (dd, 1, J=4, 13.5 Hz), 4.27 (t, 2, J=5 Hz), 6.16 (dt, 1, J=16, 5.5 Hz), 6.43 (d, 1, J=16 Hz), 7.1-7.5 (complex, 9); IR (KBr) 3300, 1515 cm -1 ; MS (DCI) m/z 363 (base), 345. Anal. Calcd. for C 23 H 23 FN 2 O: C, 76.22; H, 6.40; N, 7.73. Found: C, 75.73; H, 6.01; N, 7.91.
General procedure for the preparation of 3-substituted 2-propen-1-ols shown in Tables 11A and 11B (RS step p)
A 1.5M solution of (i-Bu) 2 AlH in toluene (24 mmol) was added under N 2 to an ice cold solution of 10 mmol of the appropriately substituted ester from Table 10A or 10B in 50 mL of THF. The solution was stirred for 1.5 h and was quenched with 2 mL of MeOH. When the initial bubbling had ceased, 100 mL of 1N aqueous HCl was added and the mixture was extracted with 300 mL of ether. The organic phase was washed sequentially with water, saturated aqueous NaHCO 3 , and brine. After drying over Na 2 SO 4 , the solvent was evaporated and the crude product was purified by recrystallization or MPLC.
TABLE 11A__________________________________________________________________________ ##STR28##Compound Mass SpectrumNumber n R.sub.1 R.sub.2 mp (°C.) m/z [M + H].sup.+__________________________________________________________________________229 0 4-FPh H 135-136 259230 1 4-FPh (4-FPh)CH.sub.2 171-173 381231 1 4-FPh c-Hex oil 355232 1 4-FPh Et yellow foam 301233 1 4-FPh Me 115-116 287234 1 4-FPh PhCHCHCH.sub.2 oil 389235 2 (4-FPh)CH.sub.2 H oil 301__________________________________________________________________________
TABLE 11B__________________________________________________________________________ ##STR29##Compound Mass SpectrumNumber n R.sub.1 R.sub.2 Y mp (°C.) m/z [M + H].sup.+__________________________________________________________________________236 0 4-FPh H CHCH 144-145 259237 1 4-FPh (2-ClPh)CH.sub.2 CHCH 177-178 397238 1 4-FPh (2-Et)Bu CHCH oil 357239 1 4-FPh (2-Nap)CH.sub.2 CHCH 205-207 413240 1 4-FPh (3-MeOPh)CH.sub.2 CHCH foam 393241 1 4-FPh (3,4-di-MeOPh)CH.sub.2 CHCH 183-184 423242 1 4-FPh (4-ClPh)CH.sub.2 CHCH 204-206 397243 1 4-FPh (4-FPh)CH.sub.2 CHCH 183-185 381244 1 4-FPh (4-MePh)CH.sub.2 CHCH 184-186 377245 1 4-FPh (4-MeOPh)CH.sub. 2 CHCH 172-173 393246 1 4-FPh (4-t-BuPh)CH.sub.2 CHCH 141-142 419247 1 4-FPh c-Hex CHCH oil 355248 1 4-FPh Et CHCH 140-142 301249 1 4-ClPh H CHCH 171-173 289250 1 4-FPh H CHCH 145-146 273251 1 4-FPh H CHC(Me) 149-150 287252 1 4-FPh Me CHCH 139-140 287253 1 4-FPh n-Pr CHCH 140-141 315254 1 4-FPh Ph(CH.sub.2).sub.2 CHCH 116-118 377255 1 4-FPh Ph(CH.sub.2).sub.3 CHCH 105-108 391256 1 4-FPh PhCHCHCH.sub.2 CHCH oil 389257 1 4-FPh s-Bu CHCH oil 329258 2 4-FPh H CHCH 104-105 287259 2 (4-FPh)CH.sub.2 H CHCH 78-79 301__________________________________________________________________________
EXAMPLE 17
(E)-3-[2-(4-Fluorophenyl)-2,4,5,6-tetrahydrobenzo[6,7]cyclohepta[1,2-c]pyrazol-3-yl]-2-propen-1-ol (CP 260, RS step q)
1-Benzosuberone (25 mmol, 4.10 g, 3.74 mL) was added dropwise under N 2 to a stirring suspension of 4.23 g (26 mmol) of 4-fluorophenylhydrazine.HCl and 2.13 g (26 mmol) of NaOAc in 15 mL of absolute EtOH. The mixture was refluxed for 3 h and allowed to stir at room temperature overnight. After concentration, the residue was partitioned between water and Et 2 O. The organic phase was washed with saturated aqueous NaHCO 3 and brine, dried over Na 2 SO 4 , and concentrated to give 6.68 g of crude hydrazone as an orange solid. The crude product was dissolved in 25 mL of THF and added dropwise under N 2 to a solution of LDA (made by adding 7.34 mL (52.3 mmol, 5.29 g) of diisopropylamine in 20 mL of THF to 33.7 mL (52.3 mmol) of 1.6M n-BuLi in hexanes) at -10° C. The resulting dark brown solution was stirred for 30 min and was treated with a solution of methyl 4-tetrahydropyranyloxy-2-butenoate (Harnish, W.; Morera, E.; Ortar, G. J. Org. Chem., 1985, 50, 1990-2) in 5 mL of THF. After 1.5 h, 42 mL of 3N aqueous HCl was added to the cold solution, which was then refluxed for 15 min. Et 2 O (150 mL) was added and the organic layer was washed with saturated aqueous NaHCO 3 and brine. After drying over Na 2 SO 4 , the mixture was concentrated to give 12 g of light brown oil. The crude residue was refluxed under N 2 for 8 h with 0.31 g (1.25 mmol) of pyridinium p-toluenesulfonate in 50 mL of MeOH. The solution was concentrated and the residue was partitioned between Et 2 O and water. The organic phase was washed with saturated aqueous NaHCO 3 and brine, dried over Na 2 SO 4 , and concentrated to give 9.2 g of brown oil. Purification by MPLC using 1:3 EtOAc:hexanes afforded 3.35 g of yellow solid which was recrystallized from EtOAc:hexanes to give 3.00 g (36%) of the title compound as a white solid, m.p. 127°-128° C.; 1 H NMR (CDCl 3 , 300 MHz) 2.15 (m, 2), 2.84 (m, 4), 4.30 (m, 2), 6.16 (dt, 1, J=16, 5 Hz), 6.44 (d, 1, J=16 Hz), 7.2 (complex, 5), 7.50 (m, 2), 8.07 (m, 1); IR (KBr) 3300 (broad), 1515, 1223 cm -1 ; MS (DCI) m/z 335 (base), 317. Anal. Calcd. for C 21 H 19 FN 2 O: C, 75.43; H, 5.73; N, 8.38. Found: C, 75.26; H, 5.52; N, 8.24.
EXAMPLE 18
(E)-3-[4,5-Dihydro-2-(4-fluorophenyl)-2H-benz[g]indazol-3-yl]-2-propen-1-ol (CP 261, RS step q)
α-Tetralone (25 mmol, 3.65 g, 3.33 mL) was added dropwise under N 2 to a stirring suspension of 4.23 g (26 mmol) of 4-fluorophenylhydrazine.HCl and 2.13 g (26 mmol) of NaOAc in 15 mL of absolute EtOH. The mixture was refluxed for 2 h, cooled, and concentrated to remove the solvent. The residue was partitioned between water and Et 2 O. The organic phase was washed with saturated aqueous NaHCO 3 and brine, dried over Na 2 SO 4 , and concentrated to give 6.21 g of crude hydrazone as a yellow solid. The crude product was dissolved in 30 mL of THF and added dropwise under N 2 to a solution of LDA (made by adding 7.18 mL (51.2 mmol, 5.18 g) of diisopropylamine in 10 mL of THF to 33.0 mL (51.2 mmol) of 1.55M n-BuLi in hexanes) at -10° C. The resulting dark brown solution was stirred for 30 min and was treated with a solution of methyl 4-tetrahydropyranyloxy-2-butenoate (Harnish, W.; Morera, E.; Ortar, G. J. Org. Chem., 1985, 50, 1990-2) in 15 mL of THF. After 1.5 h, 42 mL of 3N aqueous HCl was added to the cold solution, which was then refluxed for 1 h. Et 2 O (150 mL) was added and the organic layer was washed with saturated aqueous NaHCO 3 and brine. After drying over Na 2 SO 4 , the mixture was concentrated to give 10.2 g of a light brown oil. The crude residue was refluxed under N 2 for 8 h with 0.31 g (1.25 mmol) of pyridinium p-toluenesulfonate in 50 mL of MeOH. The solution was concentrated and the residue was partitioned between Et 2 O and water. The organic phase was washed with saturated aqueous NaHCO 3 and brine, dried over Na 2 SO 4 , and concentrated to give 8.44 g of a brown oil. Purification by MPLC using 1:3 EtOAc:hexanes afforded 3.03 g of an off-white solid which was recrystallized from EtOAc:hexanes to give 2.37 g (37%) of the title compound as an off-white solid, m.p. 149°-150° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.70 (t, 1, J=6 Hz), 2.91 (m, 2), 3.02 (m, 2), 4.31 (dt, 2, J=1.5, 4.5 Hz), 6.21 (dt, 1, J=16, 5 Hz), 6.46 (dd, 1, J=1.5, 16 Hz), 7.18 (t, 2, J=8.5 Hz), 7.25 (m, 3), 7.48 (dd, 2, J=5, 8.5 Hz), 7.92 (m, 1); IR (KBr) 3300 (broad), 1509, 1221 cm -1 ; MS (DCI) m/z 321 (base), 303. Anal. Calcd. for C 20 H 17 FN 2 O: C, 74.98; H, 5.35; N, 8.74. Found: C, 74.78; H, 5.33; N, 8.97.
EXAMPLE 19
(E)-3-[2-(4-Fluorophenyl)-7-benzyl-4,5,6,7-tetrahydro-2H-indazol-3-yl]-2-propenal (CP 262, RS step r)
MnO 2 (30 mmol, 2.20 g) was added in one portion to a stirring suspension of 0.84 g (2.32 mmol) of Compound 228 in 15 mL of benzene. The mixture was refluxed gently under N 2 for 3 h. After cooling, the slurry was filtered through a Celite pad and the solids were washed with 100 mL of CH 2 Cl 2 . The filtrate was concentrated to give 0.75 g of a yellow solid which was purified by MPLC (1:8 EtOAc:hexanes) to provide 0.529 g (63%) of the title compound as a pale yellow solid, m.p. 130°-131° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.6-2.1 (complex, 4), 2.6-2.8 (complex, 3), 3.10 (m, 1), 3.54 (dd, 1, J=4, 13.5 Hz), 6.48 (dd, 1, J=7.5, 16 Hz), 7.1-7.5 (complex, 10), 9.52 (d, 1, J=7.5 Hz); IR (KBr) 1677, 1617, 1512 cm -1 ; MS (DCI) m/z 361 (base), 307, 269, 241, 178. Anal. Calcd. for C 23 H 21 FN 2 O: C, 76.65; H, 5.87; N, 7.77. Found: C, 76.47; H, 5.61; N, 7.35.
General procedure for the preparation of 3-substituted 2-propenals shown in Tables 12A and 12B. RS step r
Method A: MnO 2 (100-120 mmol) was added in one portion to a stirring suspension of 10 mmol of the appropriately substituted alcohol from Table 11A or 11B or Example 17 or 18 in benzene (60 mL). The mixture was refluxed gently under N 2 until TLC analysis indicated that the starting material was completely consumed. After cooling, the slurry was filtered through a Celite pad and the black solids were washed with 250 mL of CH 2 Cl 2 . The filtrate was concentrated and the crude product was purified by MPLC or recrystallization.
Method B: CrO 3 (60 mmol) was added under N 2 in several portions to an ice-cold solution of 120 mmol of pyridine in 100 mL of CH 2 Cl 2 . The mixture was stirred at room temperature for 15 min and was re-cooled to 0° C. The appropriately substituted alcohol from Table 11A or 11B was either dissolved in a minimum amount of CH 2 Cl 2 and added dropwise or, if solid, was added in 5-10 portions over a 30 min period. The slurry was stirred 30-45 min at 0° C. and was allowed to stir at room temperature until TLC analysis indicated the reaction was complete. Et 2 O (200 mL) was added and the solvent was decanted from the tarry residue through a Celite pad. The residue was sonicated with two 100 mL portions of Et 2 O, which were also decanted through Celite. The combined filtrates were washed successively with 100 mL of 1N aqueous HCl, 100 mL of water, two 100 mL portions of saturated aqueous NaHCO 3 , and brine. The ethereal solution was dried (Na 2 SO 4 ), concentrated, and purified by MPLC or recrystallization.
TABLE 12A__________________________________________________________________________ ##STR30##Compound Mass spectrumNumber Method n R.sub.1 R.sub.2 mp (°C.) m/z [M + H].sup.+__________________________________________________________________________263 B 0 4-FPh H 138-139 257264 A 1 4-FPh (4-FPh)CH.sub.2 133-136 379265 A 1 4-FPh c-Hex foam 353266 A 1 4-FPh Et 118-121 299267 A 1 4-FPh Me oil 285268 A 1 4-FPh PhCHCHCH.sub.2 foam 387269 A 2 (4-FPh)CH.sub.2 H oil 299__________________________________________________________________________
TABLE 12B__________________________________________________________________________ ##STR31##Compound Mass SpectrumNumber Method n R.sub.1 R.sub.2 R.sub.3 Y mp (°C.) m/z [M__________________________________________________________________________ + H].sup.+270 B 0 4-FPh H H CHCH 127-128 257271 A 1 4-FPh (2-ClPh)CH.sub.2 H CHCH 184-185 395272 A 1 4-FPh (2-Et)Bu H CHCH 98-100 355273 A 1 4-FPh (2-Nap)CH.sub.2 H CHCH 174-175 411274 A 1 4-FPh (3-MeOPh)CH.sub.2 H CHCH 97-99 391275 A 1 4-FPh (3,4-di-MeOPh)CH.sub.2 H CHCH foam 421276 A 1 4-FPh (4-ClPh)CH.sub.2 H CHCH 144-145 395277 A 1 4-FPh (4-F Ph)CH.sub.2 H CHCH oil 379278 A 1 4-FPh (4-MePh)CH.sub.2 H CHCH 160-162 375279 A 1 4-FPh (4-MeOPh)CH.sub.2 H CHCH 141-142 391280 A 1 4-FPh (4-t-BuPh)CH.sub.2 H CHCH 145-148 417281 A 1 4-FPh 6,7-Benzo CHCH foam 319282 A 1 4-FPh c-Hex H CHCH oil 353283 A 1 4-FPh Et H CHCH 99-101 299284 B 1 4-ClPh H H CHCH 133-134 287285 B 1 4-FPh H H CHCH 122-123 271286 A 1 4-FPh H H CHC(Me) 172-173 285287 A 1 4-FPh Me H CHCH 145-146 285288 A 1 4-FPh n-Pr H CHCH 92-93 313289 A 1 4-FPh Ph(CH.sub.2).sub.2 H CHCH 132-134 375290 A 1 4-FPh Ph(CH.sub.2).sub.3 H CHCH oil 389291 A 1 4-FPh Ph CHCHCH.sub.2 H CHCH foam 387292 A 1 4-FPh s-Bu H CHCH oil 327293 A 2 4-FPh 7,8-Benzo CHCH 208-210 333294 A 2 4-FPh H H CHCH 92-93 285295 A 2 (4-FPh)CH.sub.2 H H CHCH oil 299__________________________________________________________________________
EXAMPLE 20
Ethyl (E)-(3RS,5SR)-7-[7-benzyl-2-(4-fluorophenyl)-4,5,6,7-tetrahydro-2H-indazol-3-yl]-3,5-dihydroxy-6-heptenoate (CP 47, RS step s)
A solution of 1.11 mL of ethyl acetoacetate (8.72 mmol, 1.13 g) in 10 mL of THF was added dropwise under N 2 to a stirring suspension of 0.220 g (9.16 mmol) of oil-free NaH in 10 mL of THF. The mixture was stirred for 30 min and cooled to -10° C. in an ice/acetone bath. n-BuLi in hexanes (1.6 M, 8.72 mmol, 5.45 mL) was added slowly, producing a pale yellow solution. After 30 min, a solution of 2.86 g (7.93 mmol) of Compound 262 in 25 mL of THF was added and the resulting yellow solution was stirred for 45 min. Saturated aqueous NH 4 Cl (50 mL) was added and the mixture was extracted with 100 mL of Et 2 O. The organic solution was washed with brine, dried over Na 2 SO 4 , and concentrated to give 3.84 g of crude hydroxy keto ester as an orange oil.
The crude intermediate was dissolved in 8 mL of MeOH and 25 mL of THF. A 1.0M solution of Et 3 B in THF (8.60 mmol, 8.60 mL) was added and 20 mL of air was bubbled into the solution via syringe. The solution was stirred under N 2 for 2 h and was cooled to -78° C. NaBH 4 (8.60 mmol, 0.33 g) was added in one portion. The mixture was allowed to warm slowly to room temperature and was stirred overnight. Saturated aqueous NH 4 Cl (100 mL) was added and the mixture was extracted with 150 mL of Et 2 O. The organic solution was washed with brine, dried over Na 2 SO 4 , and concentrated to give an oil which was dissolved in 50 mL of MeOH and stirred vigorously under air overnight. The solution was concentrated to give 3.86 g of a yellow oil. Purification by MPLC using 2:3 EtOAc:hexanes yielded 1.83 g (47%) of the title compound as a white foam; 1 H NMR (CDCl 3 , 300 MHz) 1.27 (t, 3, J=7 Hz), 1.3-2.0 (complex, 6), 2.48 (d, 2, J=6 Hz), 2.60 (m, 3), 3.03 (m, 1), 3.55 (m, 1), 3.63 (s, 1), 3.78 (s, 1), 4.17 (q, 2, J=7 Hz), 4.30 (m, 1), 4.50 (m, 1), 6.00 (dd, 1, J=6, 16 Hz), 6.44 (d, 1, J=16 Hz), 7.1-7.5 (complex, 9); 13 C NMR (CDCl 3 , 75 MHz) 14.2, 21.6, 22.8, 27.8, 36.2, 40.7, 41.5, 42.7, 60.9, 68.4, 72.5, 115.7, 116.0 (J C-F =23 Hz), 117.9, 125.9, 127.3 (J C-F =8 Hz), 128.2, 129.3, 135.0, 135.4, 136.2, 140.6, 153.3, 161.8 (J C-F =247 Hz), 172.5; IR (KBr) 3400 (broad), 1732, 1514 cm -1 ; MS (DCI) m/z 493, 457, 401, 333, 241, 91 (base). Anal. Calcd. for C 29 H 33 FN 2 O 4 : C, 70.71; H, 6.75; N, 5.69. Found: C, 70.90; H, 7.04; N, 5.67.
General procedure for the preparation of 7-substituted (E)-(3RS,5SR)-3,5-dihydroxy-6-heptenoates shown in Tables 13A and 13B (RS step s)
A solution of 11 mmol of ethyl acetoacetate in 10 mL of THF was added dropwise under N 2 to a stirring suspension of 11.5 mmol of oil-free NaH in 15 mL of THF. The mixture was stirred for 30 min and cooled to -10° C. in an ice/acetone bath. n-BuLi in hexanes (11 mmol of a 1.6M solution) was added slowly, producing a pale yellow solution. After 30 min, a solution of 10 mmol of the appropriately substituted aldehyde from Table 12A or 12B in 30 mL of THF was added and the resulting yellow solution was stirred for about 1 h. Saturated aqueous NH 4 Cl (75 mL) was added and the mixture was extracted with 150 mL of Et 2 O. The organic solution was washed with brine, dried over Na 2 SO 4 , and concentrated to give the crude hydroxy keto ester which was carried on without purification.
The crude intermediate was dissolved in 10 mL of MeOH and 30 mL of THF. A 1.0M solution of Et 3 B in THF (11 mmol) was added and 20 mL of air was bubbled into the solution via syringe. The solution was stirred under N 2 for 2 h and was cooled to -78° C. NaBH 4 (11 mmol) was added in one portion, causing some gas evolution. The mixture was allowed to warm slowly to room temperature and was stirred overnight. Saturated aqueous NH 4 Cl (150 mL) was added and the mixture was extracted with 200 mL of Et 2 O. The organic solution was washed with brine, dried over Na 2 SO 4 , and concentrated. The residue, which smelled of excess Et 3 B, was then dissolved in MeOH and stirred vigorously under air until TLC analysis showed complete conversion of the boron intermediates to the desired product (4-24 h). The MeOH was removed by rotary evaporation and the crude material was purified by MPLC.
TABLE 13A__________________________________________________________________________ ##STR32##Compound Mass SpectrumNumber n R.sub.1 R.sub.2 m/z [M + H].sup.+__________________________________________________________________________48 0 4-FPh H 38949 1 4-FPh (4-FPh)CH.sub.2 51150 1 4-FPh c-Hex 48551 1 4-FPh Et 43152 1 4-FPh Me 41753 1 4-FPh PhCHCHCH.sub.2 51554 2 (4-FPh)CH.sub.2 H 431__________________________________________________________________________
TABLE 13B__________________________________________________________________________ ##STR33##Compound Mass SpectrumNumber n R.sub.1 R.sub.2 R.sub.3 Y m/z [M + H].sup.+__________________________________________________________________________55 0 4-FPh H H CHCH 38956 1 4-FPh (2-ClPh)CH.sub.2 H CHCH 52857 1 4-FPh (2-Et)Bu H CHCH 48758 1 4-FPh (3-MeOPh)CH.sub.2 H CHCH 52359 1 4-FPh (3,4-di-MeOPh)CH.sub.2 H CHCH 55360 1 4-FPh (4-ClPh)CH.sub.2 H CHCH 52861 1 4-FPh (4-FPh)CH.sub.2 H CHCH 51162 1 4-FPh (4-MePh)CH.sub.2 H CHCH 50763 1 4-FPh (4-MeOPh) CH.sub.2 H CHCH 52364 1 4-FPh (4-t-BuPh)CH.sub.2 H CHCH 54965 1 4-FPh 6,7-Benzo CHCH 45166 1 4-FPh c-Hex H CHCH 48567 1 4-FPh Et H CHCH 43168 1 4-ClPh H H CHCH 41969 1 4-FPh H H CHCH 40370 1 4-FPh H H CHCMe 41771 1 4-FPh Me H CHCH 41772 1 4-FPh n-Pr H CHCH 44573 1 4-FPh Ph(CH.sub.2).sub.2 H CHCH 50774 1 4-FPh Ph(CH.sub.2).sub.3 H CHCH 52175 1 4-FPh s-Bu H CHCH 45976 2 4-FPh 7,8-Benzo CHCH 46577 2 4-FPh H H CHCH 41778 2 (4-FPh)CH.sub.2 H H CHCH 431__________________________________________________________________________
EXAMPLE 21
(E)-(4RS,6SR)-6-[2-[7-Benzyl-2-(4-fluorophenyl)-4,5,6,7-tetrahydro-2H-indazol-3-yl]ethenyl]-4-hydroxy-3,4,5,6-tetrahydro-2H-pyran-2-one (CP 79, RS step w)
A 5.0 mL (1.25 mmol) portion of 0.25N aqueous NaOH was added slowly to an ice-cold solution of 0.500 g (1.02 mmol) of Compound 47 in 15 mL of methanol. After 15 min, the solution was allowed to warm to room temperature and was stirred for 1 h. The solution was concentrated to dryness using a rotary evaporator and was mixed with 50 mL of water and 100 mL of CH 2 Cl 2 . The mixture was acidified to pH 2-3 with aqueous 1N HCl. The aqueous layer was extracted with 50 mL of CH 2 Cl 2 and the combined organic layers were washed with brine, dried over Na 2 SO 4 , and concentrated. The crude dihydroxy acid (0.49 g) was dissolved in 12 mL of CH 2 Cl 2 and cooled in an ice bath. 1-Cyclohexyl-3-(2-morpholinoethyl)carbodiimide metho-p-toluenesulfonate (1.07 mmol, 0.455 g) was added in one portion and the mixture was allowed to warm slowly to room temperature and was stirred overnight. EtOAc (100 mL) was added and the white solids were removed by suction filtration. The solids were washed with more EtOAc and the combined filtrates were washed with water and brine and dried (Na 2 SO 4 ). The solution was concentrated to give 0.60 g of crude product which was purified by MPLC (1:1 EtOAc:hexanes) to provide 0.29 g (64%) of the title compound as a white solid, m.p. 185°-187° C.; 1 H NMR (CDCl 3 , 300 MHz) 1.4-2.1 (complex, 6), 2.21 (d, 1, J=2.5 Hz), 2.62 (m, 4), 2.74 (dd, 1, J=4.5, 18 Hz), 3.06 (m, 1), 3.53 (dt, 1, J=13.5, 3.5), 4.40 (m, 1), 5.25 (m, 1), 6.01 (dd, 1, J=6.5, 16 Hz), 6.49 (d, 1, J=16 Hz), 7.1-7.5 (complex, 9); IR (KBr) 3300 (broad), 1741, 1513 cm -1 ; MS (DCI) m/z 447, 429, 385 (base), 359. Anal. Calcd. for C 27 H 27 FN 2 O 3 : C, 72.63; H, 6.09; N, 6.27. Found: C, 72.61; H, 6.10; N, 5.97.
General procedure for the preparation of 6-substituted (E)-(4RS,6SR)-4-hydroxy-3,4,5,6-tetrahydro-2H-pyran-2-ones shown in Table 14, RS step w
A 5.0 mL (1.25 mmol) portion of 0.25N aqueous NaOH was added slowly to an ice-cold solution of 1.02 mmol of the appropriately substituted ester from Table 8, 13A, or 13B in methanol (15 mL). After 15 min, the solution was allowed to warm to room temperature and was stirred for 1 h. The solution was concentrated to dryness using a rotary evaporator and was mixed with 50 mL of water and 100 mL of CH 2 Cl 2 . The mixture was acidified to pH 2-3 with aqueous 1N HCl. The aqueous layer was extracted with 50 mL of CH 2 Cl 2 and the combined organic layers were washed with brine, dried over Na 2 SO 4 , and concentrated. The crude dihydroxy acid was dissolved in 12 mL of CH 2 Cl 2 and cooled in an ice bath. 1-Cyclohexyl-3-(2-morpholinoethyl)carbodiimide metho-p-toluenesulfonate (1.1 mmol) was added in one portion and the mixture was allowed to warm slowly to room temperature and was stirred overnight. EtOAc (100 mL) was added and the white solids were removed by suction filtration. The solids were washed with more EtOAc and the combined filtrates were washed with water and brine and dried (Na 2 SO 4 ). The solution was concentrated and the crude product was purified by MPLC.
TABLE 14______________________________________ ##STR34##Compound Mass SpectrumNumber R.sub.2 mp (°C.) m/z [M + H].sup.+______________________________________80 (2-Et)Bu foam 44181 (2-Nap)CH.sub.2 foam 49782 (4-t-BuPh)CH.sub.2 foam 50383 H foam 357______________________________________ | Compounds of the general formula I: ##STR1## are disclosed as useful in the treatment or prevention of hypercholesterolemia, hyperlipoproteinemia and atherosclerosis. Novel intermediate compounds used to make the compound of formula I are also disclosed. | 2 |
[0001] This application is a continuation of U.S. patent application Ser. No. 11/807,037 filed May 25, 2007.
FIELD OF THE INVENTION
[0002] The invention relates generally to cabinets and enclosures, and more particularly to structural elements used to fabricate cabinets and enclosures.
BACKGROUND OF THE INVENTION
[0003] Cabinets and enclosures are used to house and protect a wide variety of items, which may vary greatly in size and shape. A variety of cabinet configurations have been developed for the protection of items such as electrical and electronic assemblies, vacuum tubes and other easily damaged components of the past, and state-of-the-art compact high speed hybrid and digital circuits. Today, electronic assemblies differ as to the space and proportions necessary to house them. While a cabinet the size of several cubic feet may be necessary to house a high voltage system or a multi-server system, a cabinet the size of a pack of cigarettes may be needed to house a compact electrical or embedded electronics arrangement. There are many cabinet and enclosure structures available in many sizes. However, users of such enclosures are limited to either choosing a standard size enclosure, which may be too large for their applications; or fabricating a custom size enclosure, which may require welding, a large amount of machining, or high tooling costs.
[0004] In many situations, it is beneficial to use a cabinet with multiple compartments. For example, in the case of an electrical circuit or circuits, it may be desirable to separate a high voltage section from a low voltage section, or a particularly noise-sensitive circuit from other circuits. In such cases, custom fabrication becomes considerably more difficult. Means for construction of a cabinet or enclosure or a set of modular interconnected cabinets or enclosures that provides strength, ease of assembly, and appropriate size for a particular application, large or small, has yet to be realized.
[0005] A number of attempts have been made to provide a cabinet which satisfies these criteria, but typically the cost or the complexity, the size, versatility or strength has been less than desirable. By way of example, the following U.S. patens disclose either welded or modular frame assemblies representative of cabinet structures developed in the prior art:
U.S. Pat. No. 2,167,525: Rosendale U.S. Pat. No. 5,066,161: Pinney U.S. Pat. No. 3,265,419: Durnbaugh, et al. U.S. Pat. No. 3,182,846: La Kaff U.S. Pat. No. 3,919,603: Salvati
[0011] The patents to Rosendale and Durnbaugh et al both disclose welded cabinet structures. Rosendale employs gussets, triangular pieces of metal, welded in each corner to hold three mutually perpendicular struts in a corner arrangement. Durnbaugh et al eliminates such gusset members and welds the strut members directly to each other at their intersection. However, each of the three strut members which form each corner have different end cross-sectional configurations and end profiles, which complicates manufacture and construction of the frame. Additionally, four welds are desired to join the struts to create a rigid frame structure. The cabinet structures of Rosendale and Durnbaugh et al therefore, are very labor intensive.
[0012] The patents to La Kaff and Salvati disclose cabinet configurations that involve mechanical assembly. In La Kaff, side frame struts are coupled to the top and base members using engaging elements formed of generally rectangular aluminum blocks, which are attached by welding to the top and bottom members and struts. The engaging elements have frustoconical portions configured to fit snugly together. The top and base members are matted via the engaging elements, and bolted together. Both manufacturing cost and lack of versatility make this frame an undesirable alternative. Salvati et al disclose a switchgear framework including a corner tie for supporting three structural corner members together. The corner tie has three rectangular-shaped perpendicular legs with three sides and outwardly facing flanges, the three struts being slid over the leg portions. However, the struts and leg portions have different cross-sectional configurations, and the corner tie is of a generally complex configuration, such that this frame structure is not conducive to low-cost manufacturing techniques.
[0013] The Pinney patent discloses a simplified cabinet frame structure element, however, bending, cutting at angles on corners, and welding processes may be required, which are not conducive to low-cost manufacturing techniques.
[0014] In the discovered prior art, welding is commonly used to join the frame elements together. Another development is known as T-slot or 80/20 aluminum extrusion. This is a family of extruded aluminum products intended for use in rapid frame construction for enclosures and other assemblies. It is manufactured in a variety of profiles with a variety of accessories, however there are shortcomings. Accessories such as sliding wear pads are required for most assemblies. Further, a large amount of machining and accessories is required to fabricate an enclosure with multiple compartments.
[0015] It would be advancement in the art to provide an enclosure and cabinet system based on frame elements of a single particular cross-sectional shape that allows rapid, low-cost, custom fabrication of enclosures with no welding required, little or no machining required, high strength, and modularity.
SUMMARY OF THE INVENTION
[0016] It is therefore and object of the present invention to provide a means for rapid, low-cost construction of cabinets or enclosures employing interlocking structural elements. The enclosures are generally rectangular in shape, and may be made in practically any size with practically any aspect ratio. Structural elements in accordance with the invention include interlocking means, wherein two or more cabinets can be linked together to form larger cabinets with multiple internal compartments. The structural elements also may include means for mounting components, shelves, circuit boards or other objects within the enclosure.
[0017] Structural elements in accordance with the invention are elongated struts of essentially constant cross-section, which may be formed by an extrusion process or other means. They are used to form the corner supports of the rectangular enclosure and, accordingly, resemble extruded angle iron in their basic shape. The structural elements comprise two flanges of essentially equal width at right angles to each other. The flanges are of sufficient thickness that a slot can be incorporated into them for fixing the side panels of the enclosure. The side panels may be made from flat plates of any suitable material.
[0018] Structural elements in accordance with the invention further comprise one or more interlocking protrusions on the outer surface of each flange. The protrusions are shaped and positioned such that two identical structural elements can slide together and interlock with each other, with a first side of the first element interlocking the second side of the second element. When interlocked, the non-interlocking flanges of each member are substantially coplanar. It is this interlocking feature of the invention that enables the rapid fabrication of cabinets with multiple compartments.
[0019] Structural elements in accordance with the invention may further comprise additional slots on the inside surfaces for mounting of shelves or other components within the finished enclosure. Additionally, holes may be located in the corner of the elements for later threading; such holes to be used to mount cover plates or other items on the enclosure. Grooves may also be incorporated into the structural elements to aid in locating machined features during enclosure fabrication.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a perspective view of a structural element in accordance with the present invention.
[0021] FIG. 2 is a cross-sectional view of the structural element, including some dimensional proportions.
[0022] FIG. 3 is an enlarged view of interlocking protrusions in accordance with the invention, including some dimensional proportions.
[0023] FIG. 4 is a cross-sectional view of two structural elements interlocked.
[0024] FIG. 5 is a front view of a cabinet structure, including an internal mounting plate, with front and back covers removed.
[0025] FIG. 6 is a front view of an enclosure with four compartments, two of which include internal mounting plates.
[0026] FIG. 7 is a front view of the corner of an enclosure assembly including an interlocking structure for external mounting of assemblies.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention comprises a structural element which can be used to fabricate cabinets and enclosures with one or more compartments. The element is an elongated member with at least two surfaces and means for interlocking two elements together. Such means are typically comprised of elongated protrusions on the outer surfaces of each flange, shaped and positioned for proper interlocking.
[0028] The preferred embodiment of a structural element in accordance with the invention is shown in FIG. 1 . The structural element 10 is used in the corner of the compartment or cabinet and accordingly has a top flange 11 and a side flange 12 which are at approximately a right angle to each other.
[0029] Each flange incorporates two slots 13 14 for a total of four slots. One slot 13 is parallel to the plane of the flange. The second slot 14 is perpendicular to the plane of the flange. The parallel slots are used to fix the side panels of the enclosure, while the perpendicular slots are used to mount a shelf within the enclosure.
[0030] The preferred embodiment of the invention includes v-grooves 15 16 in the top and bottom surfaces of each flange. The v-grooves 15 16 are used to locate holes 17 18 for fixing the outer wall of the enclosure to the structural element. The preferred embodiment also includes a hole 25 near the vertex of the angle between the top and side flanges 11 12 . This hole 25 extends the length of the element and may be used to fix the front and back panels onto the enclosure.
[0031] To achieve interlocking capability, outward extending protrusions 19 20 21 22 are located on the outer surface of each flange. In the preferred embodiment, the protrusions have a generally hook shaped cross section with a head 23 and a neck 24 . All four protrusions 19 20 21 22 are identical in shape, but they are located in different positions along the width of the flanges.
[0032] The cross section of the structural element is substantially uniform along the length of the element. The uniformity of the cross section is such that the preferred embodiment of the structural element may be suitably manufactured using an extrusion process.
[0033] Some of the dimensional proportions of the cross section of the various features of the element in accordance with the invention are shown in FIG. 2 . Each flange forming the right angle cross section has equal width, designated as dimension A. Each flange 11 12 includes a slot 13 13 ′ parallel to the plane of the flange, extending inward toward the vertex of the right angle. While the width and depth of the slot may vary considerably, dimensions should be chosen that permit fixing of the side panels of the enclosure without unduly compromising the structural strength of the member.
[0034] The two flanges 11 12 also include a slot 14 14 ′ perpendicular to the plane of the flange. These slots are useful for mounting shelves, circuit boards, or other objects in the final enclosure. Additionally, a hole 25 is located near the vertex of the right angle between the flanges. Preferably, the diameter of the hole should be chosen so that it can be threaded and used to secure the front and back panels onto the enclosure with suitably sized screws. Alternately, rivets or other fastening means may be used.
[0035] On the outer surface of each flange of the preferred embodiment of the structural element are located protrusions 19 20 21 22 to provide means for interlocking two identical structural elements together. All four protrusions in the preferred embodiment are identical in cross section, but vary in orientation and position relative to the vertex and edge of each flange. The pair of protrusions on the top flange has the same spacing relative to each other as the pair of protrusions on the side flange, denoted as dimension D. Further, in the preferred embodiment, each protrusion is generally hook shaped, with a head 23 and a neck 24 . The heads of the protrusions on the top flange point toward the vertex of the right angle between the flanges, while the heads of the protrusions on the side flange point away from the vertex of the right angle between the flanges.
[0036] In FIG. 2 , the width of the necks of each protrusion is denoted as dimension X, and the height as dimension Y. Dimensions L 1 and L 2 indicate the position of the protrusions relative to the outer surface of the flanges 30 31 . In the preferred embodiment, L 2 is larger than L 1 by an amount approximately equal to X. That is, L 2 =L 1 +X. The height of the protrusions, Y, is approximately twice the width of the neck, Y=2×.
[0037] FIG. 3 shows a closer view of the cross section of the interlocking protrusions 19 20 . The exact dimensions of the protrusions are chosen such that the space between the protrusions is slightly larger than a single protrusion and comparably shaped.
[0038] The surface on one side of the each protrusion 40 is approximately flat, while the other side is formed from two semi-circular surfaces with radii R 1 and R 2 . In order to ensure proper interlocking capability, R 2 is chosen to be slightly larger than R 1 . While the exact difference may vary considerably, R 2 is normally about 1% to 5% greater than R 1 . If the difference between the radii is too large, the interlocked elements will have too much freedom of motion. If the difference is too small, it may be difficult to slide two interlocking pieces together, especially if the pieces are long. In the preferred embodiment, the centers of the two radii, R 1 and R 2 , are aligned in the vertical direction. The height of the protrusion, Y, is approximately twice the sum of the two radii, R 1 and R 2 .
[0039] FIG. 4 shows an end view of two identical structural elements 10 10 ′ interlocked in accordance with the invention. The protrusions on the top flange of a first element interlock with the protrusions on the side flange of the second element. The interlocking is achieved by placing the elements end to end and sliding the second element into position relative to the first element.
[0040] FIG. 5 shows an enclosure using structural elements in accordance with the preferred embodiment. Four identical elements 50 51 52 53 are placed at each corner of the enclosure and joined by four flat panels 54 55 56 57 . The panels may be made from any rigid material such as sheet metal or fiberglass. They are fixed to the structural elements with screws or other suitable means. A shelf 58 may be slid into slots in the structural elements. A front and back panel are affixed to the structural elements using the holes 25 near the corner of the structural elements and suitable fixing means such as screws or rivets.
[0041] FIG. 6 shows a front view of an enclosure with four compartments in accordance with the invention. The enclosure of FIG. 6 is comprised of four smaller enclosures interlocked to each other. A single front and back panel can be used to complete the enclosure. This arrangement may be particularly useful if the enclosure is used to house electrical circuitry wherein it is desirable to shield each compartment from the others; or in situations where it is desirable to thermally isolate one compartment from another.
[0042] The interlocking means provided in the structural element are not limited to interlocking with identical structural elements. A flat plate with interlocking means on one side may be used to mount components external to the enclosure. FIG. 7 shows such a mounting plate 70 interlocked with a structural element 10 in a cutaway view of one corner of an enclosure. The interlocking protrusions on the mounting plate have the same shape as those on the structural element, but may be positioned in any desirable location on the mounting plate.
[0043] One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiment, which is presented for purposes of illustration and not limitation, and the present invention is limited only by the claims that follow. | An interlocking structural element is disclosed for the construction of cabinets and enclosures, including modular cabinets and enclosures. Four equal lengths of the interlocking structural element can be used in conjunction with simple flat rectangular panels to fabricate a single enclosure. Additional lengths may be used to fabricate an enclosure with multiple compartments. The interlocking structural element may be fabricated by extruding metal or other material such as plastic. The element incorporates slots for easy mounting of shelves, printed circuit boards or other objects within the enclosure. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 10/617,390, filed Jul. 11, 2003, and claims priority from U.S. Provisional Patent Application No. 60/406,933, filed on Aug. 30, 2002, the entire contents of both of which are hereby incorporated into this application by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to mechanical bearings and, more particularly, to hydrostatic bearings for linear motion guidance.
[0004] 2. Description of Related Art
[0005] A linear bearing typically includes a carriage and a rail slideably mounted on the carriage. A component, such as a moveable portion of a machine tool, is typically removably mounted on the carriage for sliding movement along the rail with the carriage. A conventional linear bearing uses rolling elements or polymer linings to reduce friction between the carriage and rail.
[0006] In a hydrostatic linear bearing, lubricating fluid is pumped into the carriage and rail at high pressures so that a thin film of lubricant is maintained between the carriage and rail as the carriage slides along the rail, even when large loads are applied to the carriage and rail. The lubricating fluid flows into shallow cavities and channels provided in the carriage and rail. These cavities in the carriage and rail are sometimes referred to as bearing pockets.
[0007] In order to maintain the thin fluid film between the carriage and the rail, some fluid flow resistance or compensation must be provided in the bearing. Typically, capillary tubes, orifices, and control valves are used to provide the required resistance or compensation. A hydrostatic bearing may also be of the self-compensating type, in which resistive lands in the bearing pockets (i.e., planar areas over which fluid flow is restricted), or other bearing pocket features, are used to provide the required flow resistance or compensation.
[0008] Hydrostatic bearings a very desirable in a number of applications because they generally have very high stiffness, high load capacity, low friction, no wear, high damping, and resistance to contamination. All of these advantages make hydrostatic bearings particularly desirable in machine tool applications, where linear bearings with high rigidity and damping capabilities are needed to enable very precise motion that is free of excessive vibration.
[0009] Despite their advantages, hydrostatic bearings have not been widely used in the machine tool industry due to a number of practical problems with their installation and use. For example, the typical compensating devices, orifices, and control valves are often too difficult to install properly in machine tools, and may also be delicate, expensive, or too prone to contamination to provide a reasonable useable lifetime. Additionally, the fluid used for lubrication is easily contaminated by chips and coolant used in the machining process. For these reasons, linear bearings based on rolling elements have been used predominantly in the machine tool industry.
SUMMARY OF THE INVENTION
[0010] One aspect of the invention relates to a self-compensating hydrostatic bearing. The self-compensating hydrostatic bearing includes a bearing rail and a bearing carriage constructed and arranged to be mounted for hydrostatically supported movement on the bearing rail. The bearing carriage includes a plurality of self-compensating bearing pads provided on surfaces that oppose the bearing rail. The bearing pads are constructed and arranged to be in fluid communication with one another and with a pressurized fluid source.
[0011] End sealing structures are provided on end portions of the bearing carriage. At least one edge of the end sealing structures engages the bearing rail to prevent hydrostatic fluid from leaking from between the bearing carriage and the bearing rail. Side sealing structures are provided on side portions of the bearing carriage and extend at least a portion of the length of the bearing carriage. At least one edge of the side sealing structure engages the bearing rail to prevent hydrostatic fluid from leaking from between the bearing carriage and the bearing rail.
[0012] The bearing also includes a fluid return system provided within portions of the bearing carriage that are sealed by the end and side sealing structures. The fluid return system is constructed and arranged to route fluid towards the pressurized fluid source.
[0013] Another aspect of the invention relates to a self-compensating hydrostatic bearing. The bearing includes a bearing rail having at least one substantially contiguous support surface constructed and arranged to support the hydrostatic bearing and a bearing carriage constructed and arranged to be mounted for hydrostatically supported movement on the bearing rail.
[0014] The bearing carriage includes a plurality of self-compensating bearing pads provided on surfaces that oppose the bearing rail. The bearing pads are constructed and arranged to be in fluid communication with one another and with a pressurized fluid source. Sealing structure is provided on portions of the bearing carriage. At least one edge of the sealing structure engages the bearing rail to prevent hydrostatic fluid from leaking from between the bearing carriage and the bearing rail. The bearing carriage also includes a fluid return system provided within portions of the bearing carriage that are sealed by the sealing structure. The fluid return system is constructed and arranged to route fluid towards the pressurized fluid source.
[0015] A further aspect of the invention relates to a bearing carriage that comprises one or more bearing pads and a fluid recovery system. The bearing pads are constructed and arranged to receive fluid from a pressurized fluid source and to cause that fluid to flow selectively over a collection of bearing grooves and resistive lands so as to create a supporting fluid layer between the bearing carriage and a structure on which the bearing carriage is mounted for movement.
[0016] The fluid recovery system is constructed and arranged to prevent fluid from flowing out of the space between the bearing carriage and the structure on which the bearing carriage is mounted for movement and to route the fluid back towards the pressurized fluid source. The fluid recovery system includes sealing structure having contiguous end and side portions. The end portions are constructed and arranged to seal ends of the bearing carriage and the side portions are constructed and arranged to extend along at least a portion of sides of the bearing carriage to seal the sides. The end portions include a double-lipped seal. A first lip of the double-lipped seal engages the structure on which the bearing carriage is mounted for movement and the second lip of the double-lipped seal prevents debris from entering the bearing carriage. The fluid recovery system also includes reservoir structure defined by portions of the bearing carriage and sealed by the sealing structure and drain grooves constructed and adapted to conduct pressurized fluid from the bearing pads to the reservoir structures.
[0017] Further aspects of the invention relate to machine tools or portions thereof mounted on hydrostatic bearings.
[0018] Yet another aspect of the invention relates to a bearing carriage. The bearing carriage comprises one or more bearing pads constructed and arranged to receive fluid from a pressurized fluid source and to cause that fluid to flow selectively over a collection of bearing grooves and resistive lands so as to create a supporting fluid layer between the bearing carriage and a structure on which the carriage is mounted for movement.
[0019] The bearing carriage also includes a fluid recovery system constructed and arranged to prevent fluid from flowing out of the space between the bearing and the structure on which the bearing carriage is mounted for movement and to route the fluid back towards the pressurized fluid source. The fluid recovery system includes a sealing structure having contiguous end and side portions. The end portions are constructed and arranged to seal ends of the bearing carriage. The side portions are constructed and arranged to extend along at least a portion of the sides of the bearing carriage to seal the sides. The end portions include a double-lipped seal. A first lip of the double lipped seal engages the structure on which the bearing carriage for movement, and a second lip of the double-lipped seal prevents debris from entering the bearing carriage.
[0020] The bearing carriage also includes reservoir structures defined by portions of the bearing carriage and sealed by the sealing structure and drain grooves constructed and arranged to conduct pressurized fluid from the bearing pads to the reservoir structures.
[0021] Another further aspect of the invention relates to a hydrostatic bearing. The hydrostatic bearing comprises a bearing rail and a bearing carriage constructed and arranged to be mounted for hydrostatically supported movement on the bearing rail. The bearing carriage includes one or more bearing pads provided on surfaces that oppose the bearing rail. The bearing pads are constructed and arranged to be in fluid communication with a pressurized fluid source.
[0022] The bearing carriage also includes seal receiving grooves and a sealing structure having contiguous end and side portions. At least a portion of the sealing structure is adapted to be received in the seal receiving grooves. End portions of the sealing structure include double-lipped seals.
[0023] A fluid return system is also included in the bearing carriage. The fluid return system includes a plurality of drain grooves in fluid communication with the bearing pads. At least some of the plurality of drain grooves are positioned between the bearing pads and the side portions of the sealing structure.
[0024] Yet another further aspect of the invention relates to a method of sealing a hydrostatic bearing carriage. The method comprises causing or allowing hydrostatic fluid to flow from hydrostatic bearing pads provided in the bearing into drain grooves provided along the sides of the bearing carriage. The method also involves preventing leakage from the drain grooves by positioning sealing structures along the sides of the bearing carriage so as to capture hydrostatic fluid flowing out from the drain grooves, collecting the hydrostatic fluid in a reservoir provided as a portion of the hydrostatic bearing carriage, preventing the hydrostatic reservoir from leaving the reservoir except through designated outlets using a first portion of an end sealing structure, and preventing debris from entering the bearing carriage using a second portion of the end sealing structure.
[0025] An additional aspect of the invention relates to a hydrostatic bearing pad. The hydrostatic bearing pad comprises a compensating groove, an adjacent pocket groove enclosing a first planar area therein, and a second planar area interposed between the compensating groove and the adjacent pocket groove. The first and second planar areas are constructed and arranged to resist the flow of pressurized fluid when the bearing pad is in a load supporting position relative to another surface. The bearing pad does not include grooves between the compensating groove and the pocket groove.
[0026] Other additional aspects of the invention relate to self-compensating hydrostatic bearings having bearing pads as described in the preceding paragraph.
[0027] These and other aspects, features and advantages of the invention will be described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The invention will be described with reference to the following drawing figures, in which like numerals represent like features throughout the figures, and in which:
[0029] FIG. 1 is a perspective view of a hydrostatic bearing in accordance with the invention without end caps or seals installed;
[0030] FIG. 2 is a side elevational view of the carriage of FIG. 1 ;
[0031] FIG. 3 is a schematic diagram of the vertical bearing pads in the carriage of FIG. 1 ;
[0032] FIG. 4 is a fluid circuit diagram showing the resistances of the bearing pads of FIG. 3 ;
[0033] FIG. 5 is a schematic diagram of the horizontal bearing pads of the carriage of FIG. 1 ;
[0034] FIG. 6 is a fluid circuit diagram showing the resistances of the bearing pad of FIG. 5 ;
[0035] FIG. 7 is another perspective view of the hydrostatic bearing of FIG. 1 , with end caps and seals installed;
[0036] FIG. 8 is a sectional view through Line 8 - 8 of FIG. 7 showing the reservoir end caps and end seals of the hydrostatic bearing;
[0037] FIG. 9 is a close-up sectional view of a portion of the structure shown in FIG. 8 , showing the end caps and seals in more detail;
[0038] FIG. 10 is a sectional elevational view of the carriage of FIG. 1 illustrating the side seals;
[0039] FIG. 11 is a close-up sectional view of a portion of the structure shown in FIG. 10 in more detail;
[0040] FIG. 12 is a side elevational view showing a machine tool table supported on several hydrostatic bearings of the type shown in FIG. 1 ;
[0041] FIG. 13 a perspective view showing the underside of the bearing carriage of FIG. 1 ;
[0042] FIGS. 14 and 15 are perspective views of the keeper portions of the bearing carriage of FIG. 1 ;
[0043] FIG. 16 is a perspective view of the side and end seals of the bearing carriage of FIG. 1 in isolation without the bearing carriage itself;
[0044] FIG. 17 is a close-up perspective view of a portion of the side and end seals shown in FIG. 16 , illustrating the engagement of the side and end seals; and
[0045] FIG. 18 is a schematic perspective view of several hydrostatic bearings according to the invention connected to a hydraulic power unit.
DETAILED DESCRIPTION
[0046] FIG. 1 is a perspective view of a hydrostatic linear bearing, generally indicated at 10 , according to the present invention. The bearing 10 is comprised of a carriage 12 that is mounted for sliding, hydrostatically supported movement along a rail 14 . The direction of movement is shown by arrow M in FIG. 1 .
[0047] In the embodiment shown in FIG. 1 , the rail 14 has a “T shaped” cross section. The carriage 12 has a central portion 16 and two keepers, 18 A, 18 B that are clamped or bolted to the central portion 16 of the carriage 12 . Alternatively, the carriage 12 may be fabricated as a single-piece structure; however, the use of the two separable keepers 18 A, 18 B makes the carriage 12 easier to fabricate, and, in particular, easier to finish grind. If the carriage 12 is fabricated as a single-piece structure, special finish grinding equipment may need to be used.
[0048] The carriage 12 also includes a number of drain grooves 106 , 108 A, 108 B, 110 A, 110 B, 112 A, and 112 B extending substantially the entirety of the length of the carriage. The drain grooves 106 , 108 A, 108 B, 110 A, 110 B, 112 A, and 112 B will be described in more detail below.
[0049] The carriage 12 and rail 14 have rectilinear cross-sections in this embodiment of the invention. (The term “rectilinear,” as used herein, refers to any shape comprised of line segments without substantial curvature between adjacent segments.) Although rectilinear cross sectional shapes are generally preferred because they are easier to machine, the carriage and rail of a hydrostatic bearing according to the invention may have any desired cross sectional shape. More generally, the carriage 12 may be shaped to engage a rail of substantially any cross-sectional shape.
[0050] As shown in FIG. 1 , the rail 14 includes drilled and counterbored holes 20 that are used to secure it to a machine tool bed or other rigid structure. The carriage 12 includes drilled and tapped holes 22 such that raised surfaces 24 A, 24 B, 24 C may be clamped rigidly to the mating surface of a machine tool table or other structure that requires linear motion guidance. (The use of the hydrostatic bearing 10 will be described in more detail below.)
[0051] In general, the overall size and shape of the carriage 12 and rail 14 , and the locations of the holes 20 , 22 in the rail and carriage may be selected so as to be “bolt-for-bolt” compatible with and of the same size as standard rolling element linear bearings. It is advantageous if this type of compatible configuration is used, because a hydrostatic bearing 10 according to the invention may then be directly substituted for a rolling element-type linear bearing in an existing machine tool or tool design.
[0052] FIG. 2 is a side elevational view of the carriage 12 . The carriage 12 is hydrostatically supported by a number of bearing pads provided in interior surfaces of the carriage 12 . The locations of the vertical bearing pads 26 A, 26 B, 28 A, 28 B and the horizontal bearing pads 30 A, 30 B are also shown in the perspective views of FIGS. 13-15 and will be described in more detail below with respect to those figures. (The terms “vertical” and “horizontal,” as used with respect to the bearing pads, refer to the direction of the applied loads that the respective bearing pads resist.) Fluid pressure exerted through the bearing pads 26 A, 26 B, 28 A, 28 B maintains the bearing carriage 12 at a small distance from the bearing rail 14 . Typically, the clearance between the bearing pads 26 A, 26 B, 28 A, 28 B, 30 A, 30 B and the rail 14 would be on the order of about 0.001 inches to about 0.005 inches.
[0053] In this description, the terms “fluid” and “hydrostatic fluid” are used interchangeably to refer to any fluid that may be used in a bearing 10 according to the present invention. Many such fluids are known in the art, including hydrocarbon-based oils, silicone-based oils, water, water-based compositions, and air or another suitable gas. In machine tool applications, hydrocarbon-based oils may be preferred for some applications. These oils tend to reduce or eliminate corrosion problems, and may also have relatively high viscosities, which help to reduce the bearing flow rate and associated pumping power needed to pressurize the bearing 10 .
[0054] Water-based hydrostatic fluids also have certain advantages and may also serve in hydrostatic bearings 10 according to the invention. One advantage of water-based hydrostatic fluid is that if machining coolant (typically a water-based composition) leaks into or mixes with the hydrostatic fluid, it may not present a serious contamination problem. Water-based hydrostatic fluids may also be used in bearings 10 that are produced for the food industry, because of the reduced risk of contaminating the consumable product. Additionally, water-based fluids generally have high thermal conductivities, which enables the heat generated by the pumping process to be removed much more easily.
[0055] FIG. 3 is a schematic diagram of the vertical pads 26 A and 28 A, showing their basic geometry and illustrating the route fluid takes through the bearing pads 26 A, 28 A. Vertical bearing pad 26 B is similar in design to pad 26 A and is therefore not shown. Vertical bearing pad 28 B is identical in design to 28 A and is therefore not shown. In the following description, it is assumed that the fluid path is the same in the non-illustrated bearing pads 26 B, 28 B. However, as those of ordinary skill in the art will realize, the design of the various vertical bearing pads 26 A, 26 B, 28 A, 28 B need not be identical.
[0056] A lubricating fluid is pressurized and supplied by pump 32 to the upper and lower bearing pads 26 A and 28 A. (The details of the hydraulic supply of bearings 10 according to the invention will be described below with respect to FIG. 18 .) The fluid enters the lower pad 28 A at supply groove 34 which has a depth sufficient to allow free flow of fluid within it. Some fluid crosses leakage lands 36 A and 36 B, which are at a tight gap distance from rail 14 , and exits bearing pad 28 A. Some fluid crosses land 38 and enters pocket groove 40 . Some fluid also crosses compensating land 42 which is at a small distance from the rail 14 ; this tight gap creates a pressure drop as the fluid enters compensator groove 44 . Some fluid leaks from compensator groove 44 across lands 46 A and 46 B and exits bearing pad 26 A. Some fluid is routed from compensator groove 44 to pocket groove 48 of bearing pad 26 A. Some fluid leaks out of pocket groove 48 across lands 50 A, 50 B, and 50 C where it exits bearing pad 26 A. Fluid is free to flow in the tight gap region between rail 14 , and central bearing pad 52 , at a pressure that is equal to the fluid pressure in pocket groove 48 . Fluid is also supplied at supply pressure from pump 32 to the supply grooves 54 A and 54 B of pad 26 A. Some fluid leaks across lands 56 A, 56 B, 56 C, and 56 D and exits the bearing pad 26 A. Some fluid crosses from supply grooves 54 A and 54 B across lands 58 A and 58 B to pocket groove 48 . Some fluid crosses from supply grooves 54 A and 54 B across compensator lands 60 A and 60 B to compensator groove 62 . Some fluid leaks from compensator groove 62 , crosses land 64 and exits bearing pad 26 A. Some fluid is routed from compensator groove 62 to bearing pad 28 A where it enters pocket groove 40 . Some fluid then flows from pocket groove 40 across lands 66 A, 66 B, and 66 C where it exits bearing pad 28 A. Fluid can flow between compensator groove 44 and pocket groove 40 but is largely restricted from doing so by land 68 . Fluid can flow between compensator groove 62 and pocket groove 48 but is largely restricted from doing so by land 70 .
[0057] Grooves 54 A, 54 B, 62 , 48 , 34 , 44 , and 40 all should have a depth that is at least about three times larger than the clearance between the pads 28 A and 26 A and the rail 14 to ensure uniform pressure within each of these grooves. In the case of grooves 48 and 40 , uniform pressure is desired to spread the load-supporting pressure over the entire pocket area. In the case of grooves 54 A, 54 B, 62 , 34 , and 44 , uniform pressure is desired in order to yield the proper hydraulic resistance on the adjacent lands so that the pressure in the respective bearing areas can be adequately controlled.
[0058] Pad 26 A should be fabricated such that lands 52 , 50 A, 50 B, 50 C, 60 A, 60 B, 56 A, 56 B, 56 C, 56 D, 64 , 58 A, 58 B, and 70 are preferably all on the same plane and at the same tight gap distance to rail 14 . Pad 28 A should be fabricated such that lands 66 A, 66 B, 66 C, 42 , 46 A, 46 B, 36 A, 36 B, 38 , and 68 are preferably all on the same plane and at the same tight gap distance to rail 14 .
[0059] FIG. 4 is a fluid circuit diagram of the vertical bearing pads 26 A and 28 A (which are identical to the counterpart vertical bearing pads 26 B and 28 B). The various lands described above with respect to FIG. 3 are shown in FIG. 4 as circuit resistors. The values of the land resistances, which can be calculated by those skilled in the art of fluid dynamics, is dependent upon the fluid viscosity, the length and width of the lands, and the clearance between each land and the rail 14 . The fluid circuit shown in FIG. 4 can be solved by those skilled in the art of circuit analysis to compute the pressure in each of the bearing grooves. These pressures may then be multiplied by the corresponding bearing areas to yield the overall vertical force developed by the bearing.
[0060] In order to evaluate how the bearing force changes in response to a change in vertical position of the carriage 12 with respect to the rail 14 , the fluid gap between the carriage 12 and the rail 14 that was used to calculate the land resistances would be changed and the analysis described above would be repeated with the new fluid gap data. A computer program could be used to carry out this repetitive analysis. Although the bearing pad geometries may be chosen to suit particular applications of the hydrostatic bearing 10 , it is preferable if the the bearing groove and land geometry are optimized to provide very high bearing stiffness and load capacity in the vertical direction with the minimum possible flow rate of fluid through the bearing 10 because high fluid flow rates typically require great amounts of pumping power.
[0061] Grooves 54 A, 54 B, 62 , 48 , 34 , 44 , and 40 are shown in FIG. 3 with rounded corners; however, they may be fabricated with sharp square corners or another geometric profile without considerable effect on bearing operation, since the hydraulic resistances of the adjacent lands will change by a very small percentage of their overall resistance values.
[0062] As shown in FIG. 3 and described above, fluid is routed between pad 28 A and pad 26 A in two places, from compensator groove 44 to pocket groove 48 , and from compensator groove 62 to pocket groove 40 . These fluid transfers may be accomplished by the use of drilled holes in carriage 12 and keeper 18 A, or they may be accomplished with the use of rigid tubing external to carriage 12 . Similarly, fluid may be routed at supply pressure from pump 32 to supply grooves 34 , 54 A, and 54 B with the use of external tubing followed by holes drilled in carriage 12 and keeper 18 A.
[0063] FIG. 5 is a schematic view of the horizontal bearing pads 30 A and 30 B, showing their basic geometry and illustrating the route that fluid takes through the bearing pads 30 A, 30 B. A lubricating fluid is pressurized and supplied by pump 32 to the upper and lower bearing pads 30 A and 30 B. (The same pump 32 may be used to supply the horizontal bearing pads 30 A, 30 B and the vertical bearing pads 26 A, 26 B, 28 A, 28 B, or two different pumps 32 may be used.) The fluid enters pad 30 A at supply groove 72 A which is at a depth sufficient to allow free flow of fluid within it. Some fluid leaks from supply groove 72 A across leakage lands 74 A and 76 A, which are at a tight gap distance from rail 14 , and exits bearing pad 30 A. Some fluid flows from supply groove 72 A across lands 78 AA and 80 AA to pocket groove 82 AA and some flows across lands 78 AB and 80 AB to pocket groove 82 AB. Some fluid flows from supply groove 72 A across compensator lands 84 AA, 86 AA, 88 AA to compensator groove 90 AA. Some of the fluid which enters compensator groove 90 AA leaks to or from pocket groove 82 AA across land 100 AA. The remainder of the fluid which enters compensator groove 90 AA is routed to bearing pad 30 B where it enters pocket groove 82 BA and provides uniform pressure to pocket groove 82 BA before leaking across lands 92 BA, 94 BA, and 96 BA and exiting bearing pad 30 B. The fluid in the tight clearance of bearing pad 98 BA will be at a pressure equal to the fluid pressure in pocket groove 82 BA because pocket groove 82 BA completely surrounds bearing pad 98 BA. Fluid is also supplied at supply pressure from pump 32 to supply groove 72 B of bearing pad 30 B. Some of the fluid which enters supply groove 72 B leaks across lands 74 B and 76 B and exits bearing pad 30 B. Some of the fluid which enters supply groove 72 B leaks across lands 78 BA and 80 BA to pocket groove 82 BA, and some leaks across lands 78 BB and 80 BB to pocket groove 82 BB. Some of the fluid which enters supply groove 72 B leaks across compensator lands 84 BA, 86 BA, and 88 BA to compensator groove 90 BA. Some fluid may across land 100 BA between compensator groove 90 BA and pocket groove 82 BA. The remainder of fluid entering compensator groove 90 BA is routed to pad 30 A where it enters pocket grooves 82 AA and leaks across lands 92 AA, 94 AA, and 96 AA and exits bearing pad 30 A. The fluid in the tight gap clearance of bearing pad 98 AA will be at a pressure equal to the fluid pressure in pocket groove 82 AA because pocket groove 82 AA completely surrounds bearing pad 98 AA. Some of the fluid which enters supply groove 72 A leaks across compensator lands 84 AB, 86 AB, and 88 AB to compensator groove 90 AB. Some fluid may across land 100 AB between compensator groove 90 AB and pocket groove 82 AB. The remainder of fluid entering compensator groove 90 AB is routed to pad 30 B where it enters pocket groove 82 BB and leaks across lands 92 BB, 94 BB, and 96 BB and exits bearing pad 30 B. The fluid in the tight gap clearance of bearing pad 98 BB will be at a pressure equal to the fluid pressure in pocket groove 82 BB because pocket groove 82 BB completely surrounds bearing pad 98 BB. Some of the fluid which enters supply groove 72 B leaks across compensator lands 84 BB, 86 BB, and 88 BB to compensator groove 90 BB. Some fluid may across land 100 BB between compensator groove 90 BB and pocket groove 82 BB. The remainder of fluid entering compensator groove 90 BB is routed to pad 30 A where it enters pocket groove 82 AB and leaks across lands 92 AB, 94 AB, and 96 AB and exits bearing pad 30 A. The fluid in the tight gap clearance of bearing pad 98 AB will be at a pressure equal to the fluid pressure in pocket groove 82 AB because pocket groove 82 AB completely surrounds bearing pad 98 AB.
[0064] Grooves 82 AA, 82 AB, 82 BA, 82 BB, 90 AA, 90 AB, 90 BA, 90 BB, 72 A, and 72 B all should have a depth that is at least three times larger than the clearance between the pads 30 A and 30 B and the rail 14 to ensure uniform pressure within each of these grooves. In the case of grooves 82 AA, 82 AB, 82 BA, and 82 BB, uniform pressure is desired in order to spread the load-supporting pressure over the entire pocket area. In the case of grooves 90 AA, 90 AB, 90 BA, 90 BB, 72 A, and 72 B, uniform pressure is desired in order to yield the proper hydraulic resistance on the adjacent lands so that the pressure in the respective bearing areas can be adequately controlled.
[0065] Pad 30 A is fabricated such that lands 98 AA, 98 AB, 84 AA, 84 AB, 86 AA, 86 AB, 88 AA, 88 AB, 92 AA, 92 AB, 94 AA, 94 AB, 96 AA, 96 AB, 78 AA, 78 AB, 80 AA, 80 AB, 100 AA, 100 AB, 74 AA, 74 AB, 76 AA, 76 AB are preferably all on the same plane and at the same tight gap distance to rail 14 . Pad 30 B should be fabricated such that lands 98 BA, 98 BB, 84 BA, 84 BB, 86 BA, 86 BB, 88 BA, 88 BB, 92 BA, 92 BB, 94 BA, 94 BB, 96 BA, 96 BB, 78 BA, 78 BB, 80 BA, 80 BB, 100 BA, 100 BB, 74 BA, 74 BB, 76 BA, 76 BB are preferably all on the same plane and at the same tight gap distance to rail 14 .
[0066] FIG. 6 is a schematic diagram showing the fluid resistances of the horizontal bearing pad 30 A. Each of the resistances shown in FIG. 6 represents one of the lands of the horizontal bearing pad 5 A. The values of the resistances of the horizontal bearing pad 30 A may be calculated as was described above with respect to the vertical bearing pads 26 A, 26 B, 28 A, 28 B.
[0067] Grooves 82 AA, 82 AB, 82 BA, 82 BB, 90 AA, 90 AB, 90 BA, 90 BB, 72 A, and 72 B are shown in FIG. 5 with rounded corners; however, they may be fabricated with sharp square corners or another geometric profile without considerable effect on bearing operation since the hydraulic resistances of the adjacent lands will change by a very small percentage of their overall resistance values.
[0068] As shown in FIG. 5 , fluid is routed between pad 30 A and pad 30 B in four places: from compensator groove 90 AB to pocket groove 82 BB, from compensator groove 90 AA to pocket groove 82 BA, from compensator groove 90 BA to pocket groove 82 AA, and from compensator groove 90 BB to pocket groove 82 AB. As with the fluid transfers in the vertical bearing pads 26 A, 26 B, 28 A, 28 B, these fluid transfers may be accomplished by the use of drilled holes in carriage 12 , or they may be accomplished with the use of rigid tubing external to carriage 12 . Similarly, fluid may be routed at supply pressure from pump 32 to supply grooves 72 A and 72 B with the use of external tubing followed by holes drilled in carriage 12 .
[0069] In the vertical and horizontal bearing pads shown in FIGS. 3 and 5 and described above, lands 58 A, 58 B, 70 , 38 , 68 , 78 AA, 78 AB, 78 BA, 78 BB, 80 AA, 80 AB, 80 BA, 80 BB, 100 AA, 100 AB, 100 BA, and 100 BB allow leakage paths between adjacent compensators, pockets, and supply grooves. These leakage paths tend to reduce the pressure response of the bearing and therefore reduce its stiffness and load-carrying capability. However, a greater factor that overcomes the effect of these fluid leakage paths is the ability to arrange pocket grooves 48 , 40 , 82 AA, 82 AB, 82 BA, and 82 BB such that they are closer to the compensating grooves, and, therefore, spread the load-supporting pocket pressures over a larger area. By better utilizing the available pad area, the bearing pad configurations of the hydrostatic bearing 10 provide higher stiffness and load capacity.
[0070] FIG. 7 is another perspective view of the hydrostatic bearing of FIG. 1 , with its seals and endcaps installed. FIG. 8 is a sectional view through Line 8 - 8 of FIG. 7 , and FIG. 9 is a close-up view of portion A (enclosed in dotted line) of FIG. 8 . FIGS. 7-9 show the hydrostatic bearing of FIG. 1 with end caps 102 A and 102 B attached to carriage 12 and keepers 18 A and 18 B. End caps 102 A and 102 B contain reservoirs 104 A and 104 B (visible in the views of FIGS. 8 and 9 ) to which the fluid flows into from bearing pads 26 A, 26 B, 28 A, 28 B, 30 A, and 30 B as well as from drain grooves 106 , 108 A, 108 B, 110 A, 110 B, 112 A, and 112 B. (As was described above, the drain grooves are provided at the corners of the carriage 12 and are visible in the views of FIGS. 1 and 2 .) Double-lipped end seals 114 A and 114 B are attached to end caps 102 A and 102 B. The double-lipped end seals 114 A, 114 B are attached to rigid plates 113 A, 113 B in order to provide them with additional stiffness. Lips 116 of end seals 114 A and 114 B are in sliding engagement with rail 14 and serve to trap the fluid into reservoirs 104 A and 104 B and largely prevent fluid from leaking directly out of the hydrostatic bearing 10 . The fluid flows out of reservoirs 104 A or 104 B through at least one drain outlet 118 A and/or 118 B. One or more of the drain outlets 118 A, 118 B may be plugged, but at least one drain outlet 118 A, 118 B is used to route the fluid to a hose or tubing assembly, where the fluid is returned to the hydraulic supply source.
[0071] FIG. 10 is a sectional side elevational view of the hydrostatic bearing 10 , illustrating side seals 120 A and 120 B that are received by acceptor grooves 122 A and 122 B within keeper portions 18 A and 18 B of the bearing carriage 12 . FIG. 11 is an enlarged sectional view of portion B of FIG. 10 , illustrating the side seals 120 A, 120 B in more detail. The side seals 120 A, 120 B slidingly engage the bearing rail 14 , serve to trap fluid, and allow the trapped fluid to be routed through drain grooves 112 A and 112 B into reservoirs 104 A and 104 B to prevent fluid from leaking directly out of the hydrostatic bearing 10 . As shown in FIG. 11 , the side seals 120 A, 120 B have a generally u-shaped portion 121 that opens upwardly, towards the top of the drain groove 112 A, 112 B. The side seals 120 A, 120 B are positioned in the acceptor groove 122 A, 122 B such that one wall of the u-shaped portion 121 of the side seal 120 A, 120 B is in contact with the keeper 18 A, 18 B and the other wall of the u-shaped portion 121 is in contact with the bearing rail 14 .
[0072] FIG. 13 is a perspective view of the underside of the central portion 16 of the carriage 12 without the keepers 18 A, 18 B installed. FIG. 13 shows the relative locations and extents of the vertical bearing pads 26 A, 26 B and the horizontal bearing pads 30 A, 30 B. FIGS. 14 and 15 are perspective views of the keepers 18 A and 18 B, showing the locations and extents of vertical bearing pads 28 A and 28 B on the keepers 18 A and 18 B. The positions of the drain grooves 106 , 108 A, 108 B, 110 A, 10 B, 112 A, and 112 B and seal acceptor grooves 122 A, 122 B are also shown.
[0073] Each side of the central portion 16 of the bearing carriage 12 has a set of threaded holes 222 provided in respective connecting surfaces 220 A and 220 B. A set of complimentary, counterbored through holes 226 are provided in the keepers 18 A and 18 B. When the keepers 18 A and 18 B and central portion 16 of the carriage 12 are assembled, bolts are inserted through the holes 226 in the keepers 18 A, 18 B and into the threaded holes 222 of the central portion 16 of the carriage 12 such that the engaging surfaces 220 A, 220 B of the central portion 16 and the engaging surfaces 224 A, 224 B of the keepers 18 A, 18 B are adjacent, as shown in FIG. 10 .
[0074] The bearing pad grooves and other surface features shown in FIGS. 13-15 may be formed by milling, electrical discharge machining, or other known techniques.
[0075] FIG. 16 is a perspective view showing the end seals 114 A, 114 B and side seals 120 A, 120 B in isolation. As was described above, the end seals 114 A, 114 B are constructed of a rubber material molded so as to attach to rigid plates 113 A, 113 B, for example, steel or aluminum plates, to provide them with greater rigidity. In alternative embodiments, the end seals 114 A, 114 B may not be attached to rigid plates 113 A, 113 B
[0076] As is shown best in FIG. 17 , a close-up perspective view of portion “C” of FIG. 16 , the side seals 120 A, 120 B are inserted into receptacles 115 formed in the end seals 114 A, 114 B such that they have an interference fit with the receptacles 115 . In one embodiment, the side seals 120 A, 120 B may be made slightly longer than required, such that they can be maintained in compression during operation. In alternative embodiments of the invention, the side seals 120 A, 120 B and the end seals 114 A, 114 B may be molded or cast as a single structure, bonded together, or otherwise caused to adhere to one another to form a unitary structure.
[0077] The bearing pads 26 A, 26 B, 28 A, 28 B, 30 A, 30 B described above are designed for a self-compensating hydrostatic bearing. However, those of ordinary skill in the art will realize that the other features of the carriage 12 and rail 14 , including the sealing structures (i.e., the end seals 114 A, 114 B and side seals 120 A, 120 B) and the drain grooves 106 , 108 A, 108 B, 110 A, 10 B, 112 A, and 112 B may be used without the particular bearing pads 26 A, 26 B, 28 A, 28 B, 30 A, 30 B described above. For example, in alternative embodiments of the invention, a carriage having end seals, side seals and a drain groove arrangement similar to that described above could be used with bearing pads that are not self-compensating. Bearing pads that are not self-compensating could use capillary tubes or valves for compensation purposes, as one of ordinary skill in the art will readily be able to appreciate.
[0078] Conversely, the self-compensating bearing pads 26 A, 26 B, 28 A, 28 B, 30 A, 30 B described above may be used on other types of hydrostatically supported devices and in other types of fluidstatic bearings without the other features described herein.
[0079] FIG. 18 is a schematic perspective view illustrating four bearing carriages 12 riding on two carriage rails 14 . In general, several bearing carriages 12 may be provided on the same carriage rail 14 , particularly if those bearing carriages 12 are fixed in position with respect to one another (e.g., by being bolted to the bed of a machine tool, as will be described below). Alternatively, several shorter segments of bearing rail 14 could be provided, one segment for each bearing carriage 12 .
[0080] FIG. 18 also illustrates the details of the hydraulic fluid connections for the bearings 10 according to the present invention. A hydraulic power unit 230 delivers hydraulic fluid under high pressure through a conduit 232 . The hydraulic power unit 230 includes all of the components necessary to deliver temperature controlled fluid that is relatively free of contaminant particles at high pressure with minimal pressure pulsations. For example, the hydraulic power unit 230 may include a reservoir, a pump, an electric motor, a filter, a pressure regulating valve, a pressure gauge, and a heat rejection system, such as an air-to-oil heat exchanger.
[0081] The conduit 232 from the hydraulic power unit 230 branches such that one branch connects with each bearing carriage 12 . The branches of the conduit 232 are received by a fluid inlets 119 in the end seals 114 A, 114 B of the bearing carriages 12 . (Depending on the configuration of the bearings 10 , the conduit 232 may connect to a fluid inlet 119 on either end seal 114 A, 114 B. The unused fluid inlet 119 may be plugged or omitted.) The connection between the conduit 232 branch and the fluid inlet 119 of the end seal may be any appropriate type of conventional hydraulic connection. From the fluid inlet 119 , the pressurized fluid is distributed to the supply grooves 34 , 54 A, 54 B by an internal network of passageways. Once used, the fluid is collected in the reservoirs 104 A, 104 B and returned via return conduits 238 , which connect to the drain outlets 118 A, 118 B and the return portions of the hydraulic power unit 232 .
[0082] FIG. 12 is a side elevational view of a machine tool 200 , illustrating a typical application for a hydrostatic bearing 10 according to the present invention. A machine tool table 66 is supported by four bearing assemblies 10 which ride on two rails 14 . Although only two bearing assemblies 10 are shown, at least four are typically used to provide adequate pitch and yaw stability to table 202 . The rails 14 of the hydrostatic bearings 10 are horizontally clamped to a machine bed 204 using wedges 206 A and 206 B. The rails 14 are clamped vertically to machine bed 204 using a plurality of bolts 208 threadedly secured within machine bed 204 through counterbored holes 20 provided in the rail 14 . Two of the hydrostatic bearings 10 are clamped horizontally to the table 202 using wedges 210 (one wedge 210 is shown in the view of FIG. 12 ). The other two hydrostatic bearings 10 are floated into alignment by pressurizing them with lubricating fluid, thus allowing hydrostatic bearings 10 to float horizontally into a self-aligning position. Once the two wedge-secured hydrostatic bearings 10 are in alignment, the bolts that secure them to the table 202 are tightened. Although FIG. 12 illustrates the use of wedges 206 A, 206 B, and 210 , many other mechanisms to clamp the rails 14 and the hydrostatic bearings 10 are possible and are within the scope of the invention.
[0083] A hydrostatic bearing 10 may be used in a number of different types of machine tools, and in any other application in which linear motion guidance is required. However, hydrostatic bearings 10 according to the invention may be particularly beneficial when used in lathes. For example, hydrostatic bearings 10 may be used in the QUEST® turning machines manufactured by HARDINGE, Inc. (Elmira, N.Y., United States). Hydrostatic bearings 10 may also be useful in grinding machines, milling machines, boring machines, and other machine tools in which a combination of high stiffness and damping are beneficial.
[0084] A hydrostatic bearing 10 according to the present invention may have certain advantageous performance characteristics. For example, a hydrostatic bearing 10 according to the invention would typically have high static and dynamic stiffnesses. A hydrostatic bearing 10 may also operate with very low friction, because the seals described above with respect to FIGS. 7-11 would generally be the only components creating friction. Because the carriage 12 rides on a layer of fluid, and for other reasons, the hydrostatic bearing 10 may have up to ten times the force damping capabilities of a conventional rolling element linear bearing. Additional advantages may include an essentially unlimited translational (feed) rate, an essentially unlimited fatigue life (with substantially no component wear because the carriage 12 and rail 14 are not in contact), substantially no change in positioning accuracy of a machine tool mounted on hydrostatic bearings 10 over time, substantially no damage to the hydrostatic bearing 10 under heavy “crash” loads (i.e., when the bearing 10 stops suddenly at the ends of its travel range). Moreover, the hydrostatic bearing 10 is self cleaning if fluid flow is maintained between the carriage 12 and rail continuously 14 .
[0085] When installed in a machine tool and used to produce parts, the features of the hydrostatic bearing 10 may also lead to certain other advantages. For example, the hydrostatic bearing 10 may improve tool life. Additionally, parts may be produced with better surface finishes and better roundnesses for round parts. A machine tool mounted on hydrostatic bearings 10 may also have improved hard turning capability, improved interrupted cutting capability, and improved positioning accuracy. Some of the advantages and benefits described above will become apparent from the following example.
EXAMPLE 1
[0086] A hydrostatic bearing 10 according to the invention is installed so as to support operational movement in a QUEST® 51 turning machine (Hardinge, Inc., Elmira, N.Y., United States) using the installation procedure described above. Four hydrostatic bearings 10 according to the present invention are installed to guide motion in the X-axis and four are installed to guide motion in the Z-axis. No adaptations to the turning machine are required in order to accommodate the hydrostatic bearings 10 ; however, hydraulic hoses are provided for each hydrostatic bearing 10 . A two-inch round A2 tool steel blank was prepared with four slots milled around its circumference for interrupted cutting. It was then hardened to 60-62 Rc. The part was then roughed with a 5/16 inch diameter round cubic boron nitride (CBN) insert at 450 SFM/0.002 ipr/0.030 doc with five passes. Subsequently, the part was finished with a 55 degree CBN insert at 550 SFM/0.003 ipr/0.005 doc with one pass, and then threaded with a CBN triangular insert. The surface finish of the part was consistently in the 5 to 6 microinch range, an improvement of approximately a factor of two when compared with an identical part machined on a comparable QUEST® 51 turning machine without a hydrostatic bearing. Additionally, the tool life of the interrupted turning insert was increased by a factor of three when compared to the life of an insert used on the turning machine without the hydrostatic bearing.
[0087] Although the invention has been described with respect to certain embodiments, those embodiments are intended to be illustrative, rather than limiting. Modifications and variations to the invention are possible, within the scope of the appended claims. | A self-compensating hydrostatic (pressurized fluid film) linear bearing that maintains a fluid gap between a carriage and a rail when relative forces are applied. The geometric shape of the rail and mating carriage enable the bearing to have very high stiffness and load capacity without exessive detrimental carriage deformation. The carriages contain bearing grooves and lands which control and use fluid pressure to provide a very high degree of restoring force in response to changes in the fluid gap. The fluid emanating from the bearing gap is prevented from immediately leaking from the bearing carriage, and is instead routed back to the source from which it is pumped, thereby sealing the bearing carriage and simplifying the handling of the lubricating fluid. The hydrostatic bearing is particularly designed to be compact and to be bolt-for-bolt compatible with conventional linear bearings. | 5 |
BACKGROUND OF THE INVENTION
The present invention is related to a topical composition which may be applied to skin for the purpose of killing fungus and/or bacteria or for the purpose of promoting hair growth.
Many fungicidal compositions are known in the art. But commonly their effectiveness in addressing fungal and/or bacterial infections in humans is quite limited. It appears in most instances that the human body's own immune system actually defends the infected area of the body, thereby reducing the amount of the antibacterial and/or fungicidal substances which pass through the barrier of the immune system and reach the infection. By reducing the free transfer of the disease from the affected area to the healthy areas, the body prevents or reduces the spread of the disease. But this function has the drawback of impeding the transfer of antibiotics and fungicides to affected areas where they may perform their function of killing the infection.
The present inventor has found that by suppressing the immune system, a freer transfer of antibiotics and/or fungicides can be achieved; the more the immune system is suppressed, the more effective the antibiotics and/or fungicides become.
Also, a number of compositions are known which are asserted to promote hair growth in humans. However, such hair growth compositions seem to work by stimulating blood flow and require constant application, suggesting that whatever hair growth results is forced. In other words, these compositions increase blood flow providing more nourishment for hair growth than occurred before the application of the compositions. Further, such compositions offer only limited success and only with a limited class of users.
Accordingly, an object of the present invention is to provide a composition which may be applied to human skin where it will successfully kill bacterial and/or fungal infections, without causing adverse side effects.
A further object of the present invention is to provide a composition which may be applied to human skin, particularly the head, where it will promote the growth of hair.
These and other objects are achieved by the present invention.
SUMMARY OF THE INVENTION
The present invention is a composition intended for the topical application to human skin, comprising
(1) an antibiotic medication such as penicillin VK (Rugby), doxycycline (Rugby) or erythrocin (Abbott Laboratories); and
(2) an antihistamine such as bromohenivamine (Schein), Chlorpromazine (Schein), diphenylhydramine hydrochloride (Parke-Davis), chlorpheniramine malate, chlorpromazine malate, and bromopheniramine.
Certain embodiments of the invention may also contain (3) an antiinflammatory medication such as aspirin (Goldline), hydrocortisone cream (Rugby), hydrocortisone powder (Parma-Tek Inc.) and hydrocortisone acetate injectable (Merck Sharp & Dohme), and/or (4) a bactericide combination of neomycin/bactracine/polymyxin B sulfate.
The inventor has surprisingly found that this combination of ingredients produces remarkable effects in treating fungal and/or bacterial infections in humans and in promoting human hair growth.
DETAILED DESCRIPTION OF THE INVENTION
The human body's immune system builds a multifunctional defensive barrier between an affected area and an unaffected area of the body. The more dangerous the immune system considers this affected area to be, the more pronounced the interference between the affected and unaffected areas becomes. The ability to provide medication to the affected area is also reduced in direct relation to the effectiveness of this interference.
The present applicant has found that by temporarily reducing the effectiveness of this defensive area, ordinary medications become very effective very quickly. The composition described herein is intended to accomplish this result.
The composition described herein has been found to be effective in the treatment of conditions, such as dandruff, staph sores, fungal infections, urethra infection, scarring, and prostate infection.
Relative amounts of 50 to 80% by weight antihistamine to 50 to 20% by weight antibiotic/fungicide appear to be effective. Preferred relative amounts being 55 to 80% by weight antihistamine to 45 to 20% by weight antibiotic/fungicide, more preferred relative amounts being 60 to 75% by weight antihistamine to 40 to 25% by weight antibiotic/fungicide, and most preferred relative amounts being 65 to 75% by weight antihistamine to 35 to 25% by weight antibiotic/fungicide.
Although many combinations of types and brands of antihistamines and antibiotics and/or fungicides may be used effectively, antibiotics and fungicides which are known to work well with the particular infection to be treated, should be tried first.
It is desirable to mix the ingredients into a paste because a liquid is needed to carry the mixture of the invention into the affected area. The paste mixture should be kept moist to continue its effectiveness and to prevent undue drying of the mixture. If the paste mixture becomes unduly dry after application to the skin surface, it will tend to fall off the skin.
If the paste mixture is allowed to be dry on the skin, the addition of a cream may be helpful in holding the mixture together in place on the skin surface.
The best results appear to be obtained with hydrocortisone cream. The antiinflammatory characteristics of the cortisone are believed to aid in the free flow of the antibiotics. Topical compositions according to the present invention, which contain cortisone cream, virtually eliminate infections within a few hours to a few days. Also, pain and bruising is reduced with the use of cortisone cream.
The components of the present invention may also be combined with blephamide as a carrier. Embodiments of the invention containing blephamide result in particularly fast recovery, as well as offering good anaesthetic effects. Blephamide appears to be particularly effective in treating conditions on the eye lid or conditions effecting the surface of the skin such as burns.
The healing process with the topical composition of the present invention appears to be different from that with conventional compositions. While the healing period with the present invention may be 50 to 75% longer than with such conventional compositions, the pain, swelling, and discoloration associated with the infected area are greatly reduced. Scarring is also reduced and may actually be eliminated. Nerve regrowth is speeded up. Further, there is little or no scab growth because the body no longer regards the infected area as a location which must be protected.
The wound should be covered completely by the composition of the present invention throughout the first half of the healing process. Also, a portion of the area peripheral to the wound should be covered. For the remaining healing time, the wound itself should remain covered. If pain returns, full coverage should be restored.
Existing scars may be softened and reduced by application of the inventive composition.
The effective use of the present invention can be accelerated if the applied inventive composition is kept covered and moist.
The application of heat to the wound is also helpful.
Penicillin has been a widely prescribed antibiotic composition since the 1930's.
Diphenylhydramine is marketed in the United States under the name BENADRYL™.
Hydrocortisone is marketed in the United States under the name HYDROSKIN™.
The bactericide combination of neomycin/bactracine/polymyxin B sulfate is marketed in the United States under the name BACTINE™.
Turning to the use of the present invention for hair growth, the present inventor has concluded that hair growth compositions seem to work by stimulating blood flow and require constant application. This suggests that whatever hair growth results is forced growth. In other words, an increased blood flow provides more nourishment for hair growth than occurred before the application of these compositions. Further, such compositions offer only limited success and only with a limited class of users.
But with the composition of the present invention, one or more applications will grow hair in about eight weeks. Further, since no maintenance applications are required, the present inventor infers that the hair growth is not forced hair growth. Since the hair growth continues, even without further applications, for six months or more, the present inventor believes that the cause of such growth is an increase in nutrients which results in greater hair growth, rather than greater blood flow. The present inventor concludes that some forms of hair loss may be caused by infection(s) in the area of the hair follicle. The composition of the present invention reduces or kills such infection(s).
On the other hand, the infection(s) seem to return after a period of six months or more. Accordingly, new applications of the inventive composition are needed to maintain the hair.
The composition of the present invention also has the effect of reducing or treating dandruff. By varying the composition of the present invention, dandruff can be virtually eliminated as hair growth renews.
In some embodiments of the present invention, 10 grains of antibiotic and 10 grains of antihistamine are mixed together. To that mixture is added 6 to 12, or even more, grains of cream or ointment. If that cream or ointment is not cortisone cream, 3 or grains of cortisone cream may be included. A liquid may be required at this point to achieve the proper consistency.
Injectable antihistamine and antiinflammatory preparations may be used. The addition of water or mineral oil to noninjectable antihistamine and antiinflammatory preparations is also effective in making paste of a workable consistency.
The present invention is further described by the following examples which should not be construed as limiting the scope of the invention in any respect.
EXAMPLE I
The powder from twelve 500 mg. penicillin tablets was combined with two 50 mg. ampules of injectable Benadryl™. Added thereto was about a 21/2" to 3" squirt of Rugby Hydroskin™ and a few drops of Bactine™ until the mixture was thinner than honey.
This composition was then rubbed into a clean scalp at night and removed each morning for eight days. Within eight weeks hair growth was observed.
EXAMPLE II
A patient suffered a fungus infection under his toenails which had ridged them up to a considerable extent. On a clean toenail three applications of the composition of Example I brought back the pink skin under the nail. All of the white was gone.
EXAMPLE III
To a patient suffering from scar tissue behind his ear was subjected to repeated applications of the composition of Example I. Over an extended period of about three months, all of the scar tissue but one wrinkle and all of the effected flesh but one dot were gone. | Disclosed is a pharmaceutical composition intended for the topical application to human skin, comprising
(A) as an effective ingredient, a mixture comprising
(1) an antibiotic medication;
(2) an antihistamine; and
(B) a physiologically acceptable carrier.
Also disclosed is a method for treatment using this composition. | 0 |
BACKGROUND OF THE INVENTION
[0001] In vertebroplasty, the surgeon seeks to treat a compression fracture of a vertebral body by injecting bone cement such as PMMA into the fracture site. One clinical report describes mixing two PMMA precursor components (one powder and one liquid) in a dish to produce a viscous bone cement; filling 10 cc syringes with this cement, injecting it into smaller 1 cc syringes, and finally delivering the mixture into the desired area of the vertebral body through needles attached to the smaller syringes.
[0002] This injection of the stabilizing material into damaged or compromised bone sites has proven highly beneficial for patients. However, these materials are typically delivered through a straight needle that accesses the vertebral body through a pedicle. Because the pedicle are present at the lateral edges of the vertebral body, pedicle-based delivery has difficulty in delivering material to the central (mid-line) region of the vertebral body. One proposed solution is to fill the central region from a lateral needle tip—however, this approach may lead to overfilling and leakage. Another proposed solution is bipedicular delivery—which is delivery through each of the pedicles. However, the proposed bipedicular access and delivery techniques necessitate multiple needle sticks and therefore a greater risk of tissue damage and infection. Also, neither proposed solution provides precision in the placement of the stabilizing material, which is desirable to prevent overfilling.
[0003] Curved needle devices have been proposed as a solution to this issue, but these are prone to breaking due to a lack of strength, rigidity and/or fatigue strength.
[0004] Therefore, a need exists in the field of vertebral body augmentation for an improved device for delivering stabilizing material to the damaged or compromised bone sites.
[0005] U.S. Pat. No. 5,002,543 (Bradshaw) discloses a steerable tip fracture reduction device. In particular, Bradshaw discloses a steerable intramedullary fracture reduction device has an elongated shaft with a steerable tip pivotally mounted to the distal end of the shaft. A tip actuating apparatus near the proximal end of the shaft enable the operator to steer the tip and the shaft into successive segments of the fractured bone, even when the segments are transversely or rotationally displaced so that the segments can be aligned by the shaft.
[0006] U.S. Pat. No. 7,476,226 (Weikel) discloses tools for use in the creation of cavities in bones. The tools include a probe, a cannula that provides percutaneous passageway to the interior of the treated bone, a bone tamp, and a system for delivering bone filler material into the cavity. The bone tamp has a shaft that is inserted into the bone through the cannula. The end of the shaft that is inserted into the bone may have a flapper tip that extends out of axial alignment with the shaft upon deployment by the physician. Once the tip is deployed, the bone tamp can be rotated to form the cavity. The cavity may then be treated with a medicament, filled with bone filler material, or both. Other tools and materials described herein may be used to lift or restore the treated bone closer to its natural anatomy.
[0007] US Patent Publication 2002-0026197 (Foley) discloses instrumentation for treatment of the spine, including an elongate member having a deformable distal end portion at least partially formed of a flexible and preferably elastic material. The distal end portion has an initial configuration for placement adjacent a vertebral body and a deformed configuration defining at least one outwardly extending projection for displacement of at least a portion of the vertebral body. The elongate member preferably comprises a rod member, a sleeve member and an actuator mechanism for imparting relative linear displacement between the rod and sleeve members to effect outward deformation of the distal end portion of the sleeve member. In one embodiment, the instrumentation is used to compact cancellous bone to form a cavity within a vertebral body. In another embodiment, the instrumentation is used to reduce a compression fracture. In yet another embodiment, the instrumentation is used to distract a disc space between adjacent vertebral bodies.
[0008] US Patent Publication 2010-0010298 (Bakos) discloses an apparatus, system, and method for use with an endoscope. A flexible overtube having a proximal end and a distal end defines a hollow lumen therebetween to receive a flexible shaft portion of an endoscope therein. The proximal end of the flexible overtube is configured to remain outside of a patient and the distal end is configured to enter the patient through a natural orifice. At least one fluid tight seal is located at the proximal end of the flexible overtube to prevent leakage of fluids around the flexible shaft of the endoscope when the flexible shaft of the endoscope is positioned within the flexible overtube. The system further includes a flexible endoscope. The method includes introducing the system into a patient though a natural orifice of the patient and performing an endoscopic translumenal procedure.
SUMMARY OF THE INVENTION
[0009] The present invention relates to devices and methods for stabilizing bone structures. More particularly, it relates to devices, systems and methods for delivering a curable, stabilizing material into a central region of a bone structure.
[0010] The present invention provides for vertebral fracture stabilization, as well as precise placement of the curable substance into a central region of a bone structure through a unipedicular approach.
[0011] One primary advantage of the present invention is its ability to create a central cavity in a vertebral body (or to centrally deliver bone cement) through a unipedicular approach.
[0012] The present invention is a curved needle having increased rigidity in its flexible end when the end is disposed in its straight position. This increased rigidity is due to a novel cable tensioning mechanism and to a segmented tube design (as opposed to the conventional longitudinally-slotted tube design).
[0013] The curved needle of the present invention also displays decreased fatigue stress in the flexible end during bending (in comparison to slotted tube designs) because no component of the tube of the present invention is internally bent. This is due to use of a cable and separate, nested tube segments in the present invention. Therefore, the present invention displays an increased durability of the flexible tubular end. Lastly, the present invention provides for increased control. This increased control is due to its slow curve progression brought about by providing a high number of driving screw turns, that is, a low pitch.
[0014] In preferred embodiments, the steerable needle has a unique driving mechanism that comprises a) a driving screw that includes both left-hand and right-hand threads, and b) cable couplings that slide in opposite directions, pulling and releasing the cable. The advantages provided by the two couplings that slide in opposite directions are the constant tension of the cables, and the rigidity and stability of the curved end.
[0015] Therefore, in accordance with the present invention, there is provided a steerable needle comprising:
i) a tube having a rigid proximal end portion and a flexible distal end portion, ii) a cable having a proximal end portion and a distal end portion, the distal end portion of the cable being attached to the flexible distal end portion of the tube, and iii) a drive mechanism comprising :
a) a driving screw comprising a proximal thread and a distal thread, wherein the proximal thread has a first direction, the distal thread has a second direction, and the first direction is opposite the second direction, and b) first and second cable couplings adapted to slide in opposite directions, pulling and releasing the cable.
iv) a proximal handle connected to the rigid proximal portion of the tube, the handle comprising an actuator connected to the proximal end portion of the cable for tensioning the cable.
[0022] In other preferred embodiments, the steerable needle comprises a cable-tensioning means.
[0023] In some embodiments, the steerable needle possesses a pre-tensioned cable. The advantage of the pre-tensioned cable is that, when used with a particular tube design, it forces the tube to a straight configuration, and so provides rigidity in the flexible distal portion of the straightened tube.
[0024] Therefore, in accordance with the present invention, there is provided a steerable needle comprising:
i) a tube having a rigid proximal end portion and a flexible distal end portion, ii) a cable attached to the flexible distal end portion of the tube, iii) a proximal handle connected to the rigid proximal portion of the tube, the handle comprising an actuator connected to the cable for tensioning the cable,
wherein the cable is under tension, and
wherein the flexible distal end portion of the tube is substantially straight.
[0028] Generally, the flexible end of the tube comprises a column of nested segments. The separate nature of these segments allows for the overall bending of the tube end without requiring any bending within any single segment. Thus, the separate nature of the nesting segments provides an increased flexural fatigue strength of the device. In some embodiments, each end of each nested cylindrical segment is flat. Accordingly, tensioning of the cable associated with these segments produces a compression of this column of segments, thereby providing rigidity to the flexible tube end in its straight configuration.
[0029] Therefore, in accordance with the present invention, there is provided a steerable needle comprising:
i) a tube having a rigid proximal end portion and a flexible distal end portion, ii) a cable running along (and preferably within) the tube and having a proximal end portion and a distal end portion, the distal end portion of the cable being attached to the flexible distal end portion of the tube, iii) a proximal handle connected to the rigid proximal portion of the tube, the handle comprising an actuator connected to the cable for tensioning the cable,
wherein the flexible distal end portion of the tube comprises a plurality of nested, separate tubular segments.
[0033] Some embodiments of the present invention are characterized by an ease of manual control. In these embodiments, motion of the flexible tube end is controlled by the controlled movement of the cable couplings, which is driven by a high number of the driving screw turns. Such control can also be attained by predetermining the pitch of the screw. Preferably, the screw thread has a pitch of between 1 mm and 2 mm. If the pitch is smaller than 1 mm, then an excessive number of turns is required to obtain appropriate curvature of the flexible distal end portion of the device. If the pitch is greater than 2 mm, the user has substantially less manual control over the device.
[0034] Therefore, in accordance with the present invention, there is provided a steerable needle comprising:
i) a tube having a rigid proximal end portion and a flexible distal end portion, ii) a cable attached to the flexible distal end portion of the tube, iii) a drive mechanism comprising :
a) a driving screw comprising a proximal thread and a distal thread, wherein the proximal thread has a first direction, the distal thread has a second direction, b) first and second cable couplings adapted to slide in opposite directions, pulling and releasing the cable,
iv) a proximal handle connected to the rigid proximal portion of the tube, the handle comprising an actuator connected to the cable for tensioning the cable,
wherein the proximal thread has a pitch of between 1 mm and 2 mm.
DESCRIPTION OF THE FIGURES
[0041] FIG. 1 discloses a curved needle assembly.
[0042] FIG. 2 discloses a driving mechanism.
[0043] FIG. 3 discloses a driving mechanism displayed without a cover.
[0044] FIG. 4 illustrates the flexible distal end portion of the steerable needle.
[0045] FIGS. 5 a and 5 b disclose distal tip segments.
[0046] FIG. 6 discloses an outer shell component of FIG. 5 a.
[0047] FIG. 7 discloses an insert 19 component of FIG. 5 a.
[0048] FIG. 8 illustrates an intermediate nesting segment.
[0049] FIG. 9 illustrates a proximal nesting segment of the flex.
[0050] FIG. 10 discloses a hypodermic tube assembly.
[0051] FIG. 11 illustrates an axial cross-section of a funnel component.
[0052] FIG. 12 illustrates one half-shell of handle insert component.
[0053] FIG. 13 illustrates a driving screw component.
[0054] FIG. 14 illustrates a cable coupling component.
[0055] FIGS. 15 , 16 and 17 illustrate the various parts of the cable clamping and tensioning mechanism.
[0056] FIGS. 18 a and 18 b illustrate views of the left cover component of the handle.
[0057] FIGS. 19 a and 19 b illustrate the right cover of the handle.
DETAILED DESCRIPTION OF THE INVENTION
[0058] Now referring to FIG. 1 , there is provided a curved needle assembly 1 . The instrument comprising: tube assembly 2 , shrink tubing 3 , handle 4 , driving handle 5 , and luer fitting 6 .
[0059] Now referring to FIG. 2 , the driving mechanism 7 comprises a split wire funnel 8 , split handle inserts 9 , left and right cable couplings 10 and driving shaft 11 .
[0060] FIG. 3 shows the driving mechanism without a cover.
[0061] FIG. 4 illustrates the flexible distal end portion of the steerable needle 13 , which comprises a top segment 14 , intermediate segments 15 and bottom segment 16 . The flexible portion acts via unidirectional action, as adjacent segments define a gap 17 therebetween. During actuation of the flex, these gaps close to produce the concave side of the flex.
[0062] FIG. 5 a discloses a distal tip segment 14 comprising outer shell 18 , pressed or welded insert 19 , central hole 20 and a side hole for injecting cement 21 . FIG. 5 b discloses one preferred distal tip segment 101 having an integral construction.
[0063] FIG. 6 shows the outer shell 18 component of FIG. 5 a.
[0064] FIG. 7 shows the insert 19 component of FIG. 5 a . The insert includes a groove 22 in its generally cylindrical body for the cable fixation, two small holes 24 for the cable insertion, and two radiused protrusions 23 for nested connection, alignment and pivoting relative to its adjacent intermediate segment 15 .
[0065] FIG. 8 illustrates intermediate nesting segment 15 comprising horizontal surfaces 25 and 26 and angled surfaces 28 and 29 , small holes for the cable insertion 30 , central hole 31 for cement injection, radiused protrusion 32 and cavity 27 .
[0066] Generally, an intermediate nesting segment comprises a distal end having one of a radiused projection and a radiused recess, and a proximal end having the other of the radiused projection and the radiused recess. In some embodiments, at least one of the nested, separate segments has a generally cylindrical shape defining a longitudinal axis, and wherein the radiused projection and radiused recess are each provided on a line parallel to the longitudinal axis. These conditions allow for linear nesting along one surface of the flexible portion of the needle.
[0067] In preferred embodiments, the distal end of the intermediate segment 15 further has a flat surface, its corresponding proximal end further has a flat surface, and the radiused projection and radiused recess are each provided on a line substantially parallel to the longitudinal axis.
[0068] In some nesting arrangements, the flexible portion of the needle comprises a first nesting segment and a second nesting segment adjacent the first nesting segment, wherein the first nesting segment comprises a projection, the second nesting projection comprises a recess, wherein the projection is nested in the recess, and wherein the first and second nesting segments define a gap therebetween.
[0069] In some embodiments, a first intermediate segment comprises a generally cylindrical shape having a first end having first and second projections extending therefrom, and a second end comprising first and second recesses therein. In some embodiments, the first and second projections define first and second end surfaces therebetween, the first and second recesses define third and fourth surfaces therebetween, wherein the first and third surfaces are parallel and the second and fourth surfaces are skewed. In embodiments producing the gap, the second and fourth surfaces are oriented towards each other.
[0070] In some embodiments, the projections define a first radius, the recesses define a second radius, and the first radius is substantially equal to the second radius. This allows for a high degree of nesting.
[0071] FIG. 9 illustrates the proximal segment 16 of the flex. It has a substantially cylindrical body, a pair of distal recesses, but no proximal projections. This segment 16 may be welded to the hypodermic tubing 34 (which is shown in FIG. 10 ) that is proximal thereto within the device.
[0072] FIG. 10 shows the hypodermic tube assembly 33 comprising the bottom segment 16 , the hypodermic tube 34 , and the coupling 35 welded to the tube 34 .
[0073] FIG. 11 illustrates an axial cross-section of funnel 8 , which includes a hole 36 for cement delivery, a hole 40 for aligning the driving shaft 11 , channels 37 for receiving the cable, a flange 39 for assembly with handle inserts 9 , holes 38 for receiving the pins that hold the funnel together, and holes 41 for attaching the funnel to the handle insert cover 9 .
[0074] FIG. 12 illustrates one half-shell of handle insert 9 comprising groove 43 for funnel assembly, holes 42 for attaching inserts to the funnel by pins, slots 44 and 46 for guiding the cable couplings 10 , the groove 45 for aligning with the flange of driving screw 11 , hole 47 for guiding the driving screw 11 , and holes 48 for assembly with the other half-shell of the handle insert using pins.
[0075] FIG. 13 illustrates the driving screw 11 comprising left 49 and right 50 threads, and an intermediate flange 51 for aligning the screw with handle inserts 9 .
[0076] FIG. 14 illustrates cable coupling 10 comprising indicator of the flex angle 52 , tensioning screw 53 , male clamp 54 , alignment guide 56 , female clamp 57 , pin 58 , and nut 59 . Cable 55 is fed into male clamp 54 to secure the cable.
[0077] In general, the cable tensioning mechanism works as follows: The cable is threaded through segments 14 - 16 , tube assembly 33 , funnel 8 and screw 53 . The cable ends are held by the female clamp 57 and male clamp 54 of the two cable couplings 10 . By turning nut 59 , the screw 53 of the two cable couplings 10 is pulled back, thereby tensioning both ends of the cable.
[0078] FIGS. 15 , 16 and 17 illustrate the various parts of the cable clamping and tensioning mechanism. FIG. 15 discloses one preferred tensioning screw component 53 of the cable coupling. This screw component 53 has a thread thereon. FIG. 16 discloses one preferred female-threaded clamp component 57 of the cable coupling. FIG. 17 discloses one preferred male-threaded clamp component 54 of the cable coupling.
[0079] FIGS. 18 a and 18 b illustrate views of the left cover 60 of the handle 4 , while FIGS. 19 a and 19 b illustrate the right cover 61 of handle 4 .
[0080] To assemble the device, the cable 55 is threaded through the hole 24 of the insert 19 , looped through the groove 22 and threaded back into hole 24 . The cable is then locked by the outer shell 18 assembly with the insert 19 . The middle segments 15 are then threaded into the cable with their horizontal surfaces 25 facing the same direction. The flexible end 13 is then assembled with the tube assembly 33 and the cable ends are threaded through the tube. The left and right couplings 10 are assembled onto the driving shaft 11 and then the assembly is surrounded with the handle inserts 9 . The funnel 8 is assembled with handle inserts 9 . The cable ends are then guided into the funnel channels 37 and the hole of the tensioning screw 53 . The tube assembly 2 is then assembled with the funnel 8 and cables are pre-tensioned by hand.
[0081] The cable ends are locked by the male clamp 54 . The final tensioning of the cable is achieved by turning the nuts. When this is done, the covers 60 and 61 are placed around the assembly and locked. The shrink tubing 3 is placed over the flexible end to prevent cement leakage.
[0082] The flexing of the distal flexible end of the device is achieved by rotating the driving handle 5 . This rotation in turn turns the driving shaft 11 , and cable couplings 10 slide in opposite directions—pulling and releasing the cable. As the cable is fixed at the tip segment, it slides through the segments, either flexing or straightening the flexible end of the device.
[0083] The present invention can be practiced through a unipedicular approach as well as a bipedicular approach.
[0084] To inject cement into the vertebral body, an injection system having a cement reservoir containing flowable cement is attached to the luer 6 and cement is flowed through the central hole of the driving screw, funnel and the tube assembly into the flexible end of the device, and is finally ejected through the side hole 21 and into the vertebral body.
[0085] In the embodiments shown, the device ejects cement through a hole in the sidewall of the tube. However, in other embodiments, the cement may be axially ejected via an endhole opening through a distal end portion of the tube.
[0086] Preferred bone pastes include bone cements (such as acrylic-based bone cements, such as PMMA-based bone cements), pastes comprising bone particles (either mineralized or demineralized or both; and either autologous, allogenic or both), and ceramic-based bone cements (such as HA and TCP-based pastes).
[0087] In some embodiments, the flexible needle of the present invention may also be used as a conduit for cement delivery. In some embodiments thereof, the proximal end portion of the tube is fluidly connected to a cement reservoir. | Devices, systems and methods for delivering a curable, stabilizing material into a central region of a bone structure. Precise placement of the curable substance into a central region of a bone structure through a unipedicular approach. One primary advantage is its ability to create a central cavity in a vertebral body (or to centrally deliver bone cement) through a unipedicular approach. A curved needle having increased rigidity in its flexible end when the end is disposed in its straight position. This increased rigidity is due to a novel tensioning mechanism and to a segmented tube design (as opposed to the conventional longitudinally-slotted tube design). | 0 |
BRIEF DESCRIPTION OF THE INVENTION
The present invention relates to a novel class of thiazole bis-phosphates and phosphonates and to their use as insecticides when used in an insecticidally effective amount. In particular, this invention relates to compounds having the formula ##STR3## in which R 1 is selected from the group consisting of methoxy, ethoxy, and alkyl having from 1 to 10 carbon atoms, preferably 1 to 5 carbon atoms;
R 2 is alkoxy having from 1 to 10 carbon atoms, preferably from 1 to 5 carbon atoms;
R 3 is hydrogen or phenyl, preferably hydrogen; and X is sulfur or oxygen, preferably sulfur.
The present invention further relates to intermediates for the above compounds, having the formula ##STR4## IN WHICH R 3 is as defined above.
All stated ranges of quantities of carbon atoms are intended to be inclusive of their upper and lower limits.
By "insecticidally effective amount" is meant the amount of the herein disclosed insecticidal compounds which when applied in any conventional manner to the habitat of insects, the feedstuffs of insects, or the insects themslves, will kill or substantially injure a significant portion thereof.
DETAILED DESCRIPTION OF THE INVENTION
The intermediates of the present invention are prepared by the condensation of thiourea with the appropriate α-chloronitrile in alcohol solvent to form the 2,4-diamino-thiazole or the 2,4-diamino-5-phenylthiazole, which is subsequently reacted with chloroacetic anhydride in the presence of a base such as triethylamine: ##STR5## where R 3 is as defined above. Reaction I is described in detail in W. Davies, J. A. MacLaren, and L. R. Wilkinson, Journal of the Chemical Society, 4, 3491-3494 (1950).
The insecticide compounds are prepared by a condensation reaction in which the intermediate is reacted with the appropriate phosphate or phosphonate: ##STR6## where R 1 , R 2 , and R 3 are as defined above, and B is a basic cation such as sodium, potassium, ammonium, or triethylammonium. This reaction can be conducted in the presence of any inert solvent. Due to the low solubility of the intermediate, dimethylformamide or dimethylsulfoxide are preferred solvents.
The following examples are offered to further illustrate the intermediates and insecticide compounds of the present invention.
EXAMPLE 1
2,4-Di-(chloroacetylamino)thiazole ##STR7##
A slurry of 15.2 g (0.1 mole) of 2,4-diaminothiazole prepared according to the method of Davies et al., J. Chem. Soc., 4, 3491-3494 (1950) in 50 ml of dimethylformamide was prepared. To the slurry was added 10.1 g (0.1 mole, 13.8 ml) of triethylamine with continuous stirring, followed by the portion-wise addition of 43 g (0.25 mole) of chloroacetic anhydride with cooling to maintain the temperature at 45° C. The mixture was then warmed to 65°-70° C and filtered. The filtrate was poured over crushed ice and diluted with water. A precipitate formed and was filtered off and washed with cold water followed by ether, then dried at 40° C to produce 18.9 g (70.5% of theory) of the title compounds, melting point 188°-192° C with decompositon.
EXAMPLE 2
2,4-Dichloroacetamido-5-phenylthiazole ##STR8##
A slurry was prepared, consisting of 11.8 g (0.052 mole) of 2,4-diamino-5-phenylthiazole, prepared according to the method of Davies et al., J. Chem. Soc., 4, 3491-3493 (1950) in 30 ml dimethylformamide. To the stirred mixture was added 25.7 g (0.15 mole) chloroacetic anhydride. The mixture was warmed to 70° C, then cooled in an ice bath. While cooling to beow 40° C, 5.3 g (0.052 mole, 72 ml) of triethylamine were added. The mixture was then heated to 60°-65° C for 5 minutes and filtered. The filtrate was poured into cold water and allowed to stand for 10 minutes, then diluted with ice water. The resulting solid was filtered off, washed consecutively with cold water and ether, and dried at 50° C. The product weighed 6.75 g (37.7% of theory), melting point 215°-216° C. The structure was confirmed by mass spectroscopy as that of the title compound.
EXAMPLE 3
2,4-Bis(O,O -dimethylphosphorodithioylacetamide)thiazole ##STR9##
To a continuously stirred solution of 7.0 g (0.04 mole) of ammonium dimethyldithioylphosphate in 25 ml of dimethylformamide was added 4.0 g (0.015 mole) of the compound of Example 1. The mixture was stirred at room temperature for 2.5 hours, allowed to stand overnight, then poured into 150 ml of cold water. To the mixture was then added 50 ml of saturated sodium chloride solution. The resulting mixture was then extracted with benzene and the benzene extract was washed with dilute sodium chloride solution and dried over anhydrous MgSO 4 , filtered, and vacuum evaporated to give 4.4 g of a thick yellow liquid, with refractive index n D 30 = 1.5781. The compound solidified on standing. The structure was confirmed by nuclear magnetic resonance spectra as that of the title compound.
EXAMPLE 4
2,4-Bis-(ethyl, O -isopropylphosphonodithioylacetamido)thiazole ##STR10##
A solution of 9.2 g (0.05 mole, 8.8 ml) of O-isopropyl, ethylphosphonodithioic acid and 5.05 g (0.05 mole) of triethylamine was prepared with stirring and cooling to below 30° C. Additional triethylamine was added to obtain a slightly basic pH. To this mixture was added 5.36 g (0.02 mole) of the compound of Example 1. The mixture was stirred at room temperature and allowed to stand overnight. The mixture was then poured into 150 ml of cold water and 50 ml of saturated sodium chloride were added. The mixture was then extracted with 150 ml of benzene. The benzene extract was washed with dilute sodium chloride solution, dried over anhydrous MgSO 4 , filtered, and vacuum evaporated to yield 11.4 g of a dark brown liquid product, with refractive index n D 30 = 1.5755. The structure was confirmed by nuclear magnetic resonance analysis as that of the title compound.
Other compounds within the scope of the invention can be prepared by similar techniques, using the appropriate starting materials. Further examples are listed in the following tables.
TABLE I______________________________________Insecticide Compounds and Physical Properties ##STR11##Compound RefractiveNo. R.sup.1 R.sup.2 R.sup.3 X Index (n.sub.D.sup.30)______________________________________1 C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O H S 1.57542 CH.sub.3 O CH.sub.3 O H S 1.57813 C.sub.2 H.sub.5 i-C.sub.3 H.sub.7 O H S 1.57554 C.sub.2 H.sub.5 C.sub.2 H.sub.5 O H S 1.59375 C.sub.2 H.sub.5 CH.sub.3 O H S 1.60366 C.sub.2 H.sub.5 i-C.sub.4 H.sub.9 O H S 1.57387 C.sub.2 H.sub.5 s-C.sub.4 H.sub.9 O H S 1.57438 C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O H O 1.54689 CH.sub.3 O CH.sub. 3 O C.sub.6 H.sub.5 S 1.594110 C.sub.2 H.sub.5 i-C.sub.3 H.sub.7 O C.sub.6 H.sub.5 S dark liquid______________________________________
TABLE II______________________________________Intermediates and Physical Properties ##STR12##Compound No. R.sup.3 Melting point (° C)______________________________________11 H 194-19712 C.sub.6 H.sub.5 215-216______________________________________
The compounds listed in Table I were evaluated for insecticidal activity according to the following procedures.
Insecticide Evaluation
A. Housefly [Musca domestica (L.) ]
The test compound is diluted in acetone and an aliquot is pipetted onto the bottom of a 55 × 15 mm aluminum dish. To insure even spreading on the bottom of the dish, 1 ml of acetone containing 0.02% peanut oil is added. After all the solvent has evaporated, the dish is placed in a circular cardboard cage containing 25 1-day-old female houseflies. The cage is covered on the bottom with cellophane and the top with tulle netting, and contains a sugar-water saturated cotton plug for maintenance of the flies. Mortality is recorded after 48 hours. The primary screening level for this test is 100 micrograms of the test compound per 25 female houseflies.
B. German Cockroach [Blatella germanica (Linne)]
The test compound is diluted in a 50-50 acetone-water solution. Two milliliters of the solution are sprayed through a DeVilbiss type EGA hand spray gun into a circular cardboard cage contaning 10 1-month-old German Cockroach nymphs. The test cage is covered on the bottom with cellophane and the top with tulle netting. Percent mortality is recorded after 7 days. The primary screening level for this test is 0.1% by weight of the test compound in the acetone-water solution.
C. Lygus bus [Lygus hesperus (Knight)]
The test compound is dissolved in a 50-50 acetone-water solution. Two cubic centimeters of the solution are sprayed through a DeVilbiss-type EGA hand spray gun into a circular cardboard cage covered on the bottom with cellophane and the top with tulle netting, containing one string bean pod and 10 adult lygus bugs. Percent mortality is recorded after 48 hours. The primary screening level for this test is 0.5% by weight of the test compound in the acetone-water solution.
D. Direct Spray Assay on Black Bean Aphid [Aphis fabae (Scop.)]
A nasturtium plant (Tropaeolum sp.), approximately 5 cm tall, is transplanted into sandy loam soil in a 3-inch clay pot and infested with 25-50 black bean aphids of mixed ages. Twenty-four hours later the plant is sprayed, to the point of runoff, with a 50-50 acetone-water solution of the test chemical. The treated plant is held in the greenhouse and mortality is recorded after 3 days. The primary screening level for this test is 0.05% by weight of the test compound in the acetone-water solution.
E. Direct Spray Assay on Green Peach Aphid [Myzus persicae (Sulzer)]
A radish plant (Rhaphanus sativus), approximately 2 cm tall, is transplanted into sandy loam soil in a 3-inch clay pot and infested with 25-50 green peach aphids of mixed ages. Twenty-four hours later the plant is sprayed, to the point of runoff, with a 50-50 acetone-water solution of the test compound. The treated plant is held in a greenhouse and mortality is recorded after 3 days. The primary screening level for this test is 0.05% by weight of the test compound in the acetone-water solution.
F. Systemic Assay on Black Bean Aphid [Aphis fabae (Scop.)]
The test chemical is diluted in acetone and an aliquot is thoroughly mixed into 500 grams of dry, sandy loam soil. The treated soil is placed in a pint ice cream carton and a nasturtium plant (Tropaeolum sp.) approximately 5 cm tall is transplanted into the carton. The plant is then infested with approximately 25 black bean aphids of mixed ages and placed in the greenhouse. Seven days later mortality is recorded. The primary screening level for this test is 10 ppm by weight of the test compound in the soil.
G. Salt-marsh Caterpillar [Estigmene acrea (Druryl)]
A test solution is prepared by dissolving the test compound in a 50-50 acetone-water solution. A section of a curly dock (Rumex crispus) leaf, aproximately 2.5 centimeters wide and 4 centimeters long, is immersed in the test solution for 2-3 seconds, then placed on a wire screen to dry. The dried leaf is placed in a petri dish containing a moistened piece of filter paper, and infested with 5 second-instar salt-marsh caterpillar larvae. Mortality of the larvae is recorded 48 hours later. If surviving larvae are still present, a piece of synthetic media is added to the dish and the larvae are observed for an additional 5 days in order to detect delayed effects of the test compound. The primary screening level for this test is 0.05% by weight of the test compound in the solution.
H. Cabbage Looper [Trichoplusia ni (Hubner)]
The procedure for cabbage looper larvae is the same as that used for salt-marsh caterpillar larvae, except that a cotyledon of hyzini squash (Calabacita abobrinha) of approximately the same size as the curly dock leaf section is used in place of the latter. The primary screening level for this test is 0.1% by weight of the test compound in the solution.
I. Tobacco Budworm [Heliotis virescens (F.)]
Larvae of the tobacco budworm are used in this test in a procedure identical to that used for salt-marsh caterpillar larvae, except that a Romaine lettace (Latua sativa) leaf section of approximately the same size as the curly dock leaf section is used in place of the latter. The primary screening level for this test is 0.1% by weight of the test compound in the solution.
J. Two-Spotted Mite [Tetranychus urticae (Koch)]
A pinto bean plant (Phaseolus sp.), approximately 10 cm tall is transplanted into sandy loam soil in a 3-inch clay pot and infested with two-spotted mites of mixed ages and sexes. Twenty-four hours later the infested plants are inverted and dipped for 2-3 seconds in a 50-50 acetone-water solution of the test compound. The treated plant is held in a greenhouse for 7 days. Mortality is then determined for both the adult mites and the nynmphs hatching from eggs which were on the plants at the time of treatment. The primary screening level for this test is 0.05% by weight of the test compound in the acetone-water solution.
K. Southern House Mosquito [Culex pipiens quinquefasciatus (Say)]
Insecticidal activity is determined using third-instar larvae of the mosquito (Culex pipiens quinquefasciatus). Ten larvae are placed in a 6-ounce, number 67 Dixie wax paper cup containing 100 milliliters of an aqueous solution of the test chemical. The treated larvae are stored at 70° F, and 48 hours later the mortality is recorded. The primary screening level for this test is 1 ppm by weight of the test compound in the solution.
Table III is a summary of the results of tests performed on the compounds of Table I. The entries in Table III were obtained as follows:
For a particular insect, each compound was initially tested at the primary screening level. For the two-spotted mite, the testing stopped at this point. Those compounds showing less than 50% kill are represented in the table by the primary screening level preceded by a "greater than" sign. For those showing more than 50% kill, a "less than" sign is used. For all other insects those compounds showing greater than 50% kill at the primary screening level were then tested at successively lower levels, until the level was found at which approximately 50% kill was achieved. This level is listed as the LD 50 (50% lethal dose) value in Table III. For those compounds showing approximately 50% kill at the primary screening level, the primary screening level itself is listed as the LD 50 .
Of those compounds which did not pass the primary screen, i.e., those showing less than 50% kill, some were tested at higher concentrations in order to find the level which would produce 50% kill. In cases where this level was found, the level is reported as the LD 50 . When the level of 50% kill was not found, the number listed is the highest concentration tested, whether primary screen or higher, preceded by a "greater than" sign to indicate that a higher level than reported must be used to achieve 50% kill.
The primary screening level in each of the above tests was selected for purposes of convenience only, and none of the figures in the table are to be understood as representing the highest level at which a viable test for insecticidal activity can be conducted. Dashes are used in Table III where no tests were performed at all.
TABLE III__________________________________________________________________________Insecticide Activity - Approximate LD.sub.50 Values 2SMCompound HF GR LB BBA GPA BAS SMC CL TBW (1) (2) MOSNo. μg % % % % ppm % % % % % ppm__________________________________________________________________________1 >100 >.1 >.05 .05 -- >10 >.05 >.1 >.1 <.05 <.05 .82 >100 >.1 >.05 .002 .03 >10 >.05 >.1 >.1 <.05 >.05 >1.03 100 >.1 .05 .00005 .001 >10 .008 .002 .005 <.05 <.05 .14 100 >.1 .05 .0003 .002 >10 .01 .005 .05 <.05 <.05 .085 75 >.1 >.05 .0005 .005 >10 .05 .02 >.05 <.05 <.05 .26 42 >.1 >.05 .0001 .005 >10 .005 .003 .05 <.05 <.05 .087 >100 >.1 > .05 .0001 .005 >10 .01 .002 >.1 <.05 <.05 .28 >100 >.1 >.05 .001 .03 >10 >.05 >.1 >.1 <.05 <.05 >1.09 >100 -- -- .2 .15 -- >.05 >.5 -- >.05 <.05 >1.010 >100 >.1 >.05 .0002 .005 >10 >.05 >.1 >.1 <.05 <.05 .4__________________________________________________________________________ Symbols for Table III: HF : housefly GR : German cockroach LB : Lygus bug BBA : black bean aphid GPA : green peach aphid BAS : bean aphid systemic SMC : salt-marsh caterpillar CL : cabbage looper TBW : tobacco budworm 2SM : two-spotted mite - (1) post-embryonic, (2) eggs MOS : Southern house mosquito >: greater than <: less than
The compounds of this invention are generally used in formulations suitable for convenient application. In general, such formulations will contain inert or occasionally active ingredients or diluent carriers in addition to the active compound. Examples of such ingredients or carriers are organic solvents, such as sesame oil, xylene range solvents, and heavy petroleum; water; emulsifying agents; surface active agents, talc; pyrophyllite; diatomite; diatomite; gypsum; clays; and propellants, such as dichlorodifluoromethane.
The active compounds can further be combined with dust carriers for application as dusts, with granular carriers for application by fertilizer spreaders or ground or airplane seeders, with wettable powders or flowable carriers for application as water suspensions, or with solvents and surface active materials for application as sprays, aerosols, or emulsions. The compounds or their formulated mixtures can be applied to any habitat of the pests. Examples of such habitats are insect dwellings, clothing, plant surfaces, and soil. If desired, however, the active compositions can be applied directly to organic matter, seeds or feedstuffs in general, upon which the pests feed, or directly to the pests themselves. When applied in such a manner, it will be advantageous to use a formulation which is not volatile.
The amount of active compound or formulation which is considered to be insecticidally effective is that amount which, when applied to the pest habitat or feedstuff, will kill or substantially injure a significant portion residing or feeding thereon. The active compounds of this invention can be employed either as the sole pesticide component of the formulation or as one of a mixture of compounds in the formulation having similar utility. Furthermore, the presently disclosed pesticide compositions need not be active as such. The purposes of this invention will be fully served by a composition which is rendered active by external influences, such as light, or by physiological action occurring when the preparation is ingested or penetrates into the body of the pest.
The precise manner in which the pesticide compounds of this invention are used in any particular instance will be readily apparent to a person skilled in the art. Generally, the active pesticidal compound will be used as a component of a liquid composition; for example, an emulsion, suspension, or aerosol spray. While the concentration of the active pesticide compound in the present formulation can vary within rather wide limits, odinarily, the pesticide composition will comprise not more than about 50.0% by weight of the formulation. | Insecticidally active compounds are disclosed, defined by the general formula ##STR1## in which R 1 is methoxy, ethoxy, or alkyl having from 1 to 10 carbon atoms;
R 2 is alkoxy having from 1 to 10 carbon atoms;
R 3 is hydrogen or phenyl; and
X is sulfur or oxygen;
And intermediates for the preparation of such compounds defined by the general formula ##STR2## IN WHICH R 3 is as defined above. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of pending International patent application PCT/DK2008/000200 filed on May 30, 2008 which designates the United States and claims priority from Danish patent application PA 2007 00789 filed on May 31, 2007 and U.S. Provisional Patent Application Ser. No. 60/941,120 filed on May 31, 2007, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a variable speed wind turbine, a resonant control system, a method of operating a variable speed wind turbine, use of a resonant control system and use of a method in a variable speed wind turbine.
BACKGROUND OF THE INVENTION
Generally a wind turbine converts energy in the wind to electrical energy supplied to a utility grid.
As wind acting on a wind turbine rotor produces rotational torque in the drive train of the wind turbine and, the rotor of the wind turbine is influenced by varying wind situations e.g. due to wind shear, alternating mean wind velocities, fluctuating wind, turbulence etc., the rotational speed of the drive train and hereby also the generator varies accordingly. This in turn have an influence on the power quality produced by the wind turbine generator. Furthermore the varying rotational speed may produce a varying mechanical torque in the drive train that can have fatigue influence on mechanical components of the drive train.
US patent application 2006/0066111 discloses a wind turbine vibration damping system that control the torque in the drive train produced by a wind turbine generator, based on information regarding the rotational speed of the generator.
One problem related to this system is that frequencies of the wind turbine, which are desired to dampen, are calculated based on Fourier transformations of a sampled signal indicative of the rotational speed of the generator. A problem related to this problem is that continuous Fourier transformations and calculations are time consuming and takes up computational power of the wind turbine controller and due to time delay the accuracy of dampening is therefore weakened.
It is an object of the present invention to provide an advantageous method of dampening varying rotational vibrations in the drive train of a wind turbine without the above mentioned disadvantages.
SUMMARY OF THE INVENTION
The invention provides a variable speed wind turbine connected to the utility grid including
a rotor, comprising at least one blade, a drive train connected to said rotor, said drive train comprising a selection of at least one gear box, and at least one electrical generator, measuring means establishing at least one rotational speed signal of the drive train, at least one wind turbine power controller connected to said at least one generator and said utility grid.
Said wind turbine further comprises at least one resonant control means modifying a power reference value in response to said at least one rotational speed signal.
Modifying a power reference value in response to at least one rotational speed signal is advantageous in that, oscillations in the mechanical system of the wind turbine that is influencing e.g. the rotational speed of the wind turbine generator, can be dampened furthermore ensuring that loads on wind turbine components can be minimized.
By using resonant control means it is even further ensured that only oscillations with specific frequencies can be selected ensuring that e.g. oscillations at drive train resonance frequencies are controlled and dampened.
By modifying a power reference value it is even further ensured that the bandwidth of the wind turbine controller system is independent of the bandwidth of the resonant control means and a faster and more accurate drive train oscillation compensation can be achieved e.g. due to different bandwidths of the external power control loop and the internal current/torque control loop.
In one aspect of the invention said resonant control means comprises one or more PID controllers such as one or more resonant PID controllers. By using PID controllers it is ensured that a well known and reliable controller technique is used ensuring that the desired characteristics of the resonant control means are obtained. Furthermore by using a resonant controller it is further ensured that specific frequencies can be selected for dampening and control such as the drive train resonance frequency.
In another aspect of the invention said resonant control means has a relative high gain at one resonance frequency of the drive train. Hereby it is ensured that even small responses or variations in said at least one rotational speed signal at said one resonance frequency results in a high value of feedback signal and thereby the modification of said power reference value which in turn results in a very effective control and/or dampening of said variations.
In yet another aspect of the invention the bandwidth of said resonant control means can be altered by altering at least one operating parameter of said resonant control means. Setting the operating parameters of said resonant control means ensures that the frequency range at which said resonant control means has a relative high gain can be controlled and that the resonant control means can produce an effective response to more close frequencies. By altering at least one of said operating parameters during operation it is furthermore ensured that if e.g. the resonant control means is basically tuned to e.g. the drive train eigen frequency, variations in the actual eigen frequency of the drive train during operation e.g. due to temperature variations can be compensated for and said variations has thereby only minor influence on the control means in order to produce an effective response.
In a further aspect of the invention the gain of said resonant control means at one resonance frequency can be altered by altering at least one operating parameter of said resonant control means e.g. at DC frequency. Hereby it is ensured that the level at which the resonant control means modifies one power reference value can be controlled and the effectiveness of e.g. drive train oscillation dampening can be controlled.
In another aspect of the invention the phase shift of said resonant control means at one resonance frequency of the drive train is substantially zero. Hereby it is ensured that an accurate non-delayed response to one rotational speed signal at one resonance frequency is obtained and that no further phase signal processing is necessary.
In yet another aspect of the invention said resonant control means has a numerical increasing phase shift at frequencies away from one resonance frequency of the drive train. Hereby it is ensured that the impact of the response of the resonant control means is degraded for frequencies away from the resonant frequency of the control means.
In a further aspect of the invention the slope of the phase shift can be altered by altering at least one operating parameter of said resonant control means. Hereby it is ensured that the level at which the response of the resonant control means is degraded for frequencies away from the resonant frequency of the control means, can be controlled further ensuring the possibility of effective dampening of selected resonance frequencies.
In yet another aspect of the invention the transfer function of said resonant control means is on the form:
H
RCM
(
S
)
=
K
P
+
K
i
·
2
ω
CU
S
S
2
+
2
ω
CU
S
+
ω
DT
2
Hereby one implementable embodiment of the invention is ensured and further that operation parameters of the resonant control means can be altered.
In a further aspect of the invention one fundamental resonant frequency of said resonant control means is one resonance frequency of the drive train such as the eigen frequency of the drive train. Hereby it is ensured that the dampening of oscillations with frequencies at or very near the drive train eigen frequency is dampened very effectively which in turn results in lesser loads on the components comprised in the drive train.
In an even further aspect of the invention one fundamental resonant frequency of said resonant control means is a calculated value e.g. a predefined calculated value. Hereby operating parameters of the resonant control means can be applied ensuring an optimal desired response for one fundamental resonance frequency such as one theoretically calculated resonance frequency of the drive train e.g. the drive train eigen frequency.
In a further aspect of the invention one fundamental resonant frequency of said resonant control means is a fixed value or can be altered during operation e.g. adaptive such as to the eigen frequency of the drive train. Hereby it is ensured that one set of operating parameters of the resonant control means can be applied and obtaining an optimal response, taking into account possible operational variations of the wind turbine e.g. due to temperature variations.
In a further aspect of the invention said resonance eigen frequency is a predefined value and/or is estimated. Hereby one set of operational parameters of the resonant control means can be applied once and said means modifies one power reference signal accordingly.
In another aspect of the invention the level of which said at least one control means modifies a power reference value is limited. Hereby it is ensured that the modification of a power reference is limited to a desired and acceptable level.
In yet another aspect of the invention the level of which said at least one control means modifies a power reference value is limited to be within a predefined level. Hereby it is ensured that the modification of a power reference is controlled and limited to a desired and acceptable level in response to e.g. fluctuations of the wind.
In a further aspect of the invention said predefined level is in the range of 0.1 to 25 percent of nominal and/or generated power of said wind turbine such as 5 percent. Hereby it is ensured that the impact of the power reference modification on the generated power is limited and that the generated power will fluctuate only limited as a result of the drive train oscillation compensation control.
In one aspect of the invention said measuring means is an encoder e.g. an encoder operated on a low speed rotor shaft and/or on a generator shaft. Hereby it is ensured that reliable values of the rotational speed are obtained and that the values are measured on influenced components of the drive train.
In another aspect of the invention said measuring means establishes at least one rotational speed signal of the drive train by processing at least one electrical parameter of the wind turbine such as rotor current, stator current etc. Hereby it is ensured that an indirect measure of one rotational speed signal of the drive train is obtained e.g. without separate measuring components. Furthermore it is ensured that parameters already obtained can be used to establish said speed signal.
In yet another aspect of the invention said power reference value is a power reference value of said power controller. Hereby it is ensured that the impact of e.g. fluctuations in rotational speed of the generator is minimized or compensated for without disturbing the common power control system of the wind turbine.
The invention also relates to a resonant control system, a method of operating, use of variable speed wind turbine, and use of a method in a variable speed wind turbine.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in the following with reference to the figures in which
FIG. 1 illustrates a large modern wind turbine including three wind turbine blades in the wind turbine rotor,
FIG. 2 illustrates schematically a cross section of an embodiment of a simplified nacelle known in the art, as seen from the side,
FIG. 3 illustrates schematically a control block diagram of drive train oscillation compensation systems of prior art,
FIG. 4 illustrates schematically a control block diagram of a drive train oscillation compensation system according to one embodiment of the invention,
FIG. 5 a illustrates a bode plot of the characteristics of a resonance control means with a first set of parameters according to one embodiment of the invention,
FIG. 5 b illustrates a bode plot of the characteristics of a resonance control means with a second set of parameters according to another embodiment of the invention, and
FIG. 5 c illustrates various bode plots of the characteristics of a resonance control means according to other embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a modern wind turbine 1 with a tower 2 and a wind turbine nacelle 3 positioned on top of the tower.
The wind turbine rotor, comprising at least one blade such as three wind turbine blades 5 as illustrated, is connected to the hub 4 through pitch mechanisms 6 . Each pitch mechanism includes a blade bearing and pitch actuating means which allows the blade to pitch. The pitch process is controlled by a pitch controller.
As illustrated in the figure, wind over a certain level will activate the rotor and allow it to rotate in a perpendicular direction to the wind. The rotation movement is converted to electric power which usually is supplied to the utility grid as will be known by skilled persons within the area.
FIG. 2 illustrates a simplified cross section of a nacelle 3 , as seen from the side. The nacelles 3 exists in a multitude of variations and configurations but in most cases the drive train 14 of the nacelle 3 almost always comprises one or more of the following components: a gear 7 , a coupling (not shown), some sort of breaking system 8 and a generator 9 .
A nacelle 3 of a modern wind turbine 1 can also include a converter 12 (also called an inverter) and additional peripheral equipment such as further power handling equipment, control cabinets, hydraulic systems, cooling systems and more which is not explicitly illustrated on this figure.
The weight of the entire nacelle 3 including the nacelle components 7 , 8 , 9 , 10 , 11 , 12 is carried by a load carrying structure 13 . The components 8 , 9 , 10 , 11 , 12 are usually placed on and/or connected to this common load carrying structure 13 . In this simplified embodiment the load carrying structure 13 only extends along the bottom of the nacelle 3 e.g. in form of a bed frame to which some or all the components 7 , 8 , 9 , 10 , 11 , 12 are connected.
In this embodiment of the invention the drive train 14 is established in a normal operation angle NA of 8° in relation a horizontal plane. The drive train is for among other reasons angled to enable that the rotor 15 can be angled correspondingly e.g. to ensure that the blades 5 do not come into collision with the tower 2 , to compensate for wind shear etc.
As the rotor is activated by the wind, variations in the wind has an impact on the operation of the wind turbine e.g. on the mechanical forces acting on the drive train 14 in overall and/or the rotational speed of the high speed shaft 11 and the rotational speed of the generator 9 in particular.
The mechanical drive train system 14 behaves as a dynamical mechanical system and may oscillate at its natural eigen frequency and/or harmonics hereof. An oscillation of said mechanical drive train system can be initiated by external influences such as variations or alternations in the wind and may cause unnecessary tear and wear, cause fatigue loads and cause noisy operation.
It is therefore desired to compensate for said variations in the wind and oscillations of the drive train 14 .
FIG. 3 illustrates schematically a control block diagram of one drive train dampening system for various wind turbines of prior art.
A power reference demand value P ref from e.g. a grid operator, park control, substation or individual wind turbine controller is received at the wind turbine and subtracted by a value of the actual generated power P* resulting in a power error input signal EP to a power controller 16 of the wind turbine.
One role of the power controller 16 is to minimize the power error signal εP which is achieved by controlling parameters of the schematically illustrated components of the power controller 16 .
The actual rotational speed of the generator ω gen is measured by measuring means and processed via a filter H( DTD ) in order to produce a current/torque drive train dampening feedback signal i/T DTD that is fed back to the internal current/torque loop of the power controller 16 .
The filter H( DTD ) may for various embodiments of prior art comprise FFT algorithms in order to extract information regarding the signal magnitude of the rotational speed of the generator w gen e.g. at the drive train eigen frequency.
One problem related to this prior art is that computations of FFT algorithms with high frequency resolution are very time consuming and therefore the generation of the current/torque feedback signal i/T DTD may be time delayed and non-accurate which in turn decreases the efficiency of dampening.
If the bandwidth of the external power control loop is high compared to the internal current/torque loop the power controller 16 seeks to control to two opposite pointed signals. A standard technique of prior art is therefore to slow down the outer power loop to e.g. 1/10 the bandwidth of the current/torque loop.
If furthermore the current/torque loop is influenced by a drive train dampening signal i/T DTD it might necessary to even further slow down the speed of the power feedback loop e.g. by a LP-filter 20 .
The result is a relative slow adaptation to influences on the power loop.
FIG. 4 illustrates schematically a control block diagram of a drive train oscillation compensation system according to one embodiment of the invention.
A power reference value P ref from e.g. a grid operator, park control, substation or individual wind turbine controller is received at the wind turbine and subtracted by a first value of the actual generated power P.
The actual rotational speed of the generator ω gen is measured by measuring means, conditioned by signal condition means 21 and processed via resonant control means H( RCM ) in order to produce a power feedback signal P RCM that is fed back and subtracted as a second value from said power reference demand value P ref .
The combined modification of P ref by subtraction of both P and P RCM results in one power error input signal εP to power controller 16 of the wind turbine 1 .
One role of the power controller 16 is to minimize the power error signal εP which is achieved by controlling parameters of the schematically illustrated components of the power controller 16 .
The resonant control means H( RCM ) may for various embodiments of the invention comprise one or more PI and/or PID controllers and for a preferred embodiment at least one of the said one or more PI and/or PID controllers is a resonant controller.
One prominent feature of the invented resonant control means is that it has a relative high gain at a given resonant frequency.
Another prominent feature of the invented resonant control means is that is has substantially zero phase shift at said given resonant frequency.
For various embodiments of the invention said resonant frequency is one fundamental resonance frequency of the drive train.
For one specific embodiment said one fundamental resonance frequency is the eigen frequency of the drive train.
For one embodiment of the invention said fundamental resonance frequency is a calculated value based on e.g. theoretical mechanical modeling.
For another embodiment of the invention said fundamental resonance frequency is based on empirical collected data and/or calculations.
For an even further embodiment of the invention the resonant frequency can be altered during operation.
For other embodiments the resonant frequency is other selective harmonic frequencies of the wind turbine.
One main advantage of the resonant control means is that it is suited to operate on selective harmonics and thus the resonant control means tuned for operating at the drive train eigen frequency will be able to diminish the influence of the drive train compensation on the power and the speed control of the turbine.
For one embodiment of the invention the resonant control means has the following transfer function:
H
RCM
(
S
)
=
K
P
+
K
i
·
2
ω
CU
S
S
2
+
2
ω
CU
S
+
ω
DT
2
For even further embodiments of the invention the level of which the power feedback signal R RCM that is fed back and subtracted as a second value to the power reference value P ref is limited to a predefined level i.e. the P RCM signal can modify the power reference value P ref ±a certain amount only.
In this way the impact of the power reference modification on the generated power is limited and the generated power will fluctuate only limited as a result of the drive train oscillation compensation control.
The limitation of P RCM may for various embodiments be in the range of e.g. 0.1 to 25 percent of nominal power or generated power of the wind turbine, such as 5 percent.
For various embodiments of the invention said limits can be fixed, can be altered or can be adaptive during different operation conditions.
FIGS. 5 a , 5 b and 5 c depicts some characteristics of this resonant control means.
At the resonant frequency ω DT =2πf DT the resonant control means has a relative high gain and the phase crosses zero. The further away from the resonant frequency the gain of the control means decreases drastically and for various embodiments converges towards a predefined gain value.
The operating parameters K p and K i are proportional gain and integral gain respectively. ω DT is the resonant frequency which for various embodiments of the invention is equal to the drive train eigen frequency. ω CU is a dampening operating parameter used to describe the sharpness of the characteristic near the resonant frequency.
For various embodiments of the invention the operating parameters of the resonant control means can be altered such as during operation.
Without dampening i.e. ω CU =0, the control means ideally has an infinite gain at the resonant frequency ω DT . A too high gain at the resonant frequency ω DT will lead to a high span of the resonant control means parameters which in turn could invoke discrete implementation errors. It is therefore desirable for a practical implementation of the resonant control means to keep the gain at a moderate level.
The gain of the resonant control means can be formulated as to be:
H
RCM
(
j
ω
)
=
ω
2
[
2
ω
CU
(
K
p
+
K
i
)
]
2
+
[
K
p
(
ω
DT
2
-
ω
2
)
]
2
ω
2
[
2
ω
CU
]
2
+
[
ω
DT
2
-
ω
2
]
2
For various embodiments of the invention the gain of the control means at DC and at the resonant frequency is listed for K p =K p and also for a pure harmonic compensator i.e. K p =0:
K p
ω
||H RCM (jω)||
K p
0
K p
K p
ω DT
K p + K i
0
0
0
0
ω DT
K i
Depending of the values of the parameters Kp and Ki, the charateristics of the resonant control means can be altered.
For a preferred embodiment of the invention the proportional parameter of the resonant control means Kp is chosen to be zero.
FIG. 5 a illustrates the characteristics of a resonant control means of the invention loaded with parameters Kp=0 and Ki=Ki according to one embodiment of the invention.
At the resonant frequency ω DT =2πf DT the gain curve 17 of the resonant control means shows a prominent peak 18 and has a high gain equal to 20 log 10(Ki). The further away from the resonant frequency ω DT the gain of the control means decreases drastically and decreases to zero at ω=0.
At the resonant frequency ω DT =2πf DT the phase curve 19 crosses zero. For relative small variations around ω DT i.e. within the bandwidth frequency limits, the phase the phase changes drastically.
For frequencies further away from the resonant frequency the phase curve 19 converges to ±90 degrees as indicated on the figure.
FIG. 5 b illustrates schematically the characteristics of a resonant control means according to another embodiment of the invention for some fictive parameter settings where the operational parameter Kp>0.
One prominent feature of this embodiment is that at the resonant frequency ω DT =2πf DT the gain curve 17 of the resonant control means peaks 18 and has a high gain equal to 20 log 10(Kp+Ki) and the further away from the resonant frequency the gain of the control means converges towards the gain level denoted X 0 which for this embodiment is 20 log 10(Kp).
Another prominent feature of this embodiment is that at the resonant frequency ω DT =2πf DT the phase curve 19 crosses zero. For relative small variations around ω DT i.e. within the bandwidth frequency limits, the phase the phase changes drastically but for frequencies away form the resonant frequency the phase converges to 0 deg.
FIG. 5 c illustrates bode plots of the characteristics of a resonance control means where the resonant control means of the invention is loaded with parameters Kp=0 and Ki=Ki for various values of ω CU according to various embodiments of the invention.
The gain curves 17 a - d in the figure illustrates how the sharpness of the gain curves is altered by changing ω CU i.e. for increasing values of ω CU the bandwidth of the control means is increased.
At the resonant frequency ω DT =2πf DT the gain curves 17 a - d of the resonant control means shows a prominent peak 18 and has a high gain equal to 20 log 10(Ki). The further away from the resonant frequency WDT the gain of the control means decreases drastically and decreases to zero at ω=0.
For all embodiments of this figure the phase curves 19 a - d crosses zero at the resonant frequency ω DT =2πf DT . For relative small variations around ω DT the phase changes drastically and for frequencies further away form the resonant frequency the phase converges to ±90 degrees as illustrated on the figure.
For various embodiments the present invention may be implemented in various types of wind turbines and generator systems such as wind turbines comprising one or more doubly-fed induction generators or wind turbines comprising full scale power converter systems such as permanent magnet wind turbines. | A variable speed wind turbine connected to a utility grid includes a rotor, having at least one blade, a drive train connected to the rotor, the drive train includes a selection of at least one gear box, and at least one electrical generator, a measuring arrangement establishing at least one rotational speed signal of the drive train, and at least one wind turbine power controller connected to the at least one generator and the utility grid. Furthermore the wind turbine includes at least one resonant controller modifying a power reference value in response to the at least one rotational speed signal. A resonant control system, a method of operating a variable speed wind turbine, use of resonant control system and use of a method in a variable speed wind turbine are also contemplated. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to foreign European Patent Application No. EP 10015001.0, filed on Nov. 25, 2010, the disclosure which is incorporated by reference in its entirety.
FIELD OF THE DISCLOSED SUBJECT MATTER
[0002] The disclosed subject matter relates to a regenerative heat exchanger including a heat accumulator arranged as a rotor, rotatably held around a central rotational axis, and configured to transmit a heat of at least one gas volume flow passing through the rotor to another gas volume flow passing through the rotor.
BACKGROUND
[0003] Regenerative heat exchangers of this kind are used for heat transmission from at least one gas volume flow to at least one other gas volume flow. A rotating heat accumulator, which is the so-called rotor, is heated in an alternating fashion by at least one gas volume flow and cooled again by at least one other gas volume flow, with thermal energy being transmitted from the one to the other gas volume flow. As a result, one of the gas volume flows can be heated and another gas volume flow can be cooled. The rotor comprises two face sides, an outside jacket and usually a segmented portion for accommodating the heat accumulator masses. The rotor is rotatably held around a central rotational axis, with said rotational axis preferably be aligned vertically.
[0004] To seal the gas volume flows guided through the regenerative heat exchanger, a sealing system with core, radial, and/or circumferential seals is provided. The radial seals are arranged on the face sides of the rotor and are provided to prevent short-circuit volume flows between the gas volume flows. The circumferential seals are arranged on the face edges of the rotor and are provided to prevent leakage volume flows into the rotor housing or into the ambient environment. The seals are arranged in a stationary manner with respect to the rotating rotor. As a result of a permanent relative movement between the rotor and these seals and a continuously changing thermal expansion of the rotor and consequently resulting uneven rotor deformations, high demands are placed on the sealing system in order to achieve a low amount of losses (leakages) and thus a high level of efficiency.
[0005] Various sealing systems are known from the state of the art, which enable a relatively small sealing gap in operation between the seal and the rotor. Reference is made in this respect for example to European Patent Application Publication Nos. EP 1 777 478 A1 and EP 2 177 855 A, the disclosures of each of which are incorporated by reference in their entireties. However, conventional sealing systems are frequently disproportionately complex and expensive in practice.
SUMMARY
[0006] It is an object of the disclosed subject matter to provide a regenerative heat exchanger of the kind mentioned above with a simple and effective sealing system.
[0007] This object is achieved by a regenerative heat exchanger in embodiments incorporating the features of claim 1 . Other aspects of embodiments of the disclosed subject matter are recited in the dependent claims.
[0008] In an embodiment of the disclosed subject matter, the sealing system for the rotor comprises at least one seal which is fixed in relation to the rotor and which is pressed against the rotor or a component belonging to the rotor (e.g. by effective weight, spring cylinders, actuators and the like) and which is supported by a plurality of rollers on the rotatable rotor or on a component belonging to the rotor, thereby being provided with forced guidance predominantly in the axial direction. This means that the respective seal is quasi subject to forced guidance, which leads in operation to the consequence that the respective seal continuously follows the thermally induced rotor deformation at a constant distance which is predetermined by the rollers, as a result of which a small and constant sealing gap is ensured.
[0009] In accordance with the disclosed subject matter, minimal sealing gaps can be realized with a comparatively low amount of constructional effort, so that short-circuit and/or leakage volume flows will occur to an exceptionally low extent. In the case of regenerative heat exchangers with suction, the gas quantity to be removed will be reduced. Similarly, the sealing gas quantity will be reduced when using sealing gas. Moreover, the disclosed subject matter has proven to be very beneficial to mounting and offers simple handling and maintenance. It is a further advantage that it is possible to omit the electromechanical and mostly sensor-controlled adjusting devices for the seals which are included in many conventional designs.
[0010] In another embodiment of the disclosed subject matter, it is preferably provided that the rollers are arranged in the fixed seal and/or are fastened to the fixed seal. The rollers can be held with a shaft on the seal or a component belonging to the seal. In another embodiment, it is further preferably provided that the rollers will roll off on at least one corresponding running or rolling surface on the rotor or a component belonging to the rotor, or are guided between two corresponding rolling surfaces which are axially spaced from one another. These rolling surfaces can be especially arranged on exchangeable wearing plates which are fastened to the rotor (a rotor body or a component belonging to the rotor). Similarly, a reverse arrangement of rollers and running surfaces can be provided.
[0011] In order to ensure a minimal sealing gap, especially in critical regions in which the seal is pressed against the rotor (actuating points), the individual rollers may be arranged at least in the region and especially only in the region of the actuating points or pressing points of the seal against the rotor.
[0012] The seal which is supported by means of the rollers is preferably a radial seal. The seal which is supported by means of the rollers is especially a circumferential seal. It is also possible to simultaneously support both the radial seals and also the circumferential seals at least on one rotor side by means of rollers on the rotating rotor.
[0013] In another embodiment there is at least one circumferential seal which is supported by means of rollers on the rotor and is coupled with a radial seal on the same rotor side, such that the respective radial seal is co-moved during the axial movement of the circumferential seal in the axial direction. For this purpose, the radial seal is movably arranged in the axial direction. The coupling between the circumferential seal and the radial seal may occur via a mechanical actuating mechanism, which transmits axial movements of the circumferential seal via at least one actuating bar or the like onto the respective radial seal. The sealing system on one rotor side can therefore perform movements which follow the rotor movements in the axial direction. The preferably radially extending actuating bar is ideally arranged in the rotor housing of the regenerative heat exchanger, namely between the respective radial seal and the wall of the housing, wherein a sealing sleeve can also be arranged in this area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention will be explained in closer detail by reference to embodiments shown in the drawings, which show the following in the schematic partial sectional views:
[0015] FIG. 1 illustrates a first embodiment of a regenerative heat exchanger;
[0016] FIG. 2 illustrates a second embodiment of a regenerative heat exchanger;
[0017] FIG. 3 illustrates a third embodiment of a regenerative heat exchanger, and
[0018] FIG. 4 illustrates a fourth embodiment of a regenerative heat exchanger.
DETAILED DESCRIPTION
[0019] FIG. 1 illustrates a regenerative heat exchanger, designated with reference numeral 1 , of which only one symmetrical half is illustrated. The regenerative heat exchanger 1 comprises a rotor 2 which is rotatably held around a vertical rotational axis A and is arranged in a rotor housing 3 . Several gas volume flows flow through the rotor 2 , with heat from at least one gas volume flow being transmitted to at least one other gas volume flow. A sealing system with radial seals 4 and circumferential seals 5 is provided for sealing the gas volume flows V guided through the regenerative heat exchanger 1 . The radial seals 4 are arranged on the face sides of the rotor 2 and are provided to prevent short-circuit volume flows between the gas volume flows V. The circumferential seals 5 are arranged on the face edges of the rotor 2 and are provided to prevent leakage volume flows into the rotor housing 3 . The radial seals 4 and the circumferential seals 5 are arranged in a stationary manner with respect to the rotating rotor 2 . The radial seals 4 and the circumferential seals 5 preferably form an inherently closed sealing frame, together with optional core seals (not illustrated). The seals which are arranged on the upper face side and on the bottom face side of the rotor 2 are arranged in a substantially identical manner. Unless stated otherwise, the following explanations relate by way of example only to the upper seals and apply analogously to the bottom seals.
[0020] The upper radial seal 4 is arranged as a sealing plate and is fastened to or suspended on the rotor housing 3 by means of several equally spaced actuating members or spring cylinders 7 , 8 and 9 . (The bottom radial seal 4 is supported respectively by spring cylinders or the like.) Each spring cylinder 7 , 8 or 9 represents an actuating point for the radial seal 4 . It is also possible to use counterweights instead of the spring cylinder 7 , 8 and 9 . The radial seal 4 is arranged in the regional direction with joints 41 and 42 which subdivide radial seal 4 into several sections. The radial seal 4 is thereby able to adjust to thermally induced rotor deformations. It is alternatively possible to arrange the radial seal 4 without joints and in a flexible way. There is a sealing gap S with the smallest possible size of the gap between the radial seal 4 and the upper face side of the rotor 2 . A sealing or expansion sleeve (see reference numeral 10 in the bottom region of the heat exchanger) can be arranged between the radial seal 4 and the wall of the rotor housing 3 , which sleeve will compensate the relative movements of the middle seal in relation to the wall the housing.
[0021] The circumferential seal 5 is arranged as an annulus-shaped sealing frame and is fastened to or suspended on the rotor housing 3 with several actuating members or spring cylinders 11 which are evenly distributed in the circumferential direction. The circumferential seal 5 can be provided with segments or joints, or be arranged in a joint-free and flexible way. In the illustrated embodiment, the circumferential seal 5 or the sealing frame provides sealing against a rotor flange 6 which protrudes radially to the outside from the rotor body. There is also a sealing gap with the smallest possible size of the gap between the circumferential seal 5 and the rotor flange 6 of the rotor 2 . Each spring cylinder 11 represents an actuating point for the circumferential seal 5 , with the circumferential seal 5 being pressed against the rotor flange 6 by means of excess weight (weight less actuating force in the spring cylinders 11 ).
[0022] In order to ensure a defined sealing gap between the circumferential seal 5 and the rotor flange 6 irrespective of thermally induced rotor deformations, the circumferential seal 5 is supported by means of a plurality of rollers 12 on the rotor flange 6 which belongs to the rotor 2 . A roller 12 is preferably provided at least in the region of every single actuating point. As a result, the circumferential seal always maintains a constant distance from the rotor flange 6 in operation and simultaneously at least follows the axial rotor deformations.
[0023] In the embodiment illustrated in FIG. 1 , the rollers 12 are arranged in a recess in the circumferential direction 5 and are preferably also rotatably held therein (e.g., by means of a shaft). During the rotation of the rotor 2 , the rollers 12 will roll off on a wearing plate 14 which is fastened to the rotor flange 6 . Preferably, the wearing plate 14 is provided with a segmented configuration in the circumferential direction. Such a wearing plate can also be provided on a corresponding rolling surface in the circumferential seal 5 . It is also possible that the rollers 12 are guided in the manner of a sandwich between two wearing plates which are spaced from one another in the axial direction a. Notice should generally be taken when configuring and/or adjusting the spring cylinders 11 (and optionally also counterweights, if they are used) that the pressing pressure between the rollers 12 and the corresponding rolling surfaces is kept at a low level. This is achieved for example in such a way that the upper spring cylinders 11 substantially absorb or at least reduce the weight load of the circumferential seal 5 .
[0024] In the embodiment illustrated in FIG. 1 , a mechanical coupling of the radial seals 4 with the circumferential seals 5 is provided both on the upper face side and also on the bottom face side of the rotor 2 , for which purpose the circumferential seals 5 and the radial seals 4 are frictionally connected with one another. As a result, the radial seals 4 will follow the forcibly guided movements of the circumferential seals 5 in the axial direction a, for which purpose the radial seals 4 are movably held in the axial direction a. Sealing of the rotor 2 is considerably increased thereby and leakages are considerably reduced.
[0025] FIG. 2 illustrates a second embodiment in which the rollers 12 fastened to the circumferential seal 5 are guided between two axially spaced rotor flanges 61 and 62 with respective rolling surfaces. This enables a “direct” forced guidance for the circumferential seal 5 . In all other respects the explanations made in connection with the first embodiment illustrated in FIG. 1 shall apply.
[0026] The third embodiment illustrated in FIG. 3 also comprises a mechanical coupling of the circumferential seals 5 with the radial seals 4 . For this purpose, the circumferential seals 5 are respectively connected with a radially extending actuating bar 16 , which causes an adjustment of the respective radial seal 4 (on the same rotor side) in the axial direction a via several actuating members 17 . As a result, the forcibly guided movement of a circumferential seal 5 is transmitted according to the lever ratios onto the respective radial seal 4 or its individual sections, for which purpose the radial seals 4 are movably held in the axial direction a or are also arranged in a flexible way for example. The radially extending actuating bars 16 are arranged in the interior of the rotor housing 3 . In some embodiments, the actuating bars 16 can also be arranged outside of the housing 3 .
[0027] FIG. 4 illustrates a fourth embodiment in which the radial seals 4 are also supported by means of rollers 18 on the face sides of the rotor 2 . As a result, the radial seals 4 can be forcibly guided in operation at a constant distance from the face sides of the rotor 2 and can continuously follow the axial rotor deformations. The rollers 18 are arranged in the region of the actuating points or spring cylinders 7 , 8 and 9 . Corresponding rolling surfaces are arranged on face sides of the rotor 2 . These rolling surfaces can be arranged on wearing plates 19 , as illustrated, by way of example, for the bottom, radial inner roller 18 .
[0028] It is expressly understood that the features of the embodiments explained above in connection with the drawings can be combined with one another insofar as this does not lead to any technical inconsistency. | A regenerative heat exchanger, including a heat accumulator arranged as a rotor, rotatably held around a central rotational axis, and configured to transmit a heat of at least one gas volume flow passing through the rotor to another gas volume flow passing through the rotor, and including a sealing system for the rotor including at least one seal which is fixed in relation to the rotor, is pressed against the rotor, and is supported by a plurality of rollers on the rotatable rotor. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention is directed to a composition that includes microstructured water having a lower vapor pressure than that of double distilled water measured under the same conditions.
[0003] 2. Background of the Related Art
[0004] Water supplies are becoming polluted at an alarming rate and the aquifers that haven't been contaminated are now under duress. Pristine aquifers are disappearing as demand for good, clean, drinkable water increases. Water has been taken for granted for the last seventy five years, and because so-called clean potable water has been so easily and readily available from our kitchen tap, the importance of water and water conservation has been lost to the masses. Several of our larger cities and many smaller ones cannot pass clean water tests. More and more chemicals are added to municipal water supplies to enable these water supplies to pass ‘safe’ levels for consumption. Adequate chemical levels are consistently being increased to accommodate the higher chemical levels found in municipal water supplies. Mining, farming, and industrial wastes have formed an intricate overlap of contaminants that in most cases cannot be cleaned out of water supplies sufficiently enough to make the water safe to bathe in, much less drink.
[0005] Water treatment facilities inadvertently add pollutants to their water at the same time it is being ‘purified’. Chlorine reacts with organic substances in the water to form trihalomethanes (THM's), a known group of carcinogens. In 1975, an EPA survey of eighty cities' water supplies was the first official alarm that there was a definite and serious problem. One particular THM, chloroform, was found in all the samples tested, with three other THM's found in most of the samples tested. In 1980, a study showed that cancer rates were extremely higher in cities that chlorinated their municipal water supplies. This was again attributed to the influence of ‘THM’s. People who drank chlorinated water were found to have 53% greater chance of contracting colon cancer and up to 93% greater chance of contracting rectal cancer. These figures are according to a report by the Presidents Council on Environmental Quality. Also noted as a common additive to water and in the same report, fluoride was reported to cause bone and kidney damage when found in quantities that were considered to be much more than adequate.
[0006] This is just the tip of the iceberg regarding clean water. In addition, a variety of contaminants can enter municipal water supplies as the water travels from the treatment plant to the kitchen tap. Many water supply systems are well over one hundred years old and are full of holes. As water mains deteriorate, asbestos, lead, and many other toxic metals and substances are released into the water. Inhibitors added to the water to slow down deterioration of the pipes are sometimes themselves toxic. Estimates indicate that there are more than 400,000 miles of asbestos-cement/clay pipe still being used everyday in the U.S.A. alone. An estimated 65 million people drink out of these water systems daily. A 1979 official test survey by the EPA found twenty percent of the cities examined had more than one million asbestos fibers per liter of water, with eleven percent of the cities having more than ten million fibers per liter of water. Studies in California and Canada link the ingestion of asbestos with an increased risk of cancer in the abdominal tract leading one to deduce that much colon cancer could be reduced and/or prevented by simply reducing or, even better, eliminating the amount of water borne asbestos from municipal pipes.
[0007] The human body is composed of from 70% to 80% water and requires a minimum of two quarts of water per day. Two quarts is what one uses up per day through urination, defecation, evaporation through the skin, and overall dehydration. This is the loss of water from an inactive individual. An athlete uses at least twice this amount or roughly at least four quarts per day. Depending on which informational research source is used, one researcher estimates that 75% of Americans are dehydrated and that 37% mistake thirst for hunger. A mere 2 percent drop in body water can trigger fatigue and mental dysfunction.
[0008] Steven Kay of the International Bottled Water Association said, “For this and other reasons, bottled water sales in the United States increased from 3.1 billion in 1995 to 4.6 billion in 1999.” In 2000, water sales topped 5.4 billion. The sweetheart of water sales from 2000 to 2001 was oxygenated water, which increased in sales by 45 percent. This culminated in over 100 million bottles being sold by the end of 2001. This unique niche of bottled water, with recent increased advertising and customer education on research regarding oxygenated waters' benefits to the body, may leave expectations of sales in the dust and push actual sales beyond anyone's wildest dreams. Coupled with humankinds' creation of urban deserts in many of today's cities, all water and beverage sales are poised to skyrocket.
[0009] With over 70,000 chemicals, all created by man and in use daily, and with an estimated 1000 new chemicals being developed each year, it is obvious why we are living in a chemical bath of our own creation. A recent study by the Clean Water Network reported that one-third of our rivers, one-half of our estuaries, and more than one-half of our lakes are not fit for fishing and swimming—forget the idea of drinking the water.
[0010] According to the Center for Disease Control, every year an estimated 120 million Americans drink tap water contaminated with waterborne diseases and known cancer causing chemicals. After undertaking one of the most comprehensive water research studies ever conducted, the Natural Resources Defense Council in 1993, found that each year more than 900,000 people in the U.S. became ill. As many as 900 of these people actually die from these waterborne diseases. The United States Environmental Protection Agency (EPA) lists over 700 toxic chemicals that can be found in our nations' tap waters. Beginning in 1976, the EPA has monitored the amount of toxins in the fat tissue of Americans; on a consistent basis, thirteen very highly toxic compounds are found in 100 percent of all the people analyzed. The EPA continues to conduct this analysis every year.
[0011] The EPA and several other governmental agencies state that they only permit chemical levels that are considered “safe” in our public water supplies. It is interesting that at every urban EPA office there is always bottled water available for drinking. The fact that our government cannot adequately protect everyone who drinks publicly supplied water is one of the main reasons that bottled water and in-home water filters have become such a huge booming business.
[0012] Over the next twenty years, the Water Infrastructure Network has estimated that $490 billion dollars will be necessary to repair and maintain public drinking water systems throughout the United States. What most Americans and people in general do not know about is the disaster that has already begun in our oldest cities. The clay pipes, many laced with asbestos to hold the clay together, have eroded to the degree that dirt and contaminants are entering into the water system. The asbestos has been tested at 70 parts per million in one liter of water in several locations. It is obvious why the bottled water business made over 7 billion dollars last year by the peoples' effort to avert drinking water problems, some not even discussed herein.
[0013] Oxygen, the most vital element of life itself, is also the key to good health. We can live without water for weeks and go without food for months, but we can survive for only minutes without oxygen. Oxygen is the life-giving, life sustaining element. Approximately 90% of the body's energy is created by oxygen. All of the activities of the body, from brain function to elimination, are regulated by oxygen. Our ability to think, feel and act comes from the energy created by oxygen. The best way to optimize health is to be sure that we oxygenate every cell in our body. The more oxygen we have in our system, the more energy we produce. This is more important today than ever before, because of a general deficiency of oxygen intake directly related to the overall lack of exercise for the average person.
[0014] One of the many reasons for a lack of oxygen is our polluted atmosphere. Other reasons for oxygen depletion in the body include: planetary deforestation; devitalized soil; processed foods and poor diet; a clogged colon; automobile emissions; vitamin and mineral deficiencies; lack of exercise; chlorinated water; bacterial and fungal infections in the body; chemical pollutants; stress; poor posture and breathing habits; and electronic smog.
[0015] There is less oxygen today (on an average) in our bodies' systems to enable production of vital metabolic energy than ever recorded. It is extremely important that we increase our intake of oxygen if we are going to function on a level that gives our, brain and body a chance to operate at peak levels.
[0016] The power of added oxygen in water was first evidenced over twenty years ago when European athletes dominated the world sports arena with the Soviet Union clearly leading the pack. Chilled water with oxygen added under pressure enabled the Soviet athletes to increase the oxygen level in their bloodstream and lower pulse rates by as much as 2 to 15 beats per minute. In addition, these athletes increased overall energy levels, biological performance, and stamina. When oxygen content is low in the body, the body becomes tired, weaker, and endurance is compromised. The Soviets outperformed the American athletes and we did not know how this was achieved at the time. It took several years for us to catch up to what the Soviets knew in the early 1970's. Knowledge of oxygenation and water structure are the keys to understanding water's biological behavior.
[0017] Blood plasma holds approximately three percent dissolved oxygen and red blood cells (hemoglobin) hold ninety seven percent. From the red blood cells the oxygen passes out into the plasma, and is transferred to cells that need oxygen during metabolic processes. These cells pass CO 2 back to the plasma where it is then picked up by the red blood cells. Free oxygen in the blood then becomes the purging agent to clean and purify the blood. However, there must be enough free oxygen in the blood to enable this process. Many times, there is too much environmental pollution to allow for this excess free oxygen in the blood, and this is where OSIRIS water/liquid has a tremendous place in the market of oxygenated water (virtually including almost every person in the world).
SUMMARY OF THE INVENTION
[0018] An object of the invention is to solve at least the above problems and/or disadvantages and to provide at least the advantages described hereinafter.
[0019] To adequately and sufficiently oxygenate and structure water insofar that when consumed, whether by internal or external absorption, there is a distinct and definite increase in hydration, oxygenation and healthy metabolic changes regarding organic life processes.
[0020] In various embodiments, a composition includes microstructured water having a lower vapor pressure than that of double distilled water measured under the same conditions.
[0021] In various embodiments, the composition may include dissolved oxygen. The dissolved oxygen may be present in an amount greater than 20 ppm.
[0022] In various embodiments, the microstructured water has a cluster size of 6-8 molecules.
[0023] In various embodiments, the microstructured water has a cluster factor of about at least 30.
[0024] In various embodiments, the composition may include at least one member selected from the group consisting of vitamins, plant extracts, animal extracts, pharmaceutically active agents, flavorants and colorants.
[0025] 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 objects and advantages of the invention may be realized and attained as particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The invention will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
[0027] FIG. 1A is a block diagram of a system for making and tuning super-oxygenated and structured water, in accordance with an embodiment of the invention;
[0028] FIGS. 1B-1C are flow charts of methods for making super-oxygenated and structured water, in accordance with an embodiment of the invention;
[0029] FIG. 1D is a flow chart of a method for tuning super-oxygenated and structured water, in accordance with an embodiment of the invention;
[0030] FIG. 2A is a block diagram of a system for preparing water with a stable negative ORP, in accordance with an embodiment of the invention;
[0031] FIG. 2B is a flow chart of a method for preparing water with a stable negative ORP, in accordance with an embodiment of the invention;
[0032] FIG. 2C is a block diagram of a water preconditioning system, in accordance with an embodiment of the invention;
[0033] FIG. 2D is a flow chart of a method for preconditioning water, in accordance with an embodiment of the invention;
[0034] FIG. 3A is a schematic side view of a magnetic structuring stage for a water preconditioning system, in accordance with an embodiment of the invention;
[0035] FIG. 3B is a graph of magnetic field strength versus location for donut rings of a magnetic structuring stage, in accordance with an embodiment of the invention;
[0036] FIG. 4A is a block diagram of an oxygen/water combining system, in accordance with an embodiment of the invention;
[0037] FIG. 4B is a flow chart of an oxygen/water combining method, in accordance with an embodiment of the invention;
[0038] FIG. 5A is a block diagram of a structured oxygen generating machine, in accordance with an embodiment of the invention;
[0039] FIG. 5B is a flow chart of a method for producing structured oxygen, in accordance with an embodiment of the invention;
[0040] FIG. 5C is a perspective/cross sectional view of the oxygen enhancer shown in FIG. 4A , in accordance with an embodiment of the invention;
[0041] FIG. 5D is a front view of a screen shown in FIG. 5C ;
[0042] FIGS. 5E-5G are front and side views of a ring shown in FIG. 5C ;
[0043] FIG. 6A is a schematic side view of a first magnetic structuring stage for a structured oxygen generating machine, in accordance with an embodiment of the invention;
[0044] FIG. 6B is a schematic side view of a second magnetic structuring stage for a structured oxygen generating machine, in accordance with an embodiment of the invention;
[0045] FIG. 7A is a schematic block diagram of a cone system, in accordance with an embodiment of the invention;
[0046] FIG. 7B is a schematic side view of an exemplary cone structure, in accordance with an embodiment of the invention;
[0047] FIG. 7C is a schematic top view of the cone structure of FIG. 7B ;
[0048] FIG. 7D is a flow chart of a method for spinning oxygen using a cone system, in accordance with an embodiment of the invention;
[0049] FIG. 8A is a schematic side view of a coil system, in accordance with an embodiment of the invention;
[0050] FIG. 8B is a schematic top view of the coil system of FIG. 8A ;
[0051] FIG. 8C is a flow chart of a method of using the coil system of FIGS. 8A-8B ;
[0052] FIGS. 9A and 9B are, respectively, schematic top and side views of a multi-coil system, in accordance with an embodiment of the invention;
[0053] FIG. 9C is a schematic side view of the multi-coil system of FIG. 9A ;
[0054] FIGS. 9D and 9E are schematic plan and side views of a pipe entry point into a coil set, according to an embodiment of the invention;
[0055] FIG. 9F is a flow chart of a method of using the multi-coil system of FIGS. 9A-9C ;
[0056] FIG. 10A is a block diagram of a structured ozone machine, in accordance with an embodiment of the invention;
[0057] FIG. 10B is a flow chart of a method structuring ozone, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0058] The process and apparatus of the present invention are also suitable for use in aerobic processes and other processes such as therapeutic processes advantageously employing oxygen containing liquids.
[0059] As used throughout the specification and the claims, reference to an “aerobic” process generally includes all chemical and microbiological processes in which such a process is carried out or is promoted in a liquid medium in the presence of oxygen. As used throughout the specification and the claims “therapeutic” processes involve the oxygenation of the body or its parts by treatment with an agent in a liquid vehicle containing dissolved oxygen.
[0060] Suitably aerobic processes in which water oxygenated in accordance with the present invention can be employed include, for example, processes in which heretofore water has been aerated such as by bubbling air thereinto, and also in situ or ex situ bioremediation of contaminated (e.g. with petroleum products) surface and ground waters; wastewater, sludge, and animal waste treatment, both by fixed film and by suspended growth methods; rehabilitation of atrophying lakes; biochemical oxygen demand (BOD) measurement techniques; fresh water aquaculture (e.g. fish farming); odor suppression barriers for anaerobic processes; and insolubilization of dissolved contaminants (e.g. Fe., and Mn ions) for removal by filtration or sedimentation.
[0061] In view of the particularly good oxygen retention of liquids oxygenated by the present invention kept in containers, a particularly advantageous new aerobic use of those liquids was discovered. In accordance with a further feature of the present invention, such oxygenated liquids can be advantageously employed as the fermentation liquor of all kinds of fermentation processes, such as drug production or food processing by microorganisms.
[0062] Microorganisms, such as bacteria, consume massive quantities of oxygen in the process of assimilating or breaking down waste. The rate at which oxygen can be introduced into the biomass is a substantial limiting factor on how quickly a breakdown by oxygenation can be achieved. The problem with known process technologies is that oxygen introduction by aeration is highly inefficient because air contains only 21% percent oxygen. Thus, 79% percent of the energy used by aerators is wasted in pumping useless nitrogen. Therefore, the use of highly oxygenated water, in accordance with the present invention, in such aerobic processes is expected to be about 5 times more efficient, also to obtain thereby a like extent of energy efficiency improvement. The dissolved oxygen content of water treated with embodiments of the present invention can be greater than 20 ppm, can be greater than 40 ppm, can be greater than 60 ppm, can be greater than 80 ppm, can be greater than 100, ppm, can be greater than 120 ppm, and can be greater than 140 ppm. Thus, the infusion of water with 40-50 mg/l of oxygen allows for a considerably more efficient and much more rapid aerobic treatment, compared to 7-10 mg/l for the normal oxygen content of water, and just slightly more when a conventional bubbling aerator is used with 20% oxygen containing air. Furthermore, as the equilibrium oxygen content of water is used up, its dissolved oxygen content rapidly decreases.
[0063] Another property of embodiments of the water involves its increased density. The increased density can be described using the term “cluster factor”, that can be defined by relative density to double distilled water minus 1.0, then multiplied by 100,000. The cluster factor of water treated with embodiments of the present invention can be greater than 150, can be greater than 200, can be greater than 250, can be greater than 300, and can be greater than 350.
[0064] Another property of embodiments of the water involves its pH. The pH of water treated with embodiments of the present invention, as measured by litmus paper, can be between 7.5 and 8.5. The pH of water treated with embodiments of the present invention, as measured by a standard glass electrode pH meter, can be between 9.2 and 9.5.
[0065] Suitable therapeutic processes in which liquids made in accordance with the present invention can be advantageously employed include, for example, increasing the oxygen content of blood and tissues; oxygenation of wounds to increase the rate of healing and to reduce infections; oxygenated organ transplant storage media; tumor oxygenation for radiation therapy and chemotherapy; lung bypass by oxygenated liquids in case of pulmonary deficiencies; carbon monoxide poisoning; mouthwashes; dentifrices; topical, including cosmetic, treatment media; contact lens treating solutions; and cell level therapeutic applications.
[0066] In view of the especially good oxygen retention of liquids oxygenated by the present invention kept in containers, a particularly advantageous new therapeutic product of those liquids was discovered. In accordance with a further feature of the present invention, such oxygenated liquids can be employed as solvents for physiological saline isotonic solutions, especially when kept in sealed, sterile containers.
[0067] In cosmetics and toiletries, the liquids of the present invention may be incorporated into a beauty product in process by addition, mixing, wetting and other methods in the course of production of the beauty product.
[0068] In this case, the state and form of the cosmetics and toiletries are not specifically limited. For example, the liquids of the present invention may be used as is, may be used in a state diluted with double distilled water, alcohol or the like, and may be used in a gel or paste state obtained by adding a thickener, which processing are conducted for improvement on handle-ability, and in other states and forms in use. The water may be mixed into a beauty product in a liquid state as is, or it may be diluted or concentrated prior to the use as desired.
[0069] The state and form as a commodity of a beauty product in the present invention is not specifically limited as far as the beauty product is a beauty product into which a liquid of the present invention is mixed, and a beauty product of the present invention has only to be processed in a similar state and form to those of a known beauty product. Concrete examples thereof in which the liquid can be used include a non-drug product, a skin-care product, a makeup product, a hair care product, fragrance, a body care product, an oral care product and the like.
[0070] Examples thereof further include a face cleansing cream, a toilet lotion, a milky lotion, cream, gel, essence, pack, mask, foundations, lip sticks, cheek rouges, a brow, eye beauty product, manicure enamels, a shaving lotion, a hair washing product, a hair raising agent, a hair makeup product, a perfume, cologne, soap, a liquid body cleaning agent, a sun care product, a hand care product, a bath product, a tooth paste, and an oral cleaning agent.
[0071] The cosmetics and toiletries of the present invention contain a liquid of the present invention mixed therein as a feature, while no specific limitation is placed on other components, and additives currently used in cosmetics and toiletries can be properly mixed in.
[0072] Concrete examples of other components include hydrocarbons, such as squalane, liquid paraffin and the like; animal/vegetable oils, such as olive oil, beef tallow and the like; esters, such as isopropyl myristate, cetyl octate and the like; natural animal/vegetable waxes, such as carnauba wax, beeswax and the like; surfactants, such as glycelyl stearate, and sorbitan stearate; silicone oils, such as dimethylpolysiloxane, methylphenylpolysiloxane and derivative thereof; fluorine containing resins, such as perfluoropolyether and the like; alcohols, such as ethanol, ethylene glycol, glycerin and the like; water-soluble polymers, such as carboxyvinyl polymer, carrageenan, carboxymethyl cellulose sodium and the like; proteins, such as collagen, elastin and the like and hydrolyzates thereof; powders of titanium dioxide, zinc oxide, talk, mica, silicic anhydride, nylon powder, alkyl polyacrlylate, powder of alumina, iron oxide and the like; an ultraviolet absorbent; vitamines; an antiphlogistic agent; amino acids and derivative thereof; lecithin; a colorant; a perfume; an antiseptic agent; an antioxidant and the like.
[0073] The extent of cosmetics and toiletries in the sense of words has been extended because of recent diverse requirements therefor, and cosmetics and toiletries of the present invention are not necessarily strictly restricted in respect of the definition thereof. That is, cosmetics and toiletries of the present invention means cosmetics and toiletries in a general sense into which an activating agent of the present invention is properly mixed. Therefore, cosmetics and toiletries of the present invention include all products by which a liquid of the present invention is taken into the body of an organism in a manner of transdermal or endermic absorption.
[0074] Food additives related to the present invention are characterized by that in which a liquid of the present invention is mixed thereinto and a food additive is added, mixed or incorporated by wetting or similar method into a food or a beverage in the course of production of the food or the beverage for the purpose of processing or preservation of the food or the beverage. A state and a form of a food additive is not specifically restricted to a particular pair and, for example, the water may be used in mixing into a sweetner, a sourness flavoring, a bitterness flavoring, a deliciousness flavoring, an oiliness flavoring and the like at a proper content. The water may also be used in a gel or paste state processed by adding a thickener or the like for improvement on handle-ability, may be used in a liquid state of 100%, or may be used in a dilute or concentrated state as well.
[0075] To be more detailed, a food additive related to the present invention can be to satisfy a person's preference and to prevent modification, or rotting of a food. That is, the food additives may be necessary for production, improvement on quality, preservation of quality and nutrition enhancement, while a state and a form in processing may be similar to those of known food additives. Concrete examples thereof include flavorings, such as a saline solution, salt, a sauce, drips, a soupe, an original broth and the like; a preserving agent; a production auxiliary; a filtering auxiliary; a clarificant; a quality sustaining agent; a sterilizing agent; an antimicrobial agent; a disinfectant and the like.
[0076] Note that in order to further improve a quality of a food additive of the present invention, the inventive water agent is preferably processed into the food additive in a working condition, in which the intermediate is brought into contact to the external air (oxygen) on the lowest possible level or in a low temperature condition. For example, the processing is preferably conducted in a condition in which no activity of mineral components is degraded, such as in a nitrogen atmosphere, at a low temperature or in a freeze drying condition. The food additive as processed is preferably immediately and in a short time packed, so as to be brought into contact with oxygen on the lowest possible level, for example in a vacuum package, in a nitrogen-filled package or in gas-tight package with an antioxidant therein. Such packages are preferably adopted, since the beneficial effects of the inventive water can be sustained over a long term.
[0077] A food related to the present invention is a food in which a liquid or a food additive of the present invention is added as a feature. Since foods can be mixed with a liquid or a food additive under various categories, such as an agricultural food, a livestock food, a fishery food, a fermented food, a canned food, an instant food and the like, according to states and forms of respective food additives described above, no specific limitation is imposed on a kind, and state and form of food related to the present invention. Concrete examples of foods that can be named include breads, noodles, bean curd, a dairy product, a meat processed product, soy source, miso, edible fat and oil, an oil and fat processed product, a fish paste product, sweet stuff, vegetables, pickles and the like. Concrete examples of addition methods and products applied therewith that can be named include: soy source obtained by mixing inventive water into soybean, wheat and seed koji to ferment them and miso obtained by mixing processed inventive water into soybean, rice and barley to ferment them.
[0078] Further examples of foods of the present invention include bean curd obtained by using the inventive water as a brine for coagulation of soybean milk, pickles obtained by using the inventive water as a salty component in a solution, a food added with an inventive liquid or a food additive for retaining freshness and a food immersed in an inventive liquid or a food additive for retaining freshness.
[0079] Still further examples of foods of the present invention include nutritional supplements and the like such as health foods in states and forms including liquid, powder, a tablet, a capsule, in which the inventive liquid or food additive is incorporated.
[0080] A beverage related to the present invention is a beverage in which a water of the present invention and/or a food additive of the present invention is added as a feature. Since, as to a kind, state and form of beverages related to the present invention, a inventive liquid or a food additive can be added to various kinds of beverages according to a kind, state and form thereof, no specific limitation is imposed on a kind, state and form of beverage. Examples thereof that can be named include alcoholic beverages such as brewed sake, synthetic sake, shochu, sweet sake, beer, whisky, liqueur, fruit liquor and the like, and favorite soft beverages, or refreshing beverages such as fruit juice, concentrated fruit juice, nectar, soda pop, cola beverage, teas, coffee, black tea and the like.
[0081] Note that in order to further improve a quality of a food and a beverage related to the present invention, the inventive liquid is preferably processed into foods or beverages in a working condition in which the intermediate is brought into contact to the external air (oxygen) on the lowest possible level or in a low temperature condition. For example, the processing is preferably conducted in a condition in which no activity of mineral components is degraded, such as in a nitrogen atmosphere, at a low temperature or in a freeze drying condition. Preferably, the food additive as processed is immediately and in a short time packed so as to be brought into contact with oxygen on the lowest possible level, for example in vacuum package, in nitrogen-filled package or in gas-tight package with an antioxidant therein. Such packages are preferably adopted since the benefits of the inventive liquid can be sustained over a long term.
[0082] The boundaries between a food additive, a food and a beverage in the sense of words have been ambiguous because of recent diverse requirements for foods. For example, since miso, soy source and the like are flavorings (food additives) and foods, sake classified in alcoholic beverages is a food and a beverage, and sweet sake classified in alcoholic beverage is also flavoring (food additive). Therefore, the boundaries in a food additive, a food and a beverage related to the present invention are not necessarily strictly restricted in respect of the definition thereof. That is, food additives, and foods and beverages of the present invention in principle means food compositions in a general sense into which a liquid of the present invention is properly mixed. Accordingly, food compositions of the present invention include all products through which an inventive liquid is taken into the body of an organism in a manner of oral uptake.
[0083] It will be recognized by those skilled in the art that the water/liquids of the present invention can be further modified in any number of ways. For example, following formation of structured water, the water may be oxygenated as described herein, further purified, flavored, distilled, irradiated, or any number of further modifications known in the art and which will become apparent depending on the final use of the water.
[0084] In another embodiment, the present invention provides methods of modulating the cellular performance of a tissue or subject. The inventive water (e.g., oxygenated microcluster water) can be designed as a delivery system to deliver hydration, oxygenation, nutrition, medications and increasing overall cellular performance and exchanging liquids in the cell and removing edema.
[0085] It is also contemplated that the water of the present invention provides beneficial effects upon consumption by a subject. The subject can be any mammal (e.g, equine, bovine, porcine, murine, feline, canine) and is preferably human. The dosage of the water (or oxygenated water) will depend upon many factors recognized in the art, which are commonly modified and adjusted. Such factors include, age, weight, activity, dehydration, body fat, etc. Typically 0.5 liters/day of the water of the invention provide beneficial results. In addition, it is contemplated that the water of the invention may be administered in any number of ways known in the art including, for example, orally, topically, buccally, sublingually, parenterally, intramuscularly or intravenously, either alone or mixed with other agents, compounds and chemicals. It is also contemplated that the water of the invention may be useful to irrigate wounds or at the site of a surgical incision. The water of the invention can have use in the treatment of infections. For example, infections by anaerobic organisms may be beneficially treated with the oxygenated forms of the water. In another embodiment, the water of the invention can be used to lower free radical levels and, thereby, inhibit free radical damage in cells.
[0086] In one embodiment, the water may contain a sweetener (i.e., a compound that imparts a sweet taste but does not increase the blood glucose levels of the patient). Examples include a sugar alcohol and non-nutritive sugars. As used herein, the term sugar alcohol refers to reduced sugars. The preferred sugar alcohol are mono-saccharide alcohols and disaccharide alcohols. The monosaccharide alcohols have the formula HO—CH2(CHOH)n—CH2OH, wherein n is 2-5. They also include tetritols, pentitols, hexitols and heptitols. Examples of sugar alcohols include erythritol, theritol, ribitol, arabinitol, xylitol, allitol, dulcitol, glucitol, sorbitol, mannitol, altritol, iditol, maltitol, lactitol, isomalt, hydrogenated starch hydrolysate and the like. The sugar alcohols, especially the monosaccharide alcohols, may be utilized as a racemic mixture or in the D or L form.
[0087] The non nutritive sweeteners are patentably sweet but are non-caloric. Examples include L-sugars, aspartame, alitame, acesulfame-K, cyclamate, stevioside, glycyrrhizin, sucralose, neohesperidin, dihydrochalcone, thaumatin saccharin and its pharmaceutically acceptable salts (e.g., calcium), and the like.
[0088] In one embodiment of the present invention, it is preferred that the sweetener be present in the water in amounts ranging from about 40% to about 80% by weight and more preferably from about 50% to about 70% and most preferably from about 55% to about 65%. In addition, it is preferred that the weight ratio of sweetener to alkyl hydroxyethyl cellulose, when present, ranges from about 400 to about 800, and, most preferably, from about 500 to about 600.
[0089] Other optional ingredients which may be present in certain waters of the present invention include buffers, such as citric acid or its corresponding salts or acetic acids and its salts, flavoring agents, such as peppermint, oil of wintergreen, orange, or cherry flavoring, and the like, surfactants, thickeners, preservatives, such as methyl and propyl parabens, and the like, anti-oxidants, such as benzoate salts, and the like, chelating agents, such as EDTA and its salts and the like.
[0090] In certain embodiments, the waters of the present invention can be administered to a mammal in need thereof by topical, systemic, subscleral, transscleral, or intravitreal delivery. Intravitreal delivery may include single or multiple intravitreal injections, or via an implantable intravitreal device that releases the water in a sustained capacity. Intravitreal delivery may also include delivery during surgical manipulations in treatment for retinal detachments, diabetic retinopathy, or macular degenerations as either an adjunct to the intraocular irrigation solution or applied directly to the vitreous during the surgical procedure.
[0091] Minimally invasive transscleral delivery can be used to deliver an effective amount of the water to the retina with negligible systemic absorption. Transscleral delivery utilizes the sclera's large and accessible surface area, high degree of hydration that renders it conductive to water-soluble substances, hypocellularity with an attendant paucity of proteolytic enzymes and protein-binding site, and permeability that does not appreciably decline with age. An osmotic pump loaded with the inventive water can be implanted in a subject so that the active compounds are transsclerally delivered to the retina in a slow-release mode. (Ambati, et al., Invest. Ophthalmol. Vis. Sci., 41: 1186-91 (2000)).
[0092] The inventive waters may also be administered topically by administering the active compounds to a patient by any suitable means, but are preferably administered by a liquid or gel suspension of the water in the form of drops, spray or gel. Alternatively, the water may be applied, for example to the eye, via liposomes. Further, the water may be infused into the tear film via a pump-catheter system. Another embodiment of the present invention involves the water contained within a continuous or selective-release device, for example, polymeric ocular inserts for the administration of drugs. (Alza Corp., Palo Alto, Calif.), or in the intra-vitreal implant for the gradual release of pharmaceuticals for the treatment of eye conditions (Bausch & Lomb, Claremont, Calif.).
[0093] As an additional embodiment, the inventive water can be contained within, carried by, or attached to contact lenses that are placed on the eye. Another embodiment of the present invention involves the water contained within a swab or sponge that can be applied to the desired surface. Another embodiment of the present invention involves the water contained within a liquid spray that can be applied to any desired surface, such as the ocular surface.
[0094] The inventive water may be administered systemically. The term “systemic” as used herein includes subcutaneous injection, intravenous, intramuscular, intraesternal injection, infusion, inhalation, transdermal administration, oral administration, and intra-operative instillation.
[0095] Liquid formulations containing water of the present invention may be sterile and non-sterile injectable formulations. For instance, the formulation may be an aqueous or oleaginous suspension. The suspensions may be formulated according to techniques known in the art using suitable dispersing or wetting agents and suspending agents.
[0096] The injectable formulation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptible diluent or solvent. Suitable diluents and solvents for injectable formulations include 1,3-butanediol, Ringer's solution and isotonic sodium chloride solution. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. Suitable fixed oils include, but are not limited to, synthetic mono- or di-glycerides, fatty acids, such as oleic acid and its glyceride derivatives, and natural pharmaceutically-acceptable oils, such as olive oil, castor oil, and polyoxyethylated derivatives thereof. (Sigma Chemical Co.; Fisher Scientific) According to a preferred embodiment, oil containing injectable formulations contain a long-chain alcohol diluent.
[0097] Topical formulations of the present invention are typically in the form of an ointment or suspension. Such formulations may be administered for diseases of the eye, the skin, and the lower intestinal tract. Suitable suspending agents, diluents, and dosing vehicles for such formulations include, but are not limited to, mineral oil, liquid petrolatum, white petrolatum, propylene glycol, polyoxyethylene, polyoxypropylene compound and emulsifying wax. (Sigma Chemical Co.; Fisher Scientific) Alternatively, the topical formulation can be in the form of a lotion or cream. Suitable suspending agents, diluents, and dosing vehicles for such formulations include, but are not limited to, mineral oil, sorbitan monostearate, polysorbate 60 cetyl esters wax, cetearyl alcohol, 2-octyldodecanol, and benzyl alcohol. (Sigma Chemical Co.; Fisher Scientific) Topical application for the lower intestinal tract can be effected in a rectal suppository formulation or in a suitable enema formulation. The formulation may also be administered via a transdermal patch as known in the art.
[0098] The liquid formulation containing the inventive water may also be applied ophthalmically. A preferred ophthalmic formulation of the present invention is a micronized suspension in isotonic, pH adjusted sterile saline. A preservative, such as benzalkonium chloride, may be included in the formulation but is not necessary as a preservative due to the nature of the invention. Alternatively, the ophthalmic formulation is in an ointment, for example, containing petrolatum.
[0099] Nasal aerosol and inhalation formulations of the invention may be prepared by any method in the art. Such formulations may include dosing vehicles, such as saline, preservatives, such as benzyl alcohol, absorption promoters to enhance bioavailability, fluorocarbons used in the delivery systems, e.g., nebulizers, etc., solubilizing agents, dispersing agents, or any combination of any of the foregoing.
[0100] The formulations of the present invention may be administered systemically. The term “systemic” as used herein includes parenteral, topical, oral, spray inhalation, rectal, nasal, bucal, and vaginal administration. The term “parenteral” as used herein includes subcutaneous, intravenous, intramuscular, intra-articular, intra-synovial, intrasternal, intrathecal, intrahepatic, intralesional and intracranial administration. Preferably, the compositions are administered orally, intraperitoneally or intravenously.
[0101] One systemic method involves an aerosol suspension of respirable particles comprising the inventive water, which the subject inhales. The water would be absorbed into the bloodstream via the lungs, and subsequently contact the lacrimal glands in a pharmaceutically effective amount. The respirable particles are preferably liquid, with a particle size sufficiently small to pass through the mouth and larynx upon inhalation. In general, particles ranging from about 1 to 10 microns, but more preferably 1-5 microns, in size are considered respirable.
[0102] Another method of systemically administering the active compounds to the eyes of a subject involves administering a liquid/liquid suspension in the form of eye drops or eye wash or nasal drops of a liquid formulation, or a nasal spray of respirable particles that the subject inhales. Liquid pharmaceutical compositions containing the inventive water for producing a nasal spray or nasal or eye drops may be prepared by combining the inventive water with a suitable vehicle, such as sterile pyrogen free water or sterile saline by techniques known to those skilled in the art.
[0103] The inventive water may also be systemically administered to eyes through absorption by the skin using transdermal patches or pads. In this embodiment, the inventive water is absorbed into the bloodstream through the skin.
[0104] Other methods of systemic administration of the inventive water involves oral administration, in which compositions containing the inventive water are in the form of lozenges, aqueous or oily suspensions, viscous gels, chewable gums, emulsion, soft capsules, or syrups or elixirs. Additional means of systemic administration of the inventive water to the eyes of the subject would involve a suppository form of the water, such that a therapeutically effective amount reaches the eyes via systemic absorption and circulation.
[0105] Further means of systemic administration of the inventive water involve direct intra-operative instillation of a gel, cream, or liquid suspension form of a therapeutically effective amount of the water.
[0106] For topical application, a solution containing the inventive water may contain a physiologically compatible vehicle, as those skilled in the ophthalmic art can select, using conventional criteria. The vehicles may be selected from the known ophthalmic vehicles which include, but are not limited to, saline solution, polyethers such as polyethylene glycol, polyvinyls such as polyvinyl alcohol and povidone, cellulose derivatives such as methylcellulose and hydroxypropyl methylcellulose, petroleum derivatives such as mineral oil and white petrolatum, animal fats such as lanolin, polymers of acrylic acid such as carboxypolymethylene gel, vegetable fats such as peanut oil, polysaccharides such as dextrans, glycosaminoglycans such as sodium hyaluronate, and salts such as sodium chloride and potassium chloride.
[0107] For systemic administration, such as injection and infusion, the pharmaceutical formulation is prepared in a sterile medium. The inventive water, depending on the vehicle and concentration used, can either be suspended or dissolved in the vehicle. Adjuvants such as local anaesthetics, preservatives and buffering agents can also be dissolved in the vehicle. The sterile injectable preparation may be a sterile injectable solution or suspension in a non-toxic acceptable diluent or solvent. Among the acceptable vehicles and solvents that may be employed are saline solution or Ringer's solution.
[0108] For oral use, an aqueous suspension may be prepared by addition of the inventive water to dispersible powders and granules with a dispersing or wetting agent, suspending agent, one or more preservatives, and other excipients. Suspending agents include, for example, sodium carboxymethylcellulose, methylcellulose and sodium alginate. Dispersing or wetting agents include naturally-occurring phosphatides, condensation products of an allylene oxide with fatty acids, condensation products of ethylene oxide with long chain aliphatic alcohols, condensation products of ethylene oxide with partial esters from fatty acids and a hexitol, and condensation products of ethylene oxide with partial esters derived from fatty acids and hexitol anydrides. Preservatives include, for example, ethyl, and n-propyl p-hydroxybenzoate. Other excipients include sweetening agents (e.g., sucrose, saccharin), flavoring agents and coloring agents. Those skilled in the art will recognize the many specific excipients and wetting agents encompassed by the general description above.
[0109] Formulations for oral use may also be presented as soft gelatin capsules wherein the inventive water is administered alone or mixed with an oil medium, for example, peanut oil, liquid paraffin or olive oil. Formulation for oral use may also be presented as chewable gums by embedding the active ingredient in gums so that the inventive water is slowly released upon chewing.
[0110] For rectal administration, the compositions in the form of suppositories can be prepared by mixing the inventive water with a suitable non-irritating excipient that is solid at ordinary temperatures but liquid at the rectal temperature and will therefore melt in the rectum to release the water. Such excipients include cocoa butter and polyethylene glycols.
[0111] FIG. 1A is a block diagram of a system for making and tuning super-oxygenated and structured water, in accordance with one embodiment of the present invention. The system 1 includes system 10 for producing or making super-oxygenated and structured water coupled via pipe 27 to a system 20 for tuning super-oxygenated and structured water. The term pipe refers to any component configured to provide fluid or gaseous communication between two components. The pipe may be, for example, a PVC pipe, a crystal pipe, flexible tubing, or other type of conduit.
[0112] System 10 includes a water preparation system 103 coupled to an oxygen/water combining system 113 via a holding tank 109 . Oxygen/water combining system 113 is in turn coupled to a cone system 121 via holding tank 109 . System 20 for tuning super-oxygenated and structured water includes a coil system 123 coupled to a structured ozone machine 125 and multi-coil system 127 .
[0113] Water preparation system 103 includes a water preconditioning system 100 and an electrolysis machine 101 coupled by a pipe 75 , which together comprise a system for preparing water with a stable negative oxidation reduction potential (ORP). Output of system 103 , in particular, from electrolysis machine 101 , is either alkaline water, which is output via a pipe 105 to holding tank 109 , or acidic water, which is output via a pipe 107 to an acid water tank 110 . Both the alkaline water output via pipe 105 and the acidic water output via pipe 107 have a stable negative oxidation reduction potential (ORP). The alkaline water is input to holding tank 109 , which is in turn output via a pipe 111 to the oxygen/water combining system 113 . Holding tank 109 may be a single tank or a plurality of tanks, for example, three tanks arranged in series. A pump 523 and pressure gauge 519 are preferably provided between the holding tank 109 and the oxygen/water combining system 113 to control the flow of water from the holding tank 109 to the oxygen/water combining system 113 .
[0114] The oxygen/water combining system 113 includes a structured oxygen generating machine 600 and a diffusion chamber 115 . The structured oxygen generating machine 600 outputs oxygen via a pipe 117 , which is coupled to pipe 111 and pipe 118 by a valve 119 . Water and oxygen flow together from valve 119 to the diffusion chamber 115 via pipe 118 . The oxygen/water combining system 113 outputs oxygen enriched water to cone system 121 via pipe 25 .
[0115] As set forth above, the system for tuning super-oxygenated and structured water 20 is coupled to the system for producing super-oxygenated and structured water 10 via pipe 27 . The system for tuning super-oxygenated and structured water 20 includes coil system 123 , structured ozone machine 125 , and multi-coil system 127 . Coil system 123 receives the oxygen enriched water from system 10 via pipe 27 , and combines and outputs oxygen enriched water via a pipe 29 . Structured ozone machine 125 outputs structured ozone via a pipe 31 , which is coupled to pipe 29 and pipe 35 by a valve 33 . The structured ozone from structured ozone machine 125 is combined with the super-oxygenated and structured water in pipe 29 at valve 33 and the combination of structured ozone and super-oxygenated and structured water is directed via pipe 35 to multi-coil system 127 .
[0116] Coil system 123 tunes water received via pipe 27 , and multi-coil system 127 tunes the combined water and ozone received via pipe 35 to yield super-oxygenated and structured water that is output via pipe 37 . Pipe 37 returns the super-oxygenated and structured water to holding tank 109 , from which the water may be, for example, bottled for human consumption or other uses.
[0117] Water preconditioning system 100 , oxygen/water combining system 113 , including structured oxygen generating machine 600 and diffusion chamber 115 , cone system 121 , coil system 123 , structured ozone machine 125 , and multi-coil system 127 will be described in more detail below.
[0118] FIG. 1B is a flow chart of a method for producing super-oxygenated and structured water, in accordance with one embodiment of the present invention, and FIG. 1C is a flow chart of a more detailed method for producing super-oxygenated and structured water, in accordance with one embodiment of the present invention. Referring to FIG. 1B , step S 202 involves receiving water from pipe 148 by system 103 for preparing water with stable negative ORP. Water preconditioning system 100 in system 103 preconditions water for electrolysis at step S 204 . Electrolysis machine 101 performs electrolysis at step S 206 . System 103 for preparing water with a stable negative ORP outputs alkaline water with its stable negative ORP via pipe 105 into holding tank 109 at step S 208 . At step S 210 water with a stable negative ORP is received from holding tank 109 and is combined with oxygen at oxygen/water combining system 113 . At step S 212 , the combined oxygen/water is received and spun by cone system 121 . Finally, at step S 214 , oxygen enriched structured water is output from cone system 121 .
[0119] FIG. 1C is a flow chart of a more detailed method for producing super-oxygenated and structured water, in accordance with one embodiment of the present invention. In particular, step S 204 from FIG. 1A includes two substeps S 204 a and S 204 b for preconditioning water. In particular, step S 204 for preconditioning water involves adding ozone to the water at step S 204 a , followed by subjecting the water to magnetic fields at step S 204 b.
[0120] Step S 210 of FIG. 1B , during which water is combined with oxygen, is subdivided in FIG. 1C into step S 210 a , in which ozone treated alkaline water is combined with oxygen, followed by step S 210 b , in which oxygen enriched ozone treated alkaline water is forced through the diffusion chamber 115 .
[0121] Step 212 of FIG. 1B , during which water is spun, is shown in FIG. 1C as step S 212 ′, in which oxygen enriched structured water is received from the diffusion chamber 115 and input into the cone system 101 .
[0122] The system for tuning super-oxygenated and structured water 20 performs the steps shown in FIG. 1D as follows. At step S 224 spun water is received from the system for producing super-oxygenated and structured water 10 , and is input into coil system 123 . The water output from the coil system 123 via pipe 29 is then combined with structured ozone received from structured ozone machine 125 via pipe 31 at step S 228 . The combination of water from coil system 123 and the structured ozone from structured ozone machine 125 is input to multi-coil system 127 via pipe 35 at step S 232 . Finally, at step S 236 , super-oxygenated, tuned, and structured water is output from the system 20 and, in particular, from multi-coil system 127 .
[0123] FIG. 2A is a block diagram of the system for preparing water with a stable negative ORP 103 . System 103 includes water preconditioning system 100 and electrolysis machine 101 . As discussed above, water preconditioning system 100 outputs water preconditioned for electrolysis machine 101 via pipe 75 . A cut off valve 75 A may be provided on pipe 75 to control the flow of the water. The preconditioned water is, in turn, received by electrolysis machine 101 , and electrolysis is performed thereon to yield both alkaline water output through pipe 105 to holding tank 109 and acidic water output through pipe 107 to acidic water tank 110 . As discussed above, both the alkaline water and acidic water have a stable negative ORP.
[0124] The acidic water output via pipe 107 is not designed for consumption, but it has many other uses and advantages. For example, acidic water can be used for cleaning many things, such as pipes, etc. It can also be mixed with hair rinse. The mixture can vary from pH 4.0 to pH 6.5 (6.7) and preferably between ˜4 parts per volume of water to ˜1 part per volume of hair rinse all the way to ˜1 part per volume of water to ˜4 parts per volume of hair rinse, and more preferably ˜1 part per volume of water with ˜1 part per volume of hair rinse. It can also be used in the same manner mixed with shampoo because it acts as a reagent and helps clean oils out of hair.
[0125] Typically, when water is output from an electrolysis system, the negative ORP that is created does not stay very long. It typically only remains for minutes at a time. The negative ORP of water treated with embodiments of the present invention can be less than −100. For both the alkaline and the acidic water at pipes 105 and 107 , respectively, typically the negative ORP begins at ˜183 ORP. However, as the water settles out, some of the electrons are given off due to a variety of reasons, and it ultimately settles out at approximately ˜−170 ORP to ˜−173 ORP. Both the alkaline and acidic water can maintain ˜−170 to ˜−173 ORP for 6 months to up to ˜2 years or more depending on the electromagnetic environment next to or near the storage area. Water in this state gives a multitude of free electrons which then can become an antioxidant in the blood. At this point the water, both the alkaline water and the acidic water, have structure. If the water in holding tank 109 is not processed within ˜24 hours, the structure begins to deteriorate, although the negative ORP remains, as discussed above. Accordingly, for structure purposes, it is advantageous to continue processing the alkaline water in holding tank 109 as quickly as possible. That is, it is advantageous to proceed to output the alkaline water in holding tank 109 via pipe 111 to the oxygen/water combining system 113 as quickly as possible.
[0126] FIG. 2B is a flow chart of a method for preparing water with a stable negative ORP, in accordance with one embodiment of the present invention. System 103 for preparing water with a stable negative ORP performs the following steps:
[0127] At step S 412 , water is preconditioned for electrolysis, and at step S 414 electrolysis is performed before outputting alkaline and/or acidic water at step S 416 . Water preconditioning system 100 performs step S 412 and electrolysis machine 101 performs step S 414 . At step S 412 , system 103 outputs alkaline water to holding tank 109 via pipe 105 and acidic water to acid water tank 110 via pipe 107 . Step S 412 for preconditioning water involves performing steps S 402 , S 404 , S 406 , S 408 , and S 410 , discussed below in connection with FIG. 2D .
[0128] FIG. 2C shows a water preconditioning system 100 for conditioning water for electrolysis, according to one embodiment of the present invention. Water preconditioning system 100 includes a filter system 104 , a UV system 108 , a circulating tank 112 , an ozone machine 116 , and a magnetic structuring stage 120 .
[0129] System 100 for preconditioning water operates generally as follows. First, high quality water is received by filter system 104 . High quality water may be water received from water source 152 , for example, an aquafier well, preferably an aquafier well located in certain geographic areas throughout the world, such as northern New Mexico and, more specifically, New Mexico, Missouri and Hawaii.
[0130] For example, a pump 140 , such as a pressure pump, can be used to pump the water from a well house 144 to filter system 104 via a pipe 148 . The aquafier well 152 may be deep, for example, ˜850 feet deep.
[0131] Water received by filter system 104 via pipe 148 is then filtered by filter system 104 and output via a pipe 156 to UV system 108 . Water output from UV system 108 via pipe 146 is then input to circulating tank 112 , which in turn is coupled via a pipe 136 to an ozone machine 116 . Pipe 1063 is provided to allow water to circulate between the circulating tank 112 , the ozone machine 116 and the magnetic structuring stage 120 .
[0132] The ozone machine 116 is selectively activatable. A valve 186 and bypass pipe 1062 are provided for selective bypass of the magnetic structuring stage 120 . After passing through magnetic structuring stage 120 , preconditioned water may be output via a pipe 164 .
[0133] Filter system 104 may be, for example, a four-stage filtering system which includes a ˜10 μm filter 124 , followed by a ˜5 μm filter 128 , followed by a ˜0.5 μm filter 132 , followed by a carbon filter 134 .
[0134] UV system 108 preferably includes a UV chamber carbon block filter (10″ 0.5 micron), and a UV #10 lamp (120V, 0.420 amp unit).
[0135] The operation of system 100 will be explained with reference to FIG. 2D , which is a flow chart of a method for preconditioning water. Water from water source 152 is received by system 100 for preconditioning water at step S 402 . The water is filtered by filtering system 104 at step S 404 . Step S 406 involves subjecting the water to ultraviolet radiation with UV system 108 . Steps S 408 -S 410 involve circulating water between circulating tank 112 , ozone machine 116 to add ozone to the water, and magnetic structuring stage 120 to preferably subject the water to a series of magnetic fields. Ozone machine 116 can be set between 1 mm/liter 10 SCFH and 1.2 mm/liter 15 SCFH, and the water is preferably exposed to ozone less than ˜15 seconds per ˜100 gallons to prevent burning, more preferably approximately between ˜two and 10 seconds per ˜100 gallons, and most preferably ˜5-8 seconds per 100 gallons. Step S 412 involves outputting water from magnetic structuring stage 120 as preconditioned water, which can then be input to electrolysis machine 101 . A residual of 0.1-0.4 PPM of ozone is typically left in the treated water.
[0136] As discussed above, circulating tank 112 is coupled via pipe 136 to ozone machine 116 , which is in turn coupled to magnetic structuring stage 120 via pipe 160 . Pipe 1063 connects magnetic structuring stage 120 to circulating tank 112 to form a complete circulation loop.
[0137] As discussed above, ozone machine 116 is preferably operated for ˜5-8 seconds for every ˜100 gallons contained in circulating tank 112 . However, ozone machine 116 may operate for up to ˜15 seconds for every ˜100 gallons in circulating tank 112 . However, operation should not exceed ˜15 seconds for every ˜100 gallons of water in circulating tank 112 in order to prevent burning. This essentially saturates and shocks the water. Typical ozone machine operations are between ˜0.08 to ˜0.8 mm per liter, which is not sufficient to saturate/shock the water. Exceeding ˜15 mm per liter results in essentially “burning” the water as mentioned above, so that the water tastes as if it were boiled. Burned water has an unnatural taste and, when one drinks it, is so caustic that it can strip out saliva from the mouth. It has utility in that it can “clear out” one's pipes and has very powerful antibacterial effect in that it can strip bacteria out that most people have a difficult time ridding from their system. For example, iron bacteria in domestic wells is a significant problem. Many believe that the only way to kill them is with excessive chlorine, but that really does not do a complete job. With this system, ˜12 seconds per 100 gallons of ozonated water kills iron bacteria.
[0138] Magnetic structuring stage 120 is shown in FIG. 3A . Water flows from pipe 160 into pipe 162 at location 200 and flows out at location 204 . Pipe 162 includes a series of magnetic donut rings 163 . According to a preferred embodiment of the invention, other magnet shapes might include north pole bar magnets or other magnets. In this embodiment, there are preferably 14 such donut rings 163 a - 163 n evenly spaced over a distance “d” of approximately 7 feet, such that their central longitudinal axis are spaced apart a distance “a” of ˜6.46″. Donut ring 163 a preferably has a magnetic field strength of ˜350 Gauss, while the magnetic field strength of donut ring 163 b linearly increases by a difference of ˜91.66 Gauss to ˜441 Gauss. Further, the magnetic field strength of each subsequent donut ring preferably increases by the same amount linearly until it reaches a maximum value of ˜900 Gauss. The magnetic field strength of donut rings 163 g and 163 h are both preferably ˜900 Gauss. The remaining magnets 163 i through 163 n preferably have magnetic field strengths or flux that are also linearly decreased by ˜91 Gauss.
[0139] FIG. 3B is a graph showing the magnetic flux of the magnetic donut rings of an exemplary magnetic structuring stage plotted versus distance or position of the donut rings. In FIG. 3B , the lowest value “LGauss” of magnetic flux for a donut ring is ˜350 Gauss, while the highest value “HGauss” of magnetic flux is ˜900 Gauss. However, HGauss value can be varied, for example to ˜1200 Gauss. When HGauss is ˜1200 Gauss, the water can become too clarifying to the colon. In another embodiment of the invention, HGauss can be varied as high as ˜1800 Gauss. The value of HGauss depends on the flow rate of the water through pipe 162 . As HGauss is increased, the maximum flow rate is preferably decreased. If the flow rate is too slow, the water breaks down.
[0140] The purpose of magnetic structuring stage 120 is to structure the water as it passes through the series of magnets 163 . The number and shape of magnets 163 can be varied. The flow rate is controlled by the pressure of the water entering location 200 of pipe 162 , which pressure can vary anywhere from ˜22 psi up to ˜30 psi. At ˜31 psi, there is a break over point. Water output at location 204 is considered structured water. When HGauss is ˜1200 Gauss, the water can hold more oxygen. The flow rate of the water preferably increases as the value of HGauss is increased in order to maintain equilibrium pressure/gauss.
[0141] FIG. 4A is a block diagram of an oxygen/water combining system, according to one embodiment of the present invention. Ozone treated alkaline water input to holding tank 109 via pipe 105 is then output from holding tank 109 to oxygen/water combining system 113 via pipe 111 . A pump 523 and pressure gauge 519 are preferably provided on pipe 111 to control water flow.
[0142] Oxygen/water combining system 113 includes a structured oxygen generator 600 , which outputs structured oxygen via pipe 117 , which is combined and coupled to pipe 111 at valve 119 . The ozone treated alkaline water is mixed with the structured oxygen from pipe 117 at valve 119 , and both are then directed via pipe 118 to diffusion chamber 115 .
[0143] Structured oxygen generating machine 600 outputs high pressure oxygen at pipe 117 . For example, structured oxygen generating machine 600 may output structured oxygen at up to ˜300 PSI changing pressures change electron ring formulation in molecule via pipe 117 before combining with the ozone treated alkaline water in pipe 111 . Pipe 111 may be, for example, an ˜1 inch pipe.
[0144] The combination of water and oxygen in pipe 118 is then sprayed into the diffusion chamber 115 via a pipe 504 in fluid communication with a spray nozzle 503 . The spray nozzle 503 has a very small orifice, for example, less than ˜0.1 inches and preferably less than ˜0.01 inches and more preferably ˜0.0078 inches in diameter.
[0145] Diffusion chamber 115 includes a cylinder 507 capable of generating a type of tornado or vortex 511 in diffusion chamber 115 . Diffusion chamber 115 may be, for example, a modified water filter rated to 250 psi with the top of the water filter replaced with a small set of fittings, for example, ˜⅜ inch brass fittings, that go through a ˜1 inch orifice, where a pipe for the water filter would normally be located. At the end of pipe 504 is spray nozzle 503 . Spray nozzle 503 may be ˜¼ inch in diameter and preferably has a spray fan which is designed to have a spray fan angle that creates a strong vortex of the oxygen-water combination in chamber 115 . The resulting spray fan angle is preferably ˜15°. The oxygen-water combination at the input of pipe 504 is preferably under a pressure of ˜60 PSI.
[0146] The tornado 511 is essentially a clockwise vortex that is created in cylinder 507 . The tornado 511 has a cream-like appearance due to the fine oxygen bubbles. That is, the tornado 511 is essentially white because all of the oxygen is pulled into the center of the vortex. The width of the tornado or vortex 511 is preferably ˜¾ inch and extends all the way to the bottom of the preferably 18″ to 24″ cylinder 507 . At the bottom of cylinder 507 is a pressure escape valve 513 which is coupled to a pipe 515 A which, in a preferred embodiment, is ˜½ inch in diameter. The pipe 515 A which is coupled to holding tank 109 . Pipe 515 B also couples diffusion chamber 115 to holding tank 109 . Pipe 25 connects oxygen/water combining system 113 to cone system 121 , with a pressure gauge 25 A and cut off valve 25 B (See FIG. 1A ) provided on pipe 25 to control water flow. Pressure escape valve 513 and pipe 515 A provide pressure relief for the system.
[0147] Oxygen is mixed with water at location 119 . It is desirable to saturate the water with oxygen so that there is an abundance of oxygen. Because there is a saturation of oxygen, it can actually add oxygen to the water rather than pull oxygen out of the water.
[0148] FIG. 4B is a flow chart of an oxygen/water combining method, according to one embodiment of the present invention, performed by the oxygen/water combining system 113 . Step S 531 involves receiving ozone treated alkaline water via pipe 111 . Step S 533 involves mixing oxygen with ozone treated alkaline water at valve 119 . Step S 535 involves forcing the mixture of oxygen and ozone treated alkaline water through spray nozzle 503 in diffusion chamber 115 to create tornado/vortex 511 . Step S 537 involves outputting oxygen enriched structured water from diffusion chamber 115 . Step S 539 involves outputting the oxygen enriched structured water from oxygen/water combining system 113 via pipe 25 .
[0149] FIG. 5A is a block diagram of a structured oxygen generating machine 600 according to one embodiment of the present invention. Structured oxygen generating machine 600 includes a compressor 604 , which is coupled via a pipe 608 to an oxygen generator 612 . Compressor 604 may be, for example, a ˜25 horsepower compressor which outputs refrigerated and cleaned air at ˜250 PSI to oxygen generator 612 . Oxygen generator 612 may be, for example, an OGS oxygen generator. Oxygen generator 612 outputs oxygen via a pipe 614 at, for example, ˜70 PSI to an oxygen storage tank 616 . Oxygen storage tank 616 in turn outputs oxygen at high pressure (up to ˜300 PSI) through a high pressure pipe 620 to an oxygen enhancer 622 . The oxygen is then directed to a valve 624 , which in turn directs the oxygen through either a first magnetic structuring stage 628 or a second magnetic structuring stage 632 . When valve 624 is in a first position, oxygen output from oxygen enhancer 622 passes through pipe 626 to first magnetic structuring stage 628 , shown in more detail in FIG. 6A . That is, oxygen from oxygen enhancer 622 is input to first magnetic structuring stage 628 via pipe 626 and, after passing through first magnetic structuring stage 628 , is output through pipe 631 to pipe 117 as structured oxygen. When valve 624 is in a second position, oxygen from oxygen enhancer 622 passes through pipe 630 to the second magnetic structuring stage 632 , shown in more detail in FIG. 6B . That is, oxygen from oxygen enhancer 622 is input to second magnetic structuring stage 632 via pipe 630 and is output via pipe 634 to pipe 117 as structured oxygen.
[0150] FIG. 5B is a flow chart of a method for producing structured oxygen, according to one embodiment of the present invention. At step S 670 , refrigerated and cleaned air is input to the oxygen generator 612 under pressure. Oxygen generator 612 , in turn, outputs highly pressurized oxygen to oxygen storage tank 616 via pipe 614 at step S 674 . At step S 678 , highly pressurized oxygen is input to either first magnetic structuring stage 628 or second magnetic structuring stage 632 . At step S 682 , magnetically structured oxygen is output from either the first magnetic structuring stage 628 or the second magnetic structuring stage 632 .
[0151] FIG. 5C is a longitudinal cross sectional view of the oxygen enhancer 622 shown in FIG. 5A . The oxygen enhancer 622 preferably has a substantially tubular body portion 6200 , and is preferably formed of a non-conductive material, such as, for example, high pressure plastic. In one embodiment of the present invention, the body portion 6200 may be between 14 and 17 inches long, and approximately 3 inches in diameter. However, other dimensions for the body portion 6200 may also be used. Ends of the body portion 6200 are preferably tapered so as to form an inlet 6210 and an outlet 6220 , which accommodate incoming and outgoing pipes 6215 and 6225 , respectively. In one embodiment of the present invention, the incoming and outgoing pipes 6215 and 6225 preferably have a ½ inch diameter, and some length thereof (e.g., ½ inch) may extend into the body portion 6200 . However, other diameters may also be used.
[0152] Ring type devices 6230 and 6240 , such as, for example, a washer, are preferably positioned at the inlet 6210 and outlet 6220 to secure and properly align the pipes 6215 and 6225 , respectively, in place. The body portion 6200 are preferably filled with a filtering material 6250 , such as, for example, carbon, to scrub the oxygen processed therethrough and absorb any contaminants that may be present. The carbon chips 6250 may vary in size, and preferably fall within an average size of between ⅛ and 1/32 inch. Carbon creates a pure, clean oxygen that is readily accepted into the water.
[0153] First and second mesh screens 6270 and 6280 , respectively, are preferably positioned in the body portion 6200 as shown in FIG. 5C , preferably with a void 6290 formed therebetween. The screens 6270 and 6280 may be made of any type of suitable metallic material, such as silver, platinum or gold. In one embodiment of the present invention, the screens 6270 and 6280 are preferably made of a gold mesh material. However, other materials, such as, for example, copper and brass, could also be used. The mesh size of the screens 6270 and 6280 may also be varied. In one embodiment of the present invention, the mesh size may preferably fall within a range of between 150 and 200 microns, and is most preferably 200 microns.
[0154] A plurality of magnets are provided on each of the first and second screens 6270 and 6280 , with a first set of magnets 6275 preferably provided on a surface of the first screen 6270 facing the inlet 6210 , and a second set of magnets 6285 preferably provided on a surface of the second screen 6280 facing the outlet 6220 . Wires 6260 , preferably made of a conductive material, such as, for example, copper, extend from the first set of magnets 6275 to the inlet ring 6230 , and from the second set of magnets 6285 to the outlet ring 6240 . The wires 6260 may be attached to the rings 6230 and 6240 by any suitable means such as, for example, soldering.
[0155] A front view of an exemplary mesh screen 6300 is shown in FIG. 5D . This exemplary mesh screen 6300 is shown with nine magnets attached thereto, with a center magnet 6310 being preferably slightly larger than surrounding magnets 6320 . However, other numbers of magnets, relative sizes, strengths, and arrangements on the mesh screen 6300 may also be used. The magnets may be made of any appropriate magnetic material. In one embodiment of the present invention, the magnets are preferably button magnets, and most preferably germanium button magnets, that are less than ½ inch in diameter, and preferably ⅜ inch in diameter, and with a strength of between 300 and 550 Gauss. Based on this type of magnet arrangement on each of the first and second screens 6270 and 6280 shown in FIG. 5C , an appropriate width for the void 6290 is approximately ½ inch. However, the number, arrangement, and strength of the magnets may be varied, and an appropriate width of the void 6290 may be determined based on the resulting strength of the magnetic flux produced by the magnets.
[0156] In FIG. 5C , the first set of magnets 6275 is preferably oriented with a north side 6276 facing the inlet 6210 , and a south side 6277 adjacent the first screen 6270 , while the second set of magnets 6285 is preferably oriented with a north side 6286 facing the outlet 6220 , and a south side 6287 adjacent the second screen 6280 . This opposing polarity arrangement causes the oxygen to “snap” as it passes through the void 6290 , thus initiating the structuring process by aligning and preparing the oxygen for further structuring as it subsequently passes through either the first or second structuring stages 628 or 632 .
[0157] FIGS. 5E and 5F are front and side views, respectively, of a ring 6291 which is preferably positioned within the void 6290 . The ring 6291 preferably includes a plurality of magnets 6292 positioned along a circumference of the ring 6291 , adhered to the ring 6291 by any suitable means. In one embodiment of the present invention, fourteen germanium magnets 6292 are preferably adhered along a circumference of the ring 6291 with a silicone based compound. In this embodiment, each of the magnets 6292 may be between ½ and ⅜ inch in diameter, and each have a strength of approximately 200 Gauss. However, it should be understood that many other combinations of type, number, and strength of the magnets may be used to provide a suitable effect. Similarly, a width W of the ring 6291 may be varied based on a corresponding width of the void 6290 formed between the screens 6270 and 6280 .
[0158] As shown in FIGS. 5E-5G , a south pole S of each of the magnets 6292 is preferably flush with an outer circumference 6293 of the ring 6291 , while a north pole N of each of the magnets 6292 preferably extends from an inner circumference 6294 of the ring 6291 and toward the center of the ring 6291 . Accordingly, when configured as such and positioned in the void 6290 formed between the screens 6270 and 6280 , the south poles S of the magnets 6292 and the outer circumference 6293 of the ring 6291 contacts an inner surface of the body portion 6200 , while the left and right faces 6295 and 6296 , respectively, of the ring 6291 contact the screens 6270 and 6280 , respectively. In one embodiment of the invention, the width W of the ring 6291 is approximately ½ inch to match the corresponding width of the void 6290 .
[0159] FIG. 6A is a schematic side view of a first magnetic structuring stage for a structured oxygen generating machine, according to one embodiment of the present invention. First magnetic structuring stage 628 includes N donut magnets 1 , 2 , 3 . . . N all arranged along pipe 626 . Each of the donut magnets 1 ˜N preferably has a strength of up to ˜3,300 Gauss. The spacing between central longitudinal axes of the donut magnets 1 and 2 of first magnetic structuring stage 628 is preferably ˜2 inches, and gradually increases to the middle 636 of first magnetic structuring stage 628 at which point the spacing is preferably ˜12 inches, and then the spacing between the subsequent donut magnets decreases until the spacing between central longitudinal axes of donut magnets N−1 and N is preferably ˜2 inches. The middle 636 of first magnetic structuring stage 628 is preferably located ˜4.5 feet from each end of the first magnetic structuring stage 628 .
[0160] Alternatively, as discussed above, oxygen can be directed by the valve 624 to the second magnetic structuring stage 632 . FIG. 6B is a schematic side view of the second magnetic structure stage for a structured oxygen generating machine, in accordance with one embodiment of the present invention. In this embodiment, there are M central longitudinal axes of donut magnets which are spaced apart distances D 1 , D 2 . . . D M , where distances D i all represent a Fibonacci sequence in inches. Hence, D i =1, 1, 2, 3, 5, 8, 13, . . . , whereby D i =D j−2 +D j−1 . In a preferred embodiment, M is an integer between 1 and 21.
[0161] The structured oxygen, which is output from either the first magnetic structuring stage 628 or the second magnetic structuring stage 632 , may be used to enrich water with oxygen according to processes described herein. When the structured oxygen output from first magnetic structuring stage 628 is mixed with properly prepared water, the resulting water may provide energy to the person or mammal that ingests the water. On the other hand, structured oxygen output from second magnetic structuring stage 632 , when used to enrich water, yields oxygen enriched water which may produce a sedating effect for people or mammals that ingest the oxygen enriched water.
[0162] FIG. 7A is a block diagram of a cone system, in accordance with one embodiment of the present invention. Combined oxygen/water is input via pipe 25 to cone system 121 . A medical grade oxygen machine 803 is coupled to pipe 25 via a pipe 805 at a valve 807 . Medical grade oxygen is output from the medical grade oxygen machine 803 and mixed with the combined oxygen/water from the system 10 at valve 807 , and together are directed via a pipe 523 to a series of cones 809 . The series of cones 809 are shown in FIG. 7A to be 6 cones 811 , 813 , 815 , 817 , 819 and 821 , according to one embodiment of the present invention. However, the number of cones in the series of cones 809 can vary from 1 to N where N can be as high as 24. The combined water/oxygen from system 10 and the medical grade oxygen 803 are mixed by each of cones 811 through 821 , which individually spin the combination, and output a resulting spun water via pipe 27 . In this embodiment, cone 811 is coupled to cone 813 by a pipe 812 , cone 813 is coupled to cone 815 by a pipe 814 , cone 815 is coupled to cone 817 by a pipe 816 , cone 817 is coupled to cone 819 by a pipe 818 , and cone 819 is coupled to cone 821 by a pipe 820 .
[0163] FIG. 7B is a schematic side view of an exemplary cone 811 , and FIG. 7C is a schematic top view of the exemplary cone 811 . Referring to FIG. 7B , pipe 523 is coupled to a tube 831 , for example, a double-bent tube, near the top of cone 811 . In this embodiment, tube 831 is preferably a crystal tube. Tube 831 preferably includes two ˜90° bends 833 and 835 . Bends 833 and 835 are preferably ˜90°, but can vary by plus or minus 45°. Also, bends 833 and 835 are preferably configured so as to impart a clockwise spin 837 in cone 811 . The combination of oxygen and water input to tube 831 is under high pressure of at least ˜30 PSI and more preferably of at least ˜34 PSI in order to create clockwise spin 837 in cone 811 . Pipe 812 is coupled to cone 813 in the same manner as pipe 523 is coupled to cone 811 , and this is also true for cones 813 through 821 as well.
[0164] Clockwise spin vortex 837 of the oxygen/water combination will be referred to herein as a clockwise vortex spin 837 . The ratio of the oxygen from medical grade oxygen machine 803 and the oxygen/water combination, together with the water pressure at tube 831 , determines the efficiency of the mixing of oxygen with water at cone 811 , as well as the rest of cones 813 - 821 . Lines 841 in vortex 837 disappear if oxygen from medical grade oxygen machine 803 is turned off. That is, clockwise vortex spin 837 remains but lines 841 disappear.
[0165] In the embodiment discussed above, the inner diameter of tube 523 is preferably ˜¼″ and the outer diameter is preferably ˜½″, the inner diameter of tube 831 is preferably ˜⅛″ and the outer diameter is preferably ˜¼″. The tube 831 is preferably ˜1¾″ long and preferably extends to a position ˜⅜″ from the edge of cone 811 , and is preferably attached to cone 811 by, for example, a solder joint 811 A. Further, cone 811 preferably has a diameter D i at a top portion of ˜6″ and a diameter D b at a bottom portion of ˜⅛″.
[0166] FIG. 7D is a flow chart of a method for spinning water with oxygen using a cone system, according to one embodiment of the present invention. Step S 861 involves receiving the oxygen/water combination. Step S 863 involves combining the oxygen/water combination with medical grade oxygen. Step S 865 involves inputting the combination of oxygen/water and the medical grade oxygen into cone series 809 . Finally, step S 867 involves outputting spun water as super-oxygenated and structured water, with its negative ORP further enhanced and locked into the water.
[0167] FIG. 8A is a schematic side view and FIG. 8B is a schematic top view of a coil system, according to one embodiment of the present invention. Coil system 123 includes a coil 871 with an outer diameter D. In this embodiment, coil 871 is preferably a crystal coil. The outer diameter D of coil 871 can vary from ˜4″ to ˜12″, and is preferably between ˜5″ and ˜9″, and more preferably ˜7 inches. Pipe 27 is coupled to tube 871 to form a bend 875 with an angle between ˜45° and ˜130° and preferably between ˜65° and ˜95° and more preferably ˜90°. In particular, pipe 27 is coupled to tube 871 to form bend 875 and water flows through pipe 27 until it reaches bend 875 at which point it is abruptly redirected to the right to begin a clockwise flow down tube 871 until it is output at pipe 29 , as shown in FIG. 8A .
[0168] In this embodiment, tube 871 is preferably cylindrical with a round cross-section. However, other shapes, such as octagonal, hexagonal, or oval, for example, can also be used.
[0169] A crystal 881 is preferably arranged approximately in the center of coil 871 , as shown in FIG. 8A . The size of crystal 881 is preferably 3″ or 12″, but is more preferably 7″. However, other crystal sizes may be used. The crystal 881 is arranged in a container 883 , which may contain a tincture or solution 885 . A battery 887 is preferably coupled via a wire 889 to crystal 881 and the other pole of battery 887 is preferably grounded in tincture or solution 885 via a wire 891 . As the water travels in a clockwise pattern down coil 871 it cuts through magnetic flux lines 893 created by the battery 887 and crystal 889 combination. The right hand or clockwise flow of the water pulls electrons into its orbit. If coil 871 is reversed, so as to provide a counterclockwise flow or a left hand spin of the water, then the left hand spin throws electrons out of the orbit. The water resulting from a left hand spin is beneficial for a short time because of detoxifying effects in the body. Independent of crystal 881 , a motion of the water in either a clockwise or counterclockwise fashion creates an electromagnetic field which can be measured, such as any charged particle in motion would create an electromagnetic field. In this embodiment, crystal 881 is preferably a vogel crystal. Solution 885 may contain herbs or any substance depending on the tint for the water. By placing different substances in solution 885 or by changing solution 885 , water output from pipe 29 can be tuned to that particular substance or solution. “Tune” can refer to the modification of the structure, character and/or property of the water.
[0170] Crystal 881 oscillates at a particular resonance frequency, which can modify the water. These frequencies can vary from ˜5 to ˜9 Hz, and preferably from ˜6 to ˜8 Hz, and more preferably from ˜6.8 to ˜7.8 Hz, and even more preferably from ˜7.2 to ˜7.8 Hz.
[0171] FIG. 8C is a flow chart of a method performed by the coil system of FIGS. 8A-8B . In particular, FIG. 8C shows step S 893 , which involves creating a magnetic flux, and step S 895 , which involves passing water in a spiral fashion through the magnetic flux. The magnetic flux is preferably created using a crystal, as discussed with respect to FIG. 8A . Also, as water is passed in a spiral fashion, it can be passed in a clockwise spiral fashion through the magnetic flux in order to maintain free electrons in the water or in a counterclockwise fashion in order to give off electrons from the water.
[0172] FIGS. 9A and 9C are, respectively, schematic top and side views of a multi-coil system, according to one embodiment of the present invention. Multi-coil system 127 preferably includes coil sets 901 , 903 , 905 , and 907 . Coil sets 901 and 907 are preferably single coils, while coil sets 903 and 905 preferably contain inner coils 903 a and 905 a , respectively, and outer coils 903 b and 905 b , respectively.
[0173] Super-oxygenated and structured water mixed with structured ozone is input via pipe 35 to multi-coil system 127 . A series of magnets 912 may be optionally placed on pipe 35 prior to entry into multi-coil system 127 . These magnets can be any shape, but are preferably donut magnets and preferably north field magnets surrounding or placed directly on the pipe 35 .
[0174] As shown in FIG. 9A , coil set 901 is coupled to coil set 905 via a pipe 914 , coil set 905 is coupled to coil set 907 via pipe 916 , and coil set 907 is coupled to coil set 903 via pipe 918 . In this embodiment, water preferably enters coil set or coil 901 at a top portion, spirals down to a bottom portion of coil 901 and then passes via pipe 914 to coil set 905 . At coil set 905 , water preferably enters a bottom portion of inner coil 905 a and spirals up against gravity to a top portion of inner coil 905 a . The water then passes into outer coil 905 b and spirals down outer coil 905 b to a bottom portion, where it exits coil set 905 via pipe 916 . The water then preferably passes into a top portion of coil set or coil 907 and spirals downward to a bottom portion, where it exits coil 907 via pipe 918 . The water next preferably enters coil set 903 at a bottom portion of inner coil 903 a , spirals up (against gravity) to a top portion of inner coil 903 a , where it passes into outer coil 903 b before spiraling downward to a bottom portion of 903 b , where it exits coil set 903 and multi-coil system 127 via pipe 37 . The super-oxygenated, tuned and structured water is then directed to holding tank 109 via pipe 37 .
[0175] As shown in FIG. 9C , multi-coil system 127 includes an outer box 941 and an inner box 943 with mica 945 contained in between inner box 943 and outer box 941 . Coil sets 901 - 907 are preferably between ˜5″ and ˜17″ inches wide and preferably between ˜14″ and ˜33 inches long, and more preferably ˜7 inches wide and ˜17 inches long. Inner coils 903 a and 905 a preferably have a diameter in the range of 2″ to ˜9″, and more preferably between ˜3″ and −5″, and most preferably ˜3″.
[0176] FIG. 9B is a schematic side view of coil set 905 of FIG. 9A . Coil set 905 , includes outer coil 905 b and inner coil 905 a . As viewed from the top, the water spirals up the inner coil 905 a in a clockwise fashion until it reaches a top portion and then spirals down the outer coil 905 b where it exits the coil system 905 . Inner coil 905 a is preferably supported by one or more supports 1070 A, preferably two dowel rods, and the outer coil 905 b is preferably supported by one or more supports 1070 B, preferably a plurality of dowel rods. The supports 1070 A and 1070 B are preferably connected to coils 905 a and 905 b using plastic ties.
[0177] As shown in FIGS. 9D and 9E , the various pipes are connected to the various coils via a tube, preferably with a bend. In this embodiment, the tube is a glass tube with an ˜90° bend. As can be seen in FIG. 9B , a crystal 923 may be placed at a base of the coil set 905 . Crystal 923 is preferably a double terminated quartz crystal, but is not limited to clear quartz. The crystals are centered at the base and extend up inside the coil. Extending the crystal further up into the coil reduces the effects. Coil set 903 also has an arrangement like that shown in FIG. 9B with respect to the coil set 905 . Each coil set 903 , 905 , and 907 also includes a crystal arranged as shown in FIG. 9B .
[0178] As shown in FIG. 9C , magnets 912 may be arranged on pipe 35 prior to entry into multi-coil system 127 , and serve to cancel frequencies that have been input or are otherwise contained in the water prior to input to multi-coil system 127 . Although multi-coil system 127 in this embodiment is shown with four coil sets, it can contain one, two, three or more than four coil sets, with various combinations of single and double coil sets. The inner diameter of the inner and outer coils for coil sets 901 - 907 is preferably ˜ 5/16 inches. The coils for coil sets 901 - 907 are preferably made of crystal and not pyrex. Crystal 923 , as well as the crystals for the other three coil sets, preferably have dimensions of ˜17″ט18″ to ˜3″ט1″, and more preferably ˜ 8½ inches long and ˜ 3½ inches across double terminated.
[0179] FIG. 9F is a flow chart of a method performed by the multi-coil system of FIGS. 9A-9E . Step S 951 involves inputting water and structured ozone into a top portion of a first coil set or coil arranged in a first magnetic flux. Step S 953 involves passing the water/ozone combination clockwise down the first coil set. Step S 955 involves coupling the water/ozone combination into the bottom of an inner coil of a second coil set arranged in a second magnetic flux. Step S 957 involves passing the water/ozone combination clockwise up the inner coil of the second coil set. Step S 959 involves coupling the water/ozone combination into the outer coil of the second coil set. Step S 961 involves passing the water/ozone combination clockwise down the outer coil of the second coil set. Step S 963 involves coupling the water/ozone combination into a top portion of a third coil set arranged in a third magnetic flux. Step S 965 involves passing the water/ozone combination clockwise down the third coil set. Step S 967 involves coupling the water/oxygen combination into a bottom portion of an inner coil of a fourth coil set arranged in a fourth magnetic flux. Step S 969 involves passing the water/ozone combination clockwise up the inner coil of the fourth coil set. Step S 971 involves coupling the water/ozone combination into the outer coil of the fourth coil set. Step S 973 involves passing the water/ozone combination clockwise down the outer coil of the fourth coil set. Step S 975 involves outputting super-oxygenated, tuned, and structured water.
[0180] FIG. 10A is a block diagram of a structured ozone machine, according to one embodiment of the present invention. Structured ozone machine 125 includes a medical grade oxygen source 746 coupled via a pipe 749 to a standard ozone machine 751 . Medical grade oxygen is output from medical grade oxygen source 746 to ozone machine 751 , which in turn produces ozone, which is output via pipe 31 . Pipe 31 may be, for example, ˜⅛ inch flex tubing. Two low Gauss magnets 753 are arranged on pipe 31 . Although the two low Gauss magnets are shown in this embodiment, a single low Gauss or more than two, including three, four, five, and so forth, low Gauss magnets can be arranged along pipe 31 . Where two low Gauss magnets are arranged on pipe 31 , they are preferably spaced between ˜½″ and ˜3 inches apart, and more preferably ˜1 inch apart. In this case, the low Gauss magnets 753 are preferably magnets which are below ˜1,000 Gauss, and more preferably below ˜500 Gauss and most preferably ˜200 Gauss each.
[0181] FIG. 10B is a flow chart of a method performed by the structured ozone machine of FIG. 10A to produce structured ozone. Step S 761 involves inputting medical grade oxygen into structured ozone machine 125 . Step S 763 involves generating ozone using the medical grade oxygen. Step S 765 involves passing the ozone generated from the medical grade oxygen through a magnetic flux to yield structured ozone.
[0182] The water flow throughout the system is preferably controlled to enhance the system's performance. That is, pipe diameters and pressures at each point P in the system are preferably configured to ensure proper functioning. Referring to FIG. 1A , pipe diameters and water pressure at each point P are preferably as follows.
[0183] At Point P 1 : Pipe diameter is preferably ˜½ to ˜3 inch(es), more preferably ˜1 to ˜1¼ inch(es), most preferably ˜1¼ inches. Pressure is preferably ˜17 to ˜36 psi, more preferably ˜18 to 30 psi, most preferably ˜27 psi.
[0184] At Point P 2 : Pipe diameter is preferably ˜⅜ to ˜1½ inch(es), more preferably ˜¾ to ˜1¼ inch(es), most preferably ˜1 inch. Pressure is preferably ˜17 to ˜36 psi, more preferably ˜18 to ˜26 psi, most preferably ˜22 psi.
[0185] At Point P 3 : Pipe diameter is preferably ˜⅜ to ˜1½ inch(es), more preferably ˜¾ to ˜1¼ inches(es), most preferably ˜1 inch. Pressure is preferably ˜12 to ˜20 psi, more preferably ˜12 to ˜15 psi, most preferably ˜15 psi.
[0186] At Point P 4 : Pipe diameter is preferably ˜⅜ to ˜1¼ inch(es), more preferably ˜½ to ˜1 inch(es), most preferably ˜1 inch. Pressure is preferably ˜12 to ˜20 psi, more preferably ˜12 to ˜15 psi, most preferably ˜15 psi.
[0187] At Point P 5 : Pipe diameter is preferably ˜¾ to ˜1½ inch(es), more preferably ˜¾ to ˜1 inch(es), most preferably ˜1 inch. Pressure is preferably ˜40 to ˜80 psi, more preferably ˜40 to ˜60 psi, most preferably ˜69 psi.
[0188] At Point P 6 : Pipe diameter is preferably ˜¼ to ˜¾ inch(es), more preferably ˜¼ to ˜ 3 / 8 inch(es), most preferably ˜⅜ inch. Flow rate should be preferably 5 liters per minute. (Pressure preferably ˜22 to ˜60 psi, more preferably ˜30 to ˜45 psi, most preferably ˜44 psi.)
[0189] At Point P 7 : Pipe diameter is preferably ˜¼ to ˜1¼ inch(es), more preferably ˜½ to ˜¾ inch(es), most preferably ˜½ inch. Pressure is preferably ˜50 to ˜75 psi, more preferably ˜49 to ˜69 psi, most preferably ˜69 psi.
[0190] At Point P 8 : Pipe diameter is preferably ˜¼ to ˜¾ inch(es), more preferably ˜½ to ˜⅝ inch(es), most preferably ˜½ inch. Pressure is preferably ˜5 to ˜25 psi, more preferably ˜5 to ˜10 psi, most preferably ˜7-10 psi.
[0191] At Point P 9 : Pipe diameter is preferably ˜½ to ˜1 inch(es), more preferably ˜⅝ to ˜¾ inch(es), most preferably ˜¾ inch. Pressure is preferably ˜18 to ˜35 psi, more preferably ˜18 to ˜25 psi, most preferably ˜25 psi.
[0192] At Point P 10 : Pipe diameter is preferably ˜¼ to ˜¾ inch(es), more preferably ˜¼ to ˜½ inch(es), most preferably ˜½ inch. Pressure is preferably ˜18 to ˜35 psi, more preferably ˜30 to ˜42 psi, most preferably ˜40-42 psi.
[0193] At Point P 11 : Pipe diameter is preferably ˜¼ to ˜¾ inch(es), more preferably ˜⅜ to ˜½ inch(es), most preferably ˜½ inch. Pressure is preferably ˜15 to ˜50 psi, more preferably ˜20 to ˜40 psi, most preferably ˜34 psi.
[0194] At Point P 12 : Pipe diameter is preferably ˜ 1/16 to ˜¼ inch(es), more preferably ˜ 1/16 to ˜⅛ inch(es), most preferably ˜⅛ inch. Flow rate is preferably ˜⅛ liter per minute.
[0195] At Point P 13 : Pipe diameter is preferably ˜ 1/16 to ˜¾ inch(es), more preferably ˜⅜ to ˜½ inch(es), most preferably ˜½ inch. Pressure is preferably ˜10 to ˜25 psi, more preferably ˜10 to ˜18 psi, most preferably ˜15-18 psi.
[0196] At Point P 14 : Pipe diameter is preferably ˜ 1/16 to ˜¾ inch(es), more preferably ˜⅜ to ˜½ inch(es), most preferably ˜½ inch. Pressure is preferably ˜15 to ˜35 psi, more preferably ˜18 to ˜22 psi, most preferably ˜22 psi.
[0197] At Point P 15 : Pipe diameter is preferably ˜ 1/16 to ˜¾ inch(es), more preferably ˜⅜ to ˜½ inch(es), most preferably ˜½ inch. Pressure is preferably ˜15 to ˜75 psi, more preferably ˜22 to ˜60 psi, most preferably ˜30-40 psi.
EXAMPLE 1
Heart Rate and Exercise Performance
[0198] The present example is provided to demonstrate the utility of the present invention for maintaining and/or restoring a desired physiological fluid oxygen level in an animal. In particular aspects, the present example will also demonstrate the utility of the present compositions for maintaining, and in some aspects normalizing, a reduced oxygenated blood level in an animal subsequent to a blood oxygen-lowering effect activity, such as what typically occurs in an animal, such as a human, after an oxygen-consuming activity, such as exercise. Changes in these physiologically measurable parameters are typically attendant an increase in physical activity, stress or other fatigue-inducing event.
[0199] The parameters that were measured in the present study were changes in subjects consuming the oxygen-enriched, microstructured water preparations verses subjects consuming conventional bottled water. The changes in these two subject populations were monitored for changes in heart rate, changes in oxygen saturation, changes in blood lactate, changes in oxygen consumption, and changes in fatigue assessment by a patient in response to a defined exercise regimen after having consumed a defined quantity of the oxygen-enriched, structured and/or microstructured water, or after consuming a conventional bottled water.
[0200] The present study was a randomized, double blind crossover study. Subjects were recruited from training facilities in Montreal. Subjects were tested on four different days during a two-week period. The subjects comprised a group of males and females of at least 18 years in age in good physical condition. None of the test subjects had any history of serious chronic disease. Each of the test subjects had been in physical training during the previous year, training at least 2 times per week, during the time preceding their participation in the present study.
[0201] The test subjects were randomly assigned to a group to receive the oxygen enriched, structured and microstructured water preparation verses a preparation of conventional tap or bottled water (Placebo).
[0202] The total duration of the study was 14 days, comprised of four (4) evaluation visits. Each subject, depending on the group assigned, was asked to drink 500 ml of the oxygen-enriched structured and microstructured water or 500 ml of the bottled Santa Fe municipal city water. Each subject was then asked to sit for 5 minutes. After 5 minutes, a baseline physiological set of measurements were recorded for each subject. These measurements included heart rate, blood pressure, blood oxygen, blood oxygen saturation, and blood lactate.
[0203] Once recorded, the subject began a 5-minute warm-up on a treadmill. After this warm-up period, the subject began a multi-stage VO 2 -max test. Each subject then underwent a standardized five-step exercise tolerance test to fatigue. During this test, each subject was asked to consume 500 ml of the oxygen-rich, microstructured water or bottled spring water, according to the initial test group to which they were originally assigned. (Total consumption by each test subject was between ½ and ¾ liter).
[0204] The multi-stage VO 2 —max test commenced at a speed of 11.3 km/hr (7.02 miles/hr) and a slope of 2 degrees. The slope was then progressively increased by 2 degrees every minute. At the end of each stage, heart rate, blood pressure and blood oxygen saturation were measured. Upon maximal exertion, VO 2 max was calculated and blood lactate was measured. A visual analog scale was used to assess perceived fatigue (i.e., maximal exertion), at the end of the VO 2 max. For this determination, the subject was asked to place an “X” on a 10 cm line indicating how tired they felt at the end of the VO 2 max test with one end of the line indication no fatigue (0), and the other end indication exhaustion (10). This routine was repeated with the same product 2 days later. A third visit took place one week later when subjects were asked to return to the gym.
[0205] Each subject then completed the same protocol of exercise a second time, this time consuming the opposite product (i.e., Group 1—Bottled Santa Fe Municipal City Water (Placebo) consumed (½ to ¾ liter) during Exercise Test Session 1; Group 1—Oxygen-enriched, Structured and Microstructured water (AGFW) consumed (½ to ¾ liter) during Exercise Test Session 2) (Group 2—Bottled Spring Water (placebo) consumed (1 Liter) during Exercise Test Session 1 (1 Liter); Group 2—Oxygen-enriched, Microstructured Water (AGFW) during Exercise Test Session2).
[0206] As demonstrated in the data presented at Tables 1, 2 and 3, the performance parameters that were assessed and compared in response to consumption of the oxygen-enriched, microstructured water preparations were heart rate, oxygen saturation, blood lactate, and oxygen consumption and fatigue assessment. As used in this study and others described throughout this application, “fatigue” is defined as the length of physical exertion needed for the subject to assess subjectively an exhaustion level of at least 7 on a scale of 0 to 10.
[0207] Table 1 presents the data collected from the subjects at a first visit and at a second visit. Table 2 presents the change demonstrated in each of the performance parameters. Table 3 presents an analysis of the differences between the changes observed in each of the performance parameters examined.
TABLE 1 Exercise Performance Parameters by Visit and Treatment Period Visit 1 Visit 2 Parameter: AGFW Placebo P-Value AGFW Placebo P-Value Change in Mean (SD) 86.93 76.00 0.001 76.25 75.76 0.999 Heart Rate (18.15) (15.60) (14.70) (13.64) 95% C.I. 81.38, 92.49 71.22, 80.78 71.76, 71.60, 80.75 79.96 Change in Mean (SD) −2.05 (2.53) −1.90 (2.32) 0.377 −2.22 −1.85 (2.37) 0.198 Oxygen (1.67) Saturation 95% C.I. −2.82, −1.27 −2.61, −1.19 −2.73, −1.71 −2.58, −1.13 (%) Blood Lactate Mean (SD) 11.30 (3.64) 9.43 (3.52) 0.007 10.29 9.44 (4.05) 0.125 (3.09) 95% C.I. 10.19, 12.41 8.35, 10.50 9.34, 8.20, 10.68 11.23 Calculated Mean (SD) 66.37 (4.23) 66.05 (4.47) 0.407 66.39 66.59 (4.92) 0.750 Oxygen (4.50) Consumption 95% C.I. 65.07, 67.66 64.68, 67.42 65.01, 65.08, 67.77 68.09 Fatigue Mean (SD) 11.94 (2.36) 11.94 (1.89) 0.539 11.94 11.82 (2.17) 0.744 Assessment (2.25) 95% C.I. 11.18, 12.66 11.36, 12.52 11.25, 11.16, 12.63 12.49
[0208]
TABLE 2
Change in Exercise Performance Parameters between Visits by
Treatment Period
AGFW
Placebo
P-Value
P-Value
P-Value
Within
Within
Between
Parameter:
Estimate
Treatment
Estimate
Treatment
Treatment
Change in Heart
Mean (SD)
−10.68
0.932
−0.22 (13.17)
0.081
0.002
Rate
(16.11)
95% C.I.
−15.61, −5.75
−4.25, 3.81
Change in
Mean (SD)
−0.17 (2.13)
0.067
0.05 (2.72)
0.070
0.519
Oxygen
95% C.I.
−0.83, 0.48
−0.78, 0.88
Saturation (%)
Blood Lactate
Mean (SD)
−1.01 (4.08)
0.604
0.01 (3.89)
0.814
0.241
95% C.I.
−2.26, 0.23
−1.18, 1.20
Calculated
Mean (SD)
0.02 (2.41)
0.040
0.54 (2.51)
0.001
0.267
Oxygen
95% C.I.
−0.71, 0.76
−0.23, 1.31
Consumption
Fatigue
Mean (SD)
0.00 (2.80)
0.342
−0.12 (2.19)
0.852
0.632
Assessment
95% C.I.
−0.85, 0.86
−0.79, 0.55
[0209]
TABLE 3
Difference in Change in Exercise Performance Parameters
between Treatment Periods
Absolute
Percent
P-Value
P-Value
Between
Between
Parameter:
Estimate
Treatment
Estimate
Treatment
Change in Heart Rate
Mean (SD)
10.46, 19.43
0.002
−0.65 (4.95)
0.038
95% C.I.
4.51, 16.41
−2.18, 0.89
Change in
Mean (SD)
0.22 (3.65)
0.519
−1.43 (1.74)
0.041
Oxygenation
95% C.I.
−0.89, 1.34
−2.04, −0.82
(%)
Blood Lactate
Mean (SD)
1.03 (4.75)
0.241
0.26 (8.17)
0.001
95% C.I.
−0.43, 2.48
−2.24, 2.76
Calculated
Mean (SD)
0.51 (3.31)
0.267
−0.49 (1.84)
0.002
Oxygenation
95% C.I.
−0.50, 1.53
−1.23, 0.25
Fatigue
Mean (SD)
−0.12 (3.29)
0.632
−0.59 (4.79)
0.050
Assessment
95% C.I.
−1.13, 0.89
−2.08, 0.90
[0210] Results:
[0211] The following efficacy outcome measures were defined to assess the effect of consuming the oxygen-enriched water preparations on exercise performance in the subject participants.
[0212] For each parameter, the measurement at each visit was determined as Pl1 (Placebo, first visit), Pl2 (Placebo, visit 2), AGFW1 (Oxygen-enriched water, visit 1), and AGFW2 (oxygen-enriched water, visit 2).
[0213] For each subject, the following variables were calculated:
CHANGE BETWEEN VISIT 2 AMD VISIT 1 FOR PLACEBO:
DPl 2-1 : Pl 2 −Pl 1
CHANGE BETWEEN VISIT 2 AND VISIT 1 FOR OXYGEN-ENRICHED PRODUCT (AGFW):
DAGFW 2-1 : AGFW 2 −AGFW 1
CHANGE BETWEEN AGFW AND PLACEBO:
DAGFW 2-1 −DP 2-1
PERCENT CHANGE BETWEEN AGFW AND PLACEBO:
100%×(DAGFW 2-1 −DPl 2-1 )/DPl 2-1
[0218] The primary outcome variable for the studies was the latter variable that measures the percent difference in the effect between the oxygen-enriched water and the placebo.
[0219] Statistical Methods:
[0220] Given that each subject used both the placebo and the oxygen-enriched preparations, and the fact that the distribution of the study outcomes deviated from normal due to the small sample size, the Kolmogorov-Smirnov paired, non-parametric tests were used to assess the statistical significance of the different water regimens. The null hypothesis tested was the mean change between the oxygen-enriched preparations (AGFW) and the placebo was zero. Two tailed significance testing was used. When the distribution of the variable deviated from the normal, the non-parametric was used.
[0221] Change in Heart Rate:
[0222] At visit one, a significant difference was observed in the heart rate of patients consuming the oxygen-enriched, structured and microstructured water, compared to subjects who consumed conventional tap water. At visit 1, a significant difference was observed in heart rate.
[0223] Heart rate (HR) is proportional to the work rate in physical activities with anaerobic energy supply. The relationship between HR and workload is highly reproducible for any individual (1). The simple way of registering HR has made it the most widely used estimate of metabolic strain in training or competition for many types of exercise (2-4). The measurement of heart rate in this study was based on the change in pulse between the beginning and the end of the exercise test defined as 80% maximum capacity. The reduction of change in heart rate during exercise until fatigue indicates that subjects who consumed the oxygen-enriched water increased their endurance by significantly reducing the increase of pulse by 65%.
[0224] The mean (SD) percent change was 0.65 (4.95), indicating that when subjects consumed the oxygen-enriched water, the change in heart rate during exercise to fatigue was reduced by 65% when compared to placebo.
EXAMPLE 2
Change in Oxygen Saturation
[0225] The present example demonstrates the utility of the present compositions and methods for inhibiting and/or onset of fatigue in a human. The maintenance of oxygen saturation levels (i.e., decreasing the change in oxygen saturation levels attendant exercise) in response to exercise is also demonstrated.
[0226] Oxygen saturation measurements were taken during the exercise periods. The change in oxygen saturation between beginning of the exercise and the end was used for the determination of effect on oxygen saturation.
[0227] When subjects consumed the oxygen-enriched water product, the change in blood oxygen saturation after a period of exercise was significantly less than the dramatic drop in blood oxygen saturation demonstrated after exercise in subjects that consumed the bottled Santa Fe municipal city water (placebo).
[0228] The results show that when the subjects used the oxygen-enriched preparations, the drop in oxygen saturation was less by a factor of 1.5 (150%), in comparison to the drop in oxygen saturation demonstrated in subjects consuming the Santa Fe Municipal City bottled water preparations (placebo). This effect is statistically significant (P=0.041).
EXAMPLE 3
Blood Lactate
[0229] The present example demonstrates the utility of the present compositions and methods for inhibiting and/or reducing the increase in levels of blood lactate attendant exercise in a human. In addition, and because blood lactate level may be directly correlated with lactic acid accumulation in muscle attendant exercise, the present example also demonstrates the utility of the presently described methods and compositions for reducing muscle soreness, and for reducing lactic acid accumulation in muscle as indicated by blood lactate levels. The present study demonstrates that consumption of the defined oxygen enriched preparation significantly inhibited (i.e., reduced) the typical increase in blood lactate levels saturation typically attendant exercise.
[0230] Patients were treated and monitored as outlined in Example 1. Blood lactate levels were obtained from all subjects. The data from these studies is presented in Tables 1, 2 and 3.
[0231] Blood Lactate:
[0232] Blood lactate levels were at least 89.95% lower in subjects consuming the oxygen-enriched water preparations, compared to blood lactate levels in subjects consuming the bottled water preparation (Placebo), after the defined exercise regimen. This difference is statistically significant (P=0.010).
[0233] Lactic Acid:
[0234] Lactate in the blood can be correlated with the accumulation level of lactic acid in muscle tissue; the present data also provides indication that the consumption of the oxygen-enriched water preparations as defined herein can significantly reduce lactic acid accumulation in tissues. It is thus further expected that the use of the oxygen-enriched water preparations as herein defined can significantly reduce the muscle soreness/burning typically attendant periods after extreme exercise.
EXAMPLE 4
Calculated Oxygen Consumption
[0235] The present example is presented to demonstrate the utility of the present methods for reducing and/or inhibiting the significant and sudden increase on oxygen consumption attendant exercise n a human.
[0236] Subjects were treated according to the regimen outlined in Example 1. The oxygen consumption data collected from the subjects that consumed the oxygen-enriched microconstructed water (AGFW) or the bottled spring water (placebo) is presented at Tables 1, 2 and 3.
[0237] The study demonstrated that consumption of the defined oxygen enriched preparation significantly inhibited (i.e., reduced) the characteristic increase in oxygen consumption levels saturation typically attendant exercise.
[0238] Over a period of three days of consumption the oxygen-enriched water preparations, a much more static, conservative and constant amount of oxygen consumption was achieved by the body. This is contrasted by the significant increase in oxygen consumption illustrated by the significant increase in oxygen consumption. Oxygen consumption was reduced by 50%. This change was also statistically significant (P=0.004).
EXAMPLE 5
Enhanced Endurance/Fatigue Onset Assesment
[0239] The present example is presented to demonstrate the utility of the present methods and compositions for reducing and/or inhibiting the onset of fatigue in response to exercise in a human.
[0240] Subjects were treated according t the regimen outlined in Example 1. The fatigue assessment data from the subjects that consumed the oxygen-enriched microstructured water (AGFW) or the bottled Santa Fe Municipal City water (placebo) is presented at Tables 1, 2 and 3.
[0241] The mean standard deviation (SD) percent change was 0.65 (4.95), indicating that when subjects consumed the oxygen enriched preparations, the change in heart rate during exercise to fatigue was reduced by 65% when compared to placebo.
[0242] A statistically significant difference with respect to subjective assessment of fatigue by a factor of 59% in subjects consuming the oxygen-enriched preparations. (P=0.04).
EXAMPLE 6
Increase in Blood Oxygen
[0243] The present example is presented to demonstrate the utility of the present methods and compositions for increasing and/or replenishing available oxygen in the blood stream by consuming the oxygen-enriched microstructured water preparations.
[0244] The present studies were conducted on humans using a medical oximeter. In these studies, it was demonstrated that consumption of the oxygen-enriched, microstructered component containing water compositions of the present invention greatly increased the availability of oxygen in the bloodstream. Using the oximeter, it is shown that a person's blood oxygen levels taken at high altitude (over 5,000 feet) can be increased within two minutes of consuming the enriched oxygen, microstructured water. The overall increase in oxygen in the blood at high altitudes usually increases from three (3) to six (6) points after drinking either ounces of the oxygen enriched, microstructured water. A medical grade oximeter provides an accurate analysis of blood oxygen levels that is not invasive to the patient and that is immediately detectable. The accuracy of the device is +/−2%. The device is slipped over the top of, for example, a finger, and allowed to moniter and take a reading of the patient/subject both before and after consuming the appropriate amount of the oxygen enriched, microstructured water.
[0245] The medical grade oximeter used in the present example demonstrated a measurable increase in the blood hemoglobin levels of the patient. These results demonstrate the utility of using the presently disclosed methods and compositions for the treatment of a variety of conditions associated and/or linked with low blood oxygen, such as altitude sickness. In addition, it is anticipated that the present compositions are also useful as a preferred beverage for consumption by professional athletes and/or those persons involved in any competitive sport, and provide for an enhancement of the persons endurance and performance as a result of the increase in available blood oxygen.
EXAMPLE 7
Bound Oxygen Stability in Open (Non-Pressurerized) Conditions
[0246] The present example demonstrates that the oxygen-enriched preparations herein are capable of retaining a higher concentration and/or amount of oxygen under open-air (i.e., open container) conditions. Absent the microstructured nature of the present preparations, the oxygen concentration would decrease and leak/evaporate away.
[0247] A WTW 300 DO meter was used to test and determine oxygen content and stability in the oxygenated alkaline structured water (this water was 6 months old). The oxygen content was tested at 76 ppm and tested every hour on the hour for three days. The water was placed in a 4 inch open beaker in a warehouse that had no air conditioning. Temperatures ranged from 74° F. at night to 101° F. during the day. Even after agitating the water in the four inch wide beaker every hour after three days, the first hour of the fourth day there was approximately 30 ppm of oxygen in the water. When the water was subsequently boiled, frozen and shaken, the water still was just as effective biologically even though the oxygen was reduced to 30% of its original levels using a DO meter.
[0248] The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the invention. The present teaching can be readily applied to other types of apparatuses. The description of the invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. | A composition includes microstructured water having a lower vapor pressure than that of double distilled water measured under the same conditions. The composition may include dissolved oxygen. The dissolved oxygen may be present in an amount greater than 20 ppm. The microstructured water may have a cluster size of 6-8 molecules, and may have a cluster factor of about at least 30. The composition may include at least one member selected from the group consisting of vitamins, plant extracts, animal extracts, pharmaceutically active agents, flavorants and colorants. | 0 |
RELATED APPLICATIONS
Reference is made to co-pending U.S. application Ser. Nos. 08/672,899 (allowed), 09/130,923, 08/840,159, 09/059,503 and 09/055,709, each of which is hereby incorporated herein by reference; and each and every document cited in those applications, as well as each and every document cited herein, is hereby incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to an interference canceling method and apparatus and, for instance, to an echo canceling method and apparatus which provides echo-canceling in full duplex communication, especially teleconferencing communications.
BACKGROUND OF THE INVENTION
Tele-conferencing plays an extremely important role in communications today. The teleconference, particularly the telephone conference call, has become routine in business, in part because teleconferencing provides a convenient and inexpensive forum by which distant business interests communicate. Internet conferencing, which provides a personal forum by which the speakers can see one another, is enormously popular on the home front, in part because it brings together distant family and friends without the need for expensive travel.
In a teleconferencing system, the sounds present in a room, hereinafter referred to as the "near-end room" such as those of a near-end speaker are received by a microphone, transmitted to a "far end system" and broadcast by a far-end loudspeaker. Similarly, the far-end speaker is received by the far-end microphones and transmitted to the near-end system, and broadcast by the near-end loudspeaker. The near-end microphone receives the broadcasted sounds along with their reverberations and transmits them back to the far-end, together with the desired signals generated by, for example, speakers at the near-end, thereby resulting in a disturbing echo heard by the speaker at the far-end. The far-end speaker will hear himself after the sound has traveled to the near-end system and back, thereby resulting in a delayed echo which will annoy and confuse the far-end speaker. The problem is compounded in video and internet conferencing systems where the delay is more extremely pronounced.
The simplest way to overcome the problem of echo is by blocking the near-end microphone while the far-end signal is broadcast by the near-end loudspeaker. Sometimes referred to as "ducking", the technique of blocking the microphone is effectively a half-duplex communication. Problematically, if the microphone is blocked for a prolonged period to avoid transmission of the reverberations, the half-duplex communication becomes a significant drawback because the far-end speaker will lose too much of the near-end speaker. In the video or Internet conferencing system, where the delay created by the communication lines is extreme, ducking becomes quite annoying.
A more complex method to avoid echo is to employ an echo canceling system which measures the signals send from the far-end and broadcast it the near-end loudspeaker, estimates the resulting signal present at the near-end microphone (including the reverberations) and subtracts those signals representing the echo from the near-end microphone signals. The echo-free signals are then transmitted back to the far-end system.
In order to reduce the echo from the near-end microphone signal, it is required to obtain the transfer function that expresses the relationship between the near-end loudspeaker signal and the reverberations as they actually appear at the near-end microphone. This transfer function depends on the relative position of the near-end loudspeaker to the near-end microphone, the room structure, position of the system and even the presence of people in the room. Since it is impossible to predict these parameters a priori, it is preferred that the echo-canceling system updates the transfer function continuously in real time.
The adaptation process by which the echo-canceling system is updated in real time may be an LMS (least means square) adaptive filter (Widrow, et al., Proc. IEEE, vol. 63, pp. 1692-1716, Proc. IEEE, vol. 55, No. 12, December 1967) with the far-end signal used as the reference signal. The LMS filter estimates the interference elements (echoes) present in the interfered channel by multiplying the reference channel by a filter and subtracting the estimated elements from the interfered signal. The resulting output is used for updating the filter coefficients. The adaptation process will converge when the resulting output energy is at a minimum, leaving an echo-free signal.
Important to the adaptation process is the selection of the size of the adaptation step of the filter coefficients. In the standard LMS algorithm the step size is controlled by a predetermined adaptation coefficient, the level of the reference channel and the output level. In other words, the adaptation process will have bigger steps for strong signals and smaller steps for weaker signals.
A better behaved system is one in which its adaptation steps are independent of the reference channel levels. This is accomplished by normalizing the adaptation coefficient by the reference channel energy, this method is called the Normalized Least Mean Square (NLMS) as, for example, described in see for example "A Family of Normalized LMS Algorithms", Scott C. Douglas, IEEE Signal Processing Letters, Vol. 1, No. 3, March 1994. It should be noted that the energy estimator, if not designed properly, may fail to track when large and fast changes in the level of the reference channel occur. Thus, the normalized coefficient may be too big during the transition period, and the filter coefficient may diverge.
Another problem is that the adaptive process feeds the output back to determine the new filter coefficients. When the interfering elements in the signal are less pronounced than the non-interfering signal, there is not much to reduce and the filter may diverge or converge to a wrong value which results in signal distortions.
When properly converged, the adaptive filter actually estimates the transfer function between the far-end loudspeaker signal and the echo elements in the main channel. However, changes in the room will effect a change in the transfer function and the adaptive process will adapt itself to the new conditions. Sudden or quick changes, in particular, will take the adaptive filter time to adjust for and an echo will be present until the filter adapts itself to the new conditions.
In order to improve the audio quality, sometimes a number of microphones are used instead of a single one. This system either selects a different microphone each time someone is speaking in the room or creates a directional beam using a linear combination of microphones. By multiplexing the microphones or steering the directional audio beam, the relationship between the loudspeaker signal and the audio signal obtained by the microphones can be changed. Problematically, each time such a transition takes place, an echo will "leak" into the system until the new condition has been studied by the adaptive filter. To allow the use of a steerable directional beam and prevent the transient echo, one can either perform continuous echo canceling on each of the microphones separately or on each of the microphone combinations (the combinations of microphones could be infinite). However, the increase in the computation load required to perform numerous echo-canceling systems concurrently on each of the microphones or allowable beams is not realistic.
An efficient echo-canceling system is needed which will reduce the echo drastically. However, because of the large dynamic ranges required by the microphone to be able to pick up very low voices, the microphone will most likely pick up some of the residual echo as well. The residual echo is most disturbing when no other signal is present but less noticed when a full duplex discussion is taking place.
Another problem typical to multi-user conferencing systems is that the background noise from several systems is transmitted to all the participating systems and it is preferred that this noise be reduced to a minimum. The beam forming process reduces the background noise but not enough to account for the plurality of systems.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an interference canceling system.
It is another object of the invention to provide an interference canceling system to cancel interference while providing full duplex communication.
It is yet another object of the invention to provide an interference canceling system to cancel an echo present in a teleconference.
It is still another object of the present invention to provide an interference canceling system to cancel an echo present in video teleconferencing.
It is further an object of the invention to allow a steerable directional audio beam to function with the interference canceling system of the present invention.
It is yet a further object of the invention to overcome background noise in the conferencing system and reduce the residual echo to a minimum.
In accordance with the foregoing objectives, the present invention provides an interference canceling system, method and apparatus for canceling, from a target signal generated from a target source, an interference signal generated by an interference source. A main input inputs the target signal generated by the target source. A reference input inputs the interference signal generated by the interference source. A beam splitter beam-splits the target signal into a plurality of band-limited target signals and beam-splits the interference signal into band-limited interference signals. Preferably, the amount and frequency of band-limited target signals equals the amount and frequency of band-limited interference signals, whereby for each band-limited target signal there is a corresponding band-limited interference signal. An adaptive filter adaptively filters, each band-limited interference signal from each corresponding band-limited target signal.
When the target signal represents speech generated at a near end of a teleconference, the adaptive filter of the present invention cancels an echo present in the reference signal broadcast from a far end of the teleconference. It is preferred that the adaptive filter is an adaptive filter array with each adaptive filter in the array filtering a different frequency band. In the exemplary embodiment the adaptive filter estimates a transfer function of the reference signal broadcast from the far end.
The adaptive filter of the present invention may further comprise an inhibitor. The inhibitor permits the adaptive filter to adapt (change coefficients) when a signal-to-noise ratio of the reference signal exceeds a predetermined threshold over a signal-to-noise ratio of the main signal. Preferably, the inhibitor determines the predetermined threshold periodically.
The beam splitter of the exemplary embodiment of the present invention is a DFT filter bank using single side band modulation. Additionally, the present invention may comprise a beam selector for selecting at least one of a plurality of beams for adaptive filtering by the adaptive filter representing a direction from which the main signal is received. In this case, the adaptive filter updates coefficients representing the transform function and comprehensively stores the coefficients for each beam selected by the beam selector. In the exemplary embodiment, the beam selector selects the plurality of the beams for simultaneous adaptive filtering by the adaptive filter. Further, the beam selector may select a beam having a fixed direction and a beam which rotates in direction.
The present invention may further comprise a noise gate for gating the main signal adaptively filtered by the adaptive filter by opening the noise gate when a signal-to-noise ratio at the near end is above a predetermined threshold and closing the noise gate when the signal-to-noise ratio at the near end is below the predetermined threshold. In this case, the noise gate determines the predetermined threshold by selecting a low threshold when a signal-to-noise ratio of the reference signal of the far end is low, updating the predetermined threshold upwards when the signal-to-noise ratio of the reference signal of the far end goes up and gradually reducing the predetermined threshold when the signal-to-noise ratio of the reference signal of the far end goes down.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention and many of its attendant advantages will be readily obtained by reference to the following detailed description considered in connection with the accompanying drawings, in which:
FIG. 1 illustrates the interference canceling system of the present invention.
FIG. 2 illustrates the beamforming unit of the present invention.
FIG. 3 illustrates the decimation unit of the present invention.
FIG. 4 illustrates the beam splitting unit of the present invention.
FIG. 5 illustrates the adaptive filter of the present invention.
FIG. 6 illustrates the recombining unit of the present invention.
FIG. 7 illustrates the noise gate of the present invention.
DETAILED DESCRIPTION
FIG. 1 illustrates the exemplary echo canceling system of the present invention. An array of microphone elements 102 receive and convert acoustic sound in a room into an analog signal which is amplified by the signal conditioning block 104 and converted into digital form by the A/D converter 106. While FIG. 1 appears to depict the microphone elements 102 as an array, it will be appreciated by those skilled in the art that other configurations are readily applicable to the present invention. The microphone elements, for example, may be arranged in a circular array, a linear, or any other type of array. The A/D converter 106 may be an array of Delta Sigma converters set to, for example, a sampling frequency of 64 KHz per channel but, of course, may be substituted with other types of converters and sampling frequencies which are suitable as those skilled in the art will readily understand.
The sampled signals of each microphone are stored in a tap delay line (not shown) and multiplied by a steering matrix in the beam forming unit 108 to form a number of directional beams. As an example, 6 beams are formed which are aimed in directions evenly spread over 360 degrees (60 degrees apart). Of course, the present invention is not limited to any specific number of beams as one skilled in the art will readily understand. The beam signals are then low pass filtered to, for example, 8 KHz and decimated by decimating unit 110 to reduce the sampling rate and hence the computational load on the system. In this manner, the sampling rate is reduced to 16 KHz for each channel. It shall be appreciated that the decimation process may be performed prior to the beamforming process to further reduce the processing burden.
The system receives an indication as to the direction of the speaker either through a direction finding system or through a manual steering process. In the exemplary embodiment, the beam select logic unit 112 selects the beam with the closest direction to that actual and performs echo cancellation processing on the selected beam.
A particular aspect of the present invention is that the selected beam is split into a number of frequency bands, preferably 16 evenly spaced bands, by the beam splitter 114 such that echo cancellation processing is performed on each frequency band separately. Without this arrangement, an echo which typically lasts for more than 100 msec would require an adaptive filter, assuming that the filter samples the 100 msec of signal at a rate of 16 KHz, to have 1600 coefficients. Such a long adaptive filter is not likely to converge in the time that the echo is present. Moreover, an adaptive filter of 1600 coefficients presents an enormous processing burden which is unrealistic to handle. By splitting the bands into, for example, 16 channels the present invention reduces the sampling rate for each adaptive filter to, in this case, 2 KHz per channel. It will be appreciated that, not only is this system much more manageable, the adaptive filters can be optimized for each frequency separately by, for example, selecting longer filters for lower frequencies where the echo is typically located and shorter filters for higher frequencies where the echo is less. In this case, the filter lengths range, for example, from 16 to 128 coefficients. With this arrangement, the adaptive filters can converge much more easily with these lengths, the treatment of each band is independent from the others thereby preventing the problem of a broadband filter concentrating on a band limited interference while ignoring less pronounced ones and the processing burden is reduced.
Meanwhile, the far end signal (referred to as the reference channel) is conditioned, sampled, decimated and split in the manner discussed above by respective signal conditioning block 122, A/D converters 124, decimating unit 126 and splitter 128. Each band of the selected beam is processed for echo reduction using echo canceling unit 116 1-m . While Normalized LMS filters are preferred, those skilled in the art will readily understand that other type of adaptive filters are applicable to the present invention. The resulting echo-free signals of the different frequency bands are recombined into one broadband output by a recombine output unit 118.
The output of the recombined process is fed into a noise gate processor 120. The purpose of the noise gate is to prevent steady background noise in the room (such as fan noise) from being transmitted to the far end system and eliminate residual echoes. The system of the present invention measures the level of the steady noise and blocks up the signals that are below a certain threshold above this noise level. When residual echoes are present they may penetrate the process and be transmitted to the far end system. In order to prevent that, the blocking threshold is actively adjusted to the level of the signal present at the reference channel (far end). When a high level energy is detected at the far end signal, the threshold will be boosted up and gradually reduced when this signal disappears. This will prevent residual echoes from being transmitted while leaving only speech signals from the near end.
FIG. 2 illustrates the beamforming unit 200 (FIG. 1, 108) of the present invention. Signals originated at a certain relative direction to the microphone array arrive at different phases to each microphone. Summing them up will create a reduced signal depending on the phase shift between the microphones. The reduction goes down to zero when the phases of the microphones are the same, thus creating a preferred direction while reducing all other directions. In the beamforming process, the microphone signals are phase shifted to create a zero phase difference for signals originated at a predetermined direction. The phase shift is achieved by multiplying the microphone signal stored in the tap delay lines 202 1-n by a FIR filter coefficient or steering vector output from steering vector units 204 1-n .
In one embodiment, a different weight is applied for each microphone to create a shading effect and reduce the side lobe level. The weighting factors are implemented as part of the FIR filter coefficients. The filters for each direction and each microphone are pre-designed and stored as a steering vector matrix 204 1-n . The microphone signals are stored in a tapped delay line 2021-n with the length of the FIR filter. For each direction, each microphone delay line is multiplied by multipliers 206 1-n by its FIR and summed with the other microphones after they have been multiplied. The process repeats for each direction resulting in a beam output for each direction.
FIG. 3 illustrates the decimation unit 300 (FIG. 1, 110, 126) of the present invention. Decimation, which is intended to reduce the sampling frequency, can be done only once the high frequency elements are removed to maintain the Nyquist criteria. For example, if the sampling frequency is to be reduced to 16 KHz, it is necessary to make sure that the signal does not contain elements above 8 KHz because sampling will result in aliasing. In order to remove the troublesome high frequencies, the signals are first filtered by a low pass filter that cuts off the higher frequencies. In more detail, the beam samples are stored in a tapped delay line 302 and multiplied via a multiplier 304 by a low pass filter coefficient produced by the low pass filter 306.
FIG. 4 illustrates the beam splitting unit 400 (FIG. 1, 114, 128) of the present invention. Although various beam splitting techniques may be employed, it is preferred that the generalized DFT filter bank using single side band modulation be employed as described, for example, in "Multirate Digital Signal Processing", Ronald E. Crochiere, Prentice Hall Signal Processing Series or "Multirate Digitals Filters, Filter Banks, Polyphase Networks, and Applications A Tutorial", P. P. Vaidyanathan, Proceedings of the IEEE, Vol. 78, No. 1, January 1990. The goal of the beam splitter is to split the input signal into a plurality of limited frequency bands, preferably 16 evenly spaced bands. In essence, the beam splitting processes, for example, 8 input points at a time resulting in 16 output points each representing 1 time domain sample per frequency band. Of course, other quantities of samples may be processed depending upon the processing power of the system as will be appreciated by those skilled in the art.
In more detail, the 8 input points 402 are stored in a 128 tap delay line 404 representing a 128 points input vector which is multiplied via a multiplier 406 by the coefficients a 128 points complex coefficients pre-designed filter 408. The 128 complex points result vector is folded by storing the multiplication result in the 128 points buffer 410 and summing the first 16 points with the second 16 points and so on using a summer 412. The folded result, which is referred to as an aliasing sequence 414, is processed through a 16 points FFT 416. The output of the FFT is multiplied via a multiplier 418 by the modulation coefficients of a 16 points modulation coefficients cyclic buffer 420. The cyclic buffer which contains, for example, 8 groups of 16 coefficients, selects a new group each cycle. The real portion of the multiplication result is stored in the real buffer 422 as the requested 16-point output 424.
FIG. 5 illustrates the adaptive filter 500 (FIG. 1, 116 1-n ) of the present invention. The reference channel that contains the far end signal is stored in a tap delay line 502 and multiplied via a multiplier 504 by a filter 506 to obtain the estimated echo elements present in the beam signal. The estimated interference signal is then subtracted via subtractor 508 from the beam signal to obtain an echo free signal.
The filter 506 is adjusted by the NLMS (Normalized Least Mean Square) processor 510 to estimate the transfer function of the loudspeaker to the beamforming process. In other words, the filter 506 simulates the transform that the far end signal goes through when transmitted by the loudspeaker into the air, bouncing back from the walls, received by the microphones and applied to the beamforming process of the present invention. In order to determine the precise filter coefficients, the system tries to obtain minimum energy at the output by modifying the filter coefficients (W) according to the following formula:
W(n,t+1)=W(n,t)+X(n)*E*A (1)
Wherein, n is the nth coefficient of W, t is time, E is the error signal output and A is a normalized factor that determines the size of the adaptation process. The normalization is obtained by dividing a fixed value (adaptation factor) by P, the reference channel energy. The normalization is intended to prevent fast steps when the signal is strong (i.e., X and E are large) and small steps when weak (i.e., X and E are small) which provides smooth performance over all ranges of signal levels.
When a fast attack in the reference signal appears, such as when an abrupt sound, e.g., speech, noise, is generated at the far end, the energy estimation process may be too slow in reaction resulting in large steps of adaptation and divergence of the filter. To prevent this, the new X*X is compared to the energy estimation calculated by power estimator 512 and if the ratio exceeds a certain threshold (meaning a fast increase in the signal level) the value of X*X replaces the energy estimation.
If the content of the near end signal is much stronger than the content of the far end signal the filter may diverge or converge to wrong values and start distorting the desired signal. It is preferred that the adaptation process will occur when relevant echo signals are present in the beam signal. To determine this, the system calculates the SNR of the far end signal and the SNR of the near end signal using the SNR estimation units 514, 516. If speech is present in the near end signal, the SNR of the beam will be stronger than that of the reference channel. Thus, when the SNR of the reference channel raises up above a predetermined threshold over the near end SNR, the inhibit update logic block 518 immediately allows the LMS coefficient to be updated. Conversely, the inhibit update logic block will allow, for example, 100 msec of adaptation and then inhibit the adaptation when the ratio drops below the threshold. At this point, the coefficients of the adaptive filter of the present invention "freeze" and the filtering will use the latest value of the coefficients. Later, when adaptation is no longer inhibited, the filters are updated from the values at which they were "frozen".
The exemplary embodiment determines the predetermined threshold for the inhibit update logic block 518 in discrete periods. The timing of these discrete periods is determined in part by the hysteresis that differentiates between the reaction time of the attack to that of the decay of the SNR ratios which are obtained through the reaction time of the energy calculation. More specifically, the SNR is computed by dividing two values, the noise level and the signal level. The energy of each block of both the reference and the beam are calculated using a exponential running average of the absolute value of the data. In the exemplary embodiment, the block size is defined as 20 msec of data which is considered to contain the signal level. The present invention searches the lowest energy of a block in the current period, for example, previous 2 sec. Every 2 Sec the system resets and starts recording the value of the block energy and replacing the value when a lower value is calculated. When the current 2 sec time period has elapsed, the calculated noise level is copied and recorded as the current noise level while the system resets the calculation process for the next noise level which will be used for the next 2 sec period.
It will be appreciated from the foregoing description that the present invention stores the values of the coefficients for each frequency band and for each beam direction separately. Once the beam selector 112 selects a new beam, the appropriate values of the beam will be selected. In this way, the system will keep a record of the transfer function between each beam and the beamformer, and the adaptation to the echoes in the new direction will be updated. This process allows the use of directional beamforming while providing a fast adaptation time which obviates the need to perform while the process for either all of the microphones or all the beams.
In another embodiment, which updates the adaptation coefficients even more frequently, the present invention as described is applied on a plurality of beams at a time. For purposes of example, the present invention selects two beams, one which is selectively directed and the other which is actively rotated periodically, for example, every 40 msec. In the alternative, predetermined beams may be selected more often than others. With this arrangement, a different beam will be selected for each block in addition to the main beam and will be processed according to the afore-mentioned adaptation process of the present invention. While this method increases computation load, it ensures that the coefficients in all directions, particularly those predetermined, are updated more frequently.
FIG. 6 illustrates the recombining unit 600 (FIG. 1, 118) of the present invention which is symmetrical, i.e., opposite, to the band splitting technique described above. The goal here is to recombine the 16 limited frequency bands of the echo free signal into one broad band output. The process goes through an IFFT process but both the input and output are time domain signals. The recombining unit of the exemplary embodiment processes 16 input points 602 each representing 1 time domain sample per frequency band resulting in 8 output points 604 of the broadband signal. Of course, those skilled in the art will readily understand that other quantities of sampling input points are applicable to the present invention.
In more detail, the new 16 input points 602 are multiplied by a multiplier 606 with a 16 points demodulation filter coefficient which is stored in a demodulation coefficients cyclic buffer 608 containing, for example, 8 groups of 16 coefficients wherein a new group is selected each cycle. The result is processed through a 16 points IFFT 610, or any equivalent transform, and the result of this Inverse Fast Fourier Transform is extracted to 128 complex points by duplicating the 16 points data 8 times. The 128 points result vector which is stored in a buffer 612 is multiplied via the multiplier 614 by a 128 point complex coefficient generated by a predesigned complex filter 616 and stored in real buffer 618. The real portion of the result is summed by summer 620 into a 128 points cyclic history buffer 622 in which the oldest 8 points are taken as the result 604 and replaced with zeros in the buffer 622 for the next iteration of the recombination process.
FIG. 7 illustrates the noise gate system 700 (FIG. 1, 120) of the present invention. The far end signal-to-noise ratio SNR is calculated by SNR estimation unit 702 which estimates the signal energy of the current block (40 msec in the exemplary embodiment) and divides the signal energy by the lowest estimated block energy in the current period (2 sec in the exemplary embodiment). The threshold is selected by the threshold select depending on the far end signal-to-noise ratio SNR. When the far end SNR is low, a low threshold is selected. Once the SNR of the far end goes up, the threshold is updated immediately upwards by the threshold selection unit 704. When the far end SNR goes down, the threshold is gradually reduced to a minimum with a decay time in the exemplary embodiment around 100 msec.
The near end signal-to-noise ratio SNR is measured by the SNR estimation unit 706 in the same manner. Then, the near end SNR signal is compared by the comparator 708 to the selected threshold. According to the logic provided by the logic circuit 710, if the difference is positive, meaning that the near end signal is present, the gate 712 is open, preferably immediately or quickly (e.g., so as to not miss a syllable, for instance in less than about 10 msec or less such as instantly or nearly instantly). On the other hand, if the result of the comparison is negative, meaning that the near end signal is not above the allowed threshold, the gate is closed and the level of sound is significantly reduced such that the reduced signal is transmitted to the far end system. The reduction of the sound or the closure of the gate is preferably gradual such as over about 100 msec or longer, e.g., over about 0.5 sec or 1.0 sec, so as to prevent a pumping sound or noise transmission when a user is speaking fast and to have the gate truly close when there is a real pause or silence.
It will be appreciated from the foregoing description that the present invention provides an echo-canceling system which overcomes the problem of background noise in the conferencing system, reduces the residual echo to a minimum, allows full duplex communication and provides a steerable directional audio beam.
Although preferred embodiments of the present invention and modifications thereof have been described in detail herein, it is to be understood that this invention is not limited to those precise embodiments and modifications, and that other modifications and variations may be effected by one skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims. | Interference canceling is provided for canceling, from a target signal generated from a target source, an interference signal generated by an interference source. The beam splitter beam-splits the target signal into a plurality of band-limited target signals band-limited frequency bands and beam-splits the interference signal into corresponding band-limited frequency bands. The adaptive filter adaptively filters each band-limited interference signal from each corresponding band-limited target signal. The inhibitor can permit the adaptive filter to adapt or change coefficients when a signal-to-noise ratio of the reference signal exceeds a predetermined threshold, to be determined periodically, over a signal-to-noise ratio of the main signal. The beam selector selects at least one of a plurality of beams for adaptive filtering by the adaptive filter representing a direction from which the main signal is received. The beam selector selects beams simultaneously to improve accuracy and, in particular, selects a beam having a fixed direction and a beam which rotates in direction. The noise gate gates the main signal adaptively filtered by the adaptive filter by opening the noise gate when a signal-to-noise ratio at the near end is above a predetermined threshold and closing the noise gate when the signal-to-noise ratio at the near end is below the predetermined threshold. When the target signal represents speech generated at a near end of a teleconference, the adaptive filter cancels an echo present in the reference signal broadcast to a far end of the teleconference. | 7 |
FIELD OF THE INVENTION
The present invention relates to refractory bearings and is particularly concerned with refractory bearings for use in contact with molten metal.
DESCRIPTION OF THE RELATED ART
Bearings typically support a rotating or otherwise moving article. In high temperature applications, bearings often comprise a refractory metal, ceramic or composite. In such applications, bearings may even be in direct contact with molten metals, such as molten zinc or aluminum.
For example, galvanization is the process of forming a protective, anti-oxidant zinc layer on a base metal. A continuous galvanizing apparatus comprises a bath of molten zinc, a sink roll at least partially immersed in the bath, a journal disposed along the longitudinal axis at each end of the sink roll around which the sink roll may rotate, and a set of roll arms with replaceable bearings for supporting the journals. The bath is maintained at a temperature sufficient to keep the zinc molten.
The sink roll forces the base metal, which is often in the form of a sheet or wire, into the molten zinc. The roll rotates as the base metal passes into the molten zinc, under the sink roll, and finally out of the molten zinc. The journals cooperate and rotate with the sink roll. The roll arms support the journals, and the journals are often covered with a hard material, such as tungsten carbide, to resist wear from the bearing. The roll arm can be moved to adjust the depth of the sink roll within the bath.
The requirements for bearings under these conditions are severe. Molten zinc is at least 420° C., typically around 460° C., and corrodes many common bearing materials. Mechanical abrasion is a ubiquitous complication. The bearings wear quickly and must be replaced frequently. Replacement requires the shutdown of the galvanizing operation while new bearings are inserted. Disruption of a continuous galvanizing operation results in significant operator costs and lost production.
Prior art bearings include metal housings, often in the shape of a ring, that are fitted to the roll arm and cooperate with the journals. During operation of a galvanizing bath, the journals contact a working face of the bearing. The high temperature and corrosive environment destroy metal bearings relatively quickly and cause the sink roll to rotate eccentrically, thereby reducing galvanizing efficiency. Worn bearings must be replaced, often at great cost. Prior art also includes metal housings having inserts comprising a refractory material selected for its erosion and corrosion resistance. The journals contact the inserts instead of the metal housing. The inserts are substantially more resistant to wear and corrosion than the metal housing alone and can extend the life of bearings many times.
Sialon is particularly useful in this capacity and consists of a solid solution and/or dispersion of aluminum oxide and aluminum nitride in a silicon nitride matrix. One or more sialon inserts are embedded into the working face of the metal housing. Typically, the inserts are polygonal shapes and are embedded in a plurality of cavities along the working face of the metal housing.
At room temperature, the inserts are secured tightly into the cavities. This may be accomplished using a retaining plate and one or more wedges to improve the tightness of fit. The retaining plate can be welded to the housing and may extend at least partially over the insert in the cavity. Still, inserts have a tendency to fall out at operating temperatures because the thermal expansion of the metal housing is greater than the ceramic inserts. Loss of an insert causes the journal to wobble or otherwise rotate eccentrically. Fortunately, the journals pressing against the inserts can hold the inserts in the cavities despite thermal expansion; however, pressure can be lost when the galvanizing operation is stopped or slowed. In such situations, the journal may separate from the insert by one-quarter inch or more. An insert can then slip from its cavity. The tendency of a ceramic insert to loosen and fall from a metal cavity increases with temperature and would be even more likely at higher temperatures, such as with molten aluminum baths which are typically at least around 700° C. and more commonly around 715° C.
A need persists for a refractory bearing comprising a housing and a wear-resistant insert where the insert is more fixedly secured to the housing and does not depend on the journals to hold it in place. Advantageously, the bearing would be easily manufactured of substantially inexpensive materials and would be suitable for use with molten zinc and aluminum.
SUMMARY OF THE INVENTION
The objective of the present invention is to provide a bearing for high temperature applications, particularly for contact with molten metals. The invention secures a wear-resistant insert to the working surface of the bearing despite disparate dimensional changes caused by thermal expansion.
One aspect of the invention describes the bearing as comprising a housing having a wear-resistant insert at least partially embedded in a cavity of a working surface of the housing. A retainer is secured to the housing and simultaneously engages a relief in the insert, thereby locking the insert into the cavity.
A further aspect of the invention describes the housing as a metal ring adapted to receive a journal. The inner surface of the ring comprises the working surface, which includes a plurality of inserts axially arranged along the working surface. One embodiment of the invention includes a metal ring having three inserts along the working surface.
Another aspect of the invention teaches inserts comprising sialon. In a further aspect of the invention, the retainer may comprise one or more metal pieces and is conveniently welded to a metal housing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a portion of a galvanizing apparatus, including sink roll and roll arms with bearings.
FIG. 2 a shows a metal ring bearing of the prior art.
FIG. 2 b is a cross-section of a prior art bearing.
FIG. 2 c is a cross-section detail of a prior art bearing.
FIG. 3 a shows a metal ring bearing of the present invention.
FIG. 3 b is a cross-section of the present invention.
FIG. 3 c is a cross-section detail of the present invention.
FIG. 4 is a side view of a metal ring bearing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Refractory bearings of the present invention can be used in many high-temperature applications, including continuous galvanizing operations in which a sheet or wire of a base metal is drawn through a bath of molten zinc to effect a zinc coating on the surface of the base metal. FIG. 1 shows a portion of a continuous galvanizing unit that uses refractory bearings.
A sink roll 11 forces the base metal into the bath of molten zinc (not shown). The sink roll 11 is at least partially immersed in the molten zinc and is supported by journals 14 extending along the rolling axis of the sink roll 11 . Roll arms 12 engage the journals 14 . Manipulation of the roll arms 12 permits the sink roll 11 to be raised or lowered within the bath. Bearings 13 facilitate rotation of the journals 14 and the sink roll 11 . The journals 14 often has a sleeve 15 to reduce wear of the journal 14 by the bearings 13 . The sleeve 15 can be any wear-resistant, refractory material, and is often a tungsten carbide cermet overlaid on a stainless steel substrate.
A refractory bearing often comprises a housing having a working surface with at least one cavity containing a wear-resistant insert. Depending on its intended use, a housing can be formed from a variety of refractory materials, including metal, ceramic and composites. Galvanizing bearings typically comprise metal housings. FIG. 2 a shows a prior art bearing for a continuous galvanizing unit. The bearing 13 comprises an annular housing 26 adapted to cooperate with a journal along the bearing's inner surface 25 . A plurality of wear-resistant inserts 21 are secured within cavities along the inner surface 25 . The inserts 21 extend beyond the inner surface 25 . Inserts 21 are wear-resistant, refractory materials such as, for example, alumina, silica, magnesia, zirconia and combinations thereof. Sialon is particularly useful because of its resistance to corrosion, mechanical wear and thermal shock.
FIG. 2 b shows a cross-section of the bearing. The insert 21 sits in a cavity of the housing 26 . In this embodiment, the insert extends from a first annular surface 27 to a second annular surface 28 . The retainer assemblages 22 are fixedly secured to the housing 26 and prevent the insert 21 from leaving the cavity along a path perpendicular to the annular surfaces. FIG. 2 c details one method of securing the retainer assemblage 22 to the housing 26 with a weld 23 . Other mechanical fasteners, such as bolts, rivets, screws, etc., or adhesive fasteners, such as a high temperature phenolic, could alternatively be used to secure the retainer to the housing. Obviously, the retainer assemblage could also be secured to the housing indirectly.
Wedges (not shown) may be used to improve the tightness of fit between the cavity, insert and retainer assemblage. Improved tightness can reduce the tendency of inserts to fall out of the cavity. Wedges include any article that may be used to improve the tightness of fit and comprise, for example, wedges, shims, and the like.
The present invention improves on the retention of the insert within the cavity. FIG. 3 a shows a bearing 13 with a housing 26 . A cross-section of the bearing 13 , as seen in FIG. 3 b , shows an insert 21 having a relief 35 . The insert 21 will commonly include more than one relief 35 depending on factors such as geometry, operating temperature and the particular materials in the bearing. FIG. 3 b shows two reliefs 35 , one on each end of the insert 21 .
The retainer assemblage 22 comprises two non-planar portions. An end plate 32 a is fixedly secured to the housing 26 . A retainer 32 b fits in a mating relationship with the relief 35 of the insert 21 , thereby locking the insert 21 in the cavity and reducing the likelihood that the insert 21 will fall out. Conveniently, for ease of manufacture, the relief 35 and the retainer 32 b are mirror images.
FIG. 3 c shows detail of the retainer assemblage 22 , insert 21 and housing 26 . The retainer 32 b mates with the relief 35 of the insert. The retainer 32 b is attached to the end plate 32 a , for example, with a weld 34 . The end plate 32 a is fixedly secured to the housing 26 , such as with a weld 23 . End plates and retainers are preferably comprised of steel and are typically about one to two inches wide. The retainer should be at least about 0.12 inch thick in order to provide a sufficient relief that would secure the insert in the cavity. The required thickness will vary depending on the material used to make the retainer, the operating temperature, the size of the retainer, operating stresses, etc. Preferably, a gap will exist between the relief and retainer. The gap allows for manufacturing variations and thermal expansion. For example, when the retainer is steel, the insert is sialon, and the application is galvanization, a gap of 0.005 inch is normally sufficient.
The relief on the insert is conveniently a rabbet to simplify manufacture. A matching rabbet on the retainer completes the joint. Alternatively, other joint constructions could be used including slanted or dovetail designs. Such joints are known to one skilled in the art. For example, the cavity could have inwardly sloping sides forming a dovetail groove. Such sides would comprise the retainer. The retainer may be an integral part of the housing, as in the dovetail design, or it may be separate, as is shown in the figures. The insert would have a relief comprising sloped sides that cooperate with the dovetail groove. The insert would be placed into the groove and an end plate would close the cavity opening, thereby preventing the insert from escaping. Importantly, the cavity and the retainer cooperate to product a mechanical interlock that cooperates with the relief of the insert to secure the insert in the cavity.
Although the retainer assemblage should be a rigid unit, it may comprise one or more pieces. The retainer assemblage may be machined from a single piece of refractory material or comprise a plurality of pieces. FIG. 3 c shows a retainer assemblage consisting of two pieces, an end plate 32 a comprising a plate and a retainer 32 b also comprising a plate. The two portions are secured together with a joining weld 34 .
The bearing may comprise one or more wear-resistant inserts. Ring-shaped bearings for use with a journal will often have three bearings. FIG. 4 shows a ring-shaped bearing 13 adapted for use with a journal and an arrow 44 representing the direction of rotation of the journal. In such a configuration, a load insert 42 supports the force exerted by the journal on the bearing 13 . A lead insert 41 wipes dross from the journal so wear of the load insert 42 is reduced. Dross includes solidified metal, slag, dirt and other impurities found in the molten metal. A trailing insert 43 stabilizes the journal in the bearing 13 . Point loading on a single insert and a three-insert arrangement typically perform better than a single insert in the shape of an arc. The three inserts are frequently arranged in an arc of less than 180°, and preferably around 90°.
Obviously, numerous modifications and variations of the present invention are possible. It is, therefore, to be understood that within the scope of the following claims, the invention may be practiced otherwise than as specifically described. | The invention relates to a refractory bearing and in particular to a bearing for use in contact with molten metal, such as zinc and aluminum. The bearing includes a housing with a working surface and at least one wear-resistant insert secured to the working surface. The insert is secured to the housing by mechanically interlocking with a retainer assemblage. In one embodiment, the retainer assemblage engages a relief in the insert to secure the insert to the housing despite dimensional changes caused by thermal expansion. The insert preferably comprises sialon. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Application No. 2006-103613, filed on Oct. 24, 2006, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Aspects of the present invention relate to a fuel processor of a fuel cell system, and more particularly, to a reformer included in a fuel processor, and a method of controlling the same.
[0004] 2. Description of the Related Art
[0005] A fuel cell is a generator of electricity that changes the chemical energy of a fuel into electrical energy, through a chemical reaction. A fuel cell can continuously generate electricity as long as the fuel is supplied. Fuel cell systems can be broadly divided into fuel cell systems that use liquid hydrogen, and fuel cell systems that use hydrogen gas. The fuel cell systems that use hydrogen gas include fuel cell stacks and fuel processors. The fuel cell stacks have a structure in which a few to a few tens of unit cells, each including a membrane electrode assembly (MEA), and a separator, are stacked.
[0006] FIG. 1 is a schematic diagram showing a configuration of a conventional fuel cell system.
[0007] Referring to FIG. 1 , a fuel, that includes hydrogen atoms, is reformed into hydrogen gas in a fuel processor, and the hydrogen gas is supplied to a fuel cell stack. In the fuel cell stack, the hydrogen gas is electrochemically reacted with oxygen to generate electrical energy.
[0008] The fuel processor includes a desulfurizer and a hydrogen generation apparatus. The hydrogen generation apparatus includes a reformer and a shift reactor. The desulfurizer removes sulfur from the fuel so that catalysts, in the reformer and the shift reactor, are not poisoned by sulfur compounds.
[0009] Hydrogen gas is generated from the hydrocarbons in the reformer, but in addition to the hydrogen gas, carbon dioxide (CO 2 ) and carbon monoxide (CO), are also produced. However, CO acts as a poison to the catalysts used on electrodes of the fuel cell stack. Therefore, the hydrogen gas generated in the reformer is not directly supplied to the fuel cell stack, but rather is supplied after the CO is removed by the shift reactor. Conventionally, the hydrogen gas that has passed through the shift reactor has a CO content of 10 ppm or less.
[0010] FIG. 2 is a cross-sectional view illustrating a conventional reformer. FIG. 3 is a graph showing the temperature distribution in the reformer of FIG. 2 , at different locations of a reforming catalyst. In FIG. 3 , the temperature distributions in the reformer are compared at different positions, in a combustion chamber thereof, when loads of 100% and 25% are applied to a burner.
[0011] Referring to FIG. 2 , a conventional reformer 10 includes a burner 15 that can eject one large flame 25 into a combustion chamber 11 , which is disposed inside a pipe-shaped reforming catalyst 20 . When a combustion fuel, composed of methane CH 4 and air, is ignited by ejecting the combustion fuel into the combustion chamber 11 , via the burner 15 , the combustion fuel is combusted, and a flame 25 is generated, heating the reforming catalyst 20 . Thus, a hydrogen generation reaction occurs in the reforming catalyst 20 .
[0012] A fuel cell system may operate at 100% of a designed power production capacity (load), or may operate at less than 100% of the designed capacity, according to power consumption of electrical equipment electrically connected to the fuel cell system. When the fuel cell system is operated with a load that is less than 100% of the designed capacity, the burner 15 of the reformer 10 is also operated at a reduced load. More specifically, the loads to the burner 15 , and the reformer 10 , are proportional to the load to the fuel cell system 100 as a whole.
[0013] Referring to FIG. 3 , different portions H, of the reforming catalyst 20 , in the reformer 10 of FIG. 2 , have different temperatures. More specifically, a central portion B, of the reforming catalyst 20 , which is closer to the flame 25 , has a relatively high temperature, and a lower and upper portions A and C of the reforming catalyst 20 , which are relatively farther from the flame 25 , have relatively lower temperatures. Also, the size of the flame 25 is larger when a load to the burner 15 is 100%, than when the load to the burner 15 is 25%. Thus, the overall temperature of the reforming catalyst 20 , when a load to the burner 15 is 100%, is higher than when the load to the burner 15 is 25%.
[0014] The hydrogen generation reaction, on the reforming catalyst 20 , is an endothermic reaction, and the hydrogen generation reaction is conducted at a temperature of approximately 700° C., or more. In the reformer 10 , there are large temperature differences, according to the height of the reforming catalyst 20 . The temperature of the central portion B can be maintained at 700° C., or more, regardless of the load to the burner 15 , but it is difficult to maintain the temperatures of the lower and upper portions A and C at 700° C., or more. In particular, it is particularly difficult to maintain the temperature of 700° C. at the lower and upper portions A and C, when the load to the burner 15 is small. Accordingly, there is a problem that, although the reforming catalysts at the lower and upper portions A and C, of the reforming catalyst 20 , are not completely consumed, all of the reforming catalyst 20 must be replaced, due to the exhaustion of the reforming catalysts in the central portion B.
SUMMARY OF THE INVENTION
[0015] Aspects of the present invention provide a reformer in which all portions of a reforming catalyst can be heated to a uniform temperature.
[0016] Aspects of the present invention also provide a reformer in which a flame can be ejected to all portions of a reforming catalyst, regardless of the load on a corresponding burner.
[0017] According to an aspect of the present invention, there is provided a reformer comprising: a reforming catalyst having a cylindrical shape; a burner comprising nozzles, which is disposed in the reformer inside of the reforming catalyst; a nozzle covering element to control the flow of a combustion fuel through the nozzles; a combustion fuel supply element that changes the amount of combustion fuel supplied to the burner; and a controller that controls the nozzle covering element, to change the degree of opening of the nozzles in connection with the amount of the combustion fuel supplied to the burner. The nozzles are disposed on an outer surface of the burner and face the reforming catalyst, and are to make flames by directing the ejection of the ignited combustion fuel towards the reforming catalyst.
[0018] The nozzle covering element may comprise a cam comprising: a central part that extends in a lengthwise direction along the length of burner, and can be rotated inside of the burner; and a plurality of covering units, attached to the central part, that each correspond to a single nozzle, and change the size of the respective openings to the nozzles, according to a rotation angle of the central part. The nozzles may have oval-shaped openings.
[0019] An inner surface of the reforming catalyst may face the plurality of nozzles. The controller may control the position of the covering units, so that flames, formed by ejecting the combustion fuel from the nozzles, reach the reforming catalyst, regardless of variations in the supply of the combustion fuel to the burner, so long as a minimum amount of combustion fuel is supplied to the burner.
[0020] The controller may control the position of the covering units so that the hottest portions of the flames, formed by ejecting the combustion fuel from the nozzles, reach the reforming catalyst.
[0021] The controller may control the position of the covering units so that the portion of each nozzle that is covered is decreased, when the amount of the combustion fuel supplied to the burner is increased, and the portion of each nozzle that is covered is increased, when the amount of the combustion fuel supplied to the burner is decreased.
[0022] According to an aspect of the present invention, there is provided a method of controlling a reformer that comprises a reforming catalyst having a cylindrical shape, and a burner which is disposed on the inside of the reforming catalyst, and comprises a plurality of nozzles on an outer surface thereof, facing the reforming catalyst. The method comprising: covering a smaller portion of each of the nozzles, when the amount of the combustion fuel supplied to the burner is increased; and covering a larger portion of each of the nozzles, when the amount of the combustion fuel supplied to the burner is reduced.
[0023] The portion of each of the nozzles that is covered may be controlled so that flames, formed by ejecting the combustion fuel from the nozzles, reach the reforming catalyst, regardless of the amount of the combustion fuel supplied to the burner, so long that a minimum amount of combustion fuel is supplied to the burner.
[0024] The degree of covering of the nozzles may be controlled so that the hottest portions of the flames, formed by ejecting the combustion fuel from the nozzles, reach the reforming catalyst.
[0025] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] 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:
[0027] FIG. 1 is a schematic diagram showing a configuration of a conventional fuel cell system;
[0028] FIG. 2 is a cross-sectional view illustrating a conventional reformer;
[0029] FIG. 3 is a graph showing the comparison of temperature distribution in the reformer of FIG. 2 , according to height of a reforming catalyst, when loads of 100% and 25% are applied to a burner;
[0030] FIG. 4 is a partial cutaway perspective view of a reformer, according to an embodiment of the present invention;
[0031] FIG. 5 is a vertical cross-sectional view of the reformer of FIG. 4 ;
[0032] FIGS. 6 and 7 respectively are horizontal cross-sectional views of the reformer of FIG. 4 , when loads of 100% and 50% are applied to the reformer; and
[0033] FIGS. 8 and 9 are views of outer surfaces of the burner showing the openings of nozzles, and the relative position of covering units depicted by virtual (dashed) lines, FIG. 8 showing when a load of 100% is applied to the reformer, and FIG. 9 showing when a load of 50% is applied to the reformer.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0034] Reference will now be made in detail to the present 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 in order to explain the present invention by referring to the figures.
[0035] FIG. 4 is a partial cutaway perspective view of a reformer 100 according to an embodiment of the present invention. FIG. 5 is a vertical cross-sectional view of the reformer 100 of FIG. 4 .
[0036] Referring to FIGS. 4 and 5 , the reformer 100 includes a cylindrically shaped reforming catalyst 101 and a cylindrically shaped burner 105 . The reforming catalyst 101 is disposed inside the reformer 100 , and the burner 105 is disposed inside of the reforming catalyst 101 . The reformer has a first end shown at the top of FIG. 5 , and a second end shown at the bottom of FIG. 5 .
[0037] A plurality of nozzles 107 are disposed on the outer surface of the burner 105 . The nozzles 107 are to make flames 150 by directing a combustion fuel towards the reforming catalyst 101 . The nozzles 107 are uniformly distributed on the outer surface of the burner 105 , so that the entire inner surface of the reforming catalyst 101 can face the plurality of nozzles 107 . Accordingly, the flames 150 can be uniformly formed to point towards the entire inner surface of the reforming catalyst 101 . As depicted in FIGS. 8 and 9 , each nozzle 107 has an oval shaped opening.
[0038] The reformer 100 includes a cam 110 , and a motor 125 to drive the cam 110 . The cam 110 is a nozzle covering element that can control the degree of opening of the nozzles 107 . The cam 110 is installed inside of the burner 105 , and includes: a central part 111 , extending in a lengthwise direction, with respect to the length of the burner 105 ; a plurality of covering units 113 which extend in a radial direction towards the inner surface of the burner 105 , with each covering unit 113 corresponding to a single nozzle 107 ; and a shaft 115 that is connected to a second end of the central part 111 , and extends out of the burner 105 . The shaft 115 transmits a rotational force from the motor 125 , to the central part 111 , to rotate the cam 110 .
[0039] The central part 111 can rotate around a central axis CL, of the central part 111 , which extends along the length of the burner 105 . The rotation can be driven by the motor 125 . The covering units 113 can control the degree of covering of the nozzles 107 , according to the amount of rotation of the central part 111 . That is, the covering units 113 can be positioned to not cover any part of the openings of the nozzles 107 , to leave the nozzles 107 entirely open as depicted in FIGS. 6 and 8 , or can be positioned to cover a portion of the openings of the nozzles 107 , as depicted in FIGS. 7 and 9 . In FIG. 9 , shaded regions indicate the regions of the openings of the nozzles 107 that are covered by the covering units 113 . The covering unit 113 is formed so that an end of the covering unit 113 , that contacts the inner surface of the burner 105 , has a concave portion 113 a . The concave portion 113 a has a shape corresponding to a side of the oval opening of the nozzle 107 . Accordingly, as depicted in FIG. 9 , when the openings of the nozzles 107 are partly covered, the uncovered portion of the openings forms a circle, or an oval with a smooth surface, thereby smoothly directing the fuel to make flames 150 . The phrases “covering the nozzles”, and “covering the openings of the nozzles”, and variations thereof, are used interchangeably herein, and refer to the same activity.
[0040] The reformer 100 includes a combustion fuel supply tube 130 connected to the second end of the burner 105 , and a combustion fuel supply valve 132 located in the combustion fuel supply tube 130 , to control the supply of a combustion fuel composed of methane CH 4 and air, to the burner 105 . The combustion fuel supply valve 132 controls the amount of fuel supplied to the inside of the burner 105 , by controlling the amount to which the combustion fuel supply tube 130 is opened.
[0041] The reformer 100 further includes a controller 140 that controls the motor 125 so that the covered portion of the nozzles 107 can be changed in connection with the amount of the combustion fuel supplied to the inside of the burner 105 . The controller 140 is connected to the combustion fuel supply valve 132 , and the motor 125 . The controller 140 is to control the rotation of the cam 110 , to change the amount of covering of the nozzles 107 , by controlling the rotation of the motor 125 , through a motor driving signal. Also, the controller 140 controls the fuel supply valve 132 , to control the amount of combustion fuel that is supplied to the burner 105 , by sending a valve driving signal to the combustion fuel supply valve 132 .
[0042] A hydrogen guide 120 to convey hydrogen H 2 , obtained from a power generation fuel, out of the first end of the reformer 100 , is formed outside of the reforming catalyst 101 . An exhaust gas path 122 provides a fluid communication between the burner 105 and the reforming catalyst 101 .
[0043] When the nozzles 107 are completely uncovered, a combustion fuel is supplied to the inside of the burner 105 , via the combustion fuel supply valve 132 . The combustion fuel is directed towards the reforming catalyst 101 by the nozzles 107 . At this point, the combustion fuel is ignited, and the flames 150 heat the reforming catalyst 101 . When the entire reforming catalyst 101 is heated to a temperature of 700° C., or more, a power generation fuel, that contains methane gas CH 4 and steam H 2 O, is supplied to the reforming catalyst 101 . Hydrogen H 2 , a small amount of carbon monoxide CO, and other gases are produced by a reforming reaction in the reforming catalyst 101 . The produced gas, that contains hydrogen H 2 , is discharged out of the first end of the reformer 100 , and can be supplied to a shift reactor (refer to FIG. 1 ) via the hydrogen guide 120 . Exhaust gas produced from the combustion is discharged from the reformer 100 via the exhaust gas path 122 .
[0044] A method of controlling the reformer 100 will now be described with reference to FIGS. 5 through 9 .
[0045] FIGS. 6 and 7 are horizontal cross-sectional views of the reformer 100 of FIG. 4 . FIG. 6 shows when a load of 100% is applied to the reformer 100 , and FIG. 7 shows when a load of 50% is applied to the reformer 100 . FIGS. 8 and 9 are views of the outer surfaces of a portion of the burner 105 , and show the openings of the nozzles, and the relative position of the covering units 113 depicted by virtual (dashed) lines. FIG. 8 shows when a load of 100% is applied to the reformer 100 , and FIG. 9 shows when a load of 50% is applied to the reformer 100 .
[0046] Referring to FIGS. 5 , 6 , and 8 , in order to operate the burner 105 at a 100% load, the controller 140 applies an appropriate valve driving signal to the combustion fuel supply valve 132 , so that the combustion fuel supply valve 132 opens completely. Also, the controller 140 applies an appropriate motor driving signal to the motor 125 , so that the openings of the nozzles 107 are completely uncovered. As depicted in FIGS. 6 and 8 , a large amount of combustion fuel is rapidly ejected through the completely uncovered nozzles 107 . When the combustion fuel ejected from the nozzles 107 is ignited, large flames 150 a reach the reforming catalyst 101 . The flames 150 a heat the reforming catalyst 101 while touching the reforming catalyst 101 , thereby increasing heating efficiency. Also, as described above, the plurality of nozzles 107 can be used to evenly heat the entire reforming catalyst 101 . The entire reforming catalyst 101 can be uniformly utilized, preventing the waste inherent with the localized utilization of the reforming catalyst 101 .
[0047] The flame 150 a can be divided into an external (oxidizing) flame 152 a , and an inner (reducing) flame 151 a . The tip of the inner flame 151 a maintains higher temperature than the external flame 152 a . In the present embodiment, a combustion fuel supply pressure and a distance between the nozzle 107 , and the reforming catalyst 101 , are determined so that the tip of the inner flame 151 a can reach the reforming catalyst 101 . Therefore, the heating efficiency of the reforming catalyst 101 is higher than when only the external flame 152 a reaches the reforming catalyst 101 .
[0048] Referring to FIGS. 5 , 7 , and 9 , in order to operate the burner 105 with a 50% load, the controller 140 partly closes the combustion fuel supply tube 130 , using the combustion fuel supply valve 132 . As a result, the supply of the combustion fuel to the inside of the burner 105 is reduced, as compared to the 100% load. Also, the controller 140 triggers the rotation the cam 110 , so that the openings of the nozzles 107 are partly covered by the covering units 113 . At this point, the amount of the combustion fuel supplied to the inner space of the burner 105 is reduced, as compared to the 100% load. However, the flow speed of the combustion fuel ejected from the nozzles 107 is not reduced, since the openings of the nozzles 107 are partially covered. When the combustion fuel ejected in this way is ignited, small flames 150 b , that are smaller than the large flames 150 a (see FIG. 6 ), made when 100% load is applied to the burner, reach the reforming catalyst 101 . The small flames 150 b have an inner flame 151 b and an outer flame 152 b . The controller 140 may control the flow rate of the combustion fuel to the burner 105 , and the degree of covering of the nozzles 107 , so that the tips of the inner flames 151 b can reach the reforming catalyst 101 , in addition to the outer flames 152 b.
[0049] The method of controlling the reformer 100 has been described by comparing cases when the loads to the burner 105 are 100% and 50%. When a load to the burner 105 is 75% and 25%, the reformer 100 can also be operated so that the flames 150 can reach the reforming catalyst 101 , and thereby directly heat the reforming catalyst 101 . The controller 140 can appropriately control the flow rate of the combustion fuel to the burner 105 , and the degree of covering of the nozzles 107 . For example, in order to switch the burner 105 from operating at the 50% load from the 100% load, the supply of the combustion fuel to the burner 105 is reduced, and the openings of the nozzles 107 are partly covered, as depicted in FIG. 9 . Also, in order to switch the burner 105 to operating at a 75%, load from operating at the 50% load, the supply of the combustion fuel to the burner 105 is increased, and the openings of the nozzles are partially uncovered. The supply of fuel for operating at a 75% load is larger than the supply for operating at the 50% load, and the openings of the nozzles 107 are less covered. For example, the openings at the 75% load are less covered that the openings as depicted in FIG. 9 and move covered than the openings depicted in FIG. 8 .
[0050] In a reformer according to aspects of the present invention, flames formed by ejecting a combustion fuel from nozzles directly heat a reforming catalyst. The size of the openings to the nozzles can be adjusted, to compensate for variations in the amount of fuel supplied to the nozzles, such that the flames always reach the reforming catalyst. The openings to the nozzles are adjusted by covering a portion of the nozzles. When the fuel supply to the nozzles is decreased, a larger portion of each of the nozzles is covered. When the supply of fuel to the nozzles in increased, a smaller portion of each of the nozzles is covered. Accordingly, the heating efficiency of the reforming catalyst can be increased, and an early replacement of the reforming catalyst, due to a localized consumption of the reforming catalyst, can thereby be prevented. This results in a more effective use of all of the reforming catalyst.
[0051] 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 this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | A reformer for a fuel cell system, and a method of controlling the reformer. The reformer includes a cylindrical reforming catalyst; a burner disposed inside of the reforming catalyst and comprising a plurality of nozzles to direct flames at the reforming catalyst; a nozzle covering element to selectively cover a portion of each of the nozzles; a combustion fuel supply valve to change the amount of a combustion fuel that is supplied to the burner; and a controller that controls the nozzle covering units and the combustion supply valve. The method of controlling the reformer includes: moving the nozzle covering element to cover a decreasing portion of each of the nozzles in response to an increasing amount of the combustion fuel being supplied to the burner; and moving the nozzle covering element to cover a increasing portion of each of the nozzles in response to a decreasing amount of the combustion fuel supplied to the burner. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to providing a power source for an inductive loopset. More particularly, this invention relates to providing operating power to an inductive loopset using battery power provided by a wireless phone.
2. Description of Related Art
Telecoil (T-coil) hearing aid users commonly experience interference from the high-frequency electromagnetic signal emitted by wireless phones when the phone is placed in close proximity to the t-coil. The interference—a “buzz” or “hum” in the hearing aid—makes the use of wireless phone handsets difficult. To assist these users, audio induction systems were created. Audio induction systems operate using the principles of electro-magnetics. When an electrical current is amplified and passed through a wire loop, an electromagnetic field is generated around the wire that varies in direct proportion to the amplitude and frequency of the signal. If another wire (or wire loop) is placed in proximity to this field, an identical current will be passed (induced) to the wire. Finally, the current representative of the original audio signal is amplified for hearing.
Personal loopsets were created to apply the audio induction principle to wireless devices so that the wireless phone could be used with t-coil hearing aids. As shown in FIG. 1 , the coil 40 of loopset 5 is worn around the user's neck. The coil 40 is coupled to an impedence-matching device 33 inside the housing 30 . The impedance-matching device 33 receives a voice signal from the wireless phone 10 , transmits the corresponding electromagnetic field to the coil 40 , and ultimately to a hearing aid placed in proximity to the coil 40 .
Current designs of loopsets use small cell batteries to power the electronics of the loopset. As shown FIG. 2 , the battery 34 provides operating power to the loopset 5 when the terminal 41 has been inserted into the jack 42 . The insertion of the terminal 41 completes an electrical path, which allows the loopset 5 to produce an induction current.
The current designs have inherent problems that, if removed, would make major strides in the loopset technology. First, in order for the loopset 5 to operate, the terminal 41 must be plugged into the jack 42 . Using this approach, a hearing impaired user is almost forced to constantly wear the loopset to hear an incoming call to the wireless phone 10 . This means that the coil 40 is constantly emitting an electromagnetic magnetic field if the loopset is being worn and the battery power is constantly being depleted. This leads to inconvenience and a short battery life. Thus, a user is forced to replace the battery often. However, if a user decides to keep the loopset in a pocket or a bag, to conserve battery power, a user must fumble to put the loopset on if a call is received while the loopset is not being worn.
Thus, the inventors have discerned that there is a need to address the above-mentioned problems by providing a loopset that is more user friendly than current configurations and overcomes the problems identified above.
SUMMARY OF THE INVENTION
As outlined above, conventional loopsets are limited in their user friendliness. Thus, it is an object of the present invention to provide a user-friendly loopset for the hearing impaired by powering the loopset using a readily available power source without causing significant reduction in the life of the power source.
This invention provides an induction-type loopset for the hearing impaired configured to connect to a wireless device. The loopset comprises a first coil configured to be electromagnetically coupled to a t-coil hearing aid and an impedance-matching device coupled to the first coil. The impedance-matching device is responsive to an audio signal from a wireless device and the induction-type loopset is selectively powered from the power source of the wireless device.
This invention also provides a power source for the wireless device that selectively supplies power to the loopset in response to an activation state of the wireless device.
This invention separately provides a method for selectively supplying power to an induction-type loopset for the hearing impaired by connecting a wireless device to the loopset and selectively supplying power to the loopset from the wireless device depending on an activation state of the wireless device. The method further provides a method for detecting a change in the activation state of the wireless device and controlling a switch based on the detecting step.
Thus, this invention provides systems and methods for powering a loopset from the power source of a wireless phone. The systems and methods of this invention take advantage of many of the features already present in wireless phone configurations. Examples of such features include battery cycle down modes and “sleep” modes of the attached wireless phone.
In the various exemplary embodiments according to this invention, power provided to the loopset is controlled by the microcontroller in the wireless phone. This method allows the loopset to take advantage of automatic power-down and battery save features provided in the wireless phone. In addition, by using the microcontroller within the wireless phone, the configuration of the loopset is simplified.
In the various exemplary embodiments according to this invention, a switch controlling power to the loopset is activated and switched using signals from the microcontroller of the wireless phone. The pattern of control of the loopset is essentially the same as the pattern of the operating modes in the wireless phone. For example, when the wireless phone is in a standby mode, no power is provided to the loopset. However, when a call is received, a signal is sent from the microprocessor of the wireless phone to activate the loopset. The loopset is then returned to the standby/off state once the call has ended and the wireless phone again enters the standby mode.
These and other features and advantages of this invention are described in or apparent from the following detailed description of the apparatus/systems and methods according to this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Various exemplary embodiments of this invention will be described in detail, with reference to the following figures, wherein:
FIG. 1 illustrates the configuration of an induction type loopset for a wireless phone;
FIG. 2 illustrates a conventional loopset configuration powered by a small battery;
FIG. 3 is a block diagram showing the configuration of a conventional loopset powered by a small battery;
FIG. 4 is a block diagram showing a first exemplary embodiment of a loopset according to this invention;
FIG. 5 is a block diagram showing a second exemplary embodiment of a loopset according to this invention;
FIG. 6 is a flowchart outlining an exemplary embodiment of a method for providing power to a loopset using the power source of a wireless phone when the wireless phone receives an incoming call; and
FIG. 7 is a flowchart outlining an exemplary embodiment of a method for providing power to a loopset using the power source of a wireless phone when a user initializes an outgoing call.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIGS. 4–7 illustrate various embodiments of the present invention. Similar reference numbers are used for similar elements between each of the FIGS. 1–7 . In this detailed description, the term “wireless phone” is used as an exemplary embodiment only. The term is intended to apply to any wireless device that has voice capability, including but not limited to devices from Research In Motion®, PALM®, Microsoft®, Dell® and cordless land-line telephones.
FIG. 3 illustrates the configuration of a conventional loopset 5 . As shown in FIG. 3 , the conventional system includes a coil 40 , a housing 30 and a wire 20 . The wire 20 is connected to a wireless phone that provides voice signals to the loopset 5 . The housing 30 contains a microphone 31 , a sound processor 32 , a battery source 34 , a gain amplifier 36 , an impedance-matching device 33 , and a common ground 35 . The cable 20 contains a connection to the common ground 35 of the connected wireless phone (not shown), an audio input line 21 and a microphone-out line 22 . The battery source 34 is typically a removable small battery, such as a “AAA” battery or at least one button cell.
The sound processor 32 can be any conventional device capable of receiving a microphone input signal from the microphone 31 and amplifying the input signal's strength to a level that is readable by the processors of the wireless phone. Carried on microphone-out line 22 , the signal output by the sound processor 32 is received by a detector circuit (not shown) within a wireless phone (not shown) for processing. During operation, the impedance-matching device 33 is excited by an audio output signal from the wireless phone. The audio output signal is passed to the loopset 10 through the audio input line 21 and through the gain amplifier 36 . The excitation of the impedance-matching device 33 outputs an electromagnetic field across the coil 40 . The output electromagnetic field is in direct proportion to the signal input from the audio input line 21 . The electromagnetic field is subsequently received by a t-coil hearing aid in proximity to the coil 40 .
As one can see from FIG. 3 , the battery source 34 supplies operating power to the components contained in the housing 30 .
Due to the need for the hearing-impaired user to hear all portions ambient sound surrounding his environment, as well as the user produced sounds (voice, movement, etc.), this application has been described such that the sound processor 32 will combine and transmit, to the coil 40 , sounds from the microphone 31 , microphone-outline 22 and the audio-out line 21 . Should any portion of the sounds resulting from these items not be transmitted to the user, it may be difficult for the user to hear necessary information. Although it is described that these component's outputs have been combined, it should be appreciated that any combination of these sounds may be excluded from the resulting combination without departing from the scope of the invention.
FIG. 4 shows a first embodiment of the present invention. The loopset 100 comprises a coil 40 , a housing 130 and a wire 120 . The wire 120 is connected to the wireless phone 10 and to the housing 130 . The wireless phone 10 provides voice signals to the loopset 100 . The housing 130 contains a microphone 31 , a sound processor 32 , a gain amplifier 36 , an impedance-matching device 33 , and a common ground 35 . The cable 120 contains a common ground 35 , an audio input line 21 , a microphone-out line 22 and a power line 15 . The power line 15 is connected to switch 13 of the wireless phone and to the control function of the gain amplifier 36 . The common ground 35 connects the ground terminal of the housing 130 and the wireless phone 10 . The wireless phone 10 also contains a wireless phone battery source 12 , a control line 14 and a microcontroller 11 . Not shown in FIG. 4 are the other conventional components of the wireless phone 10 known to those skilled in the art that are required for its operation. Those components are not necessarily relevant to the understanding and operation of this invention, thus they have not been illustrated.
In operation, under control of the microcontroller 11 , power is selectively supplied to the loopset 100 from the wireless phone battery source 12 across the power connection 15 . The operation of the switch 13 is a function of the operation of the relevant features of the wireless phone 10 . For example, because the loopset 100 only requires power during an incoming or out going call, when the wireless phone 10 transitions into an idle state from an operation state (i.e., the end of a call), a signal is sent from the microcontroller 11 to the switch 13 across control line 14 to open switch 13 and thereby disconnects the power to the loopset 100 . When a call is received or placed from the wireless phone 10 , as the microcontroller 11 transitions the cell phone state from the idle state to the operation state, switch 13 closes enabling power to be supplied to the loopset 100 from the cell phone battery source 12 .
The microcontroller 11 also controls the operation of the microphone 31 and the emission of the impedance-matching device 33 . During certain instances, the microphone 31 may not need to be active while the impedance-matching device 33 is active. For example, when a call is being placed, the microphone 31 does not need to be activated unless the call is connected. However, a user may want to hear tones emitted by the keypad of the wireless phone 10 . Table 1 illustrates an example of possible activation states of the microphone 31 and the impedance-matching device 33 of a loopset, as controlled by the microcontroller 11 of the wireless phone 10 . In the table, the “◯” indicates inactive states and “X” represent active states.
TABLE 1
Mic/Coil States
Phone State
Mic State
Coil State
Power Switch State
Idle
◯
◯
open
Wake
◯
X
closed
Receive
◯
X
closed
Call Connected
X
X
closed
SMS
◯
X
closed
It should be appreciated that in a simpler configuration of this invention, the control signals from the microcontroller 11 can simply only provide a switching command to the switch 13 without providing additional commands to control the state of the microphone 31 and the coil 40 . In this configuration, the state of the microphone 31 and the coil 40 would be on/off in conjunction with the state of the switch 13 .
A still simpler configuration may omit the switch 13 and simply rely on power supplied directly from the wireless phone for its operation.
FIG. 5 illustrates a second embodiment of the claimed invention. This embodiment contains essentially the same items as shown in the first embodiment. However, the switch 16 is placed outside of the wireless phone 10 along the cable 220 . This configuration does not require modification of the wireless phone 10 itself. Therefore, the second embodiment can be used with any configuration of current wireless phones with little modification to the microcontroller 11 such that command signals may be sent across command line 14 to control the operation of the switch 16 and ultimately operation of microphone and coil states of the loopset 100 .
FIG. 6 is a flowchart outlining one exemplary embodiment of a method of operation of a loopset during an incoming call according to this invention. As shown in FIG. 6 , the process begins at step S 60 , and continues to step S 61 , where an incoming call is received by the wireless device. The incoming call is received by the wireless phone in a manner that is well known in the art or yet to be developed. Next, in step S 62 , the wireless phone is removed from the standby mode to the operation mode or “state” consistent with Table 1 by a microcontroller of the wireless phone. The process then continues to step S 63 where the wireless phone is placed in a talk mode to establish a voice connection between the wireless phone 10 and the calling party. The process then continues to step S 64 .
In step S 64 , the microcontroller of the wireless phone sends a signal to switch 13 to close. Thus, power is provided from the power source of the wireless phone 10 to the connected loopset 100 . The process then continues to step S 65 , wherein the microphone 31 and the sound processor 32 are activated and the loopset 100 begins to transmit the appropriate electromagnetic field to a t-coil hearing aid in proximity to the loopset. Then control ends at step S 66 .
FIG. 7 is a flowchart outlining one exemplary embodiment of a method of operation of a loopset 100 during an outgoing call according to this invention. As shown in FIG. 7 , the process begins at step S 70 , and continues to step S 71 , wherein a microcontroller within a wireless phone 10 recognizes a keypad entry from a user. This keypad entry indicates that the user is making an outgoing call. Next, in step S 72 , the wireless phone 10 is transitioned from the standby state to the operation state by the microcontroller of the wireless phone. The process then continues to step S 73 where the wireless phone is placed in a talk mode ready to respond to a voice connection established by the network between the wireless phone 10 and the called party. The process then continues to step S 74 .
In step S 74 , the microcontroller 11 of the wireless phone 10 sends a command to a switch to provide power from the battery of the wireless phone to the connected loopset 100 . The process then continues to step S 75 , wherein the microcontroller 11 determines if the outgoing call has connected within a predetermined amount of time. If the call connects within the predetermined time, the process continues to step S 78 ; otherwise, the process continues to step S 76 .
In step S 78 , the microphone 31 and the sound processor 32 are activated when the loopset 100 begins to transmit the appropriate electromagnetic field to a t-coil hearing aid in proximity to the loopset. The process then continues to step S 79 where the system monitors to determine when the call has ended. When the call has ended, the process continues to step S 80 , prior to that time the process loops back to step S 79 . In step S 80 , the microprocessor 11 deactivates the microphone 31 and the sound processor 32 . The process then continues to step S 76 .
In step S 76 , power is disconnected from the loopset 100 by opening switch 13 responsive to a command from microcontroller 11 . The process finally ends at step S 77 .
While this invention has been described in conjunction with the exemplary embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. For example, the order of some steps of operation could be re-arranged. Accordingly, the exemplary embodiments of the invention, as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and the scope of the invention. | An induction-type loopset is provided that is connectable to a wireless device. The loopset contains a first coil electromagnetically coupled to a t-coil hearing aid and an impedance-matching device coupled to the first coil. The impedance-matching device is responsive to an audio signal from the wireless device. The induction-type loopset is powered from the power source of the wireless device. The power source is responsive to an activation state of the wireless device. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a security device for use with business machines and the like. In particular, it relates to a two piece clamping device that may be releasably affixed to a business machine and a cable locking device or the like.
In recent years, business offices throughout the country have experienced a rapid growth in the types and variety of business machines being used in said offices. Typically, business offices may have such business machines as, personal computers, typewriters, copiers, fascimile machines and the like. Along with the growth in the number, type and use of the business machines, the theft of such machines has also expanded.
Accordingly, it is an object of the present invention to provide security devices for use with various business machines.
It is another object of the present invention to provide a security device for business machines which will permit a number of such machines to attached together by a locking cable.
It is a further object of the present invention to provide a security device for business machines which may be easily and quickly attached and detached from said machine.
It is another object of the present invention to provide a security device for business machines which is of relative simple construction, is readily fabricated in an economical manner and may be used with a minimum amount of instructions.
The above and other objects and advantages of the presen invention will become more apparent in view of the following discussion and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the security device of the present invention;
FIG. 2 is an exploded perspective view of the device showing in FIG. 1; and
FIG. 3 is a side elevation view, with parts in sections and parts broken away, showing the security device of the present invention in an operative condition.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in detail to the drawings, and particularly to FIGS. 1 and 2, it will be seen that the security device of the present invention is generally shown at 10. As shown the device 10 is comprised of an upper elongated member 12 and a lower elongated member 14. The upper member 12 is generally in the form of a U-shaped channel although a flat member is also contemplated. Said member 12 is provided with a first aperature or opening 16 adjacent one end thereof and a second aperature or opening 18 adjacent the other end thereof. Aperatures 16 and 18 are designed to receive elements of said lower member 14 which will be explained below.
The upper member 12 is also provide with L-shaped hook means 20 extending upwardly from the top surface 22 of said member. As shown, said hook means includes a vertical portion 24 and a horizontal portion 26 which is substantially parallel to said top surface 22 so as to provide a rearwardly open hook. As shown, said hook means 20 is integral with and formed from said member 12; however, separate hook means attached to the top surface 22 of said member 12 is also contemplated.
The lower member 14 is primarily flat stock having forwardly facing hook means 27 disposed at one end thereof and a U-shaped protuberance or projection 28 disposed at the other end thereof. The forewardly facing hook means 27 is comprised of a vertical portion 30 extending upwardly from the top surface 32 of said lower member 14 and a horizontal portion 34 substantially parallel to said top surface 32.
As shown in FIGS. 1 and 3, the lower member 14 is disposed beneath said upper member 12. It is positioned so that said forwardly facing hook means is in registration with the aperature 16, and the U-shaped protuberance 28 is in registration with aperature 18. As shown, when said lower member 14 and said upper member 12 are in registration as described above, the hook means 20 and 26 form clamping means which will be further described below and the U-shaped protuberance 28 in association with the top surface 22 of the upper member 12 forms a transversely disposed aperature 35 which will also be further described below.
With reference primarily to FIG. 3, the use of the security device of the present invention will be explained. A business machine M such as a computer or typewriter is usually supported above a work surface S by legs (not shown). Most such machines are provided with an aperature 36 in the bottom surface 38 for various purposes. As shown, the security device 10 of the present invention is located below said bottom surface 38 of the machine M in the space between the machine M and the work surface S. As further shown, the clamping means, comprising the forward facing hook means 27 of the lower member 14 of the device 10 and the rearward facing hook means 20 of the upper member 12 thereof, are disposed within said aperature 36 so that the vertical portions 24 and 30 of said hook means 20 and 27 extend upwardly into said aperature 36 whereby horizontal portions 26 and 34 extend forward and rearward over the inside surface of said bottom surface 38 of said machine M. When the device 10 is disposed in said position the U-shaped protuberance is in registration with said aperature 18.
The installation of the security device of the present invention is simple and quick. First, the hook means 20 of the top member 14 is inserted into aperature 36 of the machine M and moved to a position that is substantially parallel to the bottom surface 38 of said machine M. This is followed by inserting the hook means 27 of the bottom member 14 through the aperature 16 of the top member 12 and through the aperature 36 of the machine M. The lower member 14 is then pivoted about the intersection of the vertical and horizontal portions 30 and 34 of hook means 27 until the U-shaped protuberance is in registration with the aperature 18 of the upper member 12. A cable 40 may then be inserted into the aperature 35 thereby preventing removal of said device 10 from the aperature 36 in the bottom surface 38 of the machine M.
As will be understood by those skilled in the art, a plurality of business machines may be attached to a single length of wire cable 40 and the cable 40 may be locked to the work surface S.
As will be further understood by those skilled in the art, the upper and lower members 12 and 14 of the security device of the present invention is advantageously made from flat metal bar stock which may be bent, cut and/or stamped to provide the various components of the device.
While a preferred embodiment has been shown and described, various modifications, substitutions and/or alterations may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation. | A security device for business machines, such as personal computers, typewriters and the like comprising a two piece clamp which has one end releasably affixable to said business machine and the other end thereof engagable with a locking cable or the like. | 8 |
This application is a continuation of application Ser. No. 118,407, filed Nov. 6, 1987, which was a continuation of application Ser. No. 840,343, filed Mar. 17, 1986, now abandoned, which in turn was a continuation of application Ser. No. 340,527, filed Nov. 27, 1981 now abandoned.
BACKGROUND OF THE INVENTION
In prior copending application for patent, Ser. No. 6,277, filed Jan. 25, 1979, now U.S. Pat. No. 4,239,396, disclosed a high capacity, truck-mounted blender in which a high speed impeller is mounted for rotation concentrically within an outer casing and has a solids inlet which is isolated from an outer concentric liquid inlet. In the preferred form of that invention, the blender is specifically designed for use in cementing operations or in fracturing oil and gas subsurface formations. The high speed impeller is positioned in inner spaced concentric relation to an annular chamber which causes the liquid to be directed axially past the discharge side of the impeller whereby solid material introduced through the central inlet is discharged by the impeller under centrifugal force into the fast-moving, axial stream of liquid. A mixing chamber diverges in an axial direction away from the impeller zone into a discharge port. Further, a recirculation inlet is provided to establish communication from the discharge side and the central or solids inlet so as to permit any excess of the blended material to be recirculated through the blender. A number of important advantages are seen to accrue from the isolation of the solids inlet from the liquid inlet, particularly at the interface across the impeller zone. Further, it has been found possible to greatly improve the blending of at least certain materials by closely controlling the movement of the liquid stream into the blender and along the annular space formed in surrounding relation to the impeller zone. Furthermore, it has been found that the versatility of the blender apparatus can be greatly enhanced by the use in combination therewith of a closed loop system which along with the blender can be vehicle-mounted and operated off the vehicle drive to regulate the delivery of materials to and from the blender as well as to regulate the discharge of blended materials from either side of the vehicle into a well head or other intended site of use.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide for a novel and improved liquid/liquid or liquid/solid blending method and apparatus which is adaptable for use in cementing and fracturing operations, such as, of the type employed in oil and gas wells.
It is another object of the present invention to provide for a high capacity blender method and apparatus in which the introduction of one of the constituents to be blended is completely isolated from the other constituents and is capable of intermixing the contituents in varying amounts in a high capacity blending operation.
It is a further object of the present invention to provide for a method of intermixing solid particulate materials with a high velocity, swirling liquid stream in which the solid materials are introduced through an inner zone isolated from the outer liquid zone by radially directed the solids under centrifugal force so as to intercept the liquid stream and be held in suspension for pumping to the site of intended use.
It is a further object of the present invention to provide for a novel and improved blending method and apparatus which can be vehicle-mounted and is conformable for mixing liquid-to-liquid or liquid-to solid constituents for continuous discharge to the intended point of use; and further wherein a closed loop system is employed in combination with the blender apparatus to regulate the capacity and pressure of liquid introduced into the blender as well as to control the discharge of blended materials and offers a high degree of versatility in the proportions and amounts of constituents to be blended as well as their delivery through one or more outlet or discharge ports.
In accordance with the present invention, there has been devised a novel and improved blending apparatus which is comformable for use in high capacity blending operations. In the preferred form, a truck-mounted blender apparatus has an inner solids inlet which extends axially into an impeller zone. The impeller is located in inner spaced concentric relation to an outer concentric chamber which has a tangentially directed liquid inlet for delivering liquid in a swirling, somewhat helically directed stream through the annular chamber and past the discharge side of the impeller zone. The impeller is so mounted between the solids inlet and annular chamber as to form a dynamic seal therebetween and assure the complete isolation of the solids from the liquids except at the point of discharge of the solids through the impeller zone into the swirling stream of liquid. The annular chamber is preferably designed so as to diverge along the impeller zone and create a slight reduction in pressure of the liquid stream as it advances toward the discharge end of the blender so as to assure that the solids will be carried with the liquid stream through the discharge port. A closed loop system is operative in combination with the blender to deliver liquid materials to the outer liquid inlet under a predetermined head of pressure which will not exceed the pressure limit of the blender, the system including a pump, the suction side of which is in communication with a series of inlet ports located along opposite sides of the truck so as to induce the delivery of materials from a liquid supply source for discharge under a predetermined pressure into the blender. Materials discharged from the blender are directed back through the closed loop system for discharge through the same or other ports located along opposite sides of the truck. The closed loop system is so designed that the same ports may be employed along opposite sides of the truck either for suction or discharge or can be so interconnected as to bypass the blender for flushing or other operations. A selected amount of the materials discharged from the blender may be recirculated through the closed loop system to the liquids inlet either for further blending or to reduce the amount of materials discharged to the intended point of use.
The method of the present invention carries out blending of liquids or liquid and solid constituents by introducing liquids from a closed loop system tangentially into a downwardly divergent annulus and simultaneously introducing liquid or solid materials to be mixed through a central inlet which discharges the materials through a lower outlet under a high degree of centrifugal force so as to be intimately mixed and blended with the swirling stream of liquid passing downwardly through the annulus. The materials discharged are circulated through the closed loop system for delivery through one or more outlets; or if desired, a selected amount can be recirculated through the outer annulus for further mixing and blending with additional materials introduced through the central inlet.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, advantages and features of this invention will become appreciated and understood when taken together with the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a side view in elevation illustrating the preferred embodiment of the present invention installed on a vehicle;
FIG. 2 is a plan view of the preferred embodiment shown in FIG. 1;
FIG. 3 is a cross-sectional view of the preferred form of blender as illustrated in FIGS. 1 and 2; and
FIG. 4 is a cross-sectional view but of reduced size of the impeller illustrated in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in detail to the drawings, there is illustrated in FIGS. 1 and 2 a blender system in accordance with the present invention which is broadly comprised of a blender apparatus 10 and a closed loop liquid distribution apparatus 12. The blender apparatus 10 and distribution apparatus 12 are illustrated as being mounted on a truck bed B so as to be transportable to different intended sites of use. In this connection, the apparatus of the present invention in its preferred form will be described specifically in relation to intermixing of liquid and solid constituents which are to be discharged into a well head for fracturing oil or gas subsurface formations, although it will be appreciated that the apparatus is conformable for use in other applications, such as, for instance, cementing operations.
The preferred form of blender apparatus 10, as shown in FIG. 3, comprises a central, axially directed inlet 14, an impeller 16 which is mounted for rotation at the lower end of the inlet 14, and an annular chamber 18 in outer concentric relation to the inlet 14 has a tangentially directed liquid inlet 20 at its upper end and a tangentially directed outlet port 22 at its lower end. It will be noted that the annular chamber 18 diverges in a downward direction past the impeller zone and toward the discharge end 22, the chamber being completely open throughout so as to permit the uninterrupted flow of liquid therethrough. Preferably, the central inlet 14 is formed by a hollow cylindrical casing which is positioned to project upwardly through a central opening in an upper mounting plate 25, the mounting plate having suitable connecting rings 26 to facilitate movement and installation of the blender. The upper end of the inlet 14 has a connecting flange 28 to facilitate its attachment to a tubular conduit which forms a part of a solids conveyor system, for example, of the type referred to in the hereinbefore referred to copending application for patent Ser. No. 6,277, filed Jan. 25, 1979.
The lower edge of the casing 14 is seated at the inner edge of an annular plate 30 which defines the upper boundary of the impeller zone and extends horizontally in an outward radial direction from the lower end of the casing 14. A tubular wall section 32 has its lower edge positioned on the outer edge of the plate 30 and extends upwardly therefrom in outer spaced concentric relation to the casing 14 and terminates at the underside of the top plate 25 of the blender. The wall 32 defines the inner wall of the annular chamber 18 along the upper section of the chamber opposite the inlet 20. A lower wall section 34 corresponds in diameter to the upper wall section 32 and defines the inner wall of the annular chamber 18 beneath the impeller 16 and is aligned opposite to the discharge port 22. The lower wall section 34 is interposed between an upper horizontally extending, circular flange 35 and a horizontal base plate 36 which forms the lower horizontal end wall of the blender, the plate 36 being of generally annular or circular configuration with a central opening therein. An outer, downwardly divergent wall 38 defines the outer wall of the entire blender and of the annular chamber 18, the wall 38 being of generally tubular configuration having its upper end affixed to a mounting ring 39 extending around the underside of the outer peripheral edge of the top wall 25 of the blender, and a lower end of the wall 38 is affixed to the outer peripheral edge of the bottom plate 36 of the blender. The liquid inlet port 20 extends in a tangential direction through the upper end of the wall 38 directly beneath its attachment to the top wall 25, and the outlet port 22 extends tangentially away from the lower end of the wall 38 directly above the attachment of the wall into the base plate 36 of the blender. While the degree of divergency of the outer wall section 38 may vary, preferably, the wall is comprised of a relatively straight wall portion 40 which merges into an inclined wall portion 41 of progressively increasing diameter along a region generally opposite to the impeller zone and which merges into a lower, straight wall section 32 such that the area of the chamber at the lower end approximates twice the area of the chamber at its upper end.
Preferably, the impeller 16 corresponds to that disclosed in copending application for patent Ser. No. 6,277 and is made up of upper and lower spaced, radially extending walls 43 and 44, respectively, which are interconnected by vertically disposed, circumferentially spaced vanes 45, the vanes curving outwardly along a generally sprial path from a central opening 46, the opening 46 corresponding in diameter with the central inlet 14. In order to form a complete seal along the impeller zone so as to isolate the central inlet 14 in the annular chamber 18, the surfaces of the plates 30 and 35 in confronting relation to the upper and lower walls 43 and 44 of the impeller 16 are coated with layer 48 of low coefficient of friction material, and the confronting surfaces of the upper and lower wall sections 43 and 44 of the impeller are provided with circumferentially spaced ribs 49 of spiral configuration corresponding to the spiral configuration of the vanes 45 and which ribs 49 advance across the surfaces 48 as the impeller is rotated so as to tend to expel any liquid which would otherwise tend to flow radially outwardly along the interface between the impeller and surrounding plates 30 and 35.
The lower wall section 44 of the impeller is provided with a central hub 50 which is keyed for rotation on a drive shaft 52, the latter projecting downwardly through a fixed drive sleeve 54 and into a transmission drive housing 55 affixed to the bottom wall 36 of the blender. It will be noted that the drive shaft 52 is journaled within a bushing 56 which is supported by thrust bearings 57 within the sleeve 54.
As shown in FIG. 4, vanes 45 preferably in the form of arcuate, generally radially extending blades are arranged at equally spaced circumferential intervals around the circular impeller, each blade having an inner inclined edge 58 and curving or bowing outwardly along its length to terminate in its outer vertical edge 59 which is flush with the outer extremities of the upper and lower wall sections 43 and 44. The vanes are bowed to present convex surfaces in the direction of rotation of the impeller whereby to encourage outward movement of material introduced through the central inlet 14 and to impart a high velocity to the material as is driven through the impeller region under centrifugal force into the liquid stream passing through the annular chamber 18. Since the impeller isolates the inlet 14 from the chamber 18, mixing of materials occurs only at the point of discharge of the material introduced through the inlet 14 as it passes from the outer radial extremities of the vanes 45 into the liquid stream and in a direction generally normal or perpendicular to the direction of flow of the liquid stream. In this relation, the liquid stream will follow somewhat of a helical path of advancement through the annular chamber by virtue of the tangential disposition of the inlet; and, by reason of the divergency of the chamber along the impeller region the velocity of the stream will be slowed somewhat as it reaches the impeller region but will tend to force the solid materials from the impeller to advance along the outer wall of the chamber 18. In general, the flow rate of the stream as determined by the inlet force or pressure of the liquid through the upper inlet 20 will be at a level such that it will be capable of picking up highly dense solid materials and throughly mixing the materials and maintaining them in suspension for discharge through the lower port 22.
The distribution system 12 broadly is constructed and arranged to pump liquid to the blender 10 from one or more of the ports 60L and 60R which are positioned in parallel along opposite sides of the truck bed B as well as to regulate the discharge of the mixture from the blender 10 through any one or more selected ports 60L and 60R which are not being employed as inlet ports. Preferably, the system 12 is a closed loop system which is capable of bypassing the blender and pumping liquid from a supply source through one or more of the ports 60 for direct discharge through other of the ports 60 either on the same or opposite side of the truck bed as the inlet ports. To this end, the distribution system 12 is made up of a centrifugal pump 62 which has an intake or suction end 63 and a discharge end 64. The inlet side 63 is connected into a forward, transversely extending pipe manifold 66 which interconnects outboard, left and right mainfolds 67L and 67R, respectively, disposed along opposite sides of the truck bed. In turn, the discharge side 64 is connected to a discharge conduit 68 leading therefrom and extending rearwardly for connection to the liquid inlet 20 of the blender 10 so as to pump liquid under a predetermined head of pressure from the pump 62 into the liquid inlet. Preferably, the centrifugal pump is a Model CK-6 pump manufactured by Morris Pumps, Inc. of Boldwinsville, N.Y. The pump has an impeller of a type corresponding to the impeller 16 of the preferred form of blender but of a smaller size so as to assure that the pressure generated by the pump will never exceed the designed pressure limit of the blender.
The outlet 22 of the blender is connected through a conduit 70 into a transversely extending rearward pipe mainfold 72 which interconnects the rearward ends of the outboard pipe mainfolds 67L and 67R. Valves 74 are positioned at opposite ends of the mainfolds 66 and 72 at their point of connection into the outboard manifolds 67L and 67R. In addition, main valves 75L and 75R are located in each of the outboard mainfolds 67L and 67R; and individual flow control valves 76L and 76R are provided for each of the ports 60L and 60R. It will also be seen that the discharge conduit 70 has a bypass connection 78 into the conduit 67R and a flow control valve 80 is positioned in the bypass conduit 78 to selectively open or close the bypass line between the conduits 67R, 70 for a purpose to be hereinafter described.
The truck as illustrated is of conventional design and for example may be a Model K2440 truck manufactured and sold by Oshkosh Trucks Corp. of Oshkosh, Wis. It is equipped with an Oshkosh 500 h.p. transmission as designated at 82 leading rearwardly from the front cab section of the truck along the chassis or truck bed and having a power takeoff shaft 84 into the rearward differential section of the truck all in a conventional manner. However, in accordance with the present invention, a transfer case 86 is interpositioned in the transmission train 82 so as to permit the impeller 16 of the blender 10 to be driven off of power takeoff shaft 88 leading from the transfer case 86. Another transfer case 90 is interpositioned in the power takeoff shaft 88 to drive another auxiliary drive shaft 92 for the centrifugal pump 62. By driving both the blender 10 and pump 62 off of a common power transmission, such as, that available as standard equipment on the truck, the pump 62 will not overrun the blender, or exceed its pressure limit, in supplying liquid under pressure thereto or, in other words, will maintain a balanced pressure condition therebetween.
In operation, the closed loop distribution system as described affords a high degree of versatility in permitting the system to be connected to a suitable liquid supply source from either side of the truck through any one or more of the inlet ports 60L and 60R. Typically, the inlet ports for introduction of liquid to the suction side of the pump are selected from those ports 60 located forwardly of the mainfold valves 75L and 75R on either side of the pump. The valves 74L on the side adjacent to the inlet ports 60L are open while the valves 74R are closed, unless liquid is to be drawn in from one of the ports 60R along the opposite side of the truck. The discharge conduit 64 introduces liquids under pressure through the liquid inlet 20 as solid particulate material is introduced through the upper solids inlet 14 into the blender. The mixed material discharged through the outlet 22 will then be conducted through the conduit 70 into the rearward transverse manifold 72. Assuming that the mix is to be discharged from the rearward ports along the outboard manifold 67L, the valve 74L leading into the outboard manifold 67L is open while the valve 74R leading into the other outboard mainfold 67R is closed.
In certain cases it may be desirable to recirculate at least a selected proportion of mixture from the discharge 22 of the blender through the liquid inlet 20 for further mixing in which event the material to be recirculated is reintroduced after discharge through one of the suction ports 60 and pumped into the blender. Furthermore, the entire blender 10 may be bypassed when, for example, it is desired to employ the closed loop system for flushing operations and no mixing or blending of materials is required. Thus, flow control valves 94 and 95 at the liquid inlet 20 and discharge 22, respectively, are open and, for instance, the liquid supply source will be pumped through the blender 10 for flushing same then into discharge conduit 70, the bypass conduit 78 and back through the discharge line leading from the blender for distribution or discharge through other selected ports 60 on either of the outboard manifolds 67. Assuming that the liquid is introduced through forward inlet ports 60 along the outboard mainfold 67R and is to be discharged through rearward ports on the outboard manifold 67L, each of the valves 75L and 75R would be closed with the valve 75R adjacent to outboard manifold 67R and the opposite valve 74L adjacent to manifold 67L opened so that the liquid can be pumped through the conduit 70 and manifold 72 into the rearward discharge ports 60L on the outboard manifold 67L. Similarly, the valve 74L in the manifold 66 on the side of the outboard manifold 67L would be closed while the other valves 74R would be open to permit introduction of the liquid into the intake side of the pump.
EXAMPLE
In a typical application of the blending apparatus shown in FIGS. 1 and 2 the truck is located in close proximity to the well head site and, depending upon accessibility to a source of water supply, one or more of the ports 60L or 60R toward the front end of the associated manifold 67 is connected to a delivery line from the water supply source. For instance if the water supply is on the left side of the truck, eight suction hoses will be connected to the ports 60 and valves 76 will be open. Initially, a mixture of 500 gallons of 2% KCL and water are combined to load the hole and to test the lines to the wellhead. Once the unit is started and mixer 10 and pump 62 are operating, the valves 74L and 75L connected to the water supply source will be opened. Fluid will then enter the pump 62 and fill the discharge line 68. Valves 20 and 22 are open so that the fluid will enter the mixer 10 then be discharged into line 72. By opening valves 74R and 75R the fluid will discharge from the right side of the truck through valves 76R.
The fluid is discharged into suitable pumping units which receive the fluid from delivery lines or hoses connected to ports 60R on the truck so as to fill the hole at any desired flow rate below the maximum rate of the pump 62. At the same time the blender is operated to dump 175 pounds of KCL per 1000 gallons of water into the mixer 10 by means of a suitable conveyor belt or screw auger which communicates with the upper solids inlet 14 of the blender.
In the second stage, the blender operator may connect one of the suction lines to a source of 71/2% HCL solution and pump 500 gallons of the fluid to which is added 10 lbs. of citric acid for the purpose of cleaning the casing perforations. Following the second stage, 30,000 gallons of water are pumped through the blending apparatus and are gelled with 40 lbs. of guar gum per 1,000 gallons of water, and 75,000 lbs. of 10 to 20 mesh sand. Preferably the materials are mixed or blended beginning with 0 lbs. per gallons concentration and increasing by 1 lb. per gallon of sand for every 5,000 gallons of fluid pumped into the well. Finally, 500 gallons of 2% KCL are introduced in order to displace all of the fluid and sand into the formation.
From the foregoing description it will be seen that a novel and improved method and apparatus has been devised for introducing liquids from a closed loop system into a subsurface formation, although its application to other uses will be readily appreciated. A particular advantage in the utilization of the improved form of blender apparatus as described is that by virtue of the divergency of the annular chamber leading away from the tangentially directed liquid inlet, the liquid stream will be caused to follow a helical course throughout the annular chamber and in intercepting the solid materials driven into the liquid stream by the impeller will tend to cause the solid materials to become intimately mixed with the liquid and to be carried with the swirling liquid stream out through the discharge end of the blender. The divergency of the chamber is such that its cross sectional area at the discharge end will approximate twice the area at the inlet end and, as the swirling stream advances through the chamber and particularly along the area outwardly of the impeller zone will retain the sand or other solid materials along the outer wall of the chamber so as to continue to advance with the liquid and not tend to collect along the inner walls or bottom of the chamber.
Accordingly, it is to be understood that various modifications and changes may be made in the preferred method and apparatus of the present invention as herein described without departing from the spirit and scope thereof as defined by the appended claims. | A truck-mounted apparatus is capable of blending liquid/liquid or liquid/solid constituents in a high capacity blending operation, and the apparatus achieves a high degree of versatility in the introduction of materials into a blender apparatus (10) for discharge from either or both sides of the truck or other vehicle. A closed loop system (12) permits suction of liquid maaterials as well as discharge of mixed materials from one or both sides of the truck, and is capable of flushing or other pumping operations as well. Moreover, the closed loop system (12) includes a pump (62) as a part of the closed loop system which, together with the blender (10), is operable off of a common drive, such as the power transmission train of the truck. The blender permits isolated injection of liquids and/or solid constituents through separate inlets, by means of dynamic seal, a first inlet (20) causing liquids to be introduced tangentially so as to swirl through a downwardly divergent annular chamber and the second inlet causing the materials to be introduced more in an axial direction through an impeller (16) which imparts a centrifugal force to drive the materials outwardly into the swirling stream of liquid. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from U.S. Provisional Application Ser. No. 61/278,866, filed Oct. 13, 2009.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of Cooperative Agreement No. NCC-1-02043 awarded by the National Aeronautics and Space Administration.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to high performance energy conversion devices such as sensors and electromechanical actuators, and, more particularly to energy conversion devices manufactured from boron nitride nanotubes and BNNT/polyimide composite materials.
[0005] 2. Description of Related Art
[0006] Electroactive materials have been studied extensively in the last few decades for use in a variety of applications including electromechanical sensors and actuators, ultrasonic transducers, loudspeakers, sonars, medical devices, prosthetics, artificial muscles, electric energy harvesters and devices for vibration and noise control. Electroactive ceramics such as lead zirconate titanates (PZT), lead-lanthanum zirconate titanate (PLZT), and niobium-lead zirconate titanate (PNZT) have very high piezoelectric coefficients, but have poor mechanical properties (i.e., are brittle) and high toxicity. Compared to the electroactive ceramics, electroactive polymers such as poly(vinylidene fluoride) (PVDF) offer a unique combination of favorable characteristics because they are lightweight, conformable, and tough. However, they have relatively low electroactive coefficients and poor thermal properties.
[0007] Recently, a series of amorphous piezoelectric polyimides containing polar functional groups have been developed, using molecular design and computational chemistry, for potential use as sensors in high temperature applications. The piezoelectric response of these polyimides is, however, an order of magnitude smaller than that of poly(vinylidene fluoride) (PVDF). This is due to the fact that the dipoles in the polymer do not align along the applied electric field efficiently because of limited chain mobility within the imidized closed ring structure. To increase the piezoelectric response of these polymers, synthesis with various monomers, control of the poling process, and the adding of carbon nanotubes (CNTs) have been reported.
[0008] However, there are still limitations to the use of electroactive polyimide composites in many applications. For example, CNT doped polyimides have large leakage current because the CNTs are either conductors or narrow band gap semiconductors. This limits the use of the composites for high voltage devices. Furthermore, CNTs are chemically active and can be easily oxidized at elevated temperatures (above about 350° C. in air).
[0009] Novel electroactive materials have been required for increasing electroactive performance while reducing power consumption for many applications including in the aerospace field. Many electroactive materials have been proposed, but they still have problems of poor mechanical/thermal properties or unsatisfactory electroactive performance. Recently, boron nitride nanotubes (BNNTs) have been successfully synthesized, which exhibit excellent mechanical, electronic, optical, and thermal properties. BNNTs are thought to possess high strength-to-weight ratio, high temperature resistance (about 800° C. in air), and radiation shielding capabilities. Furthermore, intrinsic piezoelectricity of BNNTs has been predicted theoretically. However, no experimental result of the piezoelectric properties of BNNTs or BNNT composites has been reported as yet. In this invention, we demonstrate electroactive actuation characteristics of novel BNNT based materials. We prepared several series of BNNT based electroactive materials including BNNT/polyimide composites and BNNT films. The BNNT based electroactive materials showed high piezoelectric coefficients, d 13 , about 14.80 pm/V as well as high electrostrictive coefficients, M 13 , 3.21×10 −16 pm 2 /V 2 . It is anticipated that the BNNT based electroactive materials will be used for novel electromechanical energy conversion devices.
[0010] An object of the present invention is to provide high performance energy conversion devices.
[0011] An object of the present invention is to provide high performance energy conversion devices such as sensors.
[0012] Another object of the present invention is to provide high performance energy conversion devices such as electromechanical actuators.
[0013] Yet another object of the present invention is to provide high performance energy conversion devices manufactured from boron nitride nanotubes and BNNT/polyimide composite materials.
[0014] Finally, it is an object of the present invention to accomplish the foregoing objectives in a simple and cost effective manner.
SUMMARY OF THE INVENTION
[0015] The present invention addresses these needs by providing a method for forming a boron nitride nanotube nanocomposite film, including the steps of combining a boron nitride nanotube solution with a polymer or ceramic matrix to form a boron nitride nanotube/polyimide mixture and synthesizing a boron nitride nanotube/polyimide nanocomposite film as an electroactive layer. The matrix is preferably synthesized from a diamine, 2,6-bis(3-aminophenoxy) benzonitrile ((β-CN)APB) and a dianhydride, pyromellitic dianhydride (PMDA). Alternatively, the matrix is polyvinylydeneflouride, polyvinylydeneflouride copolymer, polycarbonate or epoxy. The matrix can also be a highly elastic polymer such as polyurethane or polysiloxane or a ceramic such as silicon dioxides or aluminum oxides. The concentration of boron nitride nanotubes in the boron nitride nanotube/polyimide mixture is between 0 and 100% by weight. In an additional step, the boron nitride nanotube/polyimide nanocomposite film is coated with metal electrodes formed from chrome, gold or a mixture thereof. Alternatively, the boron nitride nanotube/polyimide film is coated with compliant electrodes formed from carbon nanotubes, carbon nanotube sheet, carbon nanotube/polymer composites, gold particles, silver particles or a mixture thereof.
[0016] In one embodiment, a method for forming a boron nitride nanotube/polymer nanocomposite film, includes synthesizing a high temperature piezoelectric polyimide, combining a boron nitride nanotubes solution with the high temperature piezoelectric polyimide, using a polymer as a matrix and synthesizing a boron nitride nanotube/polyimide nanocomposite film as an electroactive layer. The polymer is dianhydride, pyromellitic dianhydride and the high temperature piezoelectric polyimide is synthesized from a diamine, 2,6-bis(3-aminophenoxy)benzonitrile ((β-CN)APB) and a dianhydride, pyromellitic dianhydride (PMDA). The concentration of boron nitride nanotubes in the boron nitride nanotube/polyimide mixture is between 0 and 100% by weight. In an additional step, the boron nitride nanotube/polyimide nanocomposite film is coated with metal electrodes, preferably formed from chrome, gold or a mixture thereof. Alternatively, the boron nitride nanotube/polyimide film is coated with compliant electrodes formed from carbon nanotubes, carbon nanotube sheeting, carbon nanotube/polymer composites, gold particles, silver particles or a mixture thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] A more complete description of the subject matter of the present invention and the advantages thereof, can be achieved by reference to the following detailed description by which reference is made to the accompanying drawings in which:
[0018] FIG. 1 a shows a schematic diagram of a metal electroded BNNT/polymer composite actuator;
[0019] FIG. 1 b shows a Schematic diagram of a carbon nanotube electroded BNNT actuator;
[0020] FIG. 2 a shows a graph of thermally stimulated current (TSC) spectra of pristine polyimide and 2 wt % BNNT/polyimide composite;
[0021] FIG. 2 b shows a graph of remanent polarization (P r ) of pristine polyimide and 2 wt % BNNT/polyimide composite;
[0022] FIG. 3 shows a proto-type BNNT actuator fabricated with carbon nanotube electrodes;
[0023] FIG. 4 shows a cross-sectional SEM image of a prototype BNNT actuator fabricated with carbon nanotube electrodes;
[0024] FIG. 5 a shows a graph of the electric field induced strain of the BNNT actuator fabricated with CNT electrodes;
[0025] FIG. 5 b shows a graph of the piezoelectric response of the BNNT actuator fabricated with CNT electrodes; and
[0026] FIG. 5 c shows a graph of the electrostrictive response of the BNNT actuator fabricated with CNT electrodes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] The following detailed description is of the best presently contemplated mode of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention.
[0028] Since the first theoretical prediction of the existence of boron nitride nanotubes (BNNTs) in 1994 and the first experimentally synthesized BNNT report by Zettl's group in 1995, several types of BNNT synthesis methods have been reported. Recently, a new and conceptually simple method of producing extraordinarily long, highly crystalline BNNTs was demonstrated. BNNTs are thought to possess high strength-to-weight ratio, high thermal stability (up to about 800° C. in air), piezoelectricity, and radiation shielding capabilities. Nakhmanson's theoretical analysis predicted that the piezoelectric coefficient of BNNTs can be higher than that of poly(vinylidene fluoride) (PVDF) or poly(vinylidene fluoride-trifluoroethyene) P(VDF-TrFE). However, the piezoelectric properties of BNNTs or BNNT composites have not been reported experimentally as yet. In this invention, we make use of the electroactive characteristics of novel BNNT based materials.
[0029] First, a BNNT/polyimide nanocomposite film was synthesized as an electroactive layer by in-situ polymerization under simultaneous shear and sonication. The high temperature piezoelectric polyimide, used as a matrix for this invention, was synthesized from a diamine, 2,6-bis(3-aminophenoxy)benzonitrile ((β-CN)APB), and a dianhydride, pyromellitic dianhydride (PMDA). The concentrations of BNNTs in the polyimide were 0 and 2 wt %. In order to characterize electroactive properties of the composites, the samples were coated with metal (chrome/gold) electrodes for both sides ( FIG. 1 a ).
[0030] Thermally stimulated current (TSC) spectra of the BNNT nanocomposites were obtained using a Setaram TSC II. Each sample was polarized by a direct current (DC) electric field of 5 MV/m at an elevated temperature (T p =T g −5° C.) for a selected poling time (t p =30 min). The glass transition temperatures (T g ) of the pristine polyimide and 2% BNNT/polyimide composite, measured by a differential scanning calorimeter (DSC), are 274.3 and 271.4° C., respectively. After poling, the depolarization current was measured as the sample was heated through its glass transition temperature (T g ) at a heating rate of 7.0° C./min. As shown in FIG. 2 a , the pristine polyimide showed negligible depolarization currents until about 225° C., which indicates a good thermal stability of polarization, and then exhibited a rapid depolarization current with a maximum peak of 0.012 mA/m 2 at 255.9° C. On the other hand, the 2 wt % BNNT/polyimide nanocomposite exhibited two depolarization peaks at 119.3° C. and 255.5° C. The magnitude of the depolarization current of the nanocomposite was significantly larger than that of the pristine polyimide as seen in FIG. 2 b , and reached a maximum value of about 0.05 mA/m 2 , five times greater than that of the pristine polyimide. The remanent polarization (P r ) was calculated by integrating the current with respect to time and is plotted as a function of temperature as shown in FIG. 2 b . P r is given by,
[0000]
P
r
=
q
A
=
1
A
∫
I
(
t
)
t
(
1
)
[0000] where q is the charge, A is the electrode area, I is the current, and t is the time. Details of conventional poling procedures have been described elsewhere [J. H. Kang et al., NANO, 1, 77 (2006)]. The remanent polarization (P r ) of the 2 wt % BNNT/polyimide nanocomposite was 12.20 mC/m 2 , almost an order of magnitude higher than that of the pristine polyimide (1.87 mC/m 2 ). In general, the piezoelectricity of a material is proportional to its remanent polarization. From the TSC result, adding BNNT, even only 2 wt %, was proven to increase the piezoelectricity (remanent polarization) of the polyimide significantly.
[0031] An all nanotube film actuator, with a BNNT active layer, was fabricated by a filtering method [J. H. Kang et al., J. Polym. Sci. B: Polym Phys. 46, 2532 (2008)]. Single wall carbon nanotubes (SWCNTs) were used as electrodes for the actuator instead of metal. First, solutions of SWCNTs and BNNTs were prepared in N-methylpyrrolidone (NMP) under sonication. An adequate amount of the SWCNT solution was filtered through the surface of an anodized alumina membrane (pore size: 0.2 μm) to form a SWCNT film on the membrane. Then, the BNNT solution and finally the SWCNT solution were sequentially filtered onto the SWCNTs film on the membrane to make a three layered (SWCNT/BNNT/SWCNT) “all-nanotube actuator” structure shown in FIG. 3 . The freestanding all-nanotube actuator film, shown in FIG. 3 , was easily delaminated by breaking the brittle membrane. To increase durability, polyurethane resin was infused into the all-nanotube actuator. FIG. 4 shows the cross-sectional scanning electron microscopy (SEM) image of a prototype BNNT actuator fabricated with SWCNT electrodes (Hitachi S-5200 Field Emission Scanning Electron Microscope). The top and bottom layers are SWCNT electrodes and the middle layer is the BNNT actuating layer.
[0032] In-plane strain (S 13 ) was measured using a fiber optic device while the sample was under an alternating current (AC) electric field of 1 Hz. The strain (S 13 ) of the sample appears as a superposed curve (black solid squares in FIG. 5 a ) of linear and nonlinear strains as a function of frequency. The superposed curve was de-convoluted to a linear response (red solid circles in FIG. 5 a ) and a nonlinear response (blue solid triangles in FIG. 5 a ). The linear response seems to originate from the piezoelectric property of the BNNT active layer. From linear fitting of the data ( FIG. 5 b ), the piezoelectric coefficient, d 13 was calculated to be about 14.80 pm/V. This is comparable to the values of commercially available piezoelectric polymers such as poly(vinylidene fluoride) (PVDF). The nonlinear response showed a quadratic increase with increasing applied electric field, indicating that the mechanism of this strain is mainly an electrostrictive response ( FIG. 5 c ). The electrostrictive coefficient (M 13 ) of the BNNT active layer, calculated from the slope of a plot of the strain (S 13 ) to the square of electric field strength (E 2 ), S 13 =M 13 E 2 , was 3.21×10 −16 pm 2 /V 2 on average. This value is several orders of magnitude higher than those of electrostrictive polyurethanes (−4.6×10 −18 to −7.5×10 −17 m 2 /V 2 ).
[0033] Obviously, many modifications may be made without departing from the basic spirit of the present invention. Accordingly, it will be appreciated by those skilled in the art that within the scope of the appended claims, the invention may be practiced other than has been specifically described herein. Many improvements, modifications, and additions will be apparent to the skilled artisan without departing from the spirit and scope of the present invention as described herein and defined in the following claims. | Electroactive actuation characteristics of novel BNNT based materials are described. Several series of BNNT based electroactive materials including BNNT/polyimide composites and BNNT films are prepared. The BNNT based electroactive materials show high piezoelectric coefficients, d 13 , about 14.80 pm/V as well as high electrostrictive coefficients, M 13 , 3.21×10 −16 pm 2 N 2 . The BNNT based electroactive materials will be used for novel electromechanical energy conversion devices. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority benefit of Taiwan application serial no. 96113187, filed on Apr. 14, 2007. All disclosure of the Taiwan application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a carrier for manufacturing a memory device, a method using the same, and a portable memory device using the manufacturing method.
2. Description of Related Art
In recent years, the technology and material of an electronic integrated circuit have been developed rapidly, and the volume of a chip is increasingly reduced, but the function becomes increasingly powerful and the applications thereof have been gradually reached anywhere. Therefore, the products manufactured by using the electronic integrated circuit gradually becomes light, thin, short, and small, such as electronic dictionaries, digital cameras, and various other digital products. Furthermore, because of the gradually mature chip packaging technology, in the current market, a single chip or multiple chips are packaged into a quite slim card, to form a removable memory with a volume smaller than that of an existed magnetic recording medium by utilizing the characteristic that the chip may store a large amount of data. Such electronic media are all called memory card.
Currently, SD (secure digital) memory card is one of the most commonly used memory cards. The SD memory card uses a standard of a flash memory, for example, and is applied in portable devices, such as digital cameras, personal digital assistants (PDA), and multi-media players. The technology of the SD memory card is formed based on a format of a multi-media card (i.e., so-called MMC), but the SD memory card is slightly thicker than the MMC. The SD memory card has a high data transmission rate and the standard with which the SD memory card uses is updated continually. The profile of the common SD memory card is about 32 mm×24 mm×2.1 mm.
In recent years, as the demand for data storage capacity is increased, and the development trends of electronic devices towards light weight, thinness, shortness, and smallness, the substrate area of the memory card is gradually reduced. A miniSD specification was also introduced for the SD cards in the year of 2003, so as to reduce the size of the memory card, for example, the size is about 20 mm×21.5 mm×1.4 mm.
However, as the size of the memory card is increasingly reduced, the size of the memory dies in the memory card is also reduced accordingly, and the used printed circuit board also becomes much thinner and smaller. Under this circumstance, a carrier used in the manufacturing process plays a crucial role. How to ensure the efficiency of the memory card and to protect the components in the memory card from being damaged becomes a topic deserving further consideration.
For example, the memory card meeting the miniSD specification requirement is only 1.4 mm in thick, so the thickness of the employed printed circuit board (PCB) must be lower than 0.16 mm. If such a specification is adopted, during the process of manufacturing the memory cards, PCB manufacturers cannot overcome the problem of the bending of the PCB, i.e., the bowing problem in the field, which also causes the problem that the components cannot be installed successfully by using the Surface Mounted Technology (SMT), or deformation occurs during the reflow process. Accordingly, the problem of empty soldering occurs during a soldering process, and as a result, the flash memory may suffer a short circuit problem. This is also one of the reasons why the yield rate of the manufacturers of the miniSD memory card cannot break through 60%.
Some PCB manufacturers have suggested amending the layout of the PCB to connect the plate edges, i.e., through the manner of the edge connector of gold fingers, which however cannot overcome the aforementioned problems, so the yield rate cannot be enhanced efficiently.
In addition, some SMT manufacturers also employ a two-piece manufacturing carrier, including a bottom plate and a top cover, in which the top cover is used to press each flash memory, so as to overcome the bowing problem of the PCB. However, the conventional method is merely to add the top cover in the reflow process, which can only avoid thermal deformation occurring in the reflow process, but cannot overcome the bowing problem that has already occurred before the material of the PCB is purchased. Therefore, the two-piece manufacturing carrier only may enhance the yield rate by 10%-15%, but the additional operation steps wastes some extra working hours.
SUMMARY OF THE INVENTION
The present invention is directed to a carrier for manufacturing a memory device, a method using the same, and a portable memory device using the manufacturing method, capable of efficiently overcoming the bowing problem of the PCB and significantly enhancing the yield rate.
The present invention is directed to a carrier for manufacturing a memory device, a method using the same, and a portable memory device using the manufacturing method, capable of efficiently solving the problems that, during an SMT process, the pieces cannot be assembled successfully, an integrated circuit (IC) to be adhered is offset, or empty soldering or a short circuit occurs, so as to greatly enhance the yield rate.
The present invention provides a carrier for manufacturing a memory device, which includes a bottom plate, an intermediate cover, and a top cover. A PCB is placed and fixed on the bottom plate, which is used for forming a plurality of memory elements. The intermediate cover is used to press peripheral regions of the PCB and to expose regions where the memory elements are formed on the PCB, such that the PCB may be closely attached to the surface of the bottom plate by fixing the intermediate cover. The top cover is used to cover the memory elements formed on the PCB, and the memory elements are clamped by an external force, so as to protect the memory elements from being affected by the PCB due to thermal stress deformation.
The present invention provides a manufacturing method using a carrier for manufacturing a memory device, in which the carrier for manufacturing a memory device includes a bottom plate, an intermediate cover, and a top cover. The manufacturing method includes the steps as follows. Firstly, the PCB is fixed on the bottom plate, which is used for forming a plurality of memory elements. Next, a solder paste printing process is performed. After that, the intermediate cover is placed on the bottom plate and the PCB, which presses peripheral regions of the PCB and exposes regions where the memory elements are formed on the PCB; and the printed circuit board is closely attached onto the surface of the bottom plate by fixing the intermediate cover. Thereafter, the assembling process of the SMT is performed. Then, the top cover is placed on the intermediate cover to press the memory elements and clamp the memory elements by an external force, so as to protect the memory elements from being affected by the PCB due to thermal stress deformation.
The present invention provides a portable memory device using the above manufacturing method, which is an NAND flash memory device meeting the miniSD specification requirement, and the method of manufacturing the same includes the steps as follows. Firstly, a PCB with a thickness lower than 0.2 mm is fixed on the bottom plate, which is used for forming a plurality of memory elements meeting the miniSD specification. Then, a solder paste printing process is performed. After that, the intermediate cover is placed on the bottom plate and the PCB to press peripheral regions of the PCB and expose regions where the memory elements are formed on the PCB; and the PCB is closely attached onto the surface of the bottom plate by fixing the intermediate cover. Thereafter, the assembling process of the SMT is performed. Then, the top cover is placed to press each memory element, and the memory elements are clamped by an external force, so as to protect the memory elements from being affected by the PCB due to thermal stress deformation.
In order to make the aforementioned and other objects, features and advantages of the present invention comprehensible, preferred embodiments accompanied with figures are described in detail below.
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
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.
FIGS. 1A-1C and 2 A- 2 C respectively show a carrier for manufacturing a memory device according to a preferred embodiment of the present invention, in which FIGS. 1A , 1 B, and 1 C are schematic top views of a bottom plate, an intermediate cover, and a top cover respectively, and FIGS. 2A , 2 B, and 2 C are side views of the bottom plate, the intermediate cover, and the top cover respectively.
FIG. 3 is a detailed flow chart of a manufacturing method using the carrier for manufacturing a memory device according to the present invention.
FIGS. 4A-4E are detailed flow charts of a manufacturing method using the carrier for manufacturing a memory device according to the present invention.
DESCRIPTION OF EMBODIMENTS
The carrier for manufacturing a memory device, the method using the same, and the portable memory device using the manufacturing method provided by the present invention is capable of efficiently overcoming the bowing problem of the printed circuit board (PCB) and also efficiently solving the problems that, during a surface mounted technology (SMT) process, pieces cannot be assembled successfully, an integrated circuit (IC) to be adhered is offset, or the empty soldering or short circuit problem occurs, so as to greatly enhance the yield rate of the manufacturing process.
The carrier for manufacturing a memory device provided by the present invention is a three-piece carrier, which includes a bottom plate, an intermediate cover, and a top cover. FIGS. 1A , 1 B, and 1 C are schematic top views of the bottom plate, the intermediate cover, and the top cover, and FIGS. 2A , 2 B, and 2 C are side views of the bottom plate, the intermediate cover, and the top cover. In order to illustrate clearly, the present invention will be described below with reference to FIGS. 1A-1C and 2 A- 2 C.
FIGS. 1A and 2A are respectively a schematic top view and a side view of a bottom plate 110 of the carrier for manufacturing a memory device according to an embodiment of the present invention. The bottom plate 110 has four pillars 112 respectively disposed at four corners where the printed circuit board (PCB) of a flash memory will be fixed, such that the locating holes of the PCB are engaged with the pillars 112 . The bottom plate 110 has a plurality of louvers 114 at four edges. In addition, the position 116 , where the PCB of the flash memory will be placed, also has a plurality of louvers for dissipating heats generated during the manufacturing process. Additionally, in order to make the direction of the carrier be consistent, each piece in the three-piece carrier provided by the present invention has a direction mark, such that the pieces will not be placed incorrectly during the manufacturing process, for example, the bottom plate 110 in FIG. 1 has a direction mark 118 facing a predetermined direction 150 .
FIGS. 1B and 2B are respectively a schematic top view and a side view of an intermediate cover 120 of the carrier for manufacturing a memory device according to an embodiment of the present invention. The intermediate cover 120 has two holes 122 disposed in the upside and downside for exposing the flash memory of the PCB and a plurality of grooves 124 for carrying the top cover, and further has a direction mark 126 to prevent the intermediate cover 120 from being placed incorrectly during the manufacturing process. In addition, a plurality of protruding portions 128 is formed at positions of the holes 122 for exposing the flash memory, which is used to further fix the PCB.
FIGS. 1C and 2C are respectively a schematic top view and a side view of the top cover 130 of the carrier for manufacturing a memory device according to an embodiment of the present invention. The top cover 130 includes a plurality of holes 132 disposed in upside and downside for exposing the flash memory and a plurality of protruding portions 134 for being placed in the grooves of the intermediate cover, and further has a direction mark 136 to prevent the top cover 130 from being placed incorrectly during the manufacturing process. The holes 132 may serve as louvers for dissipating heats generated by the flash memory.
FIG. 3 shows a detailed flow chart of the method using the carrier for manufacturing a memory device according to the present invention. Firstly, in Step 310 , the bottom plate is placed on a crosser or another insulating manufacturing base. Next, in Step 320 , the PCB is placed on the bottom plate, and the four locating holes of the PCB are engaged with the four pillars, so that the PCB is fixed thereon. Then, in Step 330 , a solder paste printing process is performed to form a solder paste between the elements that should be adhered during the SMT process and the PCB. Then, in Step 340 , the intermediate cover provided by the present invention is placed on the bottom plate and the PCB. Furthermore, it is confirmed whether the intermediate cover presses the PCB or not, and the PCB should be flattened. In an embodiment, for example, a strong magnet may be used on the intermediate cover, such that the intermediate cover may be combined with the bottom plate under a force, and the PCB may be flattened as expected.
Next, in Step 350 , an SMT assembling process is performed to mount the necessary elements to be adhered. Then, in Step 360 , a top cover is placed to press each memory. Subsequently, in Step 370 , for example, the strong magnet is used to clamp the memories tightly. In this manner, the memories are protected from being offset or suffering from an empty soldering or a short circuit, when the thermal stress deformation occurs due to the reflow process of the PCB.
The detailed manufacturing method using the carrier for manufacturing a memory device provided by the present invention is further described below.
FIGS. 4A-4E are detailed flow charts of the manufacturing method using the carrier for manufacturing a memory device according to the present invention. Firstly, as shown in FIG. 4A , the bottom plate 420 is placed on the crosser 410 . Next, as shown in FIG. 4B , the PCB 430 is placed on the bottom plate 420 , and the four locating holes of the PCB 430 are engaged with the four pillars 422 , so that the PCB is fixed thereon. Then, the solder paste printing process is performed to form the solder paste between the elements that should be adhered during the subsequent SMT process and the PCB. Then, as shown in FIG. 4C , the intermediate cover 440 is placed on the bottom plate 420 and the PCB 430 , and the direction mark 442 of the intermediate cover 440 must be consistent with the direction mark 424 of the bottom plate 420 .
Subsequently, as shown in FIG. 4D , after the SMT assembling process, as shown in FIG. 4E , the top cover 450 is pressed to press each memory, for example, a strong magnet is used to clamp the memories tightly. In this manner, the memories are protected from being offset or suffering from an empty soldering or a short circuit problem, when the thermal stress deformation of the PCB 430 occurs during the subsequent reflow process of the PCB 430 .
The carrier for manufacturing a memory device and the manufacturing method provided by the present invention is capable of efficiently overcoming the bowing problem of the PCB and also efficiently solving the problems that, during the surface mounted technology (SMT) process, pieces cannot be assembled successfully, an integrated circuit (IC) to be adhered is offset, or the empty soldering or short circuit occurs, which thus greatly enhancing the yield rate.
If the carrier for manufacturing a memory device and the manufacturing method are applied in manufacturing an NAND flash memory device meeting the miniSD specification (referred as miniSD memory card below), the NAND flash memories are arranged in a form of “pages”, and each page has a storage space of 256 or 512 bytes and an assistant storage capacity of 8-16 bytes. Recently, an NAND memory with each page having a main storage space of 2048 bytes and an assistant storage space of 64 bytes has been introduced. The assistant storage space is mainly used to store error correction codes (ECCs), damaged memory marks, and data about file systems. These pages constitute a block. The NAND flash memory is read and written “page” by “page”; and the data is deleted “block” by “block”.
At this time, the size of the miniSD memory card is about 20 millimeter (mm)×21.5 mm×1.4 mm. Since the thickness of the miniSD memory card is merely 1.4 mm, the thickness of the employed PCB must be lower than 0.2 mm. However, such a thin PCB may suffer from serious problems in the conventional process, and the yield rate cannot be enhanced efficiently. However, through the carrier for manufacturing a memory device and the manufacturing method provided by the present invention, the yield rate may be increased to over 90-95%. In another exemplary embodiment of the present invention, the carrier for manufacturing a memory device and the manufacturing method are also applied in manufacturing an NAND flash memory device formed as a memory card with a profile that is not over 31 mm in length, 20 mm in width, and 1.6 mm in thickness.
In addition, it takes about 80 seconds to manufacture one panel of a flash memory, including the SMT assembling, visual inspection, changing the top cover, and clamping it out by using a clip and so on. However, if the carrier for manufacturing a memory device and the manufacturing method provided by the present invention are used, since the strong magnet is used for adsorption, for example, and the time in changing the top cover is saved, a visual inspector may have sufficient time to correct the offset of the SMT assembling process. Therefore, it only takes 45-55 seconds to manufacture one panel of the flash memory under the same quantity conditions, so as to enhance both the yield rate and the efficiency.
The carrier for manufacturing a memory device and the manufacturing method provided by the present invention may also be applied in manufacturing a memory card requiring a quite thin PCB, for example, with a thickness of lower than 0.2 mm, such as, a compact flash (CF) memory card, a memory stick (MS) card, a memory stick duo (MS Duo), a multi media card (MMC), a reduced size multi media card (RS MMC), a secure digital (SD) card, a mini secure digital (Mini SD) card, a μ card, a reduced size μ (RS μ) card, and other small memory cards with similar functions.
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. | A carrier including a bottom plate, an intermediate cover, and a top cover for manufacturing a memory device is introduced herein. A printed circuit board is disposed on the bottom plate, and memory elements are arranged and disposed on the PCB. The intermediate cover is used to press peripheral regions of the printed circuit board, and to expose the regions where the memory elements are formed on the printed circuit board. The printed circuit board is closely attached to a surface of the bottom plate by fixing the intermediate cover. The top cover is used to cover the memory elements formed on the printed circuit board after some manufacturing processes, and by exerting an external force, the formed memory elements are clamped down, so as to protect the memory elements from being affected by the printed circuit board in the following thermal process due to the thermal stress deformation. | 8 |
FIELD
[0001] The present disclosure relates to an analogue-to-digital (A/D) converter. In particular, an analogue-to-digital conversion architecture suitable for using a low energy search method is proposed.
BACKGROUND
[0002] In a typical successive approximation register analogue-to-digital conversion (SAR ADC) architecture (as shown in FIG. 1 ) the input V in is compared against a digital-to-analogue converter (DAC) output V A using a comparator ( 3 ) in several cycles. The input can first go through a sample and hold block ( 2 ). The SAR logic ( 4 ) executes a search algorithm, typically this is a binary search. In the first cycle the input is compared against the middle of the ADC range. From the comparator output the most significant bit (MSB) can be determined. In the next cycle MSB−1 is determined. A conversion to n bits ( 7 ) requires n cycles.
[0003] The DAC ( 5 ) is typically made with a capacitive DAC. Binary weighted DACs contain capacitances with weight factor 2 i for the i th bit. The least significant bit (LSB) has a capacitance C (=2 0 *C) and the MSB has a capacitance 2 n−1 *C.
[0004] In the binary search cycle with a binary weighted capacitive DAC, determining the MSB consumes most energy. The large capacitor controlling the MSB output of the DAC has to be charged to generate the reference level and subsequently discharged if the MSB is 0. With this operation, an energy 2 n−1 *C*V 2 /2 is dissipated, and this happens for half of the input samples. Several groups have proposed different configurations which try to recover the energy of this capacitor discharge. In ‘ An energy - efficient charge recycling approach for a SAR converter with capacitive DAC ’ (Ginsburg et al., Circuits and Systems, 2005, ISCAS2005) the MSB capacitor is split into b−1 binary scaled sub-capacitors. The average switching energy can be reduced by 37% compared to a conventional switching method. The method further uses a charge recycling approach by reconnecting capacitors instead of discharging them.
[0005] The power consumption of an ADC can be reduced by improving the operation of the comparator. A technique following this approach is presented in ‘ An Ultra Low Energy 12- bit Rate - Resolution Scalable SAR ADC for Wireless Sensor Nodes ’ (N. Verma et al., Journal of Solid-State Circuits, vol. 42, no. 6, pp. 1196-1205, June 2007). A variety of techniques were employed for minimizing the overall power consumption. Differential binary DACs are used with a standard binary search algorithm. The focus is on the use of a low gain comparator combined with an offset compensating latch. This latch minimizes the gain requirements of the comparator preamplifiers, providing a power reduction of approximately 70% in the preamplifiers.
[0006] In ‘ Nano - Watt silicon - on - sapphire ADC using 2 C -1 C capacitor chain ’ (Z. Fu et al., Electronics Letters, Vol. 42, No. 6, March 2006) an ultra-low power ADC is presented which combines a 2C-1C capacitor chain implementation and a switched capacitor with cascaded inverter. The latter is chosen as a high-speed and ultra-low power comparator. As a result, the ADC has a power consumption as low as 900 nW at 1.1V power supply and 1.35 μW at 1.5V. One problem with switched capacitor DACs is that of capacitor mismatch. When constructing switched capacitors, process variations such as layer-misalignment or etch variations can cause variations in capacitance values of different capacitors. These variations may only be a few percent of the total capacitance. However, for DACs such as a 10-bit DAC, the largest capacitor is C*2 9 or 512C and a 5% variation is 26C, many times larger than the smallest capacitors. To improve the matching, a DAC with a thermometer MSB sub-DAC and binary LSB sub-DAC with scrambled thermometer coding is presented in U.S. Pat. No. 6,154,162. This approach is not very profitable for the overall power consumption because the capacitors in the LSB sub-DAC are larger than the capacitors in MSB sub-DAC.
SUMMARY
[0007] The present disclosure relates to an analogue-to-digital converter for converting an input signal to a digital code representing the input signal. The converter comprises a comparator for comparing the input signal with a reference signal and producing a comparator output signal, a search logic block arranged for being fed with the comparator output signal and for determining the digital code based on the comparator output signal and a digital-to-analogue converter arranged for receiving input from the search logic block and for generating the reference signal to be applied to the comparator. For generating the reference signal the digital-to-analogue converter at least comprises a first portion implemented with equal capacitors. Preferably the capacitors are at least as big as the other (non-equal) capacitors in the D/A converter. The first portion with equal capacitors is so positioned that the reference signal can be used for deriving at least the most significant bit of the digital code. In a preferred embodiment the first portion is implemented with at least three equal capacitors. Compared to e.g. a digital-to-analogue converter implemented with binary weighted capacitors, a smaller capacitor needs to be charged and therefore the energy-consuming action of charging/discharging large capacitors is avoided.
[0008] In an embodiment, the analogue-to-digital converter further comprises a second portion implemented with binary weighted capacitors. To speed up the conversion algorithm, a digital-to-analogue converter as described herein can be combined with a second portion comprising binary weighted capacitors.
[0009] In an embodiment, the first portion of the analogue-to-digital converter is arranged for being controlled by a thermometer coded signal. A full thermometer algorithm or slope search is the most efficient search algorithm, as it avoids the discharge of capacitors and hereby does not waste energy.
[0010] In an embodiment, the second portion of the analogue-to-digital converter is arranged for being controlled by a thermometer coded signal. In another embodiment, the second portion can also be controlled by a binary coded signal. The converter avoids charging-discharging of large capacitors during the search and therefore reducing the lost energy. The idea is to discharge only limited amounts of capacitors. For example: for a 6-bit ADC whereby the first two bits are determined via the first portion in combination with a thermometer coded signal and the four remaining bits are determined via the second portion in combination with a binary coded signal. Typically the algorithm starts at half of the range. If the system needs to go to a quarter of the range then only one 16C needs to be discharged, consuming 16 C V 2 . An ADC with a binary DAC would discharge one 32C capacitor and charge one 16C capacitor, hereby consuming 48 C V 2 . In an embodiment of the converter, the most significant bits are determined by using equal capacitors controlled by a thermometer code. The power consumption is improved by avoiding big capacitors to discharge.
[0011] In an embodiment, the analogue-to-digital converter comprises a plurality of these digital-to-analogue converters. The different DACs can be coupled by an analogue addition circuit. In the case of high bit counts, binary DACs are split up in two or more capacitive sub-DACs coupled by an addition circuit. This is done to avoid too large differences in sizes and consequent risks for mismatch. The addition circuit can be a simple coupling attenuating attenuator or a weighted summing amplifier.
[0012] In another aspect, a method is described for converting an input signal to a digital code with an analogue-to-digital converter as previously described. The method comprises a step of determining the most significant bit by comparing the input signal with a signal charged on a capacitor of said first portion of the analogue-to-digital converter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention is further elucidated by means of the following description and the appended figures.
[0014] FIG. 1 represents a classical SAR architecture.
[0015] FIG. 2 represents a proposed architecture of the DAC as used in an SAR ADC as described herein.
[0016] FIG. 3 graphically represents a proposed search algorithm.
[0017] FIG. 4 represents a split capacitor DAC architecture.
[0018] FIG. 5 represents a split capacitor DAC architecture comprising a weighted summation amplifier.
DETAILED DESCRIPTION
[0019] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not necessarily correspond to actual reductions to practice of the invention.
[0020] The term “comprising”, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It should be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression “a device comprising means A and B” should not be limited to devices consisting of only components A and B.
[0021] The analogue-to-digital conversion (ADC) systems described herein endeavour to avoid charging/discharging large capacitors and as a consequence decrease the energy loss. An ADC comprises a DAC which is classically implemented with binary weighted capacitors, using a binary search algorithm to derive the digital representation of an analogue input signal. A binary search algorithm sequentially charges the binary scaled DAC capacitors for every code. For a 6-bit DAC this means that all 6 capacitors are charged (and some discharged) during the SAR search cycle. With discharging a capacitor, power is wasted. With a thermometer DAC (in which all capacitors are equal) a binary search algorithm results in much less wasted power through capacitor discharges, because part of the capacitors can remain charged when moving to a lower signal level. A further power improvement changes the search algorithm. The extreme case of this is a slope search (full thermometer/counting algorithm). With this algorithm no energy is wasted, but it is very slow (to find code 63, sixty-four clock-pulses are required) and the thermometer DAC is large (64 capacitors). The proposed algorithm uses a combination of a binary and a slope search, in which a slope search is used for the thermometer coded MSB DAC bits, or a part thereof, and a binary search is used for the lower bits. With a slope search algorithm only one Thermo-MSB capacitor is discharged.
[0022] A possible implementation splits the top capacitor in two capacitors with half of the value (2*2 n−1 *C). When moving from half of the DAC range to a quarter (which happens when the MSB is 0), only one capacitor is discharged and no extra energy is required to generate the next reference level at ¼ of the DAC range. This principle can be extended to the lower bits. It then converges to a “thermometer” DAC for the m most significant bits. FIG. 2 shows an example of a 6 bit DAC with a thermometer code ( 22 ) for the first 2 bits and a binary weighted DAC ( 23 ) for the remaining 4 bits. The thermometer code DAC ( 22 ) comprises 3 equal capacitors ( 20 ) with value 16C and a binary-thermometer decoder ( 21 ). In combination with a binary search algorithm this results in lower overall power, because less capacitors are discharged during the SAR iteration cycles. Note that for the LSB a thermometer DAC can also be used because of the guaranteed monotonicity of a thermometer DAC.
[0023] With such DAC the search algorithm can be optimized for low energy consumption rather than for speed (or low amount of iteration cycles). This means that extra conversion cycles are used to obtain lower energy consumption. A generic search algorithm can work as follows:
For the m most significant bits (which have to be connected to the thermometer portion of the DAC) scan through the 2 m bit codes, starting with 0 (or 0001) and incrementing by 1 on every iteration cycle. This is similar to a slope converter. When the comparator toggles, the conversion cycle is stopped, and the values of the m most significant bits are known. This is called the slope search cycle. For the n−m remaining bits a binary search algorithm is used.
[0026] FIG. 3 shows the search algorithm for a 6 bits ADC of which the 2 MSBs use a slope search (n=6, m=2). The 2 MSBs are determined using a slope converter technique ( 30 ). In maximum 4 cycles (and if the input is always within the input range, even in 3), the MSBs are determined. In the example given in the figure, it takes 3 cycles to find the 2 MSBs (in this case ‘10’). Then a binary search ( 31 ) is executed for the 4 LSBs which takes 4 cycles. Note that m (=# bits used in slope search cycle) does not necessarily correspond to the amount of bits connected to the thermometer DAC. The m bits should be connected to a thermometer DAC to make the conversion energy efficient, but some of the n−m bits may also be connected to a thermometer DAC to save energy. Surely, a thermometer DAC also offers power savings for a binary search cycle, as said before.
[0027] The optimum value for m comes from the trade off between the power savings in the DAC and the extra required power in the comparator and SAR logic for the extra conversion cycles. Whilst a binary search requires n conversion cycles, the proposed algorithm requires maximum 2 m +(n−m) cycles. The energy dissipated to generate the DAC levels for m most significant bits is 2 (n−m) *C*V 2 , since only one capacitor needs to be discharged (namely when the DAC output was higher than the signal input).
[0028] In addition to energy being dissipated, there is also energy stored on the capacitors to generate the reference level. That cannot be avoided. This energy is lost only at the end of the conversion cycle (once per conversion). A single slope converter combined to a thermometer DAC consumes the lowest energy in the DAC and the energy in the DAC would be directly proportional to the input signal. With DN the digital input value of the input signal V in and C the unit capacitance of the thermometer DAC, the slope converter would have consumed DN*C*V 2 /2 to generate the reference level on the DAC at the end of the AD conversion. This is theoretically the minimal energy required in the DAC. However, because of the large amount of iteration cycles and the power consumed in the comparator, clocking and logic, the total energy consumed can be larger than the proposed approach.
[0029] In the case of high bit counts, binary DACs are split up in 2 or more capacitive sub-DACs coupled by a coupling capacitor or (weighted) summation circuit. This is done to avoid too large differences in sizes and consequent risks for mismatch.
[0030] FIG. 4 shows an example with 2 sub-DACs ( 41 , 42 ). The two sub-DACs have an identical circuit and are coupled with an attenuation capacitor ( 43 ). This also means that the highest significant bit in each sub-DAC consumes an equal amount of power. In a classical configuration with sub-DACs, for example in a 12-bit DAC with 2×6 bit sub-DACs, an equal power is consumed for the 5 th and 11 th (MSB) bit. This means the principles explained in the previous paragraph for the most significant bits of each sub-DAC are applied separately. The most significant bits of each sub-DAC are generated with a thermometer DAC and the search algorithm switches to slope search mode for the most significant bits of each sub-DAC.
[0031] FIG. 5 shows a configuration in which the signals of the 2 sub-DACs are summed with a weighted summing amplifier ( 51 ). In each case, using a thermometer code and slope search for the most significant bits of each sub-DAC reduces the power consumption of the entire DAC.
[0032] In an alternative embodiment another algorithm is introduced. Instead of charging 1 MSB-thermometer capacitor, all LSB-capacitors are charged. (Binary search is possible, but to save clocks, they should be charged all at once.) If the comparator does not switch, one MSB-thermometer capacitor is added at every next clock. (In this example a [2,4] segmentation is used.). The advantage of this approach is that the biggest capacitor of the binary coded part is already charged when the search for the binary coded part starts. Only the smaller bits need to be discharged. When the comparator switches, instead of discharging a thermo (big) capacitor, the smallest LSBs (b 0 , b 1 , b 2 ) are discharged and a binary search for bits b 4 ,b 3 ,b 2 ,b 1 is started. Therefore (with a single DAC) the thermometer-capacitors are not discharged and the largest LSB is only discharged when it is required. On average with this algorithm less energy from the capacitors is discharged but it does cost 1 extra clock. | The present disclosure is related to an analogue-to-digital (A/D) converter ( 1 ) for converting an input signal (V in ) to a digital code representing said input signal. The A/D converter comprises a comparator ( 3 ) for comparing the input signal with a reference signal (V A ), a search logic block ( 4 ) for determining the digital code and a digital-to-analogue converter ( 5 ) arranged for receiving input from the search logic block and for providing the reference signal to be applied to the comparator. The digital-to-analogue converter comprises at least a first portion implemented with equal capacitors ( 20 ). The ADC optionally further comprises a second portion implemented with binary weighted capacitors. The first portion is arranged for being controlled by a thermometer coded signal. The converter avoids charging-discharging of large capacitors during the search and therefore reduces the lost energy. | 7 |
This is a continuation of application Ser. No. 07/528,223, filed May 24, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to timing circuitry and, more particularly, to methods and apparatus for controlling the timing of data output enable signals.
2. History of the Prior Art
A large percentage of the data processing chips which are sold commercially today utilize an enable signal to drive data to the output terminals. The output enable signals are utilized in order to precisely determine the time at which any particular chip provides output signals so that, for example, a plurality of chips will not be providing signals to the same destination at the same time. In all known prior art arrangements, the output enable signal is an asynchronous input signal, a signal which is not sampled by the system clock. The result is that the output is turned on as soon as possible after the enable signal is received and is turned off as soon as possible after the enable signal is removed.
The actual time at which a chip turns on and off in response to the application and removal of the output enable signal depends upon the propagation time within the particular chip. In general, the time may vary by a very large amount for any particular chip. Consequently, it is necessary in most prior art circuits operating at high clock frequencies to provide a significant amount of clock time between enable signals so that two individual sources of data will not both be driving data onto a data bus simultaneously. This provision of time between the end of one enable signal and the beginning of the next (so called dead cycles) to assure that there is no conflict between output enable signals slows the computer system significantly. Moreover, the synchronization of the different output enable signals to assure an appropriate interval for the dead cycle so that the enable signals occur at the correct time is quite difficult.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to improve the apparatus for timing the generation of output enable signals.
It is another object of the present invention to provide apparatus for allowing a single output enable signal to control the operation of a plurality of computer chips.
It is yet another object of the present invention to provide circuitry which precisely determines the length of a dead cycle between output enable signals.
These and other objects of the present invention are realized in a circuit for providing data output enable signals to a device comprising means for generating an output enable signal in response to the simultaneous application of a clock signal and a second signal, and means for terminating the output enable signal in response to the termination of the second signal alone.
These and other objects and features of the invention will be better understood by reference to the detailed description which follows taken together with the drawings in which like elements are referred to by like designations throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a typical digital circuit of the prior art in which output enable signals are utilized.
FIG. 2(a) and (b) illustrates a particular off-chip driver utilizing a output enable signal.
FIGS. 3a, 3b and 3c are timing diagrams illustrating a conflict which may occur in operating a number of chips on a bus and a typical resolution of the conflict.
FIGS. 4a, 4b and 4c are timing diagrams illustrating a resolution of a conflict in accordance with the invention and possible utilizations of the arrangement.
FIG. 5 is a block diagram of a circuit in accordance with the invention for precisely controlling output enable signals.
FIG. 6 is another timing diagram illustrating the operation of the invention.
NOTATION AND NOMENCLATURE
Some portions of the detailed descriptions which follow are presented in terms of algorithms and symbolic representations of operations on data bits within a computer memory. These algorithmic descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. An algorithm is here, and generally, conceived to be a self-consistent sequence of steps leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities.
Further, the manipulations performed are often referred to in terms, such as adding or comparing, which are commonly associated with mental operations performed by a human operator. No such capability of a human operator is necessary or desirable in most cases in any of the operations described herein which form part of the present invention; the operations are machine operations. Useful machines for performing the operations of the present invention include general purpose digital computers or other similar devices. In all cases the distinction between the method operations in operating a computer and the method of computation itself should be borne in mind. The present invention relates to apparatus and to method steps for operating a computer in processing electrical or other (e.g. mechanical, chemical) physical signals to generate other desired physical signals.
DETAILED DESCRIPTION OF THE INVENTION
As pointed out above, a large percentage of the data processing chips which are sold commercially utilize an output enable signal to drive data to the output terminals. The output enable signals are utilized in order to precisely determine the time at which any particular chip provides output signals so that, for example, a plurality of chips will not be providing signals to the same destination at the same time. FIG. 1 illustrates an arrangement 10 in which a control circuit 12 provides output enable signals to precisely control the time at which circuits 14, 15, and 16 furnish data to a destination circuit 17. Without such output enable signals, circuits 14 and 15 might both attempt to furnish data simultaneously to the circuit 17.
In all known prior art arrangements, the output enable signal is an asynchronous input signal, a signal which is not sampled by the system clock. The result is that any chip responding to an output enable signal is turned on as soon as possible when the enable signal is received and is turned off as soon as possible when the output enable signal is removed. The upper two signals referred to as DOE and Data in FIG. 3a illustrates this. When the DOE (data output enable) signal goes positive (a one condition), data is allowed to flow at the output terminal of the particular chip. When the DOE signal goes negative (is removed), the data flow at the output terminal is terminated.
An off chip driver circuit 20 for accomplishing the output enable function is illustrated in FIG. 2(a). The CMOS circuit 20 includes a pair of P devices 21 and 22 and a pair of N devices 23 and 24 connected between a voltage Vcc (one) and ground (zero). A one at the data input terminal is inverted and transmitted by the device 23 in the presence of an output enable signal at the output enable terminal which turns on the device 24. A zero at the data input terminal is inverted and transmitted by the device 22 in the presence of an output enable signal at the output enable terminal which turns on the device 21. The absence of the output enable signal disables both of the devices 22 and 23 and no output appears at the output terminal of the circuit 20. FIG. 2(b) illustrates a typical symbol for an off chip driver circuit such as that illustrated in detail in FIG. 2(a).
The actual time at which a chip turns on and off in response to the application and removal of an output enable signal depends upon the propagation time of the signal within the particular chip. In general, the time may vary by a very large amount for any particular chip. It is not atypical for different examples of supposedly identical circuits to have propagation times which vary by two to one. The effect of this is that it is necessary in most prior art circuits operating at high clock frequencies to provide a significant amount of clock time between enable signals. This is necessary so that two individual sources of data will not both be driving data onto a bus simultaneously.
FIG. 3b shows four signals DOE0, DOE1, Data0, and Data1 which illustrate this problem. DOE0 controls the transmission of Data0 while DOE1 controls the transmission of Data1. While DOE0 is high, Data0 is being transmitted. When DOE0 goes low, Data0 cuts off after some propagation delay. It is desired to transmit Data1 as soon as possible after Data0 terminates so DOE1 is driven high at the same instant that DOE0 terminates. However, it will be seen that it is possible if the propagation time of the second circuit is shorter than that of the first circuit that the Data1 signal will appear at the output before Data0 terminates. This will cause a driver conflict. For example, in the circuit 10 of FIG. 1, two source circuits will be attempting to drive data to the same destination 17 at the same time.
As was mentioned above, the typical method for resolving this problem is to provide dead time between the termination of one output enable signal and the turn on of the next output enable signal. FIG. 3c illustrates the usual solution. A first output enable signal DOE2 is driven off the clock signal CLK and is brought low to terminate the data signal Data2 from the first chip. After some period of time less than one clock cycle controlled by the signal propagation time, the data signal Data2 terminates. A second output enable signal DOE3 is initiated one clock cycle later by the falling edge of the clock signal CLK. The output enable signal DOE3 initiates the data output signal Data3 from a second chip. In this manner the two enable signals are separated by a dead cycle, and no driver conflict arises. However, in both the initiation and the termination of the data signals, a delay which is the sum of the delay to initiate the output/enable signal and the data signal is incurred.
Thus, the provision of time between the end of one enable signal and the beginning of the next to assure that there is no conflict between output enable signals slows the computer system significantly. Moreover, the synchronization of the different output enable signals to assure an appropriate interval for the dead cycle so that the enable signals occur at the correct time is difficult because of the differing propagation times encountered.
FIG. 4a is a timing diagram illustrating a resolution of driver conflict in accordance with the invention. The output enable DOE0 can occur any time between the falling edges of a clock signal CLK although the output enable signal DOE0 is typically initiated by the falling edge of the clock signal CLK. A data output signal Data0 is then initiated by both the output enable signal DOE0 going high and the next falling edge of the clock signal CLK. This assures that the data signal Data0 follows the initiation of the output enable signal by a predetermined dead cycle. The data signal Data0 is then terminated by the termination of the one condition of the output enable signal DOE0. Thus, the data output may be considered to be synchronized to the clock at initiation but asynchronous at termination so that only one delay is incurred at initiation of the data signal.
The second set of signals in the timing diagram of FIG. 4b illustrates one particular use for the invention. In this case a single output enable signal DOE2 is utilized to enable and disable distinct chips having data output signals Data2 and Data3. The output enable signal DOE2 is used in its inverted state to initiate the data output signal Data3 at a point prior to the beginning of the diagram. When the output enable signal DOE2 goes positive, the data output signal Data3 is terminated. At the falling edge of the next clock signal CLK, the one condition of the output enable signal DOE2 initiates the data output signal Data2. Thus, a single enable signal may be used to control the initiation and termination of two separate data signals and to provide a guaranteed dead cycle on the system bus. Such an arrangement is especially desirable is an arrangement in which it is desired to produce output signals on a data path from a first circuit directed to a second circuit and immediate respond to those output signals by producing output signals from the second circuit to the first circuit on the same data path. The features of such an operation are clearly illustrated by the three signals CLK3, DOE4, and Data4 illustrated in FIG. 4c.
FIG. 5 is a block diagram of a circuit 30 in accordance with the invention for precisely controlling output enable signals in the manner described above; FIG. 6 is a timing diagram of the signals processed by the circuit 30. In the arrangement of FIG. 5, an off chip driver 30 having a data input terminal and an enable terminal is shown. An output enable signal is furnished as the D input to a D flip-flop 32. A clock pulse (NOT CLK) is furnished to the clock terminal of the D flip-flop 32. Consequently, the Q terminal of the D flip-flop 32 produces an output signal when the output enable signal is high and the falling clock edge appears. This output is furnished to an AND gate 34 where it is ANDed with the output enable signal to produce an output enable signal synchronized to the system clock for enabling the data output of the off chip driver 30. The Q terminal continues to output the enable signal so long as the output enable signal is applied at the D input terminal; but when the output enable signal is removed from the AND gate 34, the enable signal is immediately removed from the driver 30 and its data output is terminated. Consequently, the arrangement produces the desired synchronous turn-on and asynchronous turn-off of the driver 30.
Although the present invention has been described in terms of a preferred embodiment, it will be appreciated that various modifications and alterations might be made by those skilled in the art without departing from the spirit and scope of the invention. The invention should therefore be measured in terms of the claims which follow. | A circuit for providing data output enable signals to a device comprising apparatus for generating an output enable signal in response to the simultaneous application of a clock signal and a second signal, and apparatus for terminating the output enable signal in response to the termination of the second signal alone. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
The present application is a continuation of international application PCT/EP2003/013263, filed 26 Nov. 2003, and which designates the U.S. The disclosure of the referenced application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a closing member for compressed air carrying polygonal tubes of the type used as a mounting rod for the drafting system in a yarn spinning machine.
In such spinning machines, pneumatically loadable top roller support and weighting arms are used, which are secured by means of brackets to a mounting rod of the machine. The mounting rod is hollow and serves at the same time as a compressed air delivery line. A drafting system of this type is described, for example, in DE 198 29 403 A1.
DE 198 30 048 A1 discloses a mounting rod that is formed from polygonal tube sections, with each tube section being provided at its ends with closing members. A mounting rod that is composed of individual tube sections permits a modular construction of the mounting rod and compressed air supply for spinning machines of different lengths. The closing members are inserted in a sealing manner into the ends of the polygonal tube sections. Between the polygonal tube sections, the compressed air is conducted through a connecting tube section which interconnects the closing members of two adjacent sections.
Sealing of non-circular hollow sections with elastic sealing elements, such as O-rings with a circular cross section, or with special section rings, presents problems, inasmuch as irregularities of the special section of the sealing element causes in the latter only a certain equalization of internal tension, without the sealing element filling all zones of the hollow section in a uniform and sealing manner. It is therefore preferred to use in the case of polygonal hollow sections, pasty sealing substances of a suitable viscosity, which must completely fill a sealing channel that is formed by the hollow section and an inserted sealing element. It is however difficult to fill the sealing channel evenly and completely, as well as in a process safe manner in the case of series production. This requires a great expenditure for production and testing. The sealing effect is often not stable for a long duration because of the aging behavior of the sealing substance and because of operational stress, for example, as a result of pressure changes. Thus a reliable, lasting sealing is not ensured.
If leakages occur in operation, sealing elements of the described type are hard to disassemble and cannot be reused. It is therefore often necessary to exchange the entire special section tube length. Likewise, the sealing substance is able to only a very limited extent retain the sealing element in the required position against the inner pressure in the special section tube. This requires additional special measures, for example, the installation of pins for securing the sealing element against axial displacement.
If an adhesive is used as sealing substance to increase the hold of the sealing element in its position at the end of the polygonal tube, it will be difficult and costly to disassemble the closing member. In this case, the closing members and, possibly, even the polygonal tube will no longer be suited for immediate reuse.
At their ends, the polygonal tubes are supported in recesses of brackets that are also known as stands, and secured in position by means of screw connections. To this end, a mounting screw extends through the special-section tube in its end region, which also mounts the respective closing member. By tightening the mounting screw, the polygonal hollow section may undergo elastic or plastic deformations, whereby the sealing effect is additionally put at risk.
Based on the foregoing state of the art, it is an object of the invention to overcome the above limitations and deficiencies of the known closing members.
SUMMARY OF THE INVENTION
The above and other objects and advantages of the invention are achieved by the provision of a closing member which is configured for being inserted in an end of a compressed air carrying polygonal tube on a yarn spinning machine, and which comprises an elastic sealing element, and with the closing member being configured such that it axially biases in its inserted state the sealing element, whereby the sealing element expands so as to seal the closing member relative to the polygonal tube.
The closing member of the invention seals the polygonal tube in a reliable and stable manner for a long duration. It is no longer necessary to secure it in addition, for example, by means of formfitting retaining pins against displacement by the air pressure that builds up in the interior of the polygonal tube, since the closing member is adequately secured in a force-locking engagement, when its sealing function is activated. In comparison with closing members of the known prior art, assembly and disassembly of the closing members are facilitated. The closing members and polygonal tubes are reusable, without having to perform additional labor, such as, for example, cleaning.
A closing member is constructed such that compressed air is allowed to flow from the polygonal tube through the closing member and into the closing member of an adjacent tube. This permits applying axial pressure to the sealing element in a uniform manner, and achieving a reliable sealing effect.
The closing member preferably comprises an end piece and a counterpart with the sealing element being constructed and arranged between the end piece and the counterpart. This permits sealing and securing at the same time, after the closing member has been inserted into the polygonal tube. It is also easy and simple to release the closing member from its secured position and to remove it from the polygonal tube.
The end piece and the counterpart are interconnected by a threaded member that extends through the sealing element, and by tightening the threaded member the end piece and the counterpart move toward each other and bias the sealing element with axial pressure. This also provides adequate space for the compressed air channel, which ensures the necessary passage of the compressed air, and it permits in addition the threaded member to engage the counterpart in the center, which counteracts a tilting of the counterpart when the threaded member is tightened. In addition, the configuration of the end piece and counterpart in the region of the compressed air channel makes it possible to prevent the parts of the closing member from being joined in an incorrect position.
The insertion of a connecting tube into the opening of the closing member, which is formed in its end face by the compressed air channel, ensures the passage of compressed air between two polygonal tubes in a simple manner.
To insure adequate and reliable sealing effect, the length of the sealing element preferably amounts to at least 1.5 times its wall thickness. Also, the sealing element is preferably formed of rubber which provides desirable elastic properties.
The end piece of the closing member may include a recess which is sized to receive differently sized mounting screws. A supporting contour provided on both sides of the recess of the end piece counteracts a deformation of the hollow tube even in the case of an excessive torque applied to the mounting screws.
The closing member is constructed such that it seals the interior of the polygonal tube toward the recess. As a result, the mounting points of the polygonal tube section are arranged in a region of the closing member, which does not carry compressed air. The openings in the polygonal tube, through which the mounting screws of a screw connection extend between the polygonal tube and the machine, need not be sealed. The shape and the position of the recess ensure an adequate staying of the end of the polygonal tube.
The closing member of the invention seals the interior of the polygonal tube in a reliable and stable manner for a long duration. Simultaneously with the sealing effect, it is possible to secure the closing member in its position against the air pressure prevailing in the interior of the polygonal tube without additional auxiliary means. A possibly needed repair of the polygonal tube that forms the mounting rod, is easily possible and requires little labor for disassembly and assembly also when the polygonal tube is installed as a part of a mounting rod between other polygonal tubes.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details of the invention will become apparent from the embodiment that is described in greater detail below, with reference to the Figures, in which:
FIG. 1 is a perspective view of the individual parts of a closing member which embodies the invention before its assembly;
FIG. 2 is a partially sectioned view of the parts of the closing member shown in FIG. 1 ; and
FIG. 3 is a sectional view of the end region of two polygonal tubes, each with a closing member and a connecting tube and taken along the line A-A of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings, there is illustrated a preferred embodiment of a closing member at 1 which embodies the invention. The member 1 comprises an end piece 2 , a sealing element 3 , and a counterpart 4 , which are aligned along a central axis which is shown by the dashed line in FIG. 1 . The member 1 also includes a threaded member 5 , and a sealing washer 6 , which are also positioned along the central axis.
The end piece 2 comprises a guide section 7 , whose outer contour is adapted to the inner contour of a polygonal tube 8 shown in phantom lines in FIG. 1 . The polygonal tube 8 is made square or of some other rectangular configuration. Adjacent the guide section 7 is a sealing section 9 with an outer contour of the same shape. The width and height of the outer contour of sealing section 9 are made somewhat smaller than the width and height of the guide section 7 .
At the end of the end piece 2 that faces the sealing section 9 , a stop 10 is formed, which interacts with an end face 11 of the polygonal tube 8 , and prevents the closing member 1 from being pulled or pushed into the polygonal tube 8 beyond a desired position. The guide section 7 includes a transverse recess 12 . Through this recess 12 and bore holes 13 , a mounting screw extends, which is not shown for reasons of simplification, and which is used to secure the polygonal tube to a bracket or stand. On both axially separated sides of the recess 12 , a supporting contour 14 , 15 is formed, which counteracts a deformation of the hollow polygonal tube 8 . The recess 12 in end piece 2 is dimensioned adequately large for the mounting screw, so as to be universally suited and usable for different screw sizes and screw positions that are dependent on the design of the stands. Along the central axis, the stop 10 includes an axial opening of a feed channel 16 for the threaded member 5 , and in off-center relationship, an outlet of a connecting channel 17 for carrying the compressed air.
The contoured shape of the sealing element 3 corresponds to the polygonal tube 8 and sealing section 9 , with the inner contour of the sealing element 3 being adapted to the outer contour of the sealing section 9 , and the outer contour of the sealing element 3 to the inner contour of the polygonal tube 8 . The sealing element 3 preferably consists of elastically deformable rubber. The wall thickness T of the sealing element 3 is somewhat smaller than the spacing that is present between the inner side of the polygonal tube 8 and the outer side of the guide section 7 , when the closing member 1 is inserted into the polygonal tube 8 . The length L of the sealing element 3 amounts to a multiple of the wall thickness T, and is dimensioned such that the counterpart 4 can adequately bias the sealing element 3 with axial pressure.
The counterpart 4 comprises a hollow section 18 of the same contoured shape as the sealing element 3 , and is closed at one end by a rear wall 19 as best seen in FIG. 2 . The rear wall 19 includes in inwardly directed relationship a support element 20 and a channel element 21 . With its edge 22 , the hollow section 18 projects beyond the support element 20 . The channel element 21 projects even beyond the edge 22 . The counterpart 4 can be joined in mating relationship with the end piece 2 , only when the somewhat projecting channel element 21 assumes its correct position. In the embodiment shown in FIG. 1 , the correct position of the channel element 21 is on the top left in the counterpart 4 . This ensures the necessary flow of the compressed air. Through the center of the rear wall 19 and support element 20 , a bore 23 extends, into which a screw thread is cut. Both the end piece 2 and the counterpart 4 preferably consist of a suitable metal, such as die-cast zinc.
The sectional view of FIG. 2 shows further details of the configuration of closing member 1 . In the interior of end piece 2 , the feed channel 16 changes to a smaller diameter. The transition to the smaller diameter of the feed channel 16 is shaped as a shoulder 24 . The connection channel 17 changes to a compressed air channel 25 , which has a smaller operative cross section than the connection channel 17 .
In the counterpart 4 , one can note a passageway opening 26 for the compressed air. The channel element 21 forms a part of the extension of compressed air channel 25 .
When assembling the closing member 1 , one begins with sliding the sealing element 3 onto the sealing section 9 of the end piece 2 as far as the guide section 7 . Subsequently, one inserts the threaded member 5 together with the sealing washer 6 into the feed channel 16 , with the sealing washer 6 being placed on the shoulder 24 . The end of threaded member 5 is turned into threaded bore 23 of the counterpart 4 only so far that it engages the screw thread, and that the counterpart 4 does not yet exert an axial pressure on the sealing element 3 .
The thus preassembled closing member 1 is inserted into the end of the polygonal tube 8 as far as the stop 10 . Subsequently, one tightens the threaded member 5 , whose head includes a hexagon socket 27 , so that the end piece 2 axially exerts with its edge 22 a pressure on the sealing element 3 . This causes the sealing element 3 to expand against the inner side of the polygonal tube 8 , to secure the position of the closing member 1 against the air pressure developing in the interior of the polygonal tube 8 , and to form a seal in an airtight manner between the polygonal tube 8 and the end piece 2 .
A closing member 1 in this state is shown in FIG. 3 . The compressed air is allowed to flow through the closing member 1 from the passageway opening 26 , via the compressed air channel 25 to the connection channel 17 , or in the opposite direction. Adjacent at a small distance from the polygonal tube 8 is a second polygonal tube 28 . A closing member 29 inserted into the polygonal tube 28 is made mirror-inverted with closing member 1 . The closing member 1 and closing member 29 are interconnected by a connection tube 30 , which is inserted with its ends into the connection channel 17 and connection channel 31 . With that, compressed air is allowed to flow unimpeded between the polygonal tube 8 and polygonal tube 28 through compressed air channels 25 and 33 . The connection tube 30 is sealed by means of O-ring seals 32 as disclosed in DE 198 30 048 A1.
The invention is not limited to the described embodiments. Within the scope of the invention, alternative configurations are possible, in particular of the end piece and the counterpart. | A closing member 1 for compressed air carrying polygonal tubes, which is inserted in a sealing manner into the polygonal tube at one end thereof. The closing member 1 includes an elastic sealing element 3 , and the closing member is constructed such that it biases in its inserted state the sealing element 3 in such a manner that it seals and secures the closing member 1 relative to the polygonal tube 8 . Closing members of this type are used to seal mounting tubes in yarn spinning machines with pneumatically loaded top roller support and weighting arms. | 3 |
FIELD OF THE INVENTION
The present invention relates to snow guns of the type used at major ski resorts.
BACKGROUND OF THE INVENTION
Many ski resorts have extensive snowmaking capability such that the resort has more control over the ski conditions throughout the ski season. Snow guns have improved dramatically over the last 30 years and resorts are able to produce a large snow base as long as the climatic conditions are generally cold. Most snow guns require a temperature of at least -5° C. and preferably -7° C. Colder temperatures make the snowmaking process easier.
Snowmaking equipment uses a combination of a pressurized liquid, generally water with certain additives thereto, in combination with compressed air, both of which are exhausted through a nozzle at high speed to form vapour droplets which basically freeze when exposed to the atmosphere or are frozen at least prior to hitting the ground. In this way, artificial snow is produced. The systems work satisfactorily, but require substantial capital investment as well as significant operating costs.
The other major snowmaking system uses fans (fan guns) which blow the water as it leaves a nozzle to provide mixing and a fine dispersion. The fans replace the compressed air requirement but increase the operation cost as well as the capital cost to bury electrical lines.
The capital costs are large due to the extensive piping for both the compressed gas and high pressure liquid as well as the compressors and pumps required to achieve the necessary operating pressures. The pumps and compressors also require substantial energy input to achieve the operating conditions necessary for snowmaking.
The present invention discloses a structure which simplifies the snowmaking process, reduces the capital costs required for a system and provides a system which has reduced operating costs.
SUMMARY OF THE INVENTION
An arrangement for making snow, according to the present invention, comprises an elongate snow boom having a tube arrangement with a series of nozzles spaced therealong with the tube arrangement closed either end. The snowmaking boom has a liquid feed arrangement for supplying pressurized liquid to the boom. The liquid is forced under high pressure through nozzles in the snow boom such that the exhausted liquid forms a fine dispersion of liquid droplets. The boom is supported at a raised position and is allowed at least a limited rotational movement about a vertical axis. With this arrangement, the snow boom can rotate to adjust to different wind conditions.
According to a preferred aspect of the invention, the boom is attached to a mast member which forms an axis about which the boom rotates.
According to a further aspect of the invention, the mast is attached to the boom at a central point in the length of the boom and forms part of the liquid feed arrangement. The mast accommodates the flow of liquid through the mast and into the boom and the boom is generally horizontal.
According to yet a further aspect of the invention, the mast is attached to the boom and rotates with the boom.
According to yet a further aspect of the invention, the boom is configured to cause liquid in the boom to drain towards the mast when the liquid is not under pressure. This allows effective drainage of the boom to reduce freezing of the liquid within the boom.
According to yet a further aspect of the invention, the arrangement includes electrical heating of the nozzles should the nozzles become frozen or require thawing prior to operating the system. As can be appreciated, the nozzles are quite small and can become frozen with a very small amount of liquid.
According to yet a further aspect of the invention, the mast supports the boom at a raised position of about 20 feet above ground level. This provides a substantial time period in which the fine vapour droplets or liquid droplets pass through the air prior to hitting the ground and will ensure that they are frozen and thus make snow prior to hitting of the ground.
According to the present invention, a method of making snow comprises providing water and appropriate additives under pressure to a boom arrangement at a raised position of at least 6 feet above ground level. The liquid is forced under high pressure, through a series of nozzles spaced along the boom to form a fine dispersion of water and additive droplets from each nozzle. The nozzles are spaced such that the fine dispersions from the nozzles do not interfere with each other. The water and additive droplets pass through the air at temperature of about 5° C. or colder and freeze, thereby forming artificial snow during the time period the droplets pass between the nozzle and ground level.
According to yet a further aspect of the invention, the method includes supporting the boom in a manner to allow rotation thereof in response to changes in wind direction such that the boom is orientated across the wind direction. With this arrangement, the fine dispersion of water and additive droplets from each nozzle basically flow with the wind and do not interfere with one another. By flowing with the wind, the wind tends to draw the dispersions away from the nozzles, and thus improves the ability to make snow.
Preferably, the boom has at least six nozzles to provide a large coverage area.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings, wherein:
FIG. 1 shows a schematic of the snowmaking arrangement;
FIG. 2 shows a partial side view of the snow boom;
FIG. 3 shows the snow boom at one end thereof and the securement of a nozzle therein;
FIG. 4 illustrates the configuration of the mast; and
FIG. 5 shows details of one nozzle secured to the snow boom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The snowmaking arrangement 2 comprises the snow boom 4 which is supported by the mast 6. The snow boom 4 includes a first arm 8 extending to one side of the mast and a second arm 10 extending to the other side of the mast. Each of the first and second arms are angled slightly upwardly to cause each arm to drain towards the mast. Each of the arms 8 and 10 are of a hollow pipe section which is closed at the end, as shown in FIG. 3. At appropriate positions along the length of the snow boom, nozzles 12 are provided which are designed to form a fine dispersion of water droplets when water is forced under high pressure through the nozzles. Typical pressure of the water is anywhere from 250 to 500 psi. Certain additives are normally incorporated in the water to improve the snowmaking ability. One such additive is called SNOMAX ® (Genencor International Inc.), a bacterial protein preparation used to induce the formation of snow and ice crystals in snowmaking. The mixture is preferably cooled to about 2° C. as is known for previous snowmaking systems.
The nozzles 12 are preferably at least 18 inches apart and a spacing of approximately 22 inches has proven most satisfactory. Sufficient spacing is provided between nozzles such that the fine dispersion created by forcing the water through the nozzle do not interfere with each other to an extent to reduced the effectiveness of making snow. The fine dispersions basically interact with the air and freeze prior to reaching ground level. If the nozzles are too close, there will be a crossover of the dispersions and there will be a very high concentration at the overlap, which can affect the snowmaking capability. A spacing of 18 inches and the preferred 22 inches ensures that the dispersions of each nozzle do not inappropriately affect each other. Each of the arms 8 and 10 are preferably of an aluminum, such as a 1 1/2 inch nominal diameter aluminum pipe. They can be closed at the end by a welded cap 13. The boom's overall length is approximately 20 feet and there are 12 nozzles placed on the boom. All of the 12 nozzles shown in FIG. 1 are on the same side of the boom. In order to provide additional support for each of the arms 8 and 10, the mast 6 includes an extension 16 which is connected to the cross connection 18, which is welded to each of the first and second arms 10. In this way, the arms 8 and 10 are angled slightly upwardly and any liquid in these arms will drain towards the mast 6. The mast 6 is connected to a high pressure water and additive supply 50 which supplies water and additives at a pressure of anywhere from 250 to 500 psi. It is preferable that the pressurized water be introduced into the boom through the mast 6. A separate hose can connect the base of the mast with the supply. In this way, when the snowmaking session is over, the mast 6 is disconnected from the supply and the boom and mast will drain quickly by gravity. In this way, the first arm, the second arm and the mast will drain, and thus will be in a condition suitable for start up of snowmaking at a later point.
The mast 6, as shown in FIG. 4, does include bushings 14 which can be supported within a column to allow rotation of the mast about the column. This is preferred as the large boom with the various vapour dispersions coming from the nozzle will orientate across the wind and thereby adjusts to the direction of the wind. This is important to keep the dispersions trailing away from the boom and to avoid interference with each other. It is important that the dispersions flow with the wind to carry them away from the boom, as, if they go into the wind, the droplets can be knocked down and will tend to merge and may not produce effective snow. Under low wind conditions this is often not a significant problem.
It is preferred that the boom be positioned at a raised position of at least 18 feet above ground level and preferably 20 to 30 feet above ground level. This provides a significant period of time from the initial expulsion of the water droplets from the nozzle to the time they reach ground level. This time will ensure that the vapour is frozen and effective snow is produced. The air temperature is typically -5° C. or colder and preferably -7° C. or colder.
Each of the nozzles is shown located within a coupling 30 which receives the threaded nozzles. The nozzles may be of the type sold by Snow Machine Inc. as SMI 078.
The exact height of the boom can vary with the particular circumstances. With the boom at six feet above the ground, the air air would have to be quite cold to produce effective snow. The quality of snow is dependent upon sufficient time for freezing of the fine dispersion while the dispersion is air borne. This time can vary with the water pressure and wind conditions as well as site conditions. The high boom height is a simple means to provide more than sufficient time for freezing, but under the right conditions, lower boom heights can also be effective.
FIG. 5 shows a further embodiment of the invention wherein each of the nozzles include an electrical heating means, in this case cable 40, provided thereabout. It has been found that even with the effective drainage of the boom, the nozzles, due to the small port through which the liquid is forced, can freeze. The heating elements 40 are connected to a 12 volt portable power supply and initially heat the nozzles prior to operating the snow boom. In this way, the nozzles will be clear at start-up, regardless of the temperature and regardless of whether they froze after completion of the last snowmaking session.
Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims. | The present invention relates to snow guns and improvements thereto. The improved snow gun has a large boom which receives liquid under pressure and forces it through small nozzles. The structure does not require high pressure compressed gas or large fan guns, and thus, is much more cost effective to install and operate. In a preferred form, the boom responds to changes in wind direction, which otherwise could reduce the effectiveness of the system. | 5 |
FIELD OF THE INVENTION
This invention relates to a carrier with straps that encircle the article that is being carried.
BACKGROUND OF THE INVENTION
My prior U.S. Pat. No. 5,137,481 describes an outboard motor tote that is excellent for helping a person to mount or remove a heavy article such as an outboard motor from the transom of a boat, which is an especially difficult job when the boat is bobbing about in a heavy sea. While this product is very good, there are certain areas in which performance can be improved. In my original design there was no way to orient strap portions on either side of the handle at an oblique angle without weakening the staps, for example, by cutting each strap and then sewing the cut portions together adjacent the handle. It is thus one object of the invention to find a better way of arranging the straps so that they are oriented at an oblique angle and diverge from one another at the point where they are connected to the handle without cutting or in any way weakening either the straps or the handle.
Another drawback of the prior design was the difficulty encountered in mounting a reinforcing plate and a somewhat complex layered construction employed for connecting the reinforcing plate to the handle and to the straps. Accordingly, it is another object to simplify construction where the reinforcing plate and handle are connected together and to make it easy for the reinforcing plate to be mounted in place and securely retained on the finished carrier.
In the prior design, it was sometimes possible for water to enter the pockets on the cover. It is another object of the invention to find a way of making it less likely for water to enter pockets provided on each side of the cover.
These and other more detailed and specific objects of the present invention will be apparent in view of the following description setting forth by way of example but a few of the various forms of the invention that will be apparent to those skilled in the art once the principles described herein are understood.
SUMMARY OF THE INVENTION
This invention provides an article carrier having a handle formed from flexible material, e.g., of woven fabric webbing, positioned at the top of the article that is to be carried and connected to a front and a rear strap, each of which forms an article-encircling loop. Each strap is twisted where it is connected to the handle to make a half turn, i.e., 180° twist, and is then folded against itself at the point where it is twisted to define an oblique angle between that portion of the strap on one side of the handle and the portion of the same strap on the opposite side of the handle. Each strap has a top and a bottom surface. The top surface of each strap is exposed on one side of the handle and, because of the twist, the bottom surface is exposed to view on the other side of the handle. In this way, the front strap is angled forwardly from the handle and the rear strap is angled rearwardly without weakening either of the straps.
Each of the straps has free, usually downwardly extending ends which, when the straps are placed around the article to be carried, are connected together by means of a suitable releasable fastener such as a buckle.
Sewing between the straps and a flexible cover sheet is located on either side of the handle to form a space that serves as a sleeve into which the reinforcing plate is slid, thereby securely holding it in place following assembly. The pockets on opposite sides of the article cover have a hollow interior including a hollow but flattened top portion which is folded downwardly when the pocket is closed to help prevent water from entering the pocket.
THE FIGURES
FIG. 1 is a top view of a carrier in accordance with the invention shown in use for carrying a pet;
FIG. 2 is a front view of the invention in use as a carrier for an outboard motor;
FIG. 3 is a side view of the carrier of FIGS. 1 and 2 as it appears in use as an outboard motor carrier;
FIG. 4 is a perspective view of the invention;
FIG. 4A is a partial perspective view of the right side of FIG. 4 with one end of the pocket lifted slightly to show the mouth at the top of the pocket.
FIG. 5 is a partial bottom view of the central portion of the carrier;
FIG. 6 is a view similar to FIG. 5 on a smaller scale showing the handle portion of the carrier;
FIG. 7 is a partial bottom perspective view of the carrier with the reinforcing plate being inserted;
FIG. 8 is a partial perspective view of the carrier as the pocket is being mounted in place on the cover; and
FIG. 9 is a perspective view of another form of carrier in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
The figures illustrate preferred forms of the invention that are intended for use in carrying a variety of articles. The invention, however, is particularly useful for carrying a heavy object such as an outboard motor as well as a variety of other items, e.g., articles that are to be taken aboard a power boat and sailing vessel. Although useful for various purposes, the carrier is shown in use for transporting a pet in FIG. 1 and an outboard motor in FIGS. 2 and 3. Other uses will be apparent.
The invention includes straps 18, 20 and handle 22 formed from flexible strap material, e.g., nylon or polyester webbing, typically about 4.0 cm in width. Except as described herein, the invention is formed from generally the same types of materials and in a manner similar to that described in my prior U.S. Pat. No. 5,137,481 which is incorporated herein by reference.
As shown in FIGS. 1-4, the carrier indicated generally at 10 includes a cover 12 formed from a generally rectangular sheet of flexible canvas or other suitable cloth, e.g., rubberized or plastic impregnated cloth, which conforms to and covers at least the upper surface of the article 11 being carried. Secured to the left and right sides of the cover 12, in this case by sewing along hems 14a and 16a (FIG. 4), are left and right pockets 14 and 16, respectively, which will be described in more detail below.
The carrier 10 also has front and rear article-encircling straps 18 and 20 which are connected at the top of the article 11 being carried to a strap-style handle 22 composed, for example, from 3.7 mm wide nylon webbing that is formed into a loop of the flexible woven strap material. The ends of the loop are connected together preferably by sewing. The handle 22 encircles the straps 18, 20. The straps 18 and 20 themselves enclose the article 11 being carried. The free ends of straps 18, 20 are connected together by buckles 18a, 20a (FIG. 3), respectively, to enable each strap to be released and refastened as required for mounting and removing the carrier 10 on the article such as a pet dog 11 (FIG. 1) or outboard motor 11a (FIGS. 2-4).
It will be seen that the straps 18, 20 diverge so as to extend away from one another proceeding away from the handle 22 (FIGS. 1, 3 and 4). This has several important benefits. It allows the straps 18, 20 to conform better to the surface of the article 11 being carried. It also places their lower ends much further apart than the distance between the ends of handle 22.
The straps 18, 20 each have a special arrangement for causing them to diverge from one another and to conform smoothly to the surface of the article 11 that is being carried without any sacrifice of strength. As best seen in FIGS. 5 and 6, the straps 18, 20 are each provided with a one-half turn, i.e., a 180° twist, and each has a fold located at the point of the 180° twist. For example, strap 18 as shown in FIG. 6 is provided with a 180° twist at the location of the carrying handle 22 and is also folded along a line 19 at the point where the twist is located so that the portions of the strap 18 on opposite sides of the handle 22 intersect at an oblique angle. Both the left and right portions of strap 18 diverge from the strap 20. Similarly, the strap 20 is provided with a one-half turn, i.e., a 180° twist and is folded at that point along a fold line 21. Portions of both of the straps 18, 20 on either side of the handle 22 intersect at an angle A which can be about, say, 140°.
The folds in straps 18, 20 are designated 19 and 21, respectively. In this way, the top surface of the strap on one side of the handle 22 is visible and the bottom surface of the same strap can be seen on the other side of the handle 22. Thus, each of the straps 18, 20 by virtue of the 180° twist and folds 19, 21 achieves the proper angle A of intersection and diverges from one another so that their lower portions are spread some distance apart, yet the straps 18, 20 conform smoothly to the surface of the article 11 being carried. In this way a divergence of the straps 18, 20 from one another is achieved without sacrificing the strength of either strap.
Adjacent to the point where each strap 18, 20 is twisted, the cover 12 is provided with slits 12a and 12b through which the strap handle 22 passes. Thus, a portion of the strap handle 22 extends below each of the straps 18, 20 and a portion extends upwardly through the slits 12a, 12b and is visible as seen in FIGS. 1-3 above the cover 12. The ends of the handle 22 are connected together to form a loop, e.g., by sewing at 22a (FIG. 7). During manufacture, the strap handle 22 is passed through slits 12a, 12b in cover sheet 12 and the free ends are connected below the straps 18, 20 by means of sewing at 22a.
Connected between the lower portions of the straps 18, 20 are two lateral tie straps 24, 25 (FIGS. 3 and 4). Straps 24 and 25 are conveniently formed from one long strap, the center part of which is stitched to a short loop 23 of strap material, e.g., cloth webbing that encircles strap 20. Straps 24 and 25 prevent the lower ends of the straps 18, 20 from spreading too far apart, i.e., maintain straps 18, 20 securely in place against the lower portion of the article that is being carried. The lateral tie straps 24, 25 are provided with releasable fasteners or buckles 24a, 25a (FIGS. 3 and 4).
Beneath the straps 18, 20 and in alignment with the handle 22 is a reinforcing plate 26 in the form of a flat bar or plate which is usually about 12 cm to 14 cm long, about 3 cm wide, and about 2 mm to 5 mm thick. The reinforcing place 26 can be formed from any suitable strong, stiff material such as wood, plastic resin reinforced with fiberglass, metal, etc. Wood has been found satisfactory.
Straps 18, 20 are secured to the lower face of the cover 12 in a special way for enabling the reinforcing plate 26 (FIGS. 5-7) to be easily mounted and reliably retained in position just below the strap handle 22 and between the straps 18, 20 and the cover 12. This accomplished by stitching the straps 18 and 20 to the cover 12 on either side of the reinforcing plate 26 to leave a gap or sleeve that facilitates insertion of the reinforcing plate 26 as shown in FIG. 7. Specifically, strap 18 is secured to the cover 12 by means of aligned, laterally spaced apart, longitudinally extending rows of stitching 18b and 18d which are parallel and just slightly further apart than the space required for the plate 26. Similar rows of parallel, laterally spaced apart stitches 20b and 20d are provided between strap 20 and the cover 12. The rows of stitches 18b, 18d are connected to stitching 18a and 18c that extend longitudinally along each edge of strap 18. In a similar manner, edge stitchings 20a and 20c extend along each edge of strap 20 proceeding away from the stitching 20b, 20d.
During manufacture, the straps 18, 20 are stitched to the cover 12. The handle 22 is then inserted through the openings 12a, 12b and its free ends sewn together at 22a. The handle 22 is then forced to one side away from the fold 19 (see FIG. 7). The reinforcing plate 26 is then inserted by sliding it in between the spaced apart rows of stitches 18b, 18d and 20b, 20d which act as a sleeve or pouch for receiving and holding the reinforcing plate 26. When the handle 22 returns to its normal position as shown in FIGS. 1-4, plate 26 is securely held in place between the straps 18, 20 and the lower portion of handle 22. During use, the reinforcing plate 26 keeps the handle 22 from buckling even when the carrier 10 is heavily loaded. In this way, the twist in each of the straps 18, 20 at the folds 19, 21 acts in cooperation with the stitching and with the reinforcing plate 26 to provide excellent strength and shock resistance as well as assuring comfort for the hand when the carrier 10 is being lifted manually by handle 22.
As seen in FIGS. 4 and 4A, the pocket 16 is a hollow, generally flattened tubular pouch with an upper mouth 50 that is positioned above a laterally extending fold line 52, the left end of which is designated 38. Extending upwardly from the mouth 50 when the pocket is open, is a cover flap 54 provided with a detachable fastening means such as a hook-and-loop fastener strip, e.g., Velcro® strip, 56 which during use is secured to a complementary Velcro strip 40. Pocket 14 of FIG. 4 is similar. When either pocket 14 or 16 is to be closed, an upper flattened tubular portion 53 which is located above the fold line 52 is folded downwardly as shown about the transverse fold line 52, and the Velcro® closure elements 36, 40 are connected together the keep the respective pockets 14 or 16 closed.
Refer now to FIG. 8 which illustrates one form of pocket in accordance with the invention. The following remarks apply to both pockets 14 and 16 of FIG. 8.
As shown in FIG. 8, the canvas cover 12 has front and rear edges 12c, 12d and side edges 12e and 12f. In the embodiment of FIG. 8, the pockets 14, 16 are removably secured to the side edges 12e and 12f of the cover 12 by means of detachable hook and loop fastener strips such as Velcro® strips 40, 42. The Velcro® strip 42 is permanently attached to each pocket 14, 16 by sewing (not shown).
Each pocket 14, 16 is a hollow, generally flattened tubular pouch with an upper open mouth 50 that is positioned considerably above a laterally extending fold line 52. Extending upwardly from the mouth 50 is a cover flap 54 provided with a detachable fastening means such as a hook and loop fastener strip, e.g., Velcro® strip 56, which during use is secured to a complementary Velcro® strip 58. When the pocket 14, 16 is to be closed, an upper flattened, tubular portion 53 of either pocket 14, 16 which is located above the fold line 52 is folded downwardly as shown in FIG. 8 about the transverse fold line 52, and the Velcro® closure elements 56, 58 are connected together to keep the pocket 14, 16 closed. By providing a flattened tubular upper portion 53 above the fold line 52, it is very unlikely for moisture to leak in from the outside. It should be noted that both the inner and outer walls of the pockets 14 or 16 are pressed together where the tubular pocket is flattened and both walls are folded along the transverse fold line 52, making it very difficult for water to enter the pocket even during long periods of rainy weather.
Refer now to FIG. 9. In FIG. 9, the cover 12 is similar to that described above and includes a rear edge 12d, a front edge 12c, and side edges 12e and 12f. While a hem is provided along the side edges 12e and 12f, there is no Velcro® strip 40 and no pocket is provided. This embodiment of the invention is more economical and, while the top of the motor is protected by the cover 12, the sides of the motor are unobstructed and hence more accessible to the operator for repair or maintenance.
Many variations of the present invention within the scope of the appended claims will be apparent to those skilled in the art once the principles described herein are understood. | The invention provides an article carrier (10) having a handle (22) formed from flexible material at the top of the article that is to be carried (11). A pair of straps (18, 20) which form article-encircling loops are both connected to the handle (22). Where the straps (18, 20) are connected to the handle (22), each is twisted to make a half turn, i.e., 180° twist, and each is folded against itself to define an oblique angle (A) between portions of each strap (18, 20) on opposite sides of the handle (22). The strap (18) at the front end of the handle (22) diverges forwardly and the strap (20) connected to the rear of the handle diverges rearwardly. Sewing between the straps and a cover (12) terminates on either side of the handle (22) to form a sleeve which serves as an opening into which a reinforcing plate (26) is placed. Pockets (14, 16) on opposite sides of the cover (12) each have a hollow interior and each includes an upper flattened tubular portion (53) which is folded downwardly when the pocket (14, 16) is closed to help prevent water from entering either pocket (14, 16). | 1 |
RELATED APPLICATIONS
This application is a continuation of, and incorporates by reference in its entirety, U.S. application Ser. No. 10/418,509, filed Apr. 16, 2003 now U.S. Pat. No. 6,945,903, which is a continuation of U.S. application Ser. No. 10/141,652, filed May 7, 2002 now U.S. Pat. No. 6,551,210, which is a continuation of U.S. application Ser. No. 09/695,757, filed Oct. 24, 2000, now U.S. Pat. No. 6,419,608, which issued Jul. 16, 2002. The U.S. application Ser. No. 10/418,509 is also a continuation-in-part of U.S. application Ser. No. 10/016,116, filed on Oct. 30, 2001, now U.S. Pat. No. 6,676,559, which is a continuation of U.S. application Ser. No. 09/823,620, filed Mar. 30, 2001, now U.S. Pat. No. 6,322,475, which is a continuation of U.S. application Ser. No. 09/133,284, filed Aug. 12, 1998, now U.S. Pat. No. 6,241,636, which in turn claims priority to U.S. provisional application No. 60/062,860, filed on Oct. 16, 1997; U.S. provisional application No. 60/056,045, filed on Sep. 2, 1997; U.S. provisional application No. 60/062,620, filed on Oct. 22, 1997 and U.S. provisional application No. 60/070,044 filed on Dec. 30, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention relates to transmissions. More particularly the invention relates to continuously variable transmissions.
2. Description of the Related Art
In order to provide an infinitely variable transmission, various traction roller transmissions in which power is transmitted through traction rollers supported in a housing between torque input and output discs have been developed. In such transmissions, the traction rollers are mounted on support structures which, when pivoted, cause the engagement of traction rollers with the torque discs in circles of varying diameters depending on the desired transmission ratio.
However, the success of these traditional solutions has been limited. For example, in U.S. Pat. No. 5,236,403 to Schievelbusch, a driving hub for a vehicle with a variable adjustable transmission ratio is disclosed. Schievelbusch teaches the use of two iris plates, one on each side of the traction rollers, to tilt the axis of rotation of each of the rollers. However, the use of iris plates can be very complicated due to the large number of parts which are required to adjust the iris plates during shifting the transmission. Another difficulty with this transmission is that it has a guide ring which is configured to be predominantly stationary in relation to each of the rollers. Since the guide ring is stationary, shifting the axis of rotation of each of the traction rollers is difficult. Yet another limitation of this design is that it requires the use of two half axles, one on each side of the rollers, to provide a gap in the middle of the two half axles. The gap is necessary because the rollers are shifted with rotating motion instead of sliding linear motion. The use of two axles is not desirable and requires a complex fastening system to prevent the axles from bending when the transmission is accidentally bumped, is as often the case when a transmission is employed in a vehicle. Yet another limitation of this design is that it does not provide for an automatic transmission.
Therefore, there is a need for a continuously variable transmission with a simpler shifting method, a single axle, and a support ring having a substantially uniform outer surface. Additionally, there is a need for an automatic traction roller transmission that is configured to shift automatically. Further, the practical commercialization of traction roller transmissions requires improvements in the reliability, ease of shifting, function and simplicity of the transmission.
SUMMARY OF THE INVENTION
The present invention includes a transmission for use in rotationally or linearly powered machines and vehicles. For example the present transmission may be used in machines such as drill presses, turbines, and food processing equipment, and vehicles such as automobiles, motorcycles, and bicycles. The transmission may, for example, be driven by a power transfer mechanism such as a sprocket, gear, pulley or lever, optionally driving a one way clutch attached at one end of the main shaft.
In one embodiment of the invention, the transmission comprises a rotatable driving member, three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis of rotation that is centrally located within each of the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, wherein the support member rotates about an axis that is centrally located within the support member, at least one platform for actuating axial movement of the support member and for actuating a shift in the axis of rotation of the power adjusters, wherein the platform provides a convex surface, at least one stationary support that is non-rotatable about the axis of rotation that is defined by the support member, wherein the at least one stationary support provides a concave surface, and a plurality of spindle supports, wherein each of the spindle supports are slidingly engaged with the convex surface of the platform and the concave surface of the stationary support, and wherein each of the spindle supports adjusts the axes of rotation of the power adjusters in response to the axial movement of the platform.
In another embodiment, the transmission comprises a rotatable driving member; three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis of rotation that is respectively central to the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, a rotatable driving member for rotating each of the power adjusters, a bearing disc having a plurality of inclined ramps for actuating the rotation of the driving member, a coiled spring for biasing the rotatable driving member against the power adjusters, at least one lock pawl ratchet, wherein the lock pawl ratchet is rigidly attached to the rotatable driving member, wherein the at least one lock pawl is operably attached to the coiled spring, and at least one lock pawl for locking the lock pawl ratchet in response to the rotatable driving member becoming disengaged from the power adjusters.
In still another embodiment, the transmission comprises a rotatable driving member, three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis that is respectively central to each of the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, wherein the support member rotates about an axis that is centrally located within the support member, a bearing disc having a plurality of inclined ramps for actuating the rotation of the driving member, a screw that is coaxially and rigidly attached to the rotatable driving member or the bearing disc, and a nut that, if the screw is attached to the rotatable driving member, is coaxially and rigidly attached to the bearing disc, or if the screw is rigidly attached to the bearing disc, coaxially and rigidly attached to the rotatable driving member, wherein the inclined ramps of the bearing disc have a higher lead than the screw.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cutaway side view of the transmission of the present invention.
FIG. 2 is a partial perspective view of the transmission of FIG. 1 .
FIG. 3 is a perspective view of two stationary supports of the transmission of FIG. 1 .
FIG. 4 is a partial end, cross-sectional view of the transmission of FIG. 1 .
FIG. 5 is a perspective view of a drive disc, bearing cage, screw, and ramp bearings of the transmission of FIG. 1 .
FIG. 6 is a perspective view of a ratchet and pawl subsystem of the transmission of FIG. 1 that is used to engage and disengage the transmission.
FIG. 7 is partial perspective view of the transmission of FIG. 1 , wherein, among other things, a rotatable drive disc has been removed.
FIG. 8 is a partial perspective view of the transmission of FIG. 1 , wherein, among other things, the hub shell has been removed.
FIG. 9 is a partial perspective view of the transmission of FIG. 1 , wherein the shifting is done automatically.
FIG. 10 is a perspective view of the shifting handlegrip that is mechanically coupled to the transmission of FIG. 1 .
FIG. 11 is an end view of a thrust bearing, of the transmission shown in FIG. 1 , which is used for automatic shifting of the transmission.
FIG. 12 is an end view of the weight design of the transmission shown in FIG. 1 .
FIG. 13 is a perspective view of an alternate embodiment of the transmission bolted to a flat surface.
FIG. 14 is a cutaway side view of the transmission shown in FIG. 13 .
FIG. 15 is a schematic end view of the transmission in FIG. 1 showing the cable routing across a spacer extension of the automatic portion of the transmission.
FIG. 16 is a schematic end view of the cable routing of the transmission shown in FIG. 13 .
FIG. 17 is a schematic diagram of an implementation of a continuously variable transmission on a scooter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following detailed description is directed to certain specific embodiments of the invention. However, the invention can be embodied in a multitude of different ways as defined and covered by the claims. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout. Furthermore, embodiments of the invention may include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the inventions herein described.
The present invention includes a continuously variable transmission that may be employed in connection with any type of machine that is in need of a transmission. For example, the transmission may be used in (i) a motorized vehicle such as an automobile, motorcycle, or watercraft, (ii) a non-motorized vehicle such as a bicycle, tricycle, scooter, exercise equipment or (iii) industrial equipment, such as a drill press, power generating equipment, or textile mill.
Referring to FIGS. 1 and 2 , a continuously variable transmission 100 is disclosed. The transmission 100 is shrouded in a hub shell 40 covered by a hub cap 67 . At the heart of the transmission 100 are three or more power adjusters 1 a, 1 b, 1 c which are spherical in shape and are circumferentially spaced equally around the centerline or axis of rotation of the transmission 100 . As seen more clearly in FIG. 2 , spindles 3 a, 3 b, 3 c are inserted through the center of the power adjusters 1 a, 1 b, 1 c to define an axis of rotation for the power adjusters 1 a, 1 b, 1 c. In FIG. 1 , the power adjuster's axis of rotation is shown in the horizontal direction. Spindle supports 2 a–f are attached perpendicular to and at the exposed ends of the spindles 3 a, 3 b, 3 c. In one embodiment, each of the spindles supports have a bore to receive one end of one of the spindles 3 a, 3 b, 3 c. The spindles 3 a, 3 b, 3 c also have spindle rollers 4 a–f coaxially and slidingly positioned over the exposed ends of the spindles 3 a, 3 b, 3 c outside of the spindle supports 2 a–f.
As the rotational axis of the power adjusters 1 a, 1 b, 1 c is changed by tilting the spindles 3 a, 3 b, 3 c, each spindle roller 4 a–f follows in a groove 6 a–f cut into a stationary support 5 a, 5 b. Referring to FIGS. 1 and 3 , the stationary supports 5 a, 5 b are generally in the form of parallel discs with an axis of rotation along the centerline of the transmission 100 . The grooves 6 a–f extend from the outer circumference of the stationary supports 5 a, 5 b towards the centerline of the transmission 100 . While the sides of the grooves 6 a–f are substantially parallel, the bottom surface of the grooves 6 a–f forms a decreasing radius as it runs towards the centerline of the transmission 100 . As the transmission 100 is shifted to a lower or higher gear by changing the rotational axes of the power adjusters 1 a, 1 b, 1 c, each pair of spindle rollers 4 a–f, located on a single spindle 3 a, 3 b, 3 c, moves in opposite directions along their corresponding grooves 6 a–f.
Referring to FIGS. 1 and 3 , a centerline hole 7 a, 7 b in the stationary supports 5 a, 5 b allows the insertion of a hollow shaft 10 through both stationary supports 5 a, 5 b. Referring to FIG. 4 , in an embodiment of the invention, one or more of the stationary support holes 7 a, 7 b may have a non-cylindrical shape 14 , which fits over a corresponding non-cylindrical shape 15 along the hollow shaft 10 to prevent any relative rotation between the stationary supports 5 a, 5 b and the hollow shaft 10 . If the rigidity of the stationary supports 5 a, 5 b is insufficient, additional structure may be used to minimize any relative rotational movement or flexing of the stationary supports 5 a, 5 b. This type of movement by the stationary supports 5 a, 5 b may cause binding of the spindle rollers 4 a–f as they move along the grooves 6 a–f.
As shown in FIGS. 4 and 7 , the additional structure may take the form of spacers 8 a, 8 b, 8 c attached between the stationary supports 5 a, 5 b. The spacers 8 a, 8 b, 8 c add rigidity between the stationary supports 5 a, 5 b and, in one embodiment, are located near the outer circumference of the stationary supports 5 a, 5 b. In one embodiment, the stationary supports 5 a, 5 b are connected to the spacers 8 a, 8 b, 8 c by bolts or other fastener devices 45 a–f inserted through holes 46 a–f in the stationary supports 5 a, 5 b.
Referring back to FIGS. 1 and 3 , the stationary support 5 a is fixedly attached to a stationary support sleeve 42 , which coaxially encloses the hollow shaft 10 and extends through the wall of the hub shell 40 . The end of the stationary support sleeve 42 that extends through the hub shell 40 attaches to the frame support and preferentially has a non-cylindrical shape to enhance subsequent attachment of a torque lever 43 . As shown more clearly in FIG. 7 , the torque lever 43 is placed over the non-cylindrical shaped end of the stationary support sleeve 42 , and is held in place by a torque nut 44 . The torque lever 43 at its other end is rigidly attached to a strong, non-moving part, such as a frame (not shown). A stationary support bearing 48 supports the hub shell 40 and permits the hub shell 40 to rotate relative to the stationary support sleeve 42 .
Referring back to FIGS. 1 and 2 , shifting is manually activated by axially sliding a rod 11 positioned in the hollow shaft 10 . One or more pins 12 are inserted through one or more transverse holes in the rod 11 and further extend through one or more longitudinal slots 16 (not shown) in the hollow shaft 10 . The slots 16 in the hollow shaft 10 allow for axial movement of the pin 12 and rod 11 assembly in the hollow shaft 10 . As the rod 11 slides axially in the hollow shaft 10 , the ends of the transverse pins 12 extend into and couple with a coaxial sleeve 19 . The sleeve 19 is fixedly attached at each end to a substantially planar platform 13 a, 13 b forming a trough around the circumference of the sleeve 19 .
As seen more clearly in FIG. 4 , the planar platforms 13 a, 13 b each contact and push multiple wheels 21 a–f. The wheels 21 a–f fit into slots in the spindle supports 2 a–f and are held in place by wheel axles 22 a–f. The wheel axles 22 a–f are supported at their ends by the spindle supports 2 a–f and allow rotational movement of the wheels 21 a–f.
Referring back to FIGS. 1 and 2 , the substantially planar platforms 13 a, 13 b transition into a convex surface at their outer perimeter (farthest from the hollow shaft 10 ). This region allows slack to be taken up when the spindle supports 2 a–f and power adjusters 1 a, 1 b, 1 c are tilted as the transmission 100 is shifted. A cylindrical support member 18 is located in the trough formed between the planar platforms 13 a, 13 b and sleeve 19 and thus moves in concert with the planar platforms 13 a, 13 b and sleeve 19 . The support member 18 rides on contact bearings 17 a, 17 b located at the intersection of the planar platforms 13 a, 13 b and sleeve 19 to allow the support member 18 to freely rotate about the axis of the transmission 100 . Thus, the bearings 17 a, 17 b, support member 18 , and sleeve 19 all slide axially with the planar platforms 13 a, 13 b when the transmission 100 is shifted.
Now referring to FIGS. 3 and 4 , stationary support rollers 30 a–l are attached in pairs to each spindle leg 2 a–f through a roller pin 31 a–f and held in place by roller clips 32 a–l. The roller pins 31 a–f allow the stationary support rollers 30 a–l to rotate freely about the roller pins 31 a–f. The stationary support rollers 30 a–l roll on a concave radius in the stationary support 5 a, 5 b along a substantially parallel path with the grooves 6 a–f. As the spindle rollers 4 a–f move back and forth inside the grooves 6 a–f, the stationary support rollers 30 a–l do not allow the ends of the spindles 3 a, 3 b, 3 c nor the spindle rollers 4 a–f to contact the bottom surface of the grooves 6 a–f , to maintain the position of the spindles 3 a, 3 b, 3 c, and to minimize any frictional losses.
FIG. 4 shows the stationary support rollers 30 a–l , the roller pins, 31 a–f , and roller clips 32 a–l , as seen through the stationary support 5 a, for ease of viewing. For clarity, i.e., too many numbers in FIG. 1 , the stationary support rollers 30 a–l , the roller pins, 31 a–f , and roller clips 32 a–l , are not numbered in FIG. 1 .
Referring to FIGS. 1 and 5 , a concave drive disc 34 , located adjacent to the stationary support 5 b, partially encapsulates but does not contact the stationary support 5 b. The drive disc 34 is rigidly attached through its center to a screw 35 . The screw 35 is coaxial to and forms a sleeve around the hollow shaft 10 adjacent to the stationary support 5 b and faces a driving member 69 . The drive disc 34 is rotatively coupled to the power adjusters 1 a, 1 b, 1 c along a circumferential bearing surface on the lip of the drive disc 34 . A nut 37 is threaded over the screw 35 and is rigidly attached around its circumference to a bearing disc 60 . One face of the nut 37 is further attached to the driving member 69 . Also rigidly attached to the bearing disc 60 surface are a plurality of ramps 61 which face the drive disc 34 . For each ramp 61 there is one ramp bearing 62 held in position by a bearing cage 63 . The ramp bearings 62 contact both the ramps 61 and the drive disc 34 . A spring 65 is attached at one end to the bearing cage 63 and at its other end to the drive disc 34 , or the bearing disc 60 in an alternate embodiment, to bias the ramp bearings 62 up the ramps 61 . The bearing disc 60 , on the side opposite the ramps 61 and at approximately the same circumference contacts a hub cap bearing 66 . The hub cap bearing 66 contacts both the hub cap 67 and the bearing disc 60 to allow their relative motion. The hub cap 67 is threaded or pressed into the hub shell 40 and secured with an internal ring 68 . A sprocket or pulley 38 is rigidly attached to the rotating driving member 69 and is held in place externally by a cone bearing 70 secured by a cone nut 71 and internally by a driver bearing 72 which contacts both the driving member 69 and the hub cap 67 .
In operation, an input rotation from the sprocket or pulley 38 , which is fixedly attached to the driver 69 , rotates the bearing disc 60 and the plurality of ramps 61 causing the ramp bearings 62 to roll up the ramps 61 and press the drive disc 34 against the power adjusters 1 a, 1 b, 1 c . Simultaneously, the nut 37 , which has a smaller lead than the ramps 61 , rotates to cause the screw 35 and nut 37 to bind. This feature imparts rotation of the drive disc 34 against the power adjusters 1 a, 1 b, 1 c. The power adjusters 1 a, 1 b, 1 c , when rotating, contact and rotate the hub shell 40 .
When the transmission 100 is coasting, the sprocket or pulley 38 stops rotating but the hub shell 40 and the power adjusters 1 a, 1 b, 1 c , continue to rotate. This causes the drive disc 34 to rotate so that the screw 35 winds into the nut 37 until the drive disc 34 no longer contacts the power adjusters 1 a, 1 b, 1 c.
Referring to FIGS. 1 , 6 , and 7 , a coiled spring 80 , coaxial with the transmission 100 , is located between and attached by pins or other fasteners (not shown) to both the bearing disc 60 and drive disc 34 at the ends of the coiled spring 80 . During operation of the transmission 100 , the coiled spring 80 ensures contact between the power adjusters 1 a, 1 b, 1 c and the drive disc 34 . A pawl carrier 83 fits in the coiled spring 80 with its middle coil attached to the pawl carrier 83 by a pin or standard fastener (not shown). Because the pawl carrier 83 is attached to the middle coil of the coiled spring 80 , it rotates at half the speed of the drive disc 34 when the bearing disc 60 is not rotating. This allows one or more lock pawls 81 a, 81 b, 81 c, which are attached to the pawl carrier 83 by one or more pins 84 a, 84 b, 84 c, to engage a drive disc ratchet 82 , which is coaxial with and rigidly attached to the drive disc 34 . The one or more lock pawls 84 a, 84 b, 84 c are preferably spaced asymmetrically around the drive disc ratchet 82 . Once engaged, the loaded coiled spring 80 is prevented from forcing the drive disc 34 against the power adjusters 1 a, 1 b, 1 c . Thus, with the drive disc 34 not making contact against the power adjusters 1 a, 1 b, 1 c , the transmission 100 is in neutral and the ease of shifting is increased. The transmission 100 can also be shifted while in operation.
When operation of the transmission 100 is resumed by turning the sprocket or pulley 38 , one or more release pawls 85 a, 85 b, 85 c, each attached to one of the lock pawls 81 a, 81 b, 81 c by a pawl pin 88 a, 88 b, 88 c, make contact with an opposing bearing disc ratchet 87 . The bearing disc ratchet 87 is coaxial with and rigidly attached to the bearing disc 60 . The bearing disc ratchet 87 actuates the release pawls 85 a, 85 b, 85 c because the release pawls 85 a, 85 b, 85 c are connected to the pawl carrier 83 via the lock pawls 81 a, 81 b, 81 c. In operation, the release pawls 85 a, 85 b, 85 c rotate at half the speed of the bearing disc 60 , since the drive disc 34 is not rotating, and disengage the lock pawls 81 a, 81 b, 81 c from the drive disc ratchet 82 allowing the coiled spring 80 to wind the drive disc 34 against the power adjusters 1 a, 1 b, 1 c. One or more pawl tensioners (not shown), one for each release pawl 85 a, 85 b, 85 c, ensures that the lock pawls 81 a, 81 b, 81 c are pressed against the drive disc ratchet 82 and that the release pawls 85 a, 85 b, 85 c are pressed against the bearing disc ratchet 87 . The pawl tensioners are attached at one end to the pawl carrier 83 and make contact at the other end to the release pawls 85 a, 85 b, 85 c. An assembly hole 93 (not shown) through the hub cap 67 , the bearing disc 60 , and the drive disc 34 , allows an assembly pin (not shown) to be inserted into the loaded coiled spring 80 during assembly of the transmission 100 . The assembly pin prevents the coiled spring 80 from losing its tension and is removed after transmission 100 assembly is complete.
Referring to FIGS. 1 , 11 , 12 , and 15 , automatic shifting of the transmission 100 , is accomplished by means of spindle cables 602 , 604 , 606 which are attached at one end to a non-moving component of the transmission 100 , such as the hollow shaft 10 or the stationary support 5 a. The spindle cables 602 , 604 , 606 then travel around spindle pulleys 630 , 632 , 634 , which are coaxially positioned over the spindles 3 a, 3 b, 3 c. The spindle cables 602 , 604 , 606 further travel around spacer pulleys 636 , 638 , 640 , 644 , 646 , 648 which are attached to a spacer extension 642 which may be rigidly attached to the spacers 8 a, 8 b, 8 c. As more clearly shown in FIGS. 11 and 12 , the other ends of the spindle cables 602 , 604 , 606 are attached to a plurality of holes 620 , 622 , 624 in a non-rotating annular bearing race 816 . A plurality of weight cables 532 , 534 , 536 are attached at one end to a plurality of holes 610 , 612 , 614 in a rotating annular bearing race 806 . An annular bearing 808 , positioned between the rotating annular bearing race 806 and the non-rotating annular bearing race 816 , allows their relative movement.
Referring to FIG. 15 , the transmission 100 is shown with the cable routing for automatic shifting.
As shown in FIGS. 1 , 9 , 11 , and 12 , the weight cables 532 , 534 , 536 then travel around the hub shell pulleys 654 , 656 , 658 , through holes in the hub shell 40 , and into hollow spokes 504 , 506 , 508 (best seen in FIG. 12 ) where they attach to weights 526 , 528 , 530 . The weights 526 , 528 , 530 are attached to and receive support from weight assisters 516 , 518 , 520 which attach to a wheel 514 or other rotating object at there opposite end. As the wheel 514 increases its speed of rotation, the weights 526 , 528 , 530 are pulled radially away from the hub shell 40 , pulling the rotating annular bearing race 806 and the non-rotating annular bearing race 816 axially toward the hub cap 67 . The non-rotating annular bearing race 816 pulls the spindle cables 602 , 604 , 606 , which pulls the spindle pulleys 630 , 632 , 634 closer to the hollow shaft 10 and results in the shifting of the transmission 100 into a higher gear. When rotation of the wheel 514 slows, one or more tension members 9 positioned inside the hollow shaft 10 and held in place by a shaft cap 92 , push the spindle pulleys 630 , 632 , 634 farther from the hollow shaft 10 and results in the shifting of the transmission 100 into a lower gear.
Alternatively, or in conjunction with the tension member 9 , multiple tension members (not shown) may be attached to the spindles 3 a, 3 b, 3 c opposite the spindle pulleys 630 , 632 , 634 .
Still referring to FIG. 1 , the transmission 100 can also be manually shifted to override the automatic shifting mechanism or to use in place of the automatic shifting mechanism. A rotatable shifter 50 has internal threads that thread onto external threads of a shifter screw 52 which is attached over the hollow shaft 10 . The shifter 50 has a cap 53 with a hole that fits over the rod 11 that is inserted into the hollow shaft 10 . The rod 11 is threaded where it protrudes from the hollow shaft 10 so that nuts 54 , 55 may be threaded onto the rod 11 . The nuts 54 , 55 are positioned on both sides of the cap 53 . A shifter lever 56 is rigidly attached to the shifter 50 and provides a moment arm for the rod 11 . The shifter cable 51 is attached to the shifter lever 56 through lever slots 57 a, 57 b, 57 c. The multiple lever slots 57 a, 57 b, 57 c provide for variations in speed and ease of shifting.
Now referring to FIGS. 1 and 10 , the shifter cable 51 is routed to and coaxially wraps around a handlegrip 300 . When the handlegrip 300 is rotated in a first direction, the shifter 50 winds or unwinds axially over the hollow shaft 10 and pushes or pulls the rod 11 into or out of the hollow shaft 10 . When the handlegrip 300 is rotated in a second direction, a shifter spring 58 , coaxially positioned over the shifter 50 , returns the shifter 50 to its original position. The ends of the shifter spring 58 are attached to the shifter 50 and to a non-moving component, such as a frame (not shown).
As seen more clearly in FIG. 10 , the handlegrip 300 is positioned over a handlebar (not shown) or other rigid component. The handlegrip 300 includes a rotating grip 302 , which consists of a cable attachment 304 that provides for attachment of the shifter cable 51 and a groove 306 that allows the shifter cable 51 to wrap around the rotating grip 302 . A flange 308 is also provided to preclude a user from interfering with the routing of the shifter cable 51 . Grip ratchet teeth 310 are located on the rotating grip 302 at its interface with a rotating clamp 314 . The grip ratchet teeth 310 lock onto an opposing set of clamp ratchet teeth 312 when the rotating grip 302 is rotated in a first direction. The clamp ratchet teeth 312 form a ring and are attached to the rotating clamp 314 which rotates with the rotating grip 302 when the grip ratchet teeth 310 and the clamp ratchet teeth 312 are locked. The force required to rotate the rotating clamp 314 can be adjusted with a set screw 316 or other fastener. When the rotating grip 302 , is rotated in a second direction, the grip ratchet teeth 310 , and the clamp ratchet teeth 312 disengage. Referring back to FIG. 1 , the tension of the shifter spring 58 increases when the rotating grip 302 is rotated in the second direction. A non-rotating clamp 318 and a non-rotating grip 320 prevent excessive axial movement of the handlegrip 300 assembly.
Referring to FIGS. 13 and 14 , another embodiment of the transmission 900 , is disclosed. For purposes of simplicity, only the differences between the transmission 100 and the transmission 900 are discussed.
Replacing the rotating hub shell 40 are a stationary case 901 and housing 902 , which are joined with one or more set screws 903 , 904 , 905 . The set screws 903 , 904 , 905 may be removed to allow access for repairs to the transmission 900 . Both the case 901 and housing 902 have coplanar flanges 906 , 907 with a plurality of bolt holes 908 , 910 , 912 , 914 for insertion of a plurality of bolts 918 , 920 , 922 , 924 to fixedly mount the transmission 900 to a non-moving component, such as a frame (not shown).
The spacer extension 930 is compressed between the stationary case 901 and housing 902 with the set screws 903 , 904 , 905 and extend towards and are rigidly attached to the spacers 8 a, 8 b, 8 c. The spacer extension 930 prevents rotation of the stationary supports 5 a, 5 b. The stationary support 5 a does not have the stationary support sleeve 42 as in the transmission 100 . The stationary supports 5 a, 5 b hold the hollow shaft 10 in a fixed position. The hollow shaft 10 terminates at one end at the stationary support 5 a and at its other end at the screw 35 . An output drive disc 942 is added and is supported against the case 901 by a case bearing 944 . The output drive disc 942 is attached to an output drive component, such as a drive shaft, gear, sprocket, or pulley (not shown). Similarly, the driving member 69 is attached to the input drive component, such as a motor, gear, sprocket, or pulley.
Referring to FIG. 16 , shifting of the transmission 900 is accomplished with a single cable 946 that wraps around each of the spindle pulleys 630 , 632 , 634 . At one end, the single cable 946 is attached to a non-moving component of the transmission 900 , such as the hollow shaft 10 or the stationary support 5 a. After traveling around each of the spindle pulleys 630 , 632 , 634 and the spacer pulleys 636 , 644 , the single cable 946 exits the transmission 900 through a hole in the housing 902 . Alternatively a rod (not shown) attached to one or more of the spindles 3 a, 3 b, 3 c, may be used to shift the transmission 900 in place of the single cable 946 .
Turning now to FIG. 17 , it illustrates one embodiment of a vehicle 1700 that includes a scooter 1750 having an input drive component 1710 coupled to a transmission, which can be the continuously variable transmission 100 described above with reference to FIG. 1 . The input drive component 1710 can be a motor, gear, sprocket, or pulley. In some embodiments, the input drive component 1710 is coupled to a driving member 69 of the continuously variable transmission 100 (see, for example, FIG. 1 ).
The foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the invention can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the invention should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the feature or aspects of the invention with which that terminology is associated. The scope of the invention should therefore be construed in accordance with the appended claims and any equivalents thereof. | A continuously variable transmission is disclosed for use in rotationally or linearly powered machines and vehicles. The single axle transmission provides a simple manual shifting method for the user. An additional embodiment is disclosed which shifts automatically dependent upon the rotational speed of the wheel. Further, the practical commercialization of traction roller transmissions requires improvements in the reliability, ease of shifting, function and simplicity of the transmission. The disclosed transmission may be used in vehicles such as automobiles, motorcycles, and bicycles. The transmission may, for example, be driven by a power transfer mechanism such as a sprocket, gear, pulley or lever, optionally driving a one way clutch attached at one end of the main shaft. | 5 |
FIELD OF THE INVENTION
The present invention relates to the general field of genetic engineering of organisms and relates, in particular, to a convenient and easy to use instrument for the insertion of foreign genetic material into the tissue of living organisms.
DESCRIPTION OF THE ART
There is much interest in the general field of the genetic engineering of living organisms. In the genetic engineering of an organism, foreign genetic material, typically a DNA vector constructed so as to express a suitable gene product in the cells of the target organism is transferred into the genetic material cells of the organism, through one of a variety of processes. In the past, the transformation techniques have varied widely. Some of the prior art mechanisms utilized for the insertion of genetic material into living tissues include: direct microinjection; electroporation, a technique in which individual cells are subjected to an electric shock to cause those cells to uptake DNA from a surrounding fluid; liposome-mediated transformation, in which DNA or other genetic material is encapsulated in bilipid vesicles which have an affinity to the cell walls of target organisms; and certain specific types of biological vectors or carriers which have the ability to transfect genetic material carried within them into specific target organisms.
One general technique exists which is applicable to a large range of host organisms. This general technique is referred to as particle mediated genetic transformation. In this technique, the genetic material, be it RNA or DNA, is coated on small carrier particles. The particles are then accelerated toward target cells where the particles impact the cells and penetrate the cell walls, carrying the DNA construct into the cells. Some proportion of the cells into which the genetic material is delivered express the inserted genetic material and another smaller proportion of the cells integrate the delivered DNA into their native genetic material.
One manner of accelerating coated carrier particles utilizes a larger carrier object, sometimes termed macroprojectile. The carrier particles are positioned inside the macroprojectile. The macroprojectile is then accelerated at a high speed toward a stopping plate. Acceleration can be by any suitable means. One means that has proven effective takes advantage of a gunpowder driven device in which the hot gases generated by a gunpowder discharge form a hot gas shock wave which accelerates the macroprojectile. When the macroprojectile strikes the stopping plate having a hole therein, the microprojectiles continue their travel through the hole and eventually strike the target cells. This and other acceleration techniques have been described in U.S. Pat. No. 4,945,050 issued to Sanford et al. and entitled "Method For Transporting Substances Into Living Cells And Tissues And Apparatus Therefore".
A second technique developed for the acceleration of carrier particles was based on a shock wave created by a high voltage electric spark discharge. This technique involves an apparatus having a pair of spaced electrodes placed in a spark discharge chamber. The high voltage discharge is then passed between the electrodes to vaporize a droplet of water placed between the electrodes. The spark discharge vaporizes the water droplet creating a pressure wave, which accelerates a carrier sheet previously placed on the discharge chamber. The carrier sheet carries thereon the carrier particles which are coated with the biological genetic materials. The carrier sheet is accelerated toward a retainer where the carrier sheet is stopped, the particles are separated from it, and only the carrier particles pass on into the biological tissues.
This second technique has been implemented in a hand-held device that can be use for accelerating particles carrying biological materials into large whole organisms which cannot readily be placed on a bench top unit. The hand held device is described in U.S. Pat. No. 5,149,655 issued to McCabe et al. which is entitled "Apparatus For Genetic Transformation".
A variation on that second technique for acceleration of carrier particles was based on an expanding gas shock wave, and a planar surface having carrier particles positioned on the target side of a planar surface. The shock wave that actually impacts the target area is substantially reduced when this technique is utilized. In addition, the apparatus used with this technique does not subject target cells to radiant, heat or appreciable acoustic energy. Hence cell differentiation and successful cell transformation is maximized. This technique is described in U.S. Pat. No. 5,204,253 which issued to Sanford et al. and was entitled "Method and Apparatus For Introducing Biological Substances Into Living Cells."
The apparatus used with this third technique involves a high pressure gas delivery system, a mechanism to generate an instantaneous gas shock out of the high pressure system, an enclosure into which the gas shock is released, contained and vented and a throat region which allows for use of interchangeable planar insertion mechanisms that translate the gas shock into particle acceleration.
When the expanding gas shock is generated it is directed at and impacts a back surface of the planar insertion mechanism (the carrier particles being on the front surface of the insertion mechanism). If the insertion is a fixed membrane and the membrane is allowed to rupture upon application of the shock wave, the particles are disbursed over a wide region of the target cells and much of the shock wave force is absorbed within the ruptured membrane.
All of the techniques discussed above utilized apparatus for the acceleration of carrier particles that can only generate a single potentially traumatic, essentially instantaneous burst of carrier particles (i.e. these are only single shot insertion apparatus). Once the carrier insertion of a single shot apparatus has been utilized it is, for genetic transformation purposes, devoid of carrier particles. In order to utilize any of the single shot apparatus a second time, a new carrier insertion having carrier particles thereon must be installed.
Although single shot apparatus might be ideal for single small area targets, if the cells of a plurality of individual small target areas are to be transformed, unloading and reloading a carrier insertion to prepare for every new transformation is inefficient.
In addition, as transformation technology has evolved past the experimental stage and has become a more commercially useful science, it has become increasingly more important to transform larger target areas. Two limitations inherently exist when a single shot apparatus is used to transform a large surface area target (i.e. a surface larger than the area which subtends a single burst of carrier particles). First, as with a plurality of small target areas, transformation of a large target area may call for a number of reloading steps, each extra step adding to the time necessary to properly transform the target.
Second, uniform transformation across a target area is difficult to accurately achieve with a single shot apparatus. After a first transformation, it is difficult to place a second carrier burst next to the first so as not to leave a gap therebetween or produce a "hot spot" where the two bursts overlap. As more single bursts are employed, proper placement becomes more difficult to achieve. Thirdly, the transformation of a continuous flow of suspended cells would be quite cumbersome, or completely impractical, with a single burst device.
SUMMARY OF THE INVENTION
The present invention is summarized in that an apparatus for injecting a continuous stream of carrier particles carrying DNA into living cells includes a body member having formed therein an acceleration channel along a central axis, the channel having an outlet at an exit end, the body also including formed therein a source chamber adapted to being connected to a source of compressed gas, the source chamber connected to the channel; a particle carrier onto which carrier particles are placed, the particle carrier mounted in the body member in a position exposed to the channel so that a gas stream flowing in the channel can pick up carrier particles off of the particle carrier; and a gas stream diverter placed on the body adjacent the outlet of the channel to divert the gas stream away from the direction of flight of the carrier particles as they exit the body.
It is an object of the present invention to provide a gene delivery instrument based on biologically-coated carrier particles in which the carrier particles are accelerated by a gas stream and in which the gas stream is separated from the carrier particles prior to the carrier particles impacting the target tissues.
It is another object of the present invention to provide a gene gun capable of producing and directing either a continuous flow of DNA coated carrier particles toward relatively large areas of a target organism, or single bursts of carrier particles toward individual target areas with only infrequent reloading.
By providing a carrier receiving ribbon that can be conveyed through the acceleration channel, a continuous supply of carrier particles can be provided to the acceleration channel. As the carrier particles reach the apex of the ribbon guide, the dislodging means frees the particles from the ribbon. The continuous gas stream within the channel moves from the closed end of the channel to the outlet. The freed particles become entrained within the moving gas and are accelerated toward the outlet. A single burst of carrier particles may be produced by conveying the ribbon only a short distance. A continuous flow of particles may be produced by continuously conveying the ribbon.
Also, in the preferred embodiment, the apparatus includes an arcuate surface forming a channel extension on a single peripheral edge of the outlet, the extension being substantially parallel to the channel axis at its proximal end and progressively more perpendicular to the axis at its distal end. As described in more detail below, the channel extension takes advantage of the Coanda effect principal and directs the gas stream emerging from the outlet downward away from the target organism while the heavier DNA coated carrier particles, having gained sufficient momentum, continue along a line parallel to the central axis of the channel (i.e. toward the target area).
Thus, it is another object of the invention to provide an accelerator that may impart high speed velocities to carrier particles directed at a target organism without bombarding the target area with a high velocity gas blast, shock wave, heat, acoustic or radiation energy. The present invention does not utilize accelerating techniques that subject target cells to heat, acoustic or radiation energy and the channel extension operates to direct the high velocity gas stream away from the target area.
Other objects, advantages and features of the present invention will become apparent from the following specification when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of the particle acceleration device constructed in accordance with the present invention as utilized to perform continuous cell genetic transformation;
FIG. 2 is a bottom view of the channel plate used in the present invention;
FIG. 3 is a side view of the channel plate shown in FIG. 2;
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 1 wherein the particle acceleration device is in assembled form;
FIG. 5 is an exploded view of a ribbon cassette used in the present invention;
FIGS. 6a-c are cross-sectional views taken along the line 6--6 of FIG. 4 illustrating the Coanda effect principal exploited in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the gene delivery instrument 8 of the present invention may be seen to broadly include six main parts: (a) a cover or channel plate 10; (b) a cassette housing 12 having a source chamber 16, the housing 12 serving as the main body of the gene delivery instrument 8; (c) a cassette 14 receivable within the source chamber 16; (d) an arcuate gas stream diverter 18 extending outwardly and downwardly from a distal edge of the cassette housing 12; (e) a dissipator shield 20 attached to a barrel member 43 of the housing 12; and (f) a high pressure gas delivery system 21.
The high pressure gas delivery system 21 includes a source of gas 22 under high pressure. Preferably, the gas is helium, because helium is lightweight and exhibits the characteristic of having a high rate of expansion. Other preferably inert lightweight gasses may also be used, if desired, such as nitrogen. The gas source 22 is provided with a suitable adjustable regulator 24 and pressure indicator 26 providing an adjustable flow of compressed gas to the instrument 8.
Referring to FIGS. 2 and 3, the channel plate 10 is largely rectangularly shaped. A rectangular channel groove 28 is formed in the bottom surface 29 of the channel plate 10. The groove 28 extends from an open end 31 opening on the distal end of the channel plate 10 more than one-half the distance to the proximal end of the channel plate 10 and does not extend to either lateral side of the plate 10. A reservoir 33 is provided at the closed end of the groove 28 and a gas port 34, centrally located in the reservoir 33 extends through the thickness of the channel plate 10. A cassette key-way 36 is a channel in the bottom surface 29 of the plate 10 adjacent the sink 33 and extending perpendicular to the length of the groove 28. The keyway 36 extends laterally so as to form an opening 38 in a single lateral side of the channel plate 10. Referring specifically to FIG. 2, the channel plate 10 is provided with a plurality of bolt holes 40 which operate in conjunction with bolts (not shown) to hold the channel plate 10 and the cassette housing 12 together. It should be understood that any suitable means may be employed for attaching the channel plate 10 and cassette housing 12 together.
Referring again to FIG. 1, the high pressure gas system is adapted to be connected to the gas port 34 in the channel plate 10 through suitable tubing 86. In the preferred embodiment, the external shape of the cassette housing 12 is formed so as to be easily gripped and manipulated. Thus, the cassette housing 12, much like a home hair dryer, can have a grip member 42 and a barrel member 43. The top surface 44 of the cassette housing 12 is substantially flat, and thus easily receives the flat bottom surface 29 of the channel plate 10. A source chamber 16 is formed within the grip member 42 and is open to a single lateral side of the grip member 42.
Referring to FIGS. 1 and 4, a tapered slot 46 extends from the top surface 44 of the grip member 42 downward and into the source chamber 16 below. The slot 46 is of an inverted "v" shape being wide near the source chamber 16 and relatively narrow at the top surface 44.
Referring to FIG. 4, when the channel plate 10 is properly positioned and attached to the cassette housing 12, the top surface 44 of the cassette housing and the channel groove 28 cooperate to from an acceleration channel 48 closed at the proximal end of the instrument 50 and having an outlet 52 at the opposite or distal end of the instrument. In one embodiment, a brush 54 was positioned within the keyway 36 directly above tapered slot 46. The brush 54 was constructed and positioned so as to gently remove carrier particles 55 from a moving ribbon 56 therebelow. It may be appreciated that carrier particles that become lodged within the bristles of the brush 54 are dislodged by the high velocity gas stream 88 moving directly through the bristles toward the outlet 52. Subsequently, it was determined that the brush 54 was not necessary for proper functioning of the instrument, and the brush was removed without adversely affecting performance of the device.
Referring to FIG. 5, the cassette 14 has a ribbon housing 58 which forms a supporting and protecting shell around a ribbon chamber 61 formed therein. The ribbon housing 58 includes a lower wall 57, two opposing upright extensions 59, and a rear wall 68. A guide member 60, centrally located with the ribbon chamber 61, extends upwardly from the lower wall 57 to support an arcuate ribbon guide 62 at its highest point. The guide member 60 divides the ribbon chamber 61 into a reservoir compartment 66 and a take-up compartment 64. A reservoir spool 72 is rotatably attached to the rear wall 68 so as to be centrally located within the reservoir compartment 66. In a like fashion, a take-up spool 70 is centrally positioned within the take-up compartment 64 for rotatable movement. Each spool 70, 72 is a cylindrical shaft with narrowed portions at each end so that it may be secured in place when the instrument is assembled. A cover plate 76, which includes a pair of shallow recesses to receive the narrowed ends of the spools 70 and 72 is provided to cover the lateral side of the instrument over the ribbon chamber 61. A drive shaft 77 extends through the housing of the source chamber 16 to engage the take-up spool 70. A rotary motor such as a small low-speed electric motor or rotary solenoid, is attached to the lateral side of the source chamber and is connected to drive the drive shaft 77. The rotary motor is capable either of stepping the shaft 70 through short rotative movements or of driving the shaft 70 in smooth uniform rotation. Thus, the drive motor can convey the ribbon 56 in a controlled fashion from the reservoir compartment 66 over the ribbon guide 62 and into the take-up compartment 64.
The carrier receiving ribbon 56 used with the invention is a long linear strip of flexible yet strong sheet material. Any number of materials are suitable for use as the ribbon 56. One useful material is a 3/4 inch Mylar™ strip (Dupont, Inc. No. 50SMMC2). The length of the strip can be any suitable length, limited only by the distance from the reservoir spool 72 over the guide 62 to the take-up spool 70 and the size of the take-up and reservoir compartments 64, 66. Prior to operation of the gene delivery instrument 8, a previously loaded ribbon 56 is attached by a leading end to the reservoir spool 72 and is wound around the reservoir spool 72 and a portion of the ribbon 56 is extended over the guide 62 and into the take-up compartment 64 where a leading end of the ribbon 56 is attached to the take-up spool 70.
Prior to being wound on the reservoir spool 72, the carrier ribbon 56 must, of course, first be loaded with the biological material to be introduced into the target cells. First the biological material, preferably genetic material such as DNA or RNA, but also possibly proteins, peptides, antigens, hormones, or other biological materials, is coated onto the carrier particles to be used. Prior art techniques used with other accelerated particle instruments can be used to coat the biological material on the carrier particles. The carrier particles themselves must be dense biologically insert particles small in relationship to the size of the target cells. Suitable carrier particles include small gold beads or spheres, 0.1 to 10 microns in size, as well as gold microcrystalline, colloidal, or aggregate materials of irregular shape and size, in which most of the particles in a batch are sized between 0.1 and 10 microns. The particles, once coated with biological material, may be coated onto the carrier ribbon 56 in any manner which is relatively uniform and which does not adhere the particles to the ribbon to fixedly to be removed. It has been found that this can be conveniently done by suspending the DNA coated carrier particles in ethanol, placing the ethanol onto the carrier ribbon 56 which has been extended linearly and placed flat, and then allowing the ethanol to evaporate, thus depositing the carrier particles on the ribbon 56.
The ribbon 56 is then wound onto reservoir spool 72 so that the surface coated with carrier particles 55 forms the outer surface of the winding on the reservoir spool 72. This will ensure that as the ribbon 56 passes over the guide 62, the carrier particle coated surface will be exposed to the gas stream.
After the ribbon 56 has been properly attached wound on the spools 70, 72, the removable cover plate 76 is positioned on the open side of the ribbon housing 58. The cover plate 76 maintains the ribbon 56 within the ribbon housing 58 during operation of the instrument.
Referring again to FIGS. 1 and 4, an arcuate gas stream diverter 18 is provided adjacent to the distal end of the barrel member 43 just below the channel outlet 52. Although the gas stream diverter 18 need not be arcuate, it has been found that the apparatus operates well when an arcuate extension having a 7 mm radius of curvature is employed. The gas stream diverter 18 is particularly helpful to proper operation of the present invention, and its function will be described in more detail below. Note here that the diverter 18 is positioned on the distal end of the housing 12 such that the top edge surface of the diverter 18 is slightly displaced below the lower edge of the channel outlet 52, for reasons that will be discussed below.
A dissipator shield 20 is provided adjacent to and surrounding the gas stream diverter 18. The dissipator shield 20 has a vertically oriented shield member 80 adjacent the housing extension 18 and a horizontal member 82 extending perpendicularly from the vertical member 80 underneath the gas stream diverter 18. The dissipator shield 20 also has two lateral side walls 84 that abut the lateral surfaces of the diverter 18. The side walls 84 are used to attach the shield 20 and the diverter 18 to the barrel member 43 of the housing 12, and also operate in conjunction with the gas stream diverter 18 to use the Coanda effect as described below to divert and dissipate the complex gas stream.
After the apparatus is fully assembled, a cassette 14 with a carrier particle coated ribbon 56 can be positioned inside the source chamber 16. When properly positioned, the ribbon guide 62 will protrude out of the tapered slot 46 and into the cassette keyway 36 above the underside of the channel plate 10. If a brush is used, in this position, the brush 54 should contact the highest portion of the ribbon 56. Preferably, the brush 54 is omitted leaving the peak of the ribbon 56 exposed to any gas stream in the keyway 36.
The portion of the ribbon 56 initially within the keyway 36 may be void of carrier particles 55. Generally, as will be explained below, until a Coanda effect gas flow pattern is established, carrier particles 55 within the acceleration channel 48 are effectively wasted.
Referring to FIG. 4, in operation, after properly preparing a target specimen, tissue, cell, or animal, the pressure regulator 24 may be adjusted so as to generate a steady high velocity gas stream 88 within the acceleration channel 48. Desired carrier velocity dictates necessary gas stream velocity. The velocity to which the carrier particles 55 must be accelerated depends on the size and density of the particles 55 to be accelerated, as well as the nature of the cells to be transformed. Once the type of target cell is known, a properly sized carrier particle 55 may be chosen. Usually, the particles have a diameter between about 100 nanometers and about 10 microns.
Once the properly sized carrier particle 55 is chosen, a corresponding proper velocity may also be chosen. The velocity to which carrier particles 55 are accelerated can be adjusted by adjusting the pressure regulator 24 and can be monitored using the pressure indicator 26. The proper velocity for a given target cell or tissue is adjusted by adjusting the pressure of input gas, and can be empirically determined for any given target tissue.
Referring to FIG. 4, after the desired pressure is adjusted within the acceleration channel 48, and equilibrium is reached within the sink 33, the velocity of the gas stream 88 will be substantially constant. Under these conditions, any particles 55 free within the channel 48 will be accelerated toward the outlet 52.
Referring now to FIGS. 6a-c, the present invention takes advantage of the Coanda effect principal, which is sometimes employed in fluidic devices intended for other applications. Under normal conditions, the apparatus of the present invention is operated at an open atmosphere and the helium within the channel 48 is pressurized to about 100 psi. At the moment the pressure regulator 26 is adjusted to allow a gas stream 88 to move down the channel 48, the gas stream 88 exiting the outlet 52 projects in a straight line, substantially coaxially with the channel axis 85. This linear flow is illustrated in FIG. 6a. Referring to FIG. 6a, it is important that the arcuate gas stream diverter 18 is provided only on a single side of the outlet 52, in this embodiment the lower side. It is also helpful that the diverter 18 has its top edge displaced very slightly (i.e. approximately 0.1 mm) below the lower edge of the outlet 52. This ensures that the diverter 18 cannot possible divert the gas stream 88 upward and also ensures that a volume of space will be trapped under the gas stream 88 at its point of exit from the outlet 52.
Whenever a stream flows into a body of stagnant air, it entrains some of the surrounding stagnant air and starts it in motion. In the case of the present invention, the ambient air 92 within and above the dissipator shield 20 is entrained and ejected along both sides of the gas stream 88, and replenishing air 94 continuously moves into the regions depleted of air. In other words, areas of low pressure are created above and below the gas stream 88. Above the gas stream 88, the replenishing air moves in unimpeded, and the average pressure along the top surface of the stream 88 remains essentially at ambient atmospheric pressure. However, below the gas stream 88, the flow of replenishing air 94 is restricted by the gas stream diverter 18 and the sides of the dissipator shield 20. Thus, the average pressure below the exiting gas stream 88 will be below atmospheric pressure and a pressure differential will be set up vertically across the gas stream 88.
Referring to FIG. 6b, the resultant differential and pressure across the top and bottom of the existing gas stream 88 causes the gas stream 88 to divert to move closer to the surface of the arcuate gas stream diverter 18. This, in turn, further restricts the area through which the replenishing air can move below the stream 88, making the pressure below the gas stream 88 decrease further, while the differential across the gas stream 88 correspondingly increases.
This action is regenerative, and continues until it terminates with the gas stream 88 essentially following the surface of the arcuate gas stream diverter 18, as best shown in FIG. 6c. The gas stream 88 remains close to the arcuate diverter 18 because of the differential pressure impressed upon it.
Once the gas stream diversion is established, the gas stream 88 being directed into the box surrounded by the dissipator shield 20, is further directed away from the target specimen and back toward the grip member 42 of the instrument. In this manner, the target experiences very little gas flow under normal operating conditions and hence undue damage to target cells and surrounding tissue from gas blast is avoided.
Referring to FIG. 4, once the vortex has been established, the pre-prepared target tissue should be properly positioned. Assuming that the target area is large, the outlet 52 of the apparatus should be positioned over one portion of the target. The flow of the gas stream 88 down the channel 28 picks the carrier particles 55 off of the ribbon 56 and carries them out of the outlet 52. The carrier particles 55 exiting the outlet 52 may experience drag in the high density air between the outlet 52 and the target surface. Thus, it may be appropriate to position the instrument close to the target surface, so that the particles experience less drag and are delivered appropriately. A mechanical spacer could be used to provide fixed spacing for that positioning.
After the apparatus is positioned correctly over the target, the driver is energized so that the spools 70, 72 convey the ribbon 56 from the reservoir compartment 66, over the ribbon guide 62 within the acceleration channel 48, and back down into the take-up compartment 64. As the ribbon 56 is conveyed, the portion of the ribbon 56 having carrier particles 55 moves up to the apex of the guide 62 within the keyway 36. The high velocity gas stream 88 picks up the carrier particles off of the ribbon 56 and accelerates the carrier particles 55, now carried in the gas stream 88, toward the channel outlet 52. If the pressure within the acceleration channel 48 was selected properly, the particles 55 should attain the desired velocity by the time they emerge from the outlet 52.
As the gas stream 88, with carrier particles 55, exits the outlet 52, the carrier particles, having a relatively large mass compared to the atoms of the gas stream 88 proceed toward the target under the force of their momentum. The carrier particles 55 are not significantly affected by the Coanda effect operating on the gas stream, due to the higher mass of the carrier particles. Meanwhile, the gas stream 88, under the effects of the Coanda principle described above, is directed downward into the dissipator box 20 and away from the target area. In other words, the gas stream 88 and the carrier particles 55 are separated without significantly diverting the direction of travel of the carrier particles 55. This construction allows the carrier particles 55 to pass to the target, but yet successfully diverts the gas stream flow completely away from the target, thus avoiding any gas impact or trauma to the target tissues.
The device of FIGS. 1-6 above offers two very clear advantages over all known prior art accelerate particle gene delivery instruments. Each of these advantages is appropriate only for certain target tissues or certain applications and each can be implemented in device configurations other than the embodiment of FIGS. 1-6 above. The first advantage is that this device illustrates that, for a device which uses a gas stream to accelerate the carrier particles, the gas stream can be separated from the carrier particles prior to the carrier particles impacting the target tissues. The second advantage is the fact that this device is capable of delivering a large number of carrier particles, either continuously or in multiple independent doses, without the need for reloading the apparatus with an additional particle carrier.
The first advantage, i.e. separation of the particles from the gas stream, is generally useful for gene delivery to animals, but is of particular use in the delivery of biological materials to sensitive tissues or cells which might be injured, moved, or disturbed, by the force of the accelerating gaseous stream. This advantage is enabled by the coanda effect diverter 18 placed adjacent the outlet 52 of the channel 48. This sort of diversion of the exiting gas stream, using the coanda effect, can be used in an instrument that is a "single-shot" device, i.e. that uses a single dose particle carrier rather than a ribbon. It is also envisioned that other geometries for the diverter 18 itself are possible. For example, the diverter 18 could have a series of steps rather than a smooth arcuate surface. The important feature of the diverter 18 is that it influences the gas stream itself to divert, using the coanda effect, while having a minimal effect on the path of travel of the carrier particles themselves.
The second advantageous feature is based on the use of a particle carrier which is elongated and movable so as to be useful either in one very long or several shorter gene delivery applications. By providing a particle carrier which has only a small portion of its extent exposed to the accelerating gas stream at any instant, and by providing a driver to move the particle carrier along to expose a different portion, a much greater amount of particle delivery is enabled without having to disassemble the device to insert a new carrier. This advantageous design is adapted where large amounts of particle delivery are needed, as in the delivery of a large amount of genetic material or of a protein to a patient is desired, and it may also prove advantageous where it is desired to deliver many serial single doses to a series of patients is necessary. Again, this feature is independent of whether or not the coanda effect gas stream diversion is used, since some target tissues, such as intact skin, seem quite capable of withstanding the impact of lower velocity gas streams.
It is to be understood that the present invention is not to be limited to the embodiment shown here, but to encompass all such modified forms thereof as come within the scope of the following claims. | An apparatus is disclosed for the genetic transformation of organisms by accelerated particle mediated transformation. Foreign genes are introduced into cells by coating on carrier particles which are physically accelerated into the cells by positioning the carrier particles on the external surface of a carrier ribbon which is wound on a cartridge, the carrier ribbon having an exposed portion. The carrier particles on the exposed portion of the ribbon are displaced and accelerated toward an exit port by a high pressure stream of helium gas. By rotating the ribbon, a continuous supply of carrier particles can be produced and hence large target areas can be transformed without the need to replace the particle carrier. Near the exit port, the gaseous stream is diverted through use of the Coanda effect to divert the gas stream away from a target area. The carrier particles, being much heavier than the gas, continue toward and into the target cells. The treated cells are recovered and a portion of the them contain the foreign gene in their genome. | 2 |
BACKGROUND OF INVENTION
This invention relates generally to a hydraulic latching spool valve and more specifically concerns a valve having a latching chamber formed in the interior of an elongate movable piston. The latching chamber is in fluid communication with the supply pressure to the valve and has an area exposed to the supply pressure that generates sufficient latching force to overcome opposing forces and latch the valve in the open position after an initial pulse of open fluid pressure.
Hydraulic valves are used in a variety of applications to control flow in hydraulic circuits. While pilot operated poppet valves have been employed for many years, recent changes in control system design have rendered traditional poppet valves less than optimal. With traditional valves, hydraulic pilot pressure is applied and maintained in order to open the valve and keep it in an open position. A poppet valve that was designed for use in a traditional hydraulic system is disclosed in U.S. Pat. No. 5,901,749 assigned to Gilmore Valve Co., the assignee of the present invention. The valve disclosed in this patent requires constant pilot pressure to stay open. If pilot pressure unintentionally drops for any reason, the valve will close because of spring force. This sometimes results in the unintentional closure of a valve.
Maintaining a constant pilot pressure to keep the valve open has a number of drawbacks.
Any hydraulic system can be troubled by leaks, and keeping a valve under constant pilot pressure may be difficult if there are leaks in the system. Further, maintaining constant pilot pressure requires energy. Thus, control systems have shifted to a design in which pilot pressure need only be pulsed in order to open the valve, and then released. There is, therefore, a need for a valve design capable of latching in the open position after only a brief pulse of pilot pressure. The term “pulsed” as used herein means that a pilot is opened and pressurized fluid is directed to a desired apparatus, for example the present invention, for 2 to 3 seconds, and then the fluid is vented and pressure falls to zero psi.
A previous attempt to address this need can be found in U.S. Pat. No. 6,209,565, however the device described suffers from several problems. For example, the device is needlessly complicated. It uses two pistons, i.e. the pilot open piston and a second piston (called a head) in the latching piston assembly. Two moving pistons require additional seals that increase the potential for leakage and failure. There is, therefore, a need for a simple, elegant valve that does not require constant pilot pressure in order to keep it in an open position.
SUMMARY OF INVENTION
The present invention provides a simple valve design that is able to remain open without constant pilot pressure, and that minimizes the risk of leakage due to the fluid pressure holding the valve open. Briefly, the present invention is a hydraulic latching spool valve which is adapted to be inserted into a valve chamber in a body. Some end users of the hydraulic latching spool valve have bodies that receive the valve and others do not. Therefore the hydraulic latching spool valve may be sold with or without a body. The valve body defines a supply port, a function port, a vent port, a pilot close port, and a pilot open port. The supply port is connected to a pressurized fluid source which delivers supply pressure to the spool valve. The pilot close port is connected to a close pilot to deliver close fluid to the spool valve when the close pilot is pulsed. The pilot open port is connected to an open pilot to deliver open fluid to the spool valve when the open pilot is pulsed.
The spool valve itself comprises a valve cage, a seal assembly carried by a moveable elongate piston, a spring, a pilot open chamber, a pilot close chamber, and a latching chamber. The valve cage is sized and arranged to be inserted into the valve chamber of the body. The valve cage defines an upper circular seat positioned between a valve supply port and a valve function port, and a lower circular seat positioned between the valve function port and a valve vent port. The seal assembly is carried by an elongate moveable piston. The piston moves from a closed position, in which the seal assembly is engaged with the first seat and disengaged with the second seat, to an open position, in which the seal assembly is engaged with the second seat and disengaged with the first seat. The spring is positioned within a chamber in fluid communication with the pilot close port and urges the piston into the closed position. The pilot open chamber is in fluid communication with the pilot open port and serves to retain fluid that exerts pressure on the head of the piston, causing the piston to move from a closed position to an open position where the piston is actuated.
The latching chamber is formed within the interior of the elongate moveable piston and is in fluid communication with the supply pressure when the valve is in the open position. The latching chamber has an area exposed to the supply pressure that generates sufficient latching force to overcome the opposing forces generated by the spring and the supply pressure acting against the piston. Thus, when the open pilot is pulsed, the elongate moveable piston moves to the open position and supply pressure fills the latching chamber. The piston is then held in the open position until the close pilot is pulsed, which added pressure combines with the pressure exerted by the spring to force the piston into the closed position. These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the preferred embodiment thereof which is illustrated in the appended drawings, which drawings are incorporated as a part hereof.
It is to be noted, however, that the appended drawings illustrate only a typical embodiment of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a section view of a portion of the body and of the hydraulic latching spool valve of the present invention. The internal valve components are in the closed position.
FIG. 2 is a section view of the hydraulic latching spool valve of FIG. 1, except the internal valve components are in the open position.
FIG. 3 is an exploded view of the hydraulic latching spool valve showing the three-dimensional structure and spatial relationship of the valve components.
DETAILED DESCRIPTION
Referring now to the drawings and first to FIGS. 1 and 2, a preferred embodiment of the present hydraulic latching spool valve is generally designated by the numeral 10 . FIG. 1 shows the spool valve 10 in the closed position, while FIG. 2 shows spool valve 10 in the open position.
In FIG. 1, a body 12 surrounds the hydraulic latching spool valve 10 . The body 12 defines a valve chamber 13 , a pilot open port 14 , a pilot close port 16 , a vent port 18 , a function port 20 , and a supply port 22 which are each in communication with valve chamber 13 . At its upper end, valve body 12 defines a threaded access opening 24 which is adapted to threadably engage a hex plug 26 which is sealed with respect to body 12 by an o-ring 28 . A valve cage 30 is inserted in the valve chamber 13 of body 12 , and is sealed with respect to valve body 12 by first upper valve cage seal assembly generally identified by the numeral 32 , comprised of an o-ring 27 and two flanking backup rings 25 and 29 , second upper valve cage seal assembly generally identified by the numeral 34 , comprised of an o-ring 31 and a backup ring 33 , first lower valve cage seal assembly generally identified by the numeral 36 , comprised of an o-ring 37 and a backup ring 35 , and second lower valve cage seal assembly generally identified by the numeral 38 , comprised of an o-ring 41 and a backup ring 39 . These seal assemblies and others described herein are better seen in FIG. 3 .
Valve cage 30 acts as a piston receptacle and guide, and further defines upper circular seat 40 and lower circular seat 42 . The upper end of valve cage 30 defines a piston and spring section having an internal cylindrical surface which defines a piston chamber 43 for receiving a piston 44 . Piston 44 has an upper cylindrical section and a lower stem section, and is sealed with respect to piston chamber 43 by first piston seal assembly generally identified by the numeral 46 , comprised of an o-ring 45 and two flanking backup rings 75 and 47 , and second piston seal assembly generally identified by the numeral 48 , comprised of an o-ring 51 and two flanking backup rings 49 and 53 . Immediately below the upper cylindrical portion of piston 44 , an annular seal gland 68 is positioned about the piston stem. Seal gland 68 defines a circular seal recess adapted to receive an upper piston stem seal assembly generally identified by the numeral 60 .
Upper piston stem seal assembly 60 is comprised of an o-ring 61 and a circumferential PEEK seal 63 . The lower end of the stem of piston 44 maintains a lower piston stem seal assembly generally identified by the numeral 62 , comprised of an o-ring 67 and a circumferential PEEK seal 65 . A spacer 74 is provided in supporting engagement between upper piston stem seal assembly 60 and lower piston stem seal assembly 62 . The bottom of the stem of piston 44 is also adapted to receive a gland nut 70 into which is positioned a cotter pin 72 which secures gland nut 70 against inadvertent rotation relative to the piston stem.
The top portion of piston 44 defines an opening adapted to receive stationary plug 50 . Stationary plug 50 is positioned between the underside of hex plug 26 and the upper end of piston 44 . Stationary plug 50 is sealed with respect to the opening in the upper end of piston 44 by latching piston seal assembly generally identified by the numeral 52 , the seal assembly being comprised of an o-ring 57 and two flanking backup rings 55 and 59 .
Piston 44 further defines an internal latching chamber 54 , having a cylindrical shape and having a wide diameter at its upper end. Latching chamber 54 is in fluid communication with supply port 22 by means of fluid port 56 located at the lower end of piston 44 . Between piston 44 and valve cage 30 , a spring 58 is operably located to bias piston 44 towards the closed position.
FIG. 1 shows hydraulic latching spool valve 10 in the closed position. Lower piston stem seal assembly 62 and lower circular seat 42 are engaged, while upper piston stem seal assembly 60 and upper circular seat 40 are disengaged. Thus, vent port 18 and function port 20 are in fluid communication with one another.
FIG. 2 shows hydraulic latching spool valve 10 in the open position. Upper piston stem seal assembly 60 and upper circular seat 40 are engaged, while lower piston stem seal assembly 62 and lower circular seat 42 are disengaged. Thus, function port 20 is in fluid communication with supply port 22 . Supply pressure fills latching chamber 54 .
The operation of hydraulic latching spool valve 10 is as follows. The “normal” condition of hydraulic latching spool valve 10 is as shown in FIG. 1, where spring 58 maintains the valve mechanism in the closed position with lower piston stem seal assembly 62 in sealing engagement with lower circular seat 42 , thus blocking supply pressure from supply port 22 from communication with function port 20 . At this point, function port 20 is open to vent port 18 .
To open the valve, the open pilot is pulsed, causing pilot open pressure to flow into pilot open chamber 64 and to act on the upper end of piston 44 , thus driving the piston downward and moving upper piston stem seal assembly 60 into sealing engagement with upper circular seat 40 . This piston and valve seal movement causes isolation of vent port 18 from function port 18 and allows supply pressure to communicate with function port 18 and latching chamber 54 . This open position of hydraulic latching spool valve 10 is shown in FIG. 2 .
As piston 44 moves into the open position, latching chamber 54 is also placed in fluid communication with supply port 22 by means of fluid port 56 . Supply fluid enters latching chamber 54 at fluid port 56 near its lower end and fills the latching chamber. As supply fluid fills the upper end of latching chamber 54 the fluid imparts pressure against piston 44 and stationary plug 50 . The effect of this pressure is to force piston 44 in a downward direction. Because of the area of the upper portion of latching chamber 54 , identified by arrows “L”, the force imparted by fluid in the latching chamber is sufficient to overcome the combined opposing force of spring 58 and the supply pressure impacting piston 44 at spacer 74 indicated by arrow “P”. Thus, the fluid in latching chamber 54 serves to latch the valve in the open position. Pilot open pressure goes to zero psi and the valve remains open because of the differential forces acting on piston 44 .
To close the valve, the close pilot is pulsed, causing pilot close pressure to flow into pilot close chamber 66 . The fluid pressure in pilot close chamber 66 acts on piston 44 forcing it in an upward direction. The force of the pilot close pressure, in combination with spring 58 , is sufficient to overcome the force imparted by fluid in latching chamber 54 . Piston 44 moves upwardly, returning the valve to its normally closed position.
FIG. 3 is an exploded view of a preferred embodiment of the present invention. The diagram shows the orientation of each component of hydraulic latching spool valve 10 relative to the others. Beginning at the top row, left to right, the parts are: hex plug 26 ; o-ring 28 ; stationary plug 50 ; stationary plug seal assembly 52 ; first piston seal assembly 46 ; latching chamber 54 ; piston 44 ; spring 58 ; second piston seal assembly 48 ; seal gland 68 ; upper piston stem seal assembly 60 ; access opening 24 ; valve cage 30 ; spacer 74 ; lower piston stem seal assembly 62 ; gland nut 70 ; cotter pin 72 ; first upper valve cage seal assembly 32 ; second upper valve cage seal assembly 34 ; first lower valve cage seal assembly 36 ; and second lower valve cage seal assembly 38 .
The invention has several advantages. Using only one moveable piston, the valve can be latched in the open position after only a brief pulse of pilot open pressure. Once the pilot open pressure is pulsed, fluid fills the latching chamber and maintains the valve in the open position even after pilot open pressure is removed. The valve remains open until pilot close pressure is applied.
Another advantage of the invention is that the risk of leakage due to the latching fluid pressure is reduced because the fluid is contained within a latching chamber located in the interior of the piston. This is preferable to the situation in which the latching fluid fills a chamber between the piston body and the valve cage because if the latching fluid fills a chamber between the piston body and the valve cage there is a risk of leakage along the various seal points between the piston body and the valve cage.
In view of the foregoing it is evident that the present invention is one well adapted to attain all of the advantages and features hereinabove set forth, together with other advantages and features which are inherent in the apparatus disclosed herein.
As will be readily apparent to those skilled in the art, the present invention may easily be produced in other specific forms without departing from its spirit or essential characteristics. The present embodiment is, therefore, to be construed as merely illustrative and not restrictive, the scope of the invention being indicated by the claims rather than the foregoing description, and all changes which come within the meaning and range of equivalence of the claims are therefore intended to be embraced therein. | A hydraulic latching spool valve has at movable piston and valve cage defining two seats. In the valve cage, a moveable piston is operable to move the valve into open and closed positions. A spring positioned in a pilot close chamber urges the piston to close. A pulse of fluid pressure at a pilot open chamber causes the piston to open. A latching chamber is formed on the interior of the piston, the latching chamber being exposed to supply pressure when the piston is in the open position. Accordingly, in the open position, supply fluid in the latching chamber generates sufficient latching force to overcome opposing forces generated by the sprig. The supply pressure holds the piston in the open position until a pulse of fluid pressure is applied to the pilot close chamber, thereby causing the valve to close. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a printing and/or coating or lacquering machine with direct and indirect rotogravure system.
As it is known, in the rotogravure printing it is very important to accurately control the contact pressure between the pressure roller or cylinder and the engraved cylinder or roller, because print quality largely depends on such a control. The most advanced systems used so far are of pneumatic type, but they make it possible to obtain only a coarse indication, so to speak, of the working pressure. Furthermore, since pneumatic systems are rather resilient, they are subject to oscillate even if provided with a damping chamber, which negatively affects the final printing results.
SUMMARY OF THE INVENTION
The main object of the present invention is to provide a printing or coating machine with a rotogravure system, provided with a device which is designed precisely to control the contact pressure between the lower pressure roller and the engraved cylinder in the case of direct rotogravure printing, and accurately to control pressure between the upper pressure roller and the lower pressure roller and between the lower pressure roller and the engraved cylinder in the case of indirect rotogravure printing.
Another object of the present invention is to provide a printing and/or coating machine with a rotogravure system which makes it possible to obtain zero contact pressure or a minimal gap (of the order of 0.01-0.5 mm), which is very convenient when coating with lacquers or paints, in which case the engraved cylinder is rotated in the opposite direction with respect to its respective pressure roller.
Another object of the present invention is to provide a contact pressure control device which makes also possible to perform pre-measurements with initial reading of the diameter of the rubber sleeves of the lower and upper pressure rollers.
Another object of the present invention is to provide a rotogravure printing machine which is provided with a new inking assembly for high-quality inking.
Another object of the present invention is to provide a rotogravure printing machine which is provided with a carriage for supporting and transferring an engraved cylinder, a doctor blade and an inking assembly.
These and other objects which will become better apparent hereinafter are achieved by a printing or spreading or coating or lacquering machine with direct and indirect rotogravure system, having one or more printing or color units, a drying hood and a control unit, each printing or color unit comprising an orientatable inlet roller for material in ribbon or tape form, a plurality of idle rollers for conveying the tape material, an upper pressure roller provided with a rubber sleeve, a lower pressure roller, a doctor blade assembly, an engraved cylinder, characterized in that at least one roller, chosen between said upper and said lower pressure rollers, is vertically movable and can be actuated by a pair of step motors and recirculating ballscrews and is supported so as to be movable along linear guides at the ends of the recirculating ballscrews, with the interposition of pressure detection means arranged to report to the control unit the linear pressure between the upper pressure roller and the lower pressure roller and between the lower pressure roller and the engraved cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects and advantages of the present invention will become apparent from the following detailed description of a specific currently preferred embodiment thereof, given merely by way of non-limitative example with reference to the accompanying drawings, wherein:
FIG. 1 is a diagrammatic elevation view, with parts shown in cross-section, of a rotogravure printing element or station;
FIG. 2A is a cross-sectional view taken along the line II--II of FIG. 1 of a carriage or truck for supporting the engraved cylinder arranged for printing according to a direct rotogravure system;
FIG. 2B is similar to FIG. 2A, but with carriage or truck for supporting the engraved cylinder arranged for printing according to an indirect rotogravure system;
FIG. 3 is a view similar to FIG. 2 but showing the opposite lateral shoulder of a printing element or station and of the lower part of said lateral shoulder, where an on-off carriage or truck is provided;
FIG. 4 is an enlarged-scale view of a detail of FIGS. 2 and 3 showing the connection between the recirulating ballscrew and its respective load cell;
FIG. 5 is a vertical sectional view, taken along the line V--V of FIG. 6, of the front shoulder of a printing station provided with an auxiliary pressure roller;
FIG. 6 is an elevation view with parts shown in cross-section of a printing or coating station provided with an auxiliary pressure roller for effectively gripping the tape material;
FIG. 7 is a side elevation view of an on-off carriage or truck for supporting an engraved cylinder, a doctor blade and an inking system which can be applied as shown in FIGS. 2B and 3;
FIGS. 8 and 9 are, respectively, a front and a plan view of the carriage or truck of FIG. 7;
FIG. 10 is a side elevation view of a double driving chain system for the entry and exit of an on-off carriage or truck which can be arranged at the base of a printing station;
FIG. 11 is a front view of an on-off carriage which is inserted and raised between the two side shoulders with a single double-chain system which engages with the intermediate portion of the truck;
FIG. 12 is a partial cross-sectional top view, taken at three different levels, of the carriage or truck of FIG. 7;
FIGS. 13 and 14 are, respectively, a front elevation and a plan view of an inking system installed on an on-off carriage; and
FIG. 15 is a cross-sectional view taken along the line XV--XV of FIG. 13.
In the accompanying drawings, identical or similar parts or components have been designated by the same reference numerals.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference first to FIGS. 1 to 4, it is clearly shown that a printing unit or station in a rotogravure printing machine of multiple-color type, for example of the eight-color type, generally designated by the reference numeral 1, is constituted substantially by a printing assembly, a drying hood 2 and a control panel or unit 3.
The printing assembly comprises two lateral shoulders, i.e. a shoulder 4 on the front side of the machine and a shoulder 5 on the rear side, on which idle rollers are mounted sequentially (only one of the rollers, designated by the reference numeral 6, is shown in the drawings. See FIGS. 2A, 2B and 3) together with an adjustable roller 7 which is arranged at the infeed of the material in ribbon or tape form 8 to be printed and can be adjusted micrometrically at both ends thereof, as shown schematically by two screws 9 and 10 in FIGS. 2A and 2B. An engraved cylinder (spreader roller) 12 is also supported on the lateral shoulders 4 and 5 together with a lower pressure roller 13 for transferring ink during printing and an upper pressure roller 14.
For printing or coating or lacquering with a direct rotogravure system, the engraved roller 12 is rotated in the direction of the arrow A (FIG. 2A), i.e., in the feed direction of the ribbon 8, whereas with the indirect rotogravure system it is rotated in the direction of the arrow B (FIG. 2B), i.e., against the feed direction of the ribbon 8 to be printed or coated or lacquered.
The engraved cylinder 12 (see FIGS. 1, 2A and 2B) is driven by an electric motor 15 with the interposition of an epicyclic reduction unit 16, a coupling 17 and an encoder 18, which is connected in axial alignement with the driving shaft. The engraved cylinder 12 can rotate in both directions and its motor 15 performs both the continuous rotation function, when the machine 1 is at rest as well as the function of orientating the roller in the home position for its on-off engagement and register pre-set. The engraved cylinder 12 and the pressure rollers 13 and 14 are moved away automatically, e.g. by approximately 2 mm, from one another every time the machine stops.
As usual, below the engraved cylinder 12 there are provided an ink tray 19, a tank 20 and an electric pump 21 for ink feeding and circulation (see FIG. 1 in particular).
Both the lower pressure roller 13 and the upper pressure roller 14 have a respective rubber sleeve 23 and 24 (see FIG. 1), which is approximately 2 mm thick and can be easily replaced between the engraved cylinder 12 and the pressure rollers simply by being laterally inserted and extracted manually with compressed air e.g. at 16 bar, through a suitable opening provided in the lateral shoulder 4, whereas its respective cylindrical core 13 and 14 is kept in the machine. The pressure rollers are rotatably mounted on self-aligning bearings which are fixed on slides which can slide on linear recirculating ballscrew guides 25 and 26 which are vertically secured inside the lateral shoulders 4 and 5. The position of the rollers 13 and 14 along the guides 25 and 26 (see FIG. 1) is controlled by step motors 27 and 28 which operate respective recirculating ballscrews 29 and 30 kinematically connected to supporting slides 31 for the lower pressure roller 13 and 32 for the upper pressure roller 14. The position of the screws 29 and 30 is controlled by an encoder which is located on the rear of the step motor in axial alignment with said recirculating ballscrews.
In order to precisely control the linear pressure applied by the step motors 27 and 28 (see FIG. 1), between the upper pressure roller 14 and the lower pressure roller 13 and between the lower pressure roller and the engraved cylinder 12, there are provided load cells 34, preferably of the explosion-proof type operating with electric-resistor straingauges. At both sliding blocks of the machine the load cell 34 is rigidly secured to the nut of the recirculating ballscrew by means of a cup-shaped sleeve 38, whereas the sliding blocks 31 and 32 supporting the pressure rollers 13 and 14 are suspended to the load cells 34 by means of a screw 35 (see FIG. 4).
Of course it is also possible to use other suitable pressure detection means, e.g. piezometric sensors or the like, instead of the load cells.
Typically, the linear pressure between the rollers can change between 3 and 30 N/cm and can be controlled and monitored with high accuracy at any stage of the printing process. The lower pressure roller 13 and the upper pressure roller 14 are positioned automatically and the value of the pressure set in the PLC at the control unit 3 is automatically attained during the first intervention of the pressure rollers actuated by the step motors 27 and 28.
It is also possible to perform through a program a pre-measurement of the diameters of the pressure rollers 13 and 14 and the initial diameters of the rubber sleeves also to detect, while printing, the extent of the wear of said rubber sleeves, thereby ensuring high printing quality in any circumstance.
FIGS. 5 and 6 show a spreading or coating station 40 provided with an auxiliary pressure roller 75 which is mounted at one end of a pair of identical arms 76, whose other end is pivoted about a horizontal pivot 78 which extends parallel to the axes of the rollers 13 and 14. The end of a stem 80 is pivoted at 79 to an intermediate point of the arms 76. Said stem 80 belongs to a respective pneumatic cylinder-and-piston assembly 81 arranged to press the auxiliary pressure roller 75 against the upper pressure roller 14, so that it forms together with the pressure roller 14 a composite traction assembly which assists in ensuring constant tension of the ribbon or tape material to be printed.
The lower pressure roller 13 and the upper pressure roller 14 are operated independently from one another by a respective electric motor, thereby making it also possible to rotate the two rollers in opposite directions. This is particularly advantageous for the application of primers with a "kiss-coating" effect in order to remove the primer ink excess with a contactless process. Thus, it is possible to apply a thicker or thinner layer of primer depending upon the rotation speed in opposite directions of the rollers 13 and 14. The automatic back movement of the rollers every time the machine stops is about 2 mm, whereas it is approximately 100 mm for a color changing.
A positive doctor blade 36 is provided on the engraved cylinder 12 and arranged to eliminate the ink in excess. The doctor blade can be actuated by two pneumatic cylinder-and-piston units 37 which are controlled by the control unit 3.
FIGS. 1 to 3 relate to a printing element or station 1 provided with a carriage or truck 41 which can be inserted into and removed from it. A priming station comprises a rotogravure printing unit, e.g. that described with reference to FIGS. 5 and 6, where no carriage 41 is provided.
The carriage or truck 41 (FIGS. 7 to 14) comprises a supporting structure, and a doctor blade 42 and an engraved printing cylinder 12 both supported by the supporting structure. The supporting structure comprises, for example, two side shoulders 45 and 46, e.g. made of steel, which are mutually rigidly connected by a cross-member 47, to which two steerable wheels, i.e. a front wheel 48 and a rear wheel 49, are secured to and along the transverse centerline of the carriage. Said wheels can be steered manually by means of a steering column 50 and a handle 51 (FIGS. 7 and 8).
Close to each side shoulder there is provided at the longitudinal centerline of the carriage a false leg 52 and 53 which terminates at its lower end with a respective free ball 54 which is located however, at a slightly higher level (e.g. approximately 5 mm) shorter than the wheels 48 and 49 (see FIG. 7), thereby ensuring easy manual handling in all directions and great versatility of the carriage 41.
The doctor blade assembly 42 is mounted on lateral slides 56 which can move along vertical guides for vertical mechanical adjustment of the entire doctor blade assembly. The doctor blade is actually mounted so that it can be angularly adjusted about a horizontal pivot 57 upon control of one or more pneumatic cylinder-and-piston units 58 with quick locking of the doctor blade.
An ink tray 60 (see FIG. 13), preferably made of stainless steel, is supported vertically adjustable (up-down) below the cylinder 12 and has an ink outlet 61 leading directly into a tank located outside the printing assembly. The tray can be easily vertically adjusted and quickly replaced.
In front of the doctor blade 42, on the opposite side with respect to the printing cylinder 12, there is an inking assembly 62 which comprises a nipple 63 (see FIG. 13) which constitutes the inlet for any ink supplied by a pump sucking from a tank located outside the printing assembly. The inking assembly 62 is arranged to form an ink film in order to fill the engravings of the printing cylinder, thereby preventing any residual ink from drying after the transfer of the print to the ribbon or tape. Preferably, inking should take place along the highest possible generatrix of the printing cylinder, so as to minimize the time in which any residual ink is exposed to the air. The inking assembly 62 is adjustably mounted on horizontal guides 64 in order to match various diameters of the printing cylinder 12.
The best inking operation is ensured at the level of the ink column, i.e. at approximately 120 mm, since the pressure on the surface of the engraved cylinder 12 is increased accordingly. The shape of the peripheral inking assembly is preferably suitable to produce considerable turbulence, which maintains the ink in continuous motion in order to dissolve any clots in it.
As shown in FIG. 10, at the lower portion of the lateral shoulders 45 and 46 or at one of the wheels 48, 49 the carriage or truck 41 has a fixed recess 65 designed to be engaged by a corresponding cantilevered pivot 66 supported by a portion, or by a respective portion, of a double chain 67 (FIG. 12), which is wound around a pair of chain sprocket wheels 68 and 69 and extends parallel to the shoulders 45 and 46. One of the sprocket wheels 68 and 69 is a driving wheel, so that when the carriage is arranged between the shoulders 4 and 5 of the printing station and the fixed recess or recesses 65 engages with the pivot or pivots 66, a sensor (not shown) detects correct positioning of the carriage and generates a control signal which causes the motor to start, thereby driving the driving sprocket wheel for the chains 67, and thus the carriage or truck is fully inserted in position inside the printing assembly and then locked in upward direction by means of two lateral hydraulic cylinders 70 and 71 which are arranged to engage two lateral pivots 72 of the carriage (see FIG. 11).
It will be easily noted that the carriage or truck 41 can be inserted in a printing unit in two different positions depending upon the print to be obtained. The carriage 41 is inserted with the doctor blade 42 being arranged on the inlet side for the tape material 8 to be printed (FIG. 2A) when direct rotogravure printing is to be performed, whereas the carriage 41 is inserted with its opposite front (FIG. 2B) when indirect rotogravure printing is to be obtained.
The above described invention is susceptible to numerous modifications and variations within the scope of protection as defined in the claims.
The disclosures in Italian Patent Application No. VR98A000008 from which this application claims priority are incorporated herein by reference. | A machine for printing or spreading primers or coatings and the like with direct and indirect rotogravure system, comprising one or more printing or color units, with a respective drying hood and control unit, each printing or color unit comprising an orientatable inlet roller for tape material, a plurality of free rollers for conveying the tape material, an upper pressure roller, provided with a rubber sleeve, a lower pressure roller, a doctor blade, and an engraved cylinder. At least one roller, chosen between the upper pressure roller and the lower pressure roller, is rotated by a respective step motor and recirculating ballscrews and is supported on linear guides at its ends, with interposed pressure detecting means arranged to forward to the control unit signals indicating the linear pressure between the upper pressure roller and the lower pressure roller and the engraved cylinder. | 1 |
BACKGROUND
[0001] Brushless motors presently in existence generally include a rotor assembly having one or more rotor magnets disposed on the periphery thereupon. The rotor magnets, when positioned upon the periphery of a rotor, may cover the entire outer surface of the rotor. Alternatively, a plurality of rotor magnets may have gaps or spaces located between each individual magnet, which gaps are either typically filled with a non-magnetic material or are left unfilled. In either case, the torque produced by a motor having such a rotor assembly is linearly proportional to the current applied. Thus, the motor torque constant K, (torque per unit current) will not vary over a given range of operating speeds.
[0002] However, in certain applications using brushless motors, such as electric power steering systems, it may desirable to have a relatively high applied torque at low motor speeds and a relatively low applied torque at high motor speeds.
SUMMARY
[0003] The problems and disadvantages of the prior art are overcome and alleviated by a rotor assembly for a brushless motor. In an exemplary embodiment of the invention, the rotor assembly includes a core having a central opening for insertion of a rotor shaft therein. A plurality of rotor magnets disposed upon a periphery of the core, wherein a space is defined between one of the plurality of rotor magnets and another of the plurality of rotor magnets. A portion of said core occupies said space, thereby defining a salient pole therewithin.
[0004] In a preferred embodiment, the brushless motor has a total output torque having a first torque component and a second torque component. The first torque component is proportional to the applied current to the brushless motor and the second torque component is proportional to the square of the applied current to the brushless motor. Furthermore, the first torque component is generated as a result of the interaction between the plurality of rotor magnets and the magnetomotive force generated in a stator of the brushless motor. The first torque component is maximized when the angle between the stator magnetomotive force and a pole axis defined by a pair of the plurality of rotor magnets is about 90 degrees. In contrast, the second torque component is generated as a result of the interaction between the plurality of salient poles and the magnetomotive force generated in the stator of the brushless motor. The second torque component is maximized when the angle between said stator magnetomotive force and a pole axis defined by a pair of said plurality of rotor magnets is about 135 degrees.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present invention will now be described, by way of example only, with reference to the accompanying drawings which are meant to be exemplary, not limiting, and wherein like elements are numbered alike in several Figures, in which:
[0006] [0006]FIG. 1 is a schematic diagram of an electric power steering system using a polyphase brushless motor in accordance with an embodiment of the invention;
[0007] [0007]FIG. 2 is a cross sectional view of an existing rotor configuration for a brushless motor;
[0008] [0008]FIG. 3 is a cross sectional view of another existing rotor configuration for a brushless motor;
[0009] [0009]FIG. 4 is a cross sectional view of another existing rotor configuration for a brushless motor;
[0010] [0010]FIG. 5 is a cross sectional view of a rotor assembly for a brushless motor, in accordance with an embodiment of the invention;
[0011] [0011]FIG. 6 is an alternative embodiment of the rotor assembly of FIG. 5; and
[0012] [0012]FIG. 7 is a graph illustrating the torque versus angle characteristics for the rotor assembly shown in FIG. 5.
DETAILED DESCRIPTION
[0013] Referring initially to FIG. 1, a motor vehicle 10 is provided with an electric power steering system 12 . Electric power steering system 12 may include a conventional rack and pinion steering mechanism 14 having a toothed rack 15 and a pinion gear (not shown) under a gear housing 16 . As steering wheel 18 is turned, an upper steering shaft 20 turns a lower shaft 22 through a universal joint 24 . Lower steering shaft 22 turns the pinion gear. The rotation of the pinion gear moves the rack 15 , which then moves tie rods 28 (only one shown). In turn, tie rods 28 move steering knuckles 30 (only one shown) to turn wheels 32 .
[0014] An electric power assist is provided through a controller 34 and a power assist actuator comprising a motor 36 . Controller 34 receives electric power from a vehicle electric power source 38 through a line 40 . The controller 34 also receives a signal representative of the vehicle velocity on line 41 , as well as steering pinion gear angle from a rotational position sensor 42 on line 44 . As steering wheel 18 is turned, a torque sensor 46 senses the torque applied to steering wheel 18 by the vehicle operator and provides an operator torque signal to controller 34 on line 48 . In addition, as the rotor of motor 36 turns, rotor position signals for each phase are generated within motor 36 and provided over bus 50 to controller 34 . In response to vehicle velocity, operator torque, steering pinion gear angle and rotor position signals received, the controller 34 derives desired motor phase currents. The motor phase currents are provided to motor 36 through a bus 52 to motor 36 , which thereby provides torque assist to steering shaft 20 through worm 54 and worm gear 56 .
[0015] Referring now to FIG. 2, an existing motor 36 features a rotor assembly 60 having a plurality of rotor magnets 62 circumferentially mounted upon a core 64 . A rotor shaft 65 is inserted through an opening in core 64 . The core 64 is circular in shape and may comprise a plurality of lamina of soft iron, steel or other magnetic material. In the embodiment shown, the rotor magnets 62 completely cover the outer surface of the core 64 . Alternatively, FIG. 3 illustrates the rotor assembly 60 wherein the rotor magnets 62 do not entirely cover the outer surface of core 64 . In this case, a space 66 is defined in between each pair of adjacent magnets 62 , which space 66 is either left unfilled or is filled with non-magnetic material 68 , such as a plastic mold filler, shown in FIG. 4.
[0016] In each of the existing rotor assembly 60 configurations shown in FIGS. 2 - 4 , the output torque of the motor 36 is directly proportional to the motor current. Furthermore, the output torque is maximized when the angle between the rotor pole axis 69 (shown by way of example in FIG. 4) for a given pair of rotor magnets 62 and the magnetomotive force generated in the stator (not shown) is at 90 electrical degrees with respect to one another. In terms of the torque produced per unit current, or torque constant K τ , this value remains a constant over the range of motor operating speeds.
[0017] Therefore, in accordance with an embodiment of the invention, a rotor assembly 80 for a brushless motor is shown in FIG. 5. For ease of description, like elements appearing in the prior Figures are shown with the same reference numerals and component designations. In addition to the elements previously described, a space 66 is defined between each pair of adjacent magnets 62 ; however each space 66 is partially filled or occupied by a protruding portion of the core, thereby defining a salient pole 82 within each space. The sailent poles 82 , being comprised of the same soft magnetic material as the core 64 , are magnetically attracted to an energized stator coil (not shown). Thus, the salient poles 82 provide another component of torque in a comparable fashion to the rotor poles of a switched reluctance motor. More specifically, the magnetic interaction between the energized coils around the poles of the stator and the salient poles 82 produces a torque.
[0018] [0018]FIG. 6 is an alternative embodiment of the rotor assembly 80 shown in FIG. 5. In the embodiment shown in FIG. 6, the salient poles 82 are dimensioned such the entire space 66 between each pair of adjacent rotor magnets 62 are filled with salient pole material.
[0019] Thus configured, rotor assembly 80 therefore provides both a first torque component τ 1 and a second torque component τ 2 . The first torque component τ 1 , being generated by the interaction between the stator and the rotor magnets 62 is directly proportional to the applied current. The second torque component τ 2 , generated as described above, is not linearly proportional to the applied motor current, but proportional to the square of the motor current. As a result, the second torque component τ 2 assists in providing an overall greater torque at lower speeds where the motor current is initially higher. In addition, since the second torque component τ 2 is also proportional to twice the angle between the rotor pole axis for a given pair of rotor magnets and the magnetomotive force generated in the stator, τ 2 is maximized at intervals of 45 electrical degrees.
[0020] Finally, FIG. 7 illustrates the relationship between the per unit torque of the first and second torque components τ 1, τ 2 versus the angle between the stator magnetomotive force. Curve 90 represents the per unit torque of the first torque component τ 1 , generated from the interaction between the stator mmf and the rotor magnets. As can be seen from the graph, τ 1 is maximized at a 90 degree angle. On the other hand, curve 92 represents the per unit torque of the second torque component τ 2 , generated from the interaction between the stator mmf and the salient poles. During the first half cycle of curve 92 , it is seen that the second torque component τ 2 opposes the first torque component τ 1 , with maximum opposition occurring at an angle of 45 degrees. During the second half cycle, the second torque component τ 2 assists the first torque component τ 1 , with maximum assistance at an angle of 135 degrees.
[0021] Curve 94 represents the total output torque resulting from τ 1 and τ 2 . It can be seen that the maximum total output torque for motor 36 , therefore, will be between 90 and 135 degrees. At relatively small motor currents, the second torque component τ 2 will have less of an effect and, thus, the maximum total torque output will occur close to 90 degrees. At higher motor currents, the second torque component will have a greater effect on total torque output. Thus, the angle at which maximum torque occurs will also increase. Over a range of operating speeds, the second torque component τ 2 contribution to the total torque will be about 0-30% of the first torque component τ 1 contribution.
[0022] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | A rotor assembly for a brushless motor is disclosed. In an exemplary embodiment of the invention, the rotor assembly includes a core having a central opening for insertion of a rotor shaft therein. A plurality of rotor magnets disposed upon a periphery of the core, wherein a space is defined between one of the plurality of rotor magnets and another of the plurality of rotor magnets. A portion of said core occupies said space, thereby defining a salient pole therewithin. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The preferred embodiment of the invention is directed to self-loading rock and aggregate separators using a combination of gravity, agitation and centrifugal force for separation. The apparatus acquires a load of aggregate (a mixture of various materials such as sand, gravel, rock, etc.), makes selected piles of different size particles and dumps the remaining mixture in still another pile. The apparatus is adjustable for successively separating a selected size particle, e.g., less than one inch, one inch, three inches, twelve inches, etc. Separation of the different materials is obtained by agitation and by forcing particles out between relatively moving portions of the apparatus by means of centrifugal forces and gravity.
[0003] 2. Description of Related Art
[0004] Prior art devices include a rake or fork separator attached to a backhoe or a bulldozer. These devices do not produce piles of different size particles and do not do a good job of separating particles because the smaller particles usually are not separated from the larger particles. In these devices, separation is dependent upon gravity alone and not by the use of vibration, agitation or centrifugal forces.
[0005] Another type of separator, known as a Grizzly separator, consists of slanted rails in which small particles fall between the rails. Large particles that cannot pass between the rails, roll off by the force of gravity. This device is also not adjustable and depends solely upon gravity, and does not achieve separation by vibration, agitation or centrifugal forces. This separator is heavy and does not do a good job of separating the mixture. Usually the separation of particles is in two groups, that is, the particles that fall between the rails and the particles that roll off the rails.
[0006] Still another type of separator, known as a rotary drum screen separator, requires a feeder. The mixture is rotated inside the drum where the mixture is screened for the smaller particles first. The slant of the drum enables larger particles to be screened at the end of the drum. The remaining large particles are then discharged. This device requires a feeder and the system is very heavy, weighing between 10-50 tons.
[0007] Another prior art device comprises a vibrating screen separator which separates the particles by different size screens arranged in multiple layers. Particles smaller than the screen size fall through the screen and onto the next size screen while particles that are too large to pass through the screen are vibrated off the screen. This device may require a feeder, requires a lot of power to run and weighs between 5-10 tons. Wet materials may cause problems in the separation process.
SUMMARY OF THE INVENTION
[0008] The purpose of the instant invention is to separate dirt and sand from rock or concrete that are mixed together, i.e., the separation of an aggregate mixture into piles according to a selected maximum size of the individual components of the aggregate. The piles may be separately placed on the ground or may be individually and sequentially placed on a conveyor belt. Plastic and like material may also be separated from dirt and sand according to size. The instant invention enables better separation of a mixture because agitation of the material is continuous, and may be repeated over and over again separating the mixture by agitation, gravity and centrifugal forces, and does not depend on a one-pass gravity procedure as in the prior art. The material to be separated is thrown out by centrifugal force from between a gap formed between a rotating disk and a stationary portion of a machine such as the bucket of a backhoe. A portion of the bottom of the bucket is removed and the rotating disk covers the cutout with a space therebetween. Required power is less since the mixture is not crushed and does not require a feeder. Wet materials may also be separated. After separation, the large particles may be used by placing them on a sand or clay bed to form a base, such as for a road bed. Once the base for the road is laid down, the smaller particles may be placed on top so that the top surface can be made smooth. The invention can be attached to a track or rubber-tired vehicle such as a front loader, farm tractor or other such equipment. The invention may also be used in a fixed installation or in conjunction with an overhead crane.
[0009] For purposes of illustrating the invention, a backhoe having a bucket with the bottom cut out may be utilized. An adjustable hydraulically-driven rotating disk attaches to the bucket and covers the cut out portion of the bottom of the bucket, the combination having a gap, or a selected spaced-apart relationship, between the stationary bucket and the rotating disk. The disk is driven by a combination hydraulic motor/transmission system the latter being well known in the art. It will also be appreciated that the disk may be mechanically driven. In the preferred embodiment, the bucket is self-loading and may be tilted back while the disk is rotating, thereby causing the mixture to be agitated by the disk and with the other particles in the bucket. Particles smaller than the selected gap distance, e.g., one inch in diameter, are thrown out, through the gap between the edge of the disk and the cutout portion of the bucket, by centrifugal force. After the particles of selected size have been separated into a pile, the gap may be increased and the bucket re-positioned so as to pile the next larger size particles of, say, one to three inches, etc. in a separate pile by repeating the process. This process is repeated until the gap has been increased to its maximum size. The pieces of rock or material larger than the selected size of the gap remain in the bucket and may be dumped out in still another pile by tilting the bucket and throwing the larger particles out of the bucket. Then, the process may be repeated by reloading the bucket with another load of a mixture, with the sand and dirt therein being separated to their respective piles as described above. Sometimes the disk may stall, due to wet material or particles hanging up in the gap, so the hydraulic motor/transmission system can be reversed to free the disk. This separator is not a rock crusher like a cone crusher.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a drawing of a prior art backhoe machine which may be modified to accommodate the instant invention.
[0011] [0011]FIG. 2A is a cut-away drawing of the invention attached to a backhoe and showing the invention in its minimum gap mode.
[0012] [0012]FIG. 2B is a cross sectional drawing of the invention shown in FIG. 2A.
[0013] [0013]FIG. 3 is a drawing of the rotating disk movably mounted on the bucket of a backhoe showing the invention in its maximum gap mode.
[0014] [0014]FIG. 4 is a drawing of the mechanism for adjusting the gap by means of a hydraulic actuator, the gap being at its minimum.
[0015] [0015]FIG. 5 shows another view of the invention with the mechanism at its maximum gap.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring now to FIG. 1 for purposes of illustration, a known machine such as a backhoe BH is shown which may be modified for use in the invention. As will be subsequently described below, the invention may also be used in a fixed position. The backhoe BH comprises a tractor TR having a boom B movably attached thereto, the boom B capable of being rotated around pin P 1 by means of the hydraulic actuator(s) B 1 so as to raise and lower the boom B. A member called a “stick” S is movably attached to the boom B at pin P 2 and is rotated forward and backward (relative to the tractor TR) around pin P 2 by hydraulic actuator S 1 . Movably attached to stick S by means of pin P 3 is a bucket K which rotates (up and down relative to stick S) around pin P 3 as hydraulic actuator K 1 lifts and lowers the back of the bucket K by acting on pin P 4 . The tractor TR, boom B, stick S and bucket K are horizontally rotatable 360° as a common unit as is well known in the art and as described above.
[0017] Refering now to FIG. 2A, the bucket K of FIG. 1 has been replaced by a bucket 1 shown in a cut-away view with part of the bottom cut out. Pins P 3 and P 4 and actuator K 1 are shown as they relate and correspond to those elements in FIG. 1. Also, since stick S is always in a near-vertical or upright position, the bucket K is shown in FIG. 2A in its “dumping” mode, i.e., after all the material has been separated except for the largest particles. The bucket 1 has been turned around 180 degrees with respect to the bucket K of FIG. 1. It will be appreciated that the bucket 1 may be operated in either position. A rotating disk 2 , shown more clearly in FIGS. 2B and 3, is rotatably mounted so as to rotate relative to the bucket 1 by means of the hydraulic motor/transmission 9 also shown more clearly in FIG. 2A. The disk 2 in the illustrative example may be, e.g., approximately forty inches in diameter but may be larger or smaller depending upon the size of the bucket 1 . The hydraulic motor/transmission 9 is fixedly attached to a frame assembly 8 , the latter being hingedly attached to bucket 1 as will be subsequently described. A variable gap 3 of, e.g., about one inch to about twelve inches may be selected and is located between the disk 2 and the bottom of the bucket 1 as shown more clearly in FIG. 2B. The hydraulic motor/transmission 9 is fixedly attached to, and supported by, a box frame 8 , the entire assembly 8 being movably attached to bucket 1 by means of support trusses T 1 , T 2 , etc. and hinges 10 as will be described. The hydraulic motor/transmission 9 /frame assembly 8 is hinged at, say, four points by hinges 10 movably pinned to the trusses T 1 , T 2 (which are fixedly attached to the bucket 1 as by welding, riveting, bolts, etc.) and to the frame assembly 8 such that the gap 3 (see FIG. 2B) may be adjusted by a hydraulic actuator 11 , the action of which is shown more clearly in FIGS. 4 and 5. Hydraulic hoses 6 and 7 provide hydraulic power for rotating the hydraulic motor/transmission 9 either clockwise or counterclockwise as desired for rotation of the disk 2 . Return or leakage hose 5 provides a path for removal of fluid leakage inside the hydraulic motor/transmission 9 . Hydraulic actuator 11 , powered by hydraulic hoses 12 , 13 is movably attached to bucket 1 by truss T 3 (also fixedly attached to bucket 1 ) at pin P 5 . The movable shaft of actuator 11 is attached to frame 8 by pin P 6 and is shown fully extended in FIG. 2A to produce a minimum gap 3 . Thus, frame assembly 8 (with hydraulic motor/transmission 9 /disk 2 attached) may be moved relative to the cut out bottom of bucket 1 so as to adjust the gap 3 therebetween, the hinges 10 “swinging” frame assembly 8 and disk 2 attached thereto toward or away from the bottom of bucket 1 . The length of the hinges 10 determines the maximum dimension of gap 3 . It will be appreciated that, during all of the herein described operations, stick S is in a near-vertical or upright position.
[0018] [0018]FIG. 2B is a cross sectional view of the bucket 1 and disk 2 assembly. The disk 2 is rotatably mounted, via hydraulic motor/transmission 9 , on a frame assembly 8 which, in turn, is movably (swivelably) mounted to the bucket 1 by means of the hinges 10 . For ease of illustration, the trusses T 1 , T 2 , etc. are not shown. The disk 2 is attached by a drive shaft (not shown) to hydraulic motor/transmission 9 which is fixedly attached to frame 8 and provides power for rotating the disk 2 relative to the bucket 1 . As the disk 2 rotates, it is supported by rollers 20 rotatably attached to plate 25 of frame 8 by means of fixed brackets 22
[0019] [0019]FIG. 3 shows the bucket 1 in position for normal operation, i.e., for separation of materials. Rotating disk 2 is positioned beneath the cut out portion of bucket 1 with the disk 2 extended by actuator 11 and hinges 10 to its maximum gap 3 . Hydraulic motor/transmission 9 is connected to the disk 2 by a drive shaft (not shown) so as to selectively rotate the disk 2 either clockwise or counterclockwise as desired by the operation. The rotating disk 2 is controlled by an additional control valve in the backhoe tractor (not shown) which controls the flow of hydraulic fluid through hoses 6 and 7 as described above. The hinges 10 are shown fully extended for maximum spacing, e.g., say about twelve inches, between the rotating disk 2 and the bottom of the bucket 1 . Thus, all particles twelve inches and smaller will be thrown out through the gap 3 between the bucket 1 and the disk 2 . Particles larger than twelve inches will remain in the bucket for dumping as previously described. For maximum gap 3 , actuator 11 is fully retracted as shown more clearly in FIG. 5.
[0020] [0020]FIGS. 4 and 5 show, in more detail, the mechanism for adjusting the gap between the rotating disk 2 and the cutout portion of bucket 1 . FIG. 4 shows the invention at the minimum gap 3 (actuator 11 fully extended) and FIG. 5 shows the invention at the maximum gap 3 (actuator 11 fully retracted). The gap 3 is decreased or increased by extending or retracting, respectively, the hydraulic cylinder 11 as shown in FIGS. 4 and 5 by means of hydraulic hoses 12 and 13 (see FIG. 2A). Cylinder 11 is controlled by an additional valve (not shown) on the tractor TR which valve controls the flow of hydraulic fluid through hydraulic hoses 12 and 13 to and from the cylinder 11 . The backhoe BH is normally powered by a motor that drives multiple hydraulic pumps as is well known to those skilled in the art. The backhoe is equipped with many valves (not shown) for controlling the position of the bucket, i.e., to tilt the bucket, swing the bucket, etc. as is well known to those skilled in the art. The disk 2 is rotated by a hydraulic motor/transmission 9 controlled by a valve (not shown) which supplies hydraulic fluid to hydraulic hoses 6 and 7 .
[0021] The separator disclosed herein can adjust for material discharge size by adjusting the gap 3 between the cutout portion of the bucket 1 and the disk 2 . This gap is determined by the cylinder 11 shown in FIGS. 4 and 5, cylinder 11 being controlled by another hydraulic valve (not shown) on the tractor TR. The cross frame 8 is movably attached to the bucket 1 by four hinges 10 as previously described, and as the hinges 10 (and frame assembly 8 ) are swung by the hydraulic cylinder 11 , the gap 3 between the disk 2 and the bucket 1 may be adjusted between its minimum distance (FIG. 4) and its maximum distance (FIG. 5). In this manner, the gap 3 may be adjusted from, e.g., about one-half inch to about twelve inches. In actual practice, the gap 3 can be adjusted to zero, i.e., to completely cover the cutout portion of bucket 1 without a gap therebetween.
[0022] In operation, a first preferred size of particle to be separated is selected and the gap 3 between the disk 2 and the bucket 1 is adjusted accordingly by the hydraulic cylinder 11 . The bucket 1 is then loaded by tilting and crowding the bucket 1 (as shown in FIG. 2A) thereby loading an aggregate mixture into the bucket 1 . The hydraulic motor/transmission 9 rotates the disk 2 thereby agitating the aggregate mixture such that the particles smaller than the selected gap 3 size e.g., one inch in diameter, are thrown through the gap 3 and onto the ground by gravity and centrifugal force. The bucket 1 may be tilted so as to feed the rotating disk 2 until all the smaller particles are thrown out. The remaining larger particles may then be dumped out in another pile and the bucket 1 reloaded with another batch of aggregate, whereupon the process may be repeated. Alternatively, after ejecting all of the smaller size particles, the gap 3 may be increased and the process repeated until all of the aggregate material in the bucket 1 has been ejected in separate piles as desired.
[0023] In the above description, a preferred embodiment incorporates the invention into a backhoe as shown. It will be appreciated that the invention may be used in a fixed or permanent configuration; that is, the tractor TR may be eliminated and the stick S (or its equivalent) may be fixedly attached to e.g., an overhead beam. The bucket, instead of being self-loading, may then be filled by other means such as a dump truck, backhoe, etc. In this embodiment, a much larger bucket may be utilized for handling much larger loads. The overhead beam may include means for moving the bucket along the beam, much like an overhead crane, so as to enable the forming of a plurality of piles of different size particles. Alternatively, the piles may be accumulated on a movable conveyor belt. | Aggregate mixtures such as dirt, sand, rock, concrete, etc. are separated into piles according to size by continuous agitation of the mixture and by gravitational and centrifugal forces exerted thereon. A container for the material, such as the bucket of a backhoe, has the bottom thereof at least partially open. An adjustable, hydraulically-driven rotating disk attaches to and covers the open portion of the bottom of the container, the combination having a gap, or a selected spaced-apart relationship, between the stationary container and the rotating disk. The mixture is agitated by the rotating disk and by contact with the other particles in the container. Particles smaller than the selected gap distance are thrown out through the gap between the disk and the open portion of the container by centrifugal force. Material larger than the selected gap size remains in the container. | 8 |
BACKGROUND OF THE INVENTION
The present invention is related to the following GE commonly assigned applications:
GE
SERIAL
DOCKET
NUMBER
DATE FILED
218215
11/586060
Oct. 25, 2006
219734
11/586049
Oct. 25, 2006
219736
11/591695
Nov. 2, 2006
219737
11/586050
Oct. 25, 2006
219743
11/586051
Oct. 25, 2006
219744
11/586052
Oct. 25, 2006
219745
11/586046
Oct. 25, 2006
219746
11/586053
Oct. 25, 2006
219747
11/586054
Oct. 25, 2006
219748
11/591694
Nov. 2, 2006
219749
11/586085
Oct. 25, 2006
219750
11/586055
Oct. 25, 2006
219751
11/586088
Oct. 25, 2006
219757
11/586086
Oct. 25, 2006
219758
11/586045
Oct. 25, 2006
219759
11/586087
Oct. 25, 2006
219761
11/586092
Oct. 25, 2006
219762
11/591693
Nov. 2, 2006
219763
11/586090
Oct. 25, 2006
219765
11/586089
Oct. 25, 2006
219766
11/586091
Oct. 25, 2006
219767
11/591691
Oct. 25, 2006
219768
11/591692
Nov. 2, 2006
The present invention relates to airfoils for a rotor blade of a gas turbine. In particular, the invention relates to compressor airfoil profiles for various stages of the compressor. In particular, the invention relates to compressor airfoil profiles for either inlet guide vanes, rotors, or stators at various stages of the compressor.
In a gas turbine, many system requirements should be met at each stage of a gas turbine's flow path section to meet design goals. These design goals include, but are not limited to, overall improved efficiency and airfoil loading capability. For example, and in no way limiting of the invention, a blade of a compressor stator should achieve thermal and mechanical operating requirements for that particular stage. Further, for example, and in no way limiting of the invention, a blade of a compressor rotor should achieve thermal and mechanical operating requirements for that particular stage.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with one exemplary aspect of the instant invention, an article of manufacture having a nominal profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in TABLE 1. Wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape.
In accordance with another exemplary aspect of the instant invention, a compressor comprises a compressor wheel. The compressor wheel has a plurality of articles of manufacture. Each of the articles of manufacture includes an airfoil having an airfoil shape. The airfoil comprises a nominal profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in TABLE 1, wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape.
In accordance with yet exemplary another aspect of the instant invention, a compressor comprises a compressor wheel having a plurality of articles of manufacture. Each of the articles of manufacture includes an airfoil having an uncoated nominal airfoil profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in TABLE 1, wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic exemplary representation of a compressor flow path through multiple stages of a gas turbine and illustrates an exemplary airfoil according to an embodiment of the invention;
FIGS. 2 and 3 are respective perspective exemplary views of a rotor blade according to an embodiment of the invention with the rotor blade airfoil illustrated in conjunction with its platform and its substantially or near axial entry dovetail connection;
FIGS. 4 and 5 are side elevational views of the rotor blade of FIG. 2 and associated platform and dovetail connection as viewed in a generally circumferential direction from the pressure and suction sides of the airfoil, respectively;
FIG. 6 is a cross-sectional view of the rotor blade airfoil taken generally about on line 6 - 6 in FIG. 5 ;
FIG. 7 is a perspective views of a rotor blade according to an exemplary embodiment of the invention with coordinate system superimposed thereon; and
FIG. 8 is a perspective view of a stator blade according to an exemplary embodiment of the invention with coordinate system superimposed thereon.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 illustrates an axial compressor flow path 1 of a gas turbine compressor 2 that includes a plurality of compressor stages. The compressor stages are sequentially numbered in the Figure. The compressor flow path comprises any number of rotor stages and stator stages, such as eighteen. However, the exact number of rotor and stator stages is a choice of engineering design. Any number of rotor and stator stages can be provided in the combustor, as embodied by the invention. The seventeen rotor stages are merely exemplary of one turbine design. The eighteen rotor stages are not intended to limit the invention in any manner.
The compressor rotor blades impart kinetic energy to the airflow and therefore bring about a desired pressure rise across the compressor. Directly following the rotor airfoils is a stage of stator airfoils. Both the rotor and stator airfoils turn the airflow, slow the airflow velocity (in the respective airfoil frame of reference), and yield a rise in the static pressure of the airflow. The configuration of the airfoil (along with its interaction with surrounding airfoils), including its peripheral surface provides for stage airflow efficiency, enhanced aeromechanics, smooth laminar flow from stage to stage, reduced thermal stresses, enhanced interrelation of the stages to effectively pass the airflow from stage to stage, and reduced mechanical stresses, among other desirable aspects of the invention. Typically, multiple rows of rotor/stator stages are stacked in axial flow compressors to achieve a desired discharge to inlet pressure ratio. Rotor and stator airfoils can be secured to rotor wheels or stator case by an appropriate attachment configuration, often known as a “root”, “base” or “dovetail” (see FIGS. 2-5 ).
A stage of the compressor 2 is exemplarily illustrated in FIG. 1 . The stage of the compressor 2 comprises a plurality of circumferentially spaced rotor blades 22 mounted on a rotor wheel 51 and a plurality of circumferentially spaced stator blades 23 attached to a static compressor case 59 . Each of the rotor wheels is attached to aft drive shaft 58 , which is connected to the turbine section of the engine. The rotor blades and stator blades lie in the flow path 1 of the compressor. The direction of airflow through the compressor flow path 1 , as embodied by the invention, is indicated by the arrow 60 ( FIG. 1 ). This stage of the compressor 2 is merely exemplarily of the stages of the compressor 2 within the scope of the invention. The illustrated and described stage of the compressor 2 is not intended to limit the invention in any manner.
The rotor blades 22 are mounted on the rotor wheel 51 forming part of aft drive shaft 58 . Each rotor blade 22 , as illustrated in FIGS. 2-6 , is provided with a platform 61 , and substantially or near axial entry dovetail 62 for connection with a complementary-shaped mating dovetail, not shown, on the rotor wheel 51 . An axial entry dovetail, however, may be provided with the airfoil profile, as embodied by the invention. Each rotor blade 22 comprises a rotor blade airfoil 63 , as illustrated in FIGS. 2-6 . Thus, each of the rotor blades 22 has a rotor blade airfoil profile 66 at any cross-section from the airfoil root 64 at a midpoint of platform 61 to the rotor blade tip 65 in the general shape of an airfoil ( FIG. 6 ).
To define the airfoil shape of the rotor blade airfoil, a unique set or loci of points in space are provided. This unique set or loci of points meet the stage requirements so the stage can be manufactured. This unique loci of points also meets the desired requirements for stage efficiency and reduced thermal and mechanical stresses. The loci of points are arrived at by iteration between aerodynamic and mechanical loadings enabling the compressor to run in an efficient, safe and smooth manner.
The loci, as embodied by the invention, defines the rotor blade airfoil profile and can comprise a set of points relative to the axis of rotation of the engine. For example, a set of points can be provided to define a rotor blade airfoil profile.
A Cartesian coordinate system of X, Y and Z values given in the Table below defines a profile of a rotor blade airfoil at various locations along its length. The airfoil, as embodied by the invention, could find an application as a 9 th stage airfoil stator vane. The coordinate values for the X, Y and Z coordinates are set forth in inches, although other units of dimensions may be used when the values are appropriately converted. These values exclude fillet regions of the platform. The Cartesian coordinate system has orthogonally-related X, Y and Z axes. The X axis lies parallel to the compressor blade's dovetail axis, which is at a angle to the engine's centerline, as illustrated in FIG. 7 for a rotor and FIG. 8 for a stator. A positive X coordinate value is axial toward the aft, for example the exhaust end of the compressor. A positive Y coordinate value directed normal to the dovetail axis. A positive Z coordinate value is directed radially outward toward tip of the airfoil, which is towards the static casing of the compressor for rotor blades, and directed radially inward towards the engine centerline of the compressor for stator blades.
For reference purposes only, there is established point- 0 passing through the intersection of the airfoil and the platform along the stacking axis, as illustrated in FIG. 5 . In the exemplary embodiment of the airfoil hereof, the point- 0 is defined as the reference section where the Z coordinate of the table above is at 0.000 inches, which is a set predetermined distance from the engine or rotor centerline.
By defining X and Y coordinate values at selected locations in a Z direction normal to the X, Y plane, the profile section of the rotor blade airfoil, such as, but not limited to the profile section 66 in FIG. 6 , at each Z distance along the length of the airfoil can be ascertained. By connecting the X and Y values with smooth continuing arcs, each profile section 66 at each distance Z can be fixed. The airfoil profiles of the various surface locations between the distances Z are determined by smoothly connecting the adjacent profile sections 66 to one another, thus forming the airfoil profile. These values represent the airfoil profiles at ambient, non-operating or non-hot conditions and are for an uncoated airfoil.
The table values are generated and shown to three decimal places for determining the profile of the airfoil. There are typical manufacturing tolerances as well as coatings, which should be accounted for in the actual profile of the airfoil. Accordingly, the values for the profile given are for a nominal airfoil. It will therefore be appreciated that ± typical manufacturing tolerances, such as, ± values, including any coating thicknesses, are additive to the X and Y values. Therefore, a distance of about ±0.0160 inches in a direction normal to any surface location along the airfoil profile defines an airfoil profile envelope for a rotor blade airfoil design and compressor. In other words, a distance of about ±0.0160 inches in a direction normal to any surface location along the airfoil profile defines a range of variation between measured points on the actual airfoil surface at nominal cold or room temperature and the ideal position of those points, at the same temperature, as embodied by the invention. The rotor-blade airfoil design, as embodied by the invention, is robust to this range of variation without impairment of mechanical and aerodynamic functions.
The coordinate values given in TABLE 1 below provide the nominal profile envelope for an exemplary 9 th stage airfoil stator vane.
TABLE 1
X-LOC
Y-LOC
Z-LOC
1.71
−1.229
0
1.71
−1.23
0
1.708
−1.234
0
1.704
−1.24
0
1.695
−1.248
0
1.675
−1.255
0
1.648
−1.25
0
1.613
−1.24
0
1.569
−1.228
0
1.512
−1.211
0
1.445
−1.193
0
1.375
−1.173
0
1.296
−1.15
0
1.208
−1.124
0
1.111
−1.095
0
1.01
−1.065
0
0.905
−1.033
0
0.795
−1
0
0.681
−0.964
0
0.564
−0.926
0
0.442
−0.885
0
0.317
−0.841
0
0.188
−0.792
0
0.061
−0.741
0
−0.064
−0.687
0
−0.188
−0.628
0
−0.309
−0.566
0
−0.428
−0.498
0
−0.544
−0.425
0
−0.657
−0.346
0
−0.765
−0.261
0
−0.868
−0.17
0
−0.965
−0.074
0
−1.055
0.028
0
−1.137
0.132
0
−1.212
0.238
0
−1.278
0.343
0
−1.336
0.446
0
−1.387
0.548
0
−1.432
0.648
0
−1.471
0.745
0
−1.503
0.836
0
−1.528
0.919
0
−1.548
0.995
0
−1.563
1.063
0
−1.574
1.122
0
−1.582
1.172
0
−1.587
1.215
0
−1.59
1.251
0
−1.59
1.281
0
−1.588
1.305
0
−1.586
1.324
0
−1.582
1.337
0
−1.578
1.348
0
−1.573
1.356
0
−1.567
1.36
0
−1.561
1.361
0
−1.552
1.359
0
−1.543
1.355
0
−1.532
1.348
0
−1.519
1.337
0
−1.502
1.322
0
−1.483
1.303
0
−1.462
1.277
0
−1.437
1.246
0
−1.408
1.209
0
−1.375
1.165
0
−1.336
1.114
0
−1.293
1.057
0
−1.243
0.993
0
−1.188
0.922
0
−1.127
0.847
0
−1.062
0.768
0
−0.992
0.688
0
−0.918
0.606
0
−0.84
0.523
0
−0.756
0.44
0
−0.667
0.355
0
−0.573
0.27
0
−0.476
0.187
0
−0.378
0.107
0
−0.278
0.028
0
−0.176
−0.048
0
−0.073
−0.123
0
0.03
−0.196
0
0.135
−0.268
0
0.24
−0.339
0
0.347
−0.408
0
0.454
−0.476
0
0.562
−0.544
0
0.666
−0.608
0
0.768
−0.669
0
0.867
−0.727
0
0.962
−0.782
0
1.054
−0.835
0
1.143
−0.884
0
1.228
−0.931
0
1.31
−0.976
0
1.385
−1.016
0
1.452
−1.052
0
1.512
−1.083
0
1.568
−1.113
0
1.617
−1.138
0
1.655
−1.157
0
1.685
−1.173
0
1.705
−1.188
0
1.713
−1.205
0
1.713
−1.215
0
1.712
−1.222
0
1.712
−1.225
0
1.711
−1.227
0
1.711
−1.228
0
1.708
−0.905
0.656
1.707
−0.907
0.656
1.706
−0.91
0.656
1.702
−0.915
0.656
1.695
−0.923
0.656
1.678
−0.931
0.656
1.653
−0.929
0.656
1.621
−0.92
0.656
1.581
−0.909
0.656
1.529
−0.895
0.656
1.469
−0.879
0.656
1.405
−0.861
0.656
1.333
−0.842
0.656
1.253
−0.819
0.656
1.165
−0.795
0.656
1.073
−0.77
0.656
0.977
−0.743
0.656
0.878
−0.715
0.656
0.774
−0.685
0.656
0.666
−0.654
0.656
0.555
−0.62
0.656
0.441
−0.585
0.656
0.322
−0.546
0.656
0.205
−0.506
0.656
0.088
−0.464
0.656
−0.028
−0.419
0.656
−0.143
−0.371
0.656
−0.256
−0.32
0.656
−0.367
−0.265
0.656
−0.476
−0.206
0.656
−0.582
−0.143
0.656
−0.685
−0.077
0.656
−0.786
−0.005
0.656
−0.883
0.071
0.656
−0.974
0.149
0.656
−1.059
0.229
0.656
−1.136
0.309
0.656
−1.207
0.39
0.656
−1.272
0.47
0.656
−1.331
0.549
0.656
−1.384
0.628
0.656
−1.429
0.702
0.656
−1.468
0.771
0.656
−1.5
0.834
0.656
−1.526
0.891
0.656
−1.546
0.941
0.656
−1.561
0.984
0.656
−1.573
1.022
0.656
−1.581
1.054
0.656
−1.585
1.08
0.656
−1.587
1.102
0.656
−1.586
1.119
0.656
−1.584
1.131
0.656
−1.58
1.141
0.656
−1.576
1.148
0.656
−1.571
1.152
0.656
−1.566
1.155
0.656
−1.558
1.157
0.656
−1.549
1.157
0.656
−1.537
1.156
0.656
−1.522
1.151
0.656
−1.503
1.144
0.656
−1.48
1.133
0.656
−1.454
1.117
0.656
−1.423
1.097
0.656
−1.388
1.072
0.656
−1.346
1.043
0.656
−1.299
1.008
0.656
−1.247
0.967
0.656
−1.188
0.922
0.656
−1.123
0.871
0.656
−1.053
0.816
0.656
−0.979
0.758
0.656
−0.901
0.698
0.656
−0.82
0.637
0.656
−0.736
0.574
0.656
−0.648
0.509
0.656
−0.556
0.443
0.656
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6.556
−0.659
0.242
6.556
−0.588
0.18
6.556
−0.514
0.117
6.556
−0.439
0.055
6.556
−0.363
−0.006
6.556
−0.286
−0.065
6.556
−0.208
−0.124
6.556
−0.129
−0.181
6.556
−0.05
−0.237
6.556
0.03
−0.292
6.556
0.111
−0.346
6.556
0.193
−0.399
6.556
0.275
−0.45
6.556
0.358
−0.501
6.556
0.44
−0.549
6.556
0.518
−0.594
6.556
0.595
−0.637
6.556
0.67
−0.677
6.556
0.743
−0.715
6.556
0.813
−0.749
6.556
0.881
−0.782
6.556
0.947
−0.811
6.556
1.006
−0.837
6.556
1.061
−0.859
6.556
1.109
−0.879
6.556
1.155
−0.897
6.556
1.195
−0.912
6.556
1.226
−0.923
6.556
1.25
−0.932
6.556
1.269
−0.938
6.556
1.281
−0.947
6.556
1.284
−0.954
6.556
1.285
−0.959
6.556
1.285
−0.962
6.556
1.284
−0.963
6.556
1.284
−0.964
6.556
It will also be appreciated that the exemplary airfoil(s) disclosed in the above Table 1 may be scaled up or down geometrically for use in other similar compressor designs. Consequently, the coordinate values set forth in the Table 1 may be scaled upwardly or downwardly such that the airfoil profile shape remains unchanged. A scaled version of the coordinates in Table 1 would be represented by X, Y and Z coordinate values of Table 1 multiplied or divided by a constant.
While various embodiments are described herein, it will be appreciated from the specification that various combinations of elements, variations or improvements therein may be made by those skilled in the art, and are within the scope of the invention. | An article of manufacture having a nominal profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in a TABLE 1. Wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape. | 5 |
FIELD AND BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of medicine, and in particular to a new and useful method and apparatus for administering an active agent, i.e. a medicine or medication, to a subject by transdermal or other surface absorption of the agent into the tissues in and around one or both eyes of the subject.
[0002] Punctal plugs are known which are made in suitable dimensions and of suitable materials to be removably inserted into the upper and/or lower punctal apertures or punctum of the eye, to block the opening and the canaliculus communicating therewith, to prevent drainage of lacrimal fluid (tears). Such plugs are known to be made of suitable materials, such as polymers, for example polytetrafluorethylene (known by the trademark TEFLON), or hydroxyethylmethacrylate (HEMA), hydrophilic polymer, methyl methacrylate, or silicon, or even of stainless steel or other inert metal material.
[0003] It is also known to apply an active agent such as nicotine or a birth control drug, to the inner surface of a patch which can be worn against the skin of a subject for transdermally administering the active agent to the subject.
SUMMARY OF THE INVENTION
[0004] It is an object of the present invention to provide a method and an apparatus for administering an active agent to a subject by applying the active agent to at least one surface of an ocular implant such as a punctal plug, and installing the implant, e.g. inserting the punctal plug into a punctal aperture of the subject.
[0005] If the active agent or drug is meant for treating the tissues at the walls of the canaliculus, for example, the drug is applied only to inner surfaces of the plug that are adapted to be in contact with or near the tissues of the canaliculus. The presence of tears is highly advantageous as a natural vehicle or carrier for the agent.
[0006] If the active agent or drug is meant for treating the eye itself, the drug is applied only to outer surfaces of the implant or plug that are adapted to be outside the canaliculus. Here the presence of previously secreted tears or a tear pool is again advantageous as a natural vehicle or carrier for the agent.
[0007] Any or all surfaces of the implant may carry the active agent there the desire is simply to have the agent enter the subjects blood stream via the tissues in and around the eye.
[0008] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In the drawings:
[0010] FIG. 1 is a schematic perspective view of an ocular implant in the form of a punctal plug according to the present invention; and
[0011] FIG. 2 is a perspective view of the area around the eye with other embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] Referring now to the drawing, FIG. 1 shows a punctal plug generally designated 10 , having a stem 12 for insertion into the punctal aperture 20 of an eye 24 , and along the canaliculus 22 communicating with the aperture.
[0013] Plug 10 has a large stopper structure 14 connected to the outer end of stem 12 for seating against the aperture 20 and sealing the canaliculus 22 against the flow of tears onto the surface of the eye or eyeball 24 .
[0014] FIG. 2 , where the same of similar numerals are used to designate functionally similar parts, illustrates an eye 24 communicating with upper and lower canaliculi 22 a and 22 b, each with their our implant 10 a and 10 b. Implant 10 a is a substantially cylindrical and solid collagen plug that has been inserted into the upper punctum or tear duct 20 a, to block the flow of tears while lower implant 10 b is hollow like a straw for the passage of tears. Implant 10 b includes a tapered shaft or stem 12 a with a flared open end 12 b immobilized at the lower punctum 20 b. A mushroom shaped inner stopper 14 a is formed at the opposite end of shaft 12 a for further setting the location of the implant in the tear duct.
[0015] One of the embodiments illustrated in FIG. 2 , e.g. the upper implant, may include a hollow core of the plug and another, e.g. the lower one, may include a hollow core filled with medication.
[0016] The active agent, e.g. a medicine or medication is applied, e.g. in one or more bands of polymer material 16 at the inner end of the stem, or at 18 on the outer end of the stopper 14 in the embodiment of FIG. 1 , or over some or all of the surfaces of the implants of FIG. 2 , or otherwise. Polymer that is absorbent to the agent is preferable so that sufficient agent is present and available for discharge into the surrounding tissues. A porous or absorbent material can alternatively be used to make up the entire plug or implant which can be saturated with the active agent.
[0017] The hollow implant 10 b of FIG. 2 is also particularly useful in that the active agent can be applied to, or is otherwise available at the inner surface or interior of the implant, and is uniquely structured to pass tears and thus administer the active agent to the tear stream in a fashion that is controlled by the flow of tears which thus act as the carrier for the agent. Unlike the usual tear stopping punctal plug, the hollow implant of the present invention provides a very different drug administering method, scheme and structure.
[0018] Non-limiting examples of the active agents or medications which are appropriate for use with the invention include, for example only: topical prostaglandin derivatives such as latanoprost, travaprost and bimataprost used for the topical treatment of glaucoma. Also a treatment for corneal infections is appropriate using ciprofloxacin, moxifloxacin or gatifloxacin. Systemic medications useful for this invention are those used for hypertension such as atenolol, nifedipine or hydrochlorothiazide. Any other chronic disease requiring chronic medication could be used.
[0019] The treatment of allergic conjunctivitis and rhinitis are also good applications for the invention, e.g. using antihistamine and anti-allergy medication such as olopatadine and cromalyn sodium in or on the implant.
[0020] The advantage is that there would be no need for chronic pill-taking or drop taking. A once-per 3-6 month visit to the eye doctor would be all that is needed. Also the issue of non-compliance, a major impediment to successful treatment, would by avoided by the invention.
[0021] This list of active agents is not comprehensive in that many other agents can be used with the present invention. For example, a treatment for dry eye by topical cyclosporin is particularly interesting for administration by the present invention, but many other active agents can also be administered using the method and apparatus of the invention.
[0022] The invention is meant to embody all implants or devices which are implanted into the eye-lid canalicular puncta of the naso-lacrimal system with the goal of delivering drug to the eye or to the body.
[0023] The implant is inserted into either the inferior (lower) or superior (upper) punctum or possibly both. The apparatus is constructed so as to have a drug attached to one or both sides of the implant and an occlusive plug of some inert biocompatible material.
[0024] Depending on the desired therapy, the implant could be oriented in the punctal canal to deliver the drug either to the tear lake and thus the eye, or to the nasolacrimal system and thus the body's systemic circulation. The drawings illustrate only three embodiments of the punctal plug or implant delivery system of the invention.
[0025] 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. | A method and apparatus for administering an active agent such as a medicine to a subject, uses an ocular implant such as a punctal plug, to which the active agent has been applied. The implant is installed at the eye of the subject for administering the active agent via tissues of the eye. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 11/837,117 and claims priority to and the benefit of that application. U.S. patent application Ser. No. 11/837,117 in turns claims the benefit of the filing date of U.S. Provisional Application Ser. No. 60/822,218 entitled “Image Recognition Authentication and Advertising System” and filed on Aug. 11, 2006.
[0002] The above cross-referenced related applications are hereby incorporated by reference herein in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] None.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to authentication of persons purchasing items in retail establishments, collection of data associated with such purchases, and personalization of advertising based upon collected data of a purchaser.
[0006] 2. Brief Description of the Related Art
[0007] In the present era of homeland security, facial image recognition has become a focus of progress in the government security industry. Many companies and individuals have presented systems and methods for performing facial image recognition and improving the accuracy and speed of such systems. Examples of such efforts to perform and improve facial image recognition systems include the systems and methods disclosed in U.S. Patent Application Publication No. US2006/0104504 entitled “Face Recognition Method and Apparatus,” No. US2006/0082439 entitled “Distributed Stand-Off ID Verification Compatible with Multiple Face Recognition Systems (FRS),” No. US2006/0062435 A1 entitled “Image Processing Device, Image Processing Method and Image Processing Program,” No. US2006/0034517 entitled “Method and Apparatus for Face Description and Recognition,” No. US2005/0276452 A1 entitled “2-D to 3-D Facial Recognition System,” and No. US2004/0151349 entitled “Method and Apparatus to Perform Automated Facial Recognition and Comparison Using Multiple 2D Facial Images Parsed from a Captured 3D Facial Image.”
[0008] Many patents and patent applications are directed to the use of facial image recognition in authenticating a person's identification or identifying persons of interest. An example of such a system is disclosed in U.S. Patent Application Publication No. US2006/0020630 A1, entitled “Facial Database Methods and Systems.” In that application, the inventors disclose various arrangements for use of biometric data. For example, a police officer may capture image data from a driver license (e.g., by using a camera cell phone). Facial recognition vectors are derived from the captured image data corresponding to photo on the license, and compared against a watch list. In another arrangement, a watch list of facial image data is compiled from a number of government and private sources. This consolidated database is then made available as a resource against which facial information from various sources can be checked. In still another arrangement, entities that issue photo ID credentials check each newly-captured facial portrait against a consolidated watch list database, to identify persons of interest. In yet another arrangement, existing catalogs of facial images that are maintained by such entities are checked for possible matches between cataloged faces, and faces in the consolidated watch list database. Other examples include U.S. Patent Application Publication No. US2004/0062423 A1 entitled “Personal Authentication Apparatus and Personal Authentication Method,” No. US2006/0136743 entitled “System and Method for Performing Security Access Control Based on Modified Biometric Data,” and No. US2006/0133652 A1 entitled “Authentication Apparatus and Authentication Method.” While such systems may have proved useful in the field of government security, they have not been appreciable applied to the commercial sector.
[0009] At the same time, the retail sales industry has begun to understand the usefulness of tracking a customer's purchases for purpose of marketing, advertising and making a variety of business decisions. Retail establishments often provide customers with frequent shopper cards or “bonus cards” in exchange for customers providing various personal data, such as their name, address and telephone number to the retail establishment. To encourage customers to provide such data, the retail establishments often provide the customers with sale prices, discounts, rebates, prizes or other types of rewards for purchasing items from the establishment. Such systems have proved useful, but often are burdensome for customers who must either carry the reward card with them or must enter some type of data, such as a telephone number, into the retail establishment's system at the time of each purchase. Further, the systems suffer from many limitations, from being completely reliant upon a customer entering correct data into the system, providing correct data at the time of registering for the reward program, and being unable to identify a customer prior to their actual checkout. Such systems also lack any ability to assist retail establishments in combating problems such as credit card and/or check fraud.
SUMMARY OF THE INVENTION
[0010] In accordance with the present invention, stores may use image recognition to identify a customer in real time, for example, as they enter the store or as they step to the register to make a purchase. This image may then be compared with a database to identify the personal shopping habits of the customer in order to use more specific advertisement strategies. Image recognition may also be used to aide in the identification of a customer in the case of, for example, payment by credit card or check.
[0011] The present invention utilizes real time image recognition to associate a digitized image of a customer with credit card information in order to circumvent a manual identification check or to generate customer specific advertisements. Revenue loss due to credit card or check fraud and identity theft is on the rise, and with the only means of prevention (manual identification check) being time consuming, there is a need for a solution. The present invention can not only greatly reduce loss due to credit card or check fraud, but it can also speed up routine transactions and make for an overall better shopping experience for the customer.
[0012] When the system is implemented, a database is generated over time to correlate facial images to information such as a credit card numbers, bank account numbers, or shopping habit data. Other information may similarly be correlated to the facial images. The database may be used to authenticate a customer, for example, attempting to pay by credit card. The authentication is performed by generating a current digital facial image of the customer and inputting information of the credit card the customer seeks to use. The current image and the credit card data each are compared to the database to determine whether the customer previously has been entered into the system and/or whether the credit card data previously has been entered into the database. If a match of either or both the image and credit card data are found in the database, the system performs one or more comparisons of the current data with the data in the database to confirm the identify of the customer.
[0013] Once the database is generated, another embodiment of the invention uses video cameras to capture an initial image of the customer upon entry and/or at the register prior to checkout. The image is then sent via LAN, wireless LAN, or any other means for communication between electronic components to a computer, CPU or processor with image recognition software. The computer is connected to a credit card reader and to a database, which in one preferred embodiment is an in-store database, where it can then be checked for a matching image. While a credit card reader is used in a preferred embodiment, credit or other financial information may be entered by other means, such as by other electronic means or even by manually inputting the information.
[0014] In a further preferred embodiment of the present invention, the computer will then choose from a pool of advertisements to find one that matches the current customer's shopping habits most accurately. The advertisement will then be projected onto a monitor in the customer's field of vision. At checkout, if the customer pays with a credit card, the information on the card will be sent to the computer where it will also be checked for a match in the database. The in-store database may be connected with a larger central database which shares all recorded information with all stores. In alternative embodiments, the database may be located in a different location rather than being an in-store database.
[0015] In a preferred embodiment, the present invention is method for authenticating a purchaser comprising the steps of acquiring an image associated with the purchaser, digitizing the image, adding the digitized image to database, inputting financial data associated with the purchaser; and adding the financial data to the database and associating the financial data with the image of the purchaser. The acquired image may comprise, for example, a facial image or a fingerprint. The method may further comprise adding purchase data associated with the purchaser to the database and associating the purchase data with the acquired image. The financial data may comprise credit card data, debit card data, check data, or any other financial data.
[0016] In another embodiment, the present invention is a method for authenticating a customer comprising the steps of acquiring an image associated with the customer, digitizing the acquired image, comparing the digitized acquired image to digitized images in a database, inputting financial data associated with the customer, if the comparing step results in a matching image being found in the database, comparing the inputted financial data to financial data in the database associated with the matching image, if the inputted financial data matches the financial data associated with the matching image in the database, approving a transaction with the customer. The steps need not be performed in this exact sequence, as other sequences of these steps will be apparent to those of skill in the art. The method may further comprise the steps of adding the acquired image to the database if no matching image is found in the database and requesting a manual identity verification. The method may further comprising the step of adding the financial data to the database and associated the financial data with the acquired image in the database if the customer's identity is manually verified. Still further, if the customer's identity is not manually verified, the acquired image may be flagged in the database for increased security measures in connection with future purchases.
[0017] In yet another embodiment, the method may further comprise the steps of inputting current purchase data; and associating the current purchase data with the matching image in the database.
[0018] In still another embodiment, the method according to the present invention further comprises the step of adding the acquired image to the database when a matching image is found and associating the acquired image in the database with all matching images in the database. The acquired image may further be associated in the database with all financial data associated with any matching image in the database and any purchase data associated with any matching image in the database.
[0019] In another embodiment, the present invention further comprises the step of selecting an advertisement based upon purchase data associated with the matching image in the database. The selected advertisement may be displayed on a monitor in the customer's field of vision. A general advertisement may be displayed on a monitor in the customer's field of vision if no matching image is found in the database or a specific advertisement may be displayed in a match is found. An advertisement that best matches data of previous purchases of the customer may be selected from a queue of advertisements.
[0020] In another embodiment, the present invention is an apparatus that comprises an image acquisition device, a financial data input device, a computer connected to the image acquisition device and the financial data input device, and storage means connected to the computer for storing images and financial data associated with the images. The image acquisition device may comprise, for example, a camera, a video camera, or a fingerprint scanner.
[0021] Still other aspects, features, and advantages of the present invention are readily apparent from the following detailed description, simply by illustrating a preferable embodiments and implementations. The present invention is also capable of other and different embodiments and its several details can be modified in various obvious respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive. Additional objects and advantages of the invention will be set forth in part in the description which follows and in part will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description and the accompanying drawings, in which:
[0023] FIG. 1 is a flow chart illustrating a method for authentication and data collection in accordance with a preferred embodiment of the present invention.
[0024] FIG. 2 is a flow chart illustrating a comparison of a method of selecting an advertisement in accordance with a preferred embodiment of the present invention.
[0025] FIG. 3 is a flow chart illustrating a comparison of a method for authentication and data collection in accordance with a preferred embodiment of the present invention.
[0026] FIG. 4 is a flow chart illustrating a comparison of a method for authentication and data collection in accordance with a preferred embodiment of the present invention.
[0027] FIG. 5 is a diagram illustrating a system for taking, retrieving, and storing digitized images and credit card information in accordance with a preferred embodiment of the present invention.
[0028] FIG. 6 is a diagram illustrating a more specific system for taking, retrieving, and storing digitized images and credit card information at the checkout phase in accordance with a preferred embodiment of the present invention.
[0029] FIG. 7 is a diagram illustrating a system for linking all in-store databases to one large central database in accordance with a preferred embodiment of the present invention.
[0030] FIG. 8 is a diagram illustrating a more specific system for taking, retrieving, and storing digitized images and credit card information upon entry of the store in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The present invention may applied to many different environments and incorporate many different features or functionalities. A system of the present invention uses authentication techniques to identify an individual and then uses that information in a variety of ways to reduce criminal acts such as credit card or check fraud by such individuals and/or to improve the shopping experience of such individuals through personalization. Preferably, the system uses facial image recognition because such a system is passive in the sense that the individual being identified or authenticated need not even know the system exists. While facial image recognition is preferred, the invention also may be implemented with other authentication techniques such as fingerprint recognition.
[0032] In a preferred embodiment the system has a database that evolves over time as the system is used. Data is entered into the database, for example, each time an individual makes a purchase at an establishment using the system. The data preferably would include an image (such as facial or fingerprint) of an individual, credit card data (names, numbers, etc.), and shopping habit data. Through the following description, embodiments are described with respect to facial images due to the passivity of such systems, but such embodiments likewise could be implemented using other identification or authentication techniques such as fingerprint recognition. When an individual makes a purchase, the image of the individual is added to the database along with any other information such as a credit card or bank account number and data of the customer's current purchase. If the individual's image has not previously been entered into the system, a manual identity check such as viewing a passport or driver's license is performed. If the person's image previously was entered into the system, the person's identity can be verified through the various image and data comparisons without any manual identification check.
[0033] A preferred embodiment of the present invention is described herein by way of example with respect to a sporting goods store. Those of skill in the art will understanding applications of the present invention in many other environments. Upon entry, the customer is already subject to constant surveillance for security reasons. In real time, the invention may use these same cameras or other cameras to capture an initial image which will be digitized and sent via LAN or wireless LAN to a computer where it will then be compared with a database of images. If a positive match is found, the computer will then search the database for the purchase history of the customer and determine the most suitable advertisement in the queue of advertisements. This advertisement will then be moved into the first position in the queue and be displayed on an advertisement monitor in the customer's field of vision. For example, if the customer bought a golf club in the past, an advertisement for a sale on golf balls and their location within the store might be the most suitable advertisement for the customer and will thus be displayed next on the advertisement monitor. This process may be done at any location in the store as long as there is an advertisement monitor in the customer's field of vision. An image of the customer may also be taken at the register during checkout and the same process may be applied.
[0034] If the customer uses a credit card to purchase any items, the computer will search the database for a previous use of the credit card by the same customer. If a match is found, the clerk need not manually check the customer's ID since this was done for a previous purchase and found to be authentic. This will help to speed up the transaction, cut down on human error on the clerk's behalf in positively confirming the identification of the customer, and make for a better overall shopping experience for the customer. This will also eliminate the need for all bonus or frequent shopper cards since the purchase history of all customers will be automatically recorded. Alternatively, if there is no match or if there is a discrepancy between the credit card and the information in the database, the computer will display a message to the clerk and the clerk will manually authenticate the credit card and the image, the credit card data, and the purchase history will be added to the database for future use. In the case of a customer unlawfully using a stolen credit card, the customer's image and the credit card information will be flagged for possible notification of law enforcement. This security embodiment of the invention may be implemented separate from or together with the advertising embodiment in the preceding paragraph and vice versa.
[0035] A method of performing authentication, collecting data, and selecting personalized advertisements in accordance with a preferred embodiment of the present invention is described with reference FIGS. 1-4 . An image is acquired 300 , for example, upon entry to the store or upon checkout. The image is then digitized 302 , and the digitized image is compared to a database 304 . The system then looks for a match 305 . If there is no match 320 , the system may perform the steps in FIG. 3 . If there is a match 306 , the system may perform the steps in FIG. 2 . After the steps of FIG. 2 are run, in an embodiment incorporating those steps, the system then determines payment type 307 . In this embodiment, if the customer uses a method of payment that is not a credit card, the system completes the sale and adds purchase history to the database 310 . In other embodiments, authentication may be implemented with respect to purchases by means other than credit cards, such as by check or by debit card. Continuing with reference to FIG. 1 , if the customer pays with a credit card, the system compares the digitized image data with card data in the database 308 . The system then determines if the card matches the image 309 . If there is a match, the system completes the sale and adds purchase history and the image to the database 322 . If there is not a match, the system determines if the name on the credit card matches 307 . If there is a match, the system completes the sale and adds purchase history, the image, and the credit card data to the database 324 . If there is not a match, the system displays a message to the clerk to check the customer's ID 312 . The clerk then determines if the ID passes 311 . If the clerk inputs a positive match (referred to here as a “yes” entry) the system completes the sale and adds purchase history, the image, and the credit card data to the database 324 . If the clerk inputs no match (referred to herein as a “no” entry) the card is rejected, there is no sale 316 , and the system flags the image 318 in the database.
[0036] FIG. 2 is a flow chart of a plurality of steps that may be implemented together with FIG. 1 . The system scans the database for the record of previous purchases 400 by the customer and then determines if the current customer is a previous customer 401 . If the customer is recognized as having made previous purchases, the system may run customer specific advertisements on the advertisement monitor behind the counter and/or generate customer specific coupons. If the customer is not recognized as having made previous purchases, the system may run a general advertisement or no advertisement on the advertisement monitor behind the counter. As noted previously, this advertisement portion of the invention need not be used together with the authentication portions of the invention and vice versa.
[0037] FIG. 3 is a flow chart of a plurality of steps that may be performed together with FIG. 1 . The system adds the digitized image to the database 500 . The system then determines payment type 307 . If the customer uses a method of payment that is not a credit card, the system completes the sale and adds purchase history to the database 310 . If the customer pays with a credit card or other means that can be associated with the customer, the system inputs the credit card or other data 502 and compares the credit card or other data to the database 504 . The system then looks for a match 305 . If there is a match 506 , the system may perform the steps in FIG. 4 . If there is no match, the system displays a message to the clerk to check the customer's ID 312 . The clerk then determines if the ID passes 311 and types yes or no into the system. If the clerk enters “yes” the system completes the sale and adds purchase history, the image, and the credit card data to the database 324 . If the clerk enters “no” the card is rejected and there is no sale 316 and the system flags the image 318 .
[0038] FIG. 4 is a flow chart of steps that may be performed in conjunction with FIGS. 1 and/or 3 . The system retrieves the image associated with the credit card 600 and compares the retrieved image to the current image 604 . Additionally the system may acquire a second image, digitize it, and compare it with the retrieved image 602 . The system then looks for a match 305 . If there is a match, the system completes the sale and adds purchase history, the image, and the credit card data to the database 324 . If there is not a match, the system displays a message to the clerk to check the customer's ID 312 . The clerk then determines if the ID passes 311 and types yes or no into the system. If the clerk enters “yes” the system completes the sale and adds purchase history, the image, and the credit card data to the database 324 . If the clerk enters “no” the card is rejected and there is no sale 316 and the system flags the image 318 .
[0039] FIG. 5 is a diagram in which an image is acquired from video camera 210 and sent to a computer 200 that contains image recognition software 202 . The image is then compared to all images on in-store database 230 . If the customer swipes a credit card at credit card reader 260 , the information travels to computer 200 and is compared to all credit card information on in-store database 230 .
[0040] FIG. 6 is a more accurate and alternative view of the process in FIG. 1 in which the video cameras 210 acquire an image of the customer in front of the registers 250 . The image is then sent via LAN or wireless LAN 204 to computer 200 and is compared with all images on in-store database 230 (not shown). If a match is found, a customer specific advertisement will be displayed on advertisement monitor 240 . If no match is found, a random advertisement will be displayed instead. If the customer swipes a credit card at credit card reader 260 , the information travels to computer 200 and is compared to all credit card information on in-store database 230 .
[0041] FIG. 7 is a diagram showing the connection between all in-store databases 230 and the central database 270 for all images and credit card information to be securely shared between all stores in the chain.
[0042] FIG. 8 is a diagram showing an alternative use for the patent in which the initial image is acquired by video camera 210 at the store entrance 270 upon the entry of the customer. The image is then sent to computer 200 and is compared with all images on in-store database 230 . If a match is found, a customer specific advertisement will be displayed on advertisement monitor 240 . If no match is found, a random advertisement will be displayed instead.
[0043] The foregoing description of the preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiment was chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents. The entirety of each of the aforementioned documents is incorporated by reference herein. | A system for authenticating a purchaser, collecting data of purchasers, and displaying personalized advertisements. The system uses video cameras to capture an initial image of the customer upon entry and/or at the register prior to checkout. The image is then sent via LAN or wireless LAN to a computer with image recognition software. The computer is connected to a credit card reader and to an in-store database where it can then be checked for a matching image. The database will then choose from a pool of advertisements to find one that matches the current customers shopping habits most accurately. The advertisement will then be projected onto a monitor in the customer's field of vision. At checkout, if the customer pays with a credit card, the information on the card will be sent to the computer where it will also be checked for a match in the database. The in-store database is connected with a larger central database which shares all recorded information with all stores. | 6 |
FIELD OF THE INVENTION
This invention relates to a shower door and a method for installing a shower door.
BACKGROUND OF THE INVENTION
Shower doors are typically installed with a rigid safety glass or plexiglass material. These doors are heavy and expensive due to the glass materials. The weight of the glass materials makes it more difficult and expensive to move or transport the doors. Also, these doors usually require professional installation, since they are intended to be permanently mounted to a shower enclosure. The required installation thus also significantly increases the overall cost of the shower door. Accordingly, a need exists for an improved shower door and, more particularly, a low-cost, lightweight alternative to existing shower doors.
SUMMARY OF THE INVENTION
This invention is a shower door assembly for enclosing a tub or shower enclosure having sides and a base. It includes an upper support member adapted to be positioned against opposing sides of the enclosure and a lower support member adapted to be positioned against the base of the enclosure. A first frame member is connected to the upper support member and the lower support member and is positioned for movement about a vertical axis. A second frame member is adapted to be releasably connected to the upper support member. A brace member connects the first and second frame members in order to form a structure for the door, and the brace member is adapted to apply an upward force on the second frame member in order to maintain a releasable connection with the upper support member. In use, a section of fabric extends across the frame members in order to provide a water barrier for the door.
This invention is also a method of installing a shower door assembly for enclosing a tub or shower enclosure having sides and a base. The method includes the following steps. An upper support member is installed and positioned against opposing sides of the enclosure, and a lower support member is installed and positioned against the base of the enclosure. A sealing member is installed against one of the sides of the enclosure. A first end of a first frame member is connected to the upper support member proximate the sealing member, and a second end of the first frame member is connected to the lower support member for movement about a vertical axis. A brace member is connected to the first frame members and a second frame member. The second frame member has a first end adapted to be releasably connected to the upper support member such that the brace member is adapted to apply an upward force on the second frame member in order to maintain the second end of the second frame member in releasable connection with the upper support member. A panel is installed, extending from the sealing member past the first frame member to the second frame member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an example of a tub or shower enclosure into which is mounted a shower door assembly in accordance with the principles of the present invention.
FIG. 2 is a face view of a shower door assembly in accordance with the principles of the present invention.
FIG. 3 is a face view of the shower door assembly with a fabric water barrier.
FIG. 4 is an enlarged face view of an upper left portion of the shower door assembly.
FIG. 5 is an enlarged face view of an upper middle portion of the shower door assembly.
FIG. 6 is an enlarged face view of an upper right portion of the shower door assembly.
FIG. 7 is an enlarged face view of a lower left portion of the shower door assembly.
FIG. 8 is an enlarged face view of a lower middle portion of the shower door assembly.
FIG. 9 is an enlarged face view of a lower right portion of the shower door assembly.
FIG. 10 is an enlarged face view of a handle for the shower door assembly.
FIG. 11 is a side view of the handle, showing both a first handle on the inside and a second handle on the outside of the shower door assembly.
FIGS. 12-14 are linkage diagrams illustrating the use of a fabric door for the shower door assembly.
DETAILED DESCRIPTION
This invention provides a low cost, light weight shower door assembly. The door is easily transported and installed by the consumer. Since the door is not necessarily permanently mounted in a shower enclosure, the purchaser has the advantage of being able to remove the door when moving, for example, and reinstall it. In addition, the shower door uses a removable fabric or vinyl water barrier. This means that one can purchase the fabric or vinyl in a variety of different colors or patterns in order to match a particular bathroom or shower enclosure. The fabric or vinyl is thus easily and inexpensively replaced without having to replace the entire shower door assembly.
FIG. 1 is an example of a tub or shower enclosure into which is mounted the shower door assembly. The enclosure typically includes opposing sides A and B, and a base C. The shower door assembly provides a water barrier at the opening defined by sides A and B, and base C. The shower enclosure may include a tub with base C being the tub ledge. The shower enclosure may also include simply a shower stall with the base C being at or approximately level with the floor. Other shower enclosures are possible for use with the present invention.
FIG. 2 is a face view of a shower door assembly 1 without the fabric water barrier. FIG. 3 is a face view of the fully installed shower door assembly 1 with the fabric 9. The following explains installation of the shower door assembly 1 with one door 19. The second door is assembled, installed, and operates in a similar manner as the first door 19.
Referring again to FIG. 1, there is a longitudinally extending cardboard template indicated by the numeral 2. This template has suitable transverse perforations appropriate for either a 54" or a 60" shower enclosure. Template 2 is folded along these perforations into a U-shape with the central horizontal portion positioned on the tub ledge and with the opposite vertical portions extending up shower walls A and B. Only shower wall A is shown in FIG. 7, but there would be a vertical extension of 2 oppositely disposed from that shown.
There are two generally cylindrical plastic parts, with external threads, designated by parts 11 in FIG. 2 (see FIGS. 7 and 9 for more detail of parts 11). Parts 11 have flat bottoms with suitable adhesive tape material to be used in anchoring parts 11 to the tub ledge as shown in FIGS. 2, 7 and 9. A paper backing from the flat bottom of parts 11 is removed and parts 11 are anchored to the tub ledge through the holes cut in template 2. These holes are indicated on FIG. 1 by the numerals 2A and 2B. There are two internally threaded plastic rings 12 which thread onto parts 11 to temporarily lock template 2 onto the tub ledge in the appropriate position (see FIG. 9). The upper end of the vertical extensions of template 2 each have a cut-out portion designated 2C which is used to appropriately position valance 3.
This sets the rough height of valance 3 (see FIGS. 4 and 6 for more detail of the attachment of valance 3 to sides A and B). The valance is also referred to as an upper support member and is preferably implemented with aluminum tubing. The plastic snaps of 5 and 6 are pushed into the holes of part 3. The telescoping sections 4 are turned in order to adjust the length of part 3 such that a light, snug fit exists between rubber pucks 23 and the shower enclosure walls A and B, thus securing valance 3. Items 20 (fabric wall snap) are aligned with the vertical edge of 2 towards the inside of the shower enclosure, marked 2D on FIG. 1, paper backings are peeled away from the tape on the flat bottom of items 20, and one is attached onto enclosure wall A and the other is attached onto enclosure wall B. Template 2 is then removed by unthreading the rings 12 from each of the anchor members 11. The anchor members 11 are also referred to as lower support members.
Referring particularly to FIGS. 7 and 9, dam members 21 should now be installed. The flat bottoms of 21 also have adhesive material and paper backing. The paper backing is removed. The right-hand end of member 21 has a hole which fits over cylindrical anchor 11 with the radius end of item 21 against the shower wall A. Referring to FIG. 2, it shows the valance 3 to be positioned against sides A and B, and also dams 21 and anchors 11 to be secured to the tub ledge or base C.
Shower doors 19 are assembled as follows. End caps 16 and 17 are pushed into the door frame members 7A and 7B (see FIGS. 4 and 8). The frame members 7A and 7B are preferably implemented with aluminum tubing. Flexible rod mounts 8 are pushed into the holes of frame members 7A and 7B. The ends of flexible rods 18 are placed into the flexible rod mounts 8 (see FIGS. 4, 5, and 7). When installed, the flexible rods 18, or base members, are bowed slightly in order to apply an upward force on frame member 7B. The required bend in the flexible rods 18 may be accomplished by proper orientation of the mounts 8 in the frame members 7A and 7B. The flexible rods 18 are preferable bowed a sufficient amount so that frame member 7B moves about 1.5 inches in the vertical direction from the open to closed positions.
Fabric 9, shown in FIG. 3, is unrolled and positioned with its hem at what will be the upper end of the door 19. The fabric 9 is typically implemented with vinyl such as that used in conventional shower curtains. A fabric stiffening rod 25 is slid into this hem (see FIG. 3). Starting at the mating surface of 17, edge frame seal 10 is pushed into the longitudinally extending channel of door frame member 7B and the inwardly spaced frame seal 10 is pushed into the longitudinally extending channel of frame member 7A. The fabric has a flat and clean appearance. Grabbing the ends of member 15 (base or tub ledge seal), the donut-shaped ends are lightly stretched into the grooves of end caps 16 and 17.
After the door 19 is assembled, it can be put into position. Upper end cap 16 of door frame member 7A is mated into T-shaped socket joint 5, or connector bracket, (see FIG. 4) and the lower end cap 16 of frame member 7A is mated into part 11 or lower socket joint (see FIG. 7). The length of valance 3 may need to be adjusted slightly by turning telescoping ends 4. The door 19 is closed by pulling down on door frame member 7B and setting the hard end cap 16, which is at the upper end of door frame member 7B, into door closure detent 6 (see FIG. 5). With the door 19 closed, the longitudinal position of upper socket joint 5 is adjusted slightly by the valance telescoping ends 4. Part 13 (fabric seal guard) is pushed over door frame member 7A and part 14 (door to door seal or flange) is pushed over door frame member 7B. The bottom edge of 14 should be flush with the tub ledge. The left-hand extrusion 24 (fabric to wall seal) should be pushed into the longitudinally extending channel in wall fabric connector member 20.
When the door 19 is installed, the fabric 9 includes three seals. A first seal is formed by part 24, which is within the fabric 9, being held into part 20 (see FIG. 4). A second seal is formed by inwardly spaced frame seal 10 and fabric seal guard (see FIG. 7). As seen in FIGS. 3 and 7, the fabric 9 connected between the first and second seals form a side panel between frame member 7A an a side of the enclosure. A third seal is formed by edge frame seal 10 and frame member 7B (see FIG. 5). At the bottom of the shower door assembly 1, the dam members 21 and parts 15 (base or tub ledge seal) help prevent water from escaping between the bottom of the fabric 9 and the base C of the shower enclosure.
Referring to FIGS. 10 and 11, the door 19 also includes handles 22 on both inside and outside sides of the door 19. A backing from the adhesive tape on the cylindrical surface of handle 22 is removed. The handles 22 are then attached onto the approximate midpoint of 14 on both sides.
The handles are attached to the doors with the open end facing up in order to assist a person in opening the doors. In order to open the doors, such as door 19, one grasps the handle 22 and pulls downward slightly to release the frame member 7B from the detent 6. The soft part 15B (see FIG. 8) allows one to move 7B downward when the door 19 is in the closed position. The door 19 can then be swung outward by rotation of frame member 7A about a vertical axis. The slight bend in flexible rods 18 thus allows one to easily open the door 19 by moving frame member 7B downward and also holds the door 19 in a closed position by applying an upward force on frame member 7B to hold it in contact with detent 6.
Referring to FIGS. 12-14, the following explains how the incline of flexible rods 18 aids in keeping the fabric 9 taut when the door 19 is in a closed position. As the common perpendicular distance between frame members 7A and 7B increases, the fabric becomes more taut. The shortest distance between two points is a straight line. Therefore, as flexible rods 18 unflex the distance between the endpoints of the flexible rods 18 increases.
The shower door assembly 1 can be modeled as a simple four bar linkage, as shown in FIGS. 12 and 13, ignoring the slight flexing of flexible rods 18. As demonstrated in FIGS. 12 and 13, the common perpendicular distance between frame members 7A and 7B increases. This distance increase more than makes up for the flexing of flexible rod 18 when closing the door 19 bringing 7A and 7B closer due the to the phenomenon described above. If flexible rods 18 were horizontal and bent, which they have to be in order for the door 19 to work, either the fabric 9 would have to be taut both open and closed or slack in the closed position. Having the fabric 9 taut when both open and closed effectively adds links 5 and 6, as shown in FIG. 14. This overconstrains the mechanism, i.e., it cannot move.
While the present invention has been described in connection with a preferred embodiment thereof, it will be understood that many modifications will be readily apparent to those skilled in the art, and this application is intended to cover any adaptations or variations thereof. It is manifestly intended that this invention be limited only by the claims and equivalents thereof. | A lightweight, low cost shower door assembly for enclosing a tub or shower enclosure having sides and a base. It includes an upper support member adapted to be positioned against opposing sides of the enclosure and a lower support member adapted to be positioned against the base of the enclosure. A door in the assembly includes a flexible rod connecting first and second frame members. The first frame member is connected to the upper and lower support members and positioned for movement about a vertical axis. The flexible rod is bowed to apply an upward force on the second frame member in order to maintain it in releasable connection with the upper support member. In use, a section of replaceable fabric or vinyl extends across the frame members in order to provide a water barrier for the door. | 4 |
This application is a continuation-in-part of Ser. No. 07/598,932, filed Oct. 17, 1990, now U.S. Pat. No. 5,111,885.
FIELD OF THE INVENTION
This invention relates to a carrier onto which are mounted explosive charges so as to punch a hole in a central string of pipes in a well-type casing of an oil or gas well from within the well, over 360° of the central string of pipes.
BACKGROUND OF THE INVENTION
In the oil and gas industry, it is necessary when abandoning a well or isolating different zones of the well to seal an annular space between a central string of pipes and a surrounding protective string of pipes. To seal the annular space, it is desired to punch a hole in an innermost pipe of a series of at least two concentric strings of pipe so as to only penetrate the innermost pipe string without damaging or penetrating any other surrounding pipe strings in the well. Further, the punched pipe must not be fractured or damaged except for a limited size hole punched in a side wall.
Since it is impossible to effect a perfectly vertical well bore, there is always some degree of offset from a perfectly vertical orientation of the well bore to produce a high and a low side. Therefore, previous to the present invention, a zero degree phase gun has been lowered into a well bore and, due to the effect of gravity, the gun lays along one side (the low side) of a central casing of the well bore. A magnetizer holds the gun against the one side of the steel central casing.
The zero degree phase gun explodes a charge against the low side of the well bore.
Cement is then fed through the central casing and passed through the opening produced by the explosive charge to fill an annular gap between a central casing and a surrounding protection casing. It is important to seal the annular gap between the central casing and only the next adjacent protective pipe string so as to seal any naturally produced gases or to isolate different zones of the well bore. If an additional string of pipe is perforated by accident, it is not possible to assure that gases are being sealed by the filling with cement of the annular gap between the innermost and the most adjacent string of pipe.
Further, with a zero degree phase gun, an electrical line must be fed down through the well casing with a magnetic decentralizer gun, which ensures contact of the gun with a side wall of the steel well casing. As mentioned above, this contact with the well casing will be, due to gravity, on the low side of the well casing. Cement therefore poured through the well casing which is supposed to pass through the opening produced by the explosive charge into the space between the well casing and the protective casing does not usually fill this space on the high side of the well casing, leaving pockets or "channelling" through which it is possible for natural pressure to escape to the surface.
Examples of perforating charges lowered into a pipe string are disclosed is U.S. Pat. No. 4,688,640 to Pritchard, Jr., U.S. Pat. No. 4,552,234 to Revett, U.S. Pat. No. 3,426,850 to McDuffie, Jr., U.S. Pat. No. 3,280,913 to Smith, U.S. Pat. No. 4,352,397 to Christopher, U.S. Pat. No. 4,760,883 to Dunn, U.S. Pat. No. 3,011,550 to Kenneday, and U.S. Pat. No. 3,366,188 to Hicks.
The most common method of punching holes today is to use a 1 11/16 inch outside diameter steel carrier gun with a zero degree phase and a 1 11/16 inch magnetic decentralizer which is magnetized on one side. The magnet and perforating charge must face the same direction. This tool automatically finds the low side of the well bore and always perforates the casing on this low side. This results in a poor cementing of the annular space between a central string of pipe and a surrounding protection casing.
SUMMARY OF THE INVENTION
By the present invention, the disadvantages encountered in the prior art have been overcome.
An explosive charge carrier is lowered into a well pipe casing. The carrier includes wear plates that slide along the inner diameter of the pipe and which are biased against the inner wall of the well pipe casing. A string of explosive charges having a density of up to six charges per foot are mounted between disks of the carrier which are separated by 12 inches. Spaced about the periphery of the separated disks are a maximum density of six strings of charges separated by 60° for 36 explosive charges. Alternately, four strings of charge may be spaced about the periphery of the separated disks at a spacing of 90° for 16 explosive charges.
Control of the force of perforation of the perforating charges is accomplished by varying the standoff distance of the explosive charge from the casing wall to the face of the perforating charge. This can be accomplished by varying the distance between the contact surface of the wear plate when compressed radially inward and the face of the perforating charge from the inner surface of the innermost pipe string. Since the contacting surface of the wear plate will be forced against the interior surface of the well pipe casing, the distance of standoff of the perforating charge from the inner wall of the well pipe casing can be determined prior to entry of the perforating charge carrier into a well pipe casing.
Further, by controlling the spacing between the interior of the well pipe casing and the face of the penetrating charge, it is possible, when desired, to penetrate two strings of casings of, for example, 75/8 inches in diameter and 95/8 inches in diameter without penetrating a concentric third string having a diameter of 133/8 inches. This is achieved by locating the explosive charge approximately one inch from the inner surface of the innermost pipe string.
It is therefore an object of the present invention to provide an explosive charge carrier having a density of four strings of explosive charges with the capacity of four perforating charges per foot spaced about the periphery of an inner wall of a well pipe casing.
It is another object of the present invention to provide an explosive charge carrier having a density of four strings of explosive charges with the capacity of four perforating charges per foot spaced about the periphery of an inner wall of a well pipe casing where the density of charges may be increased to six strings of perforating charges per foot with up to six charges each, which may be spaced about the inner wall of a well pipe casing.
It is another object of the present invention to provide an explosive charge carrier having a density of four strings of explosive charges with the capacity of four perforating charges per foot spaced about the periphery of an inner wall of a well pipe casing where the density of charges may be increased to six strings of perforating charges per foot with up to six charges each, which may be spaced about the inner wall of a well pipe casing with the perforating charges being biased towards the inner wall of the well pipe casing.
It is yet still another object of the present invention to provide an explosive charge carrier having a density of four strings of explosive charges with the capacity of four perforating charges per foot spaced about the periphery of an inner wall of a well pipe casing where the density of charges may be increased to six strings of perforating charges per foot with up to six charges each, which may be spaced about the inner wall of a well pipe casing with the perforating charges being biased towards the inner wall of the well pipe casing with the distance between the wall of the well pipe casing and the face of the perforating charge being varied to control the extent of perforation of the well pipe casing and any surrounding protection casing.
These and other objects of the invention, as well as many of the intended advantages thereof, will become more readily apparent when reference is made to the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a six-way decentralized casing hole puncher.
FIG. 2 illustrates the casing hole puncher located within a well pipe casing which is surrounded by a protection casing mounted in cement.
FIG. 3 is a sectional view of the casing hole puncher.
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3.
FIG. 5 is a sectional view taken along line 5--5 of FIG. 3.
FIG. 6 illustrates a wear plate.
FIG. 7 illustrates a four-way decentralized casing hole punching.
FIG. 8 is a sectional view taken along line 8--8 of FIG. 7.
FIG. 9 is a sectional view taken along 9--9 of FIG. 8.
FIG. 10 is a plan view of a separating disk.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In describing a preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
With reference to the drawings, in general, and to FIGS. 1 through 6, in particular, a six-way decentralized casing hole puncher embodying the teachings of the subject invention is generally designated as 20. With reference to its orientation in FIG. 1, the casing hole puncher comprises a central longitudinal shaft 22 which is threaded. In FIG. 1, the embodiment shown is illustrative of a device for punching of holes over a twelve-inch length. However, by repetition of the structure shown in FIG. 1, it is possible to have multiple lengths of explosive charges from one to forty feet in length.
At the lowermost end 24 of the shaft 22 is a nut 26, which acts as a stop for further downward movement of the casing hole puncher along the length of the shaft 22. A lower disk 28 includes two supporting arms 30 which are connected to a hub 32 which fits over the shaft 22. A nut 34 is located on the opposite side of the hub 32 from the nut 26. Similarly, above and below the disk 28 are securing nuts 36 and 38, respectively. The nuts 26, 34, 36 and 38 maintain the position of the disk 28 so that the plans of the disk extends perpendicular to the longitudinal axis of the shaft 22.
Spaced above the disk 28, by approximately twelve inches is an upper disk 38, having three arms 40 terminating in a hub 42 fitted over the shaft 22. Nuts 44 and 46 secure the hub on the shaft 22, while nuts 48 and 50 secure the disk 38 on the shaft so that the plane of the disk 38 extends perpendicular to the longitudinal axis of the shaft 22.
A nut 52, located at an upper end 54 of the shaft 22, is used in securing the shaft 22 to a raising and lowering assembly. The assembly 56, shown in FIG. 2, includes a mounting cap 58 which is secured to the upper end 54 of the shaft 22 and which abuts tightly against the nut 42. A ring 60 is secured tot he cap 58. A steel cable 62 is crimped by wrapping 64 so as to secure the cable 62 to the ring 60.
Located between the disks 28 and 38 is a centrally located hex nut 64. In each of the six faces of the nut 64 is located a threaded bore for receipt of a set screw 66. Secured to the nut 64 by set screw 66 is an elongated spring member 68 having two arms 70 located on opposite sides of the nut 64. The arms 70 taper radially outwardly from the nut 64 and terminate in end portions 72 which extend parallel to the longitudinal axis of the shaft 22. The terminal portions 72 are secured to a rearward surface of a wear block 74. A forward surface of the wear block 74 acts as a wear plate 76. Due to the springiness of the arm portion between the wear block and the nut 64, the wear block is biased radially outwardly away from the shaft 22.
Extending downwardly through the six pairs of slots 78, in the disk 38, is a U-shaped biwire 80. The legs 82 of the biwire 80 pass downwardly through the slots 78 through aligned openings 84 in the wear block and continue downwardly to pass through apertures 84 which extend through opposite sides of explosive charges 86. In FIGS. 1 through 3, there are six perforating charges 86 located on each of the six biwires 80 with the six biwires spaced about the periphery of disk 38 at a separation of 60°.
The biwires after passing through the six charges 86 again pass through openings 84 of the lowermost wear block 72 and through corresponding slots 88 which are aligned with the pairs of slots 78 in the upper disk 38.
As shown in FIG. 2, the casing hole puncher is lowered through an innermost well pipe casing 90, which is concentrically located within a protection casing 92. An annular space 94 is located between the well pipe casing and protection casing 92. Surrounding the casing 92 is cement 95 for anchoring the well bore without escape of gases to the surface along the side of the well bore.
By the bias of the wear blocks mounted at the ends of the elongated spring member 68, the inner wall of the well bore casing 90 is contacted by the wear blocks 72. Depending upon the location of the openings 84 in the wear blocks, the separation distance between the face of the perforation charges 86 and the inner wall of the well bore casing can be adjusted. In the example shown in FIG. 2, the perforating charges 86 are mounted so that the face of the perforating charges is aligned so as to be in intimate contact with the inner wall of the well pipe casing.
Depending upon the amount of separation between the well pipe casing 90 and surrounding strings of pipes, typically surrounded by at least two additional strings of pipe, the number of strings of pipes which are to be punched or perforated is controlled. In FIG. 2, the location of the explosive charges in intimate contact with the pipe casing 90 provides for a punching of only the pipe casing 90 to form a defined hole without further damaging or causing fractures of the pipe casing 90. When the explosive charges 86 are backed away from the inner face of the pipe casing 90, depending upon the distance from the face of the inner surface of the pipe casing, the pipe casing will be penetrated along with adjacent strings of pipe. The holes produced in this instance will be more of a destructive force rather than a deformation force resulting from the intimate contact of the explosive charge with the inner face of the pipe casing 90.
As shown in FIG. 3, primer cord 96 is shown in dotted lines as representative of a standard mechanism for exploding the explosive charges from the surface. The primer cord 96 for each string of charges on a biwire 80 passes through the holes 98 in the upper disk 38.
Holes 98 in disk 38, as well as corresponding holes in the lower disk 28, allow well fluid to pass through the casing hole puncher to facilitate lowering of the casing hole puncher. In addition, any debris disturbed by the explosion of the explosive charges is also allowed to pas through these holes without affecting the casing hole puncher.
By the use of the casing hole puncher shown in FIGS. 1 through 3, it is possible to detonate 36 explosive charges per foot through the innermost string of a series of concentric strings without any damage to surrounding strings. The placement of the face of the perforating charge in intimate contact with the inner surface of the string 90 achieves this result.
By this method, the innermost string maintains its integrity with a hole being punched in the string without any loss of metal by the explosion. The steel string 90 is simply pushed back or deformed at the location of the charge without loss of any of the metal deformed by the charge. By this method, the casing integrity is maintained without fracture of the casing.
Cement is thereby able to be passed through the casing and into the annular space between the next adjacent string for a complete filling of the annular space about the innermost string so as to isolate one zone from another when control of the zones between the strings of casing is required or when a well bore is to be abandoned. In addition, there is no "channeling" between the strings which would allow communication between a lower zone and the surface.
All previous attempts on hole punching of the innermost string with decentralized charges located in contact with the inner wall of the innermost string have only allowed a maximum of six shots per foot at only one side of the string. By the present invention, it is possible to obtain a maximum of 36 shots per foot spaced about the circumference (360°) of the innermost string or any desired lesser number of shot density.
In FIGS. 7 through 10, a four-way decentralized casing hole puncher 100 is shown. In this embodiment, two one-foot sections 102 and 104 are shown mounted on a single shaft. In this embodiment, four charges are mounted on a single biwire 106 with four strings of charges being spaced circumferentially between an upper disk 108 and a central disk 110, and between central disk 110 and lower disk 112. Therefore, sixteen shots per foot are achieved.
In FIGS. 7 through 10, similar structure to that disclosed for FIGS. 1 through 6 has been labeled with the same reference numerals as in FIGS. 1 through 6 with a prime indication. The equivalent to hex nut 64 is a four-sided nut 114.
When the perforating charges 86 are recessed from the inner wall of the innermost string by approximately one inch, they act as a perforating charge to punch through the walls of the inner string and all surrounding strings so as to pass into the surrounding cement sheet and natural formation.
Having described the invention, many modifications thereto will become apparent to those skilled in the art to which it pertains without deviation from the spirit of the invention as defined by the scope of the appended claims. | An explosive charge carrier is provided which is lowered into a well pipe casing. The carrier includes wear plates that slide along the inner diameter of the pipe and which are biased against the inner wall of the well pipe casing. A string of explosive charges having a density of up to six charges per foot are mounted between disks of the carrier which are separated by 12 inches. Spaced about the periphery of the separated disks are a maximum density of six strings of charges separated by 60° for 36 explosive charges. Alternately, four strings of charges may be spaced about the periphery of the separated disks at a spacing of 90° for 16 explosive charges. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to an improvement made to weaving machines and, more particularly, to a new way of ensuring drive and synchronization between the various means which the machine comprises, in order to produce a fabric.
In the rest of the description, the invention will be described with regard to a weaving machine, in which the insertion of the weft is carried out by means of two grippers introduced simultaneously into the shed from each side of the machine, one gripper serving for delivering the weft yarn, taken from a bobbin located on one side of the machine, as far as the middle of the width of the latter, where there is then a transfer to the second gripper which, during its retraction, delivers the yarn on the side opposite to the feed side, the displacements of the said grippers within the shed being ensured by an assembly commonly referred to by the expression "rapier or flexible band".
It is clear that this is not limiting, and that the invention could equally be used for other types of weaving machine employing means other than positive grippers for ensuring the insertion of the weft.
The production of a fabric involves:
on the one hand, ensuring the unrolling of the lap of warp yarns, the formation of the shed and the winding-up of the fabric produced, and;
on the other hand, inserting the weft yarn when the shed is open and of beating it up against the last pick made by means of a reed carried by a batten.
Hitherto, for executing the control and synchronization of the various elements which make it possible to carry out these operations, weaving machines have comprised a single motor which, by means of a clutch/brake assembly, drives in rotation a driveshaft, known as a "main shaft", which extends over the entire width of the machine and from which mechanical connections make it possible to ensure that the various members of the machine are driven in synchronism.
From a practical point of view, such a concept is satisfactory, but it nevertheless has the disadvantages that it requires a high-power motor capable of transmitting a high torque which, as an indication, is of the order of 70 m.kg for a weaving machine which makes it possible to obtain articles having a width of 2 to 4 meters and which rotates at a speed of 400 to 500 strokes per minute.
Moreover, the transmission of movement to the various members (warp-yarn beam, winding-up system, advance and retraction of the insertion grippers, control of the batten) utilizing mechanical transmissions appreciably complicates the structure of these machines.
A solution making it possible to solve all these problems has been found, this being the subject of the present invention.
SUMMARY OF THE INVENTION
In general terms, therefore, the invention relates to an improvement made to weaving machines, in which the insertion of the weft is carried out by means of two grippers introduced simultaneously into the shed from each side of the machine, one gripper serving for delivering the weft yarn, taken from a bobbin located on one side of the machine, as far as the middle of the width of the latter, where there is then a transfer to the second gripper which, during its retraction, delivers the yarn on the side opposite to the feed side, the pick put in place subsequently being beaten up against the last pick of the fabric by means of a reed carried by a batten.
The invention is characterized in that the control of the weft insertion means and of the batten is carried out by means of two electric motors arranged on each side of the machine:
each motor driving a machine shaft controlling the weft insertion means and the batten-carrying housing located on the same side as the said motor;
these two motors being supplied in parallel by means of one or more frequency converters and being connected to one another by synchronizing means; such synchronizing means consist in a simple way of a rigid connection connecting the two machine shafts to one another.
Although it is possible to consider ensuring the control of the warp unwinder and of the fabric winder, on the one hand, and of the displacement of the frames ensuring the formation of the shed, on the other hand, by means of mechanical connections with the two abovementioned driveshafts, according to a preferred embodiment of the invention each of these elements is likewise controlled by means of an electric motor. In such a case, the synchronization of all the motors which the weaving machine comprises is obtained by means of a central control unit.
By virtue of such a concept, in which the control of the various members of the weaving machine is carried out by means of specific motors associated with each means, it is possible not only to eliminate a large number of mechanical connections required by conventional machines, in which all the movements are taken off from a main shaft controlled by a single motor, but also to obtain a much more rapid increase in speed of the machine, the torque to be transmitted being much lower.
However, the invention and the advantages which it affords will be better understood from the exemplary embodiment which is given below as a non-limiting indication and which is illustrated by the single figure which is a diagrammatic perspective view of a weaving machine produced according to the invention.
These and other objects of the invention will be explained in further detail below in association with the accompanying drawing which is a perspective view of a weaving machine embodying the teachings of present inventions.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will be explained in conjunction with the associated drawing which is a perspective view of a weaving machine containing a pair of grippers for delivering a weft into a shed from opposite sides of the machine wherein the grippers and the batten are controlled by electric motors that are linked together by a synchronizing mechanism.
DESCRIPTION OF THE INVENTION
Referring to the accompanying diagram, the weaving machine according to the invention is therefore composed, like all weaving machines, of a beam (1) of warp yarns (2), of heald frames (3) (only one being indicated in the diagram) or Jacquard system for the control of the warp yarns, making it possible to ensure the formation of the shed (4), of a take-up system (5) for the formed fabric (6) and of a roller (7) for winding up the said fabric.
The control of the warp yarns is obtained by all suitable means, such as, for example, a dobby (8) or a Jacquard mechanism.
The weft (9) is stored on a bobbin arranged on one side of the machine. The machine may, of course, be designed to make it possible to insert a plurality of wefts of different colours and/or types according to a rhythm depending on the fabric to be produced. In such an instant, weft yarns may be fed in accordance with the teachings of FR-A-2,695,414.
Insertion of the weft yarn (9) is obtained by means of an assembly comprising two positive grippers (10, 11) arranged on each side of the machine and introduced simultaneously into the shed (4), the gripper (10) driving the weft thread (9) and transferring this end of the latter to the gripper (11) in the middle of the shed by transfer means (35), this gripper (11) delivering the weft on the other side of the machine. The weft introduced is beaten up against the last pick of the fabric (6) by means of a reed (12) mounted on a batten controlled by two housings (13, 14).
Since all the abovementioned means are conventional means, they will not be described in detail for the sake of simplification.
According to the invention, the means (10, 11) allowing the insertion of the weft (9) and the reed (4) carried by the batten are controlled by means of two electric motors (15, 16) arranged on each side of the machine.
The motor (15) drives the machine shaft (17) which controls the means (28) (cam boxes) controlling the displacements of the insertion gripper (10), the batten-carrying housing (13) located on the left-hand side of the machine and, where appropriate, the mechanism for forming the shed, the motor (16) located on the right-hand side driving a second shaft (18) as well as the means (19) (cam boxes) controlling the displacements of the gripper (11) and the batten-carrying housing (14).
These two motors (15, 16) are, for example, motors of the asynchronous type. They are supplied in parallel by means of a frequency converter (30) and are connected to one another by synchronizing means. If appropriate, each motor could be supplied by a frequency converter.
In the exemplary embodiment illustrated in the accompanying diagram, such synchronizing means consist of a rigid connection (20) connecting the two shafts (17, 18) to one another.
Moreover, in the example illustrated, the beam (1) and the take-up system (5) for the formed fabric are controlled by two individual motors (21) and (22).
Finally, although it is possible to consider controlling members for the formation of the shed, for example a dobby, by means of a mechanical connection (belt (23)/shaft (24)), according to a preferred embodiment this control is obtained by means of an individual motor (25).
Such a machine is put into operation as follows.
When the machine is started up, the various members being at their starting point, an increase in speed of the motors (15, 16) is carried out over a plurality of revolutions of the machine, with the unwinder (21), the take-up (22) and the dobby (8) being at a standstill, the weft (9) is then offered to the insertion gripper (10), and, simultaneously, the motors (21, 22, 25) are actuated, allowing a normal weaving process.
After a stop, which is deliberate or the result of a break, when the machine is started up again, where appropriate after the repair of the yarn, all the motors are actuated in order to execute a return in reverse amounting to two revolutions. When this has taken place, the motors (15, 16) are started up and are accelerated over one revolution, a new pick (9) is then inserted at the second revolution, and, simultaneously, the motors (21, 22, 25) controlling the warp unwinder and the dobby are reactivated. | A weaving machine in which the weft is inserted by two grippers into a shed from opposite sides of the machine and the pick being beaten by a reed carried by a batten. The grippers and the batten are controlled by electrical motors supplied in parallel by one or more frequency converters and are linked together by a synchronizing mechanism. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to a temperature responsive fluid control valve. Temperature responsive valves are presently used to control fluid flow between a pressure or vacuum source and a fluid actuator, as for control of a vehicle radiator shutter or the like. Such a valve typically has a thermoresponsive element positioned in the engine coolant through a port in the engine. See e.g. U.S. Pat. Nos. 3,853,269 and 3,135,495. The shutter is therefore operated in response to engine temperature for control of the engine temperature. See e.g. U.S. Pat. No. 3,198,298. Some engines also employ a fan drive clutch which is operated in response to engine temperature conditions. Such a clutch is typically controlled by a second control valve with its higher temperature thermoresponsive element also in the engine coolant via a second port in the engine. The shutter regulates the amount of air allowed to flow through the radiator. The fan clutch regulates the amount of air dynamically drawn or blown, i.e. propelled through the radiator.
Optimally, these two separately functioning systems should operate cooperatively to create a large range of variable air flow conditions for engine temperature control. But, because the two operate independently, their operation can be mutually conflicting. This possibility of mutual interference can be caused for example by one or both of the units not being accurately preset or not properly located in the engine cooling system or one or both not functioning accurately for some other reason. At best they require the expense of two control valves and two ports in the engine block to the coolant systems.
SUMMARY OF THE INVENTION
The present temperature responsive fluid flow control valve regulates two fluid flow systems and hence the two functions, in positive sequential fashion, using the same temperature sensor. The control is particularly suitable for controlling an automatic radiator shutter and an air operated fan drive clutch of an engine in cooperative fashion. Only one port in the engine block is necessary. The same valve unit sequentially controls the fluid supply to both the shutter and the fluid supply to the clutch. The two functions cannot overlap and interfere with each other. Rather, their cooperative function assures a wide range of regulated air flow conditions to optimize engine operating temperature for better fuel economy and longer engine life.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the novel control valve;
FIG. 2 is an elevational view of the valve in FIG. 1 taken on plane II--II;
FIG. 3 is a sectional view of the valve taken on plane III--III of FIG. 2; and
FIG. 4 is an end view of the valve taken on plane IV--IV of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the embodiment of this invention depicted in the drawings, the assembly 10 includes an elongated valve housing 12 formed of a pair of interfitting components 12a and 12b interconnected by fasteners 14. Extending the length of this elongated housing is a passage 16 having passage portions 16a and 16b. Threadably connected in one end of this passage and specifically of passage portion 16a is a thermoresponsive subassembly 18 of conventional type. It includes a temperature sensing bulb 18' which extends into the coolant flow passage of an engine block shown by phantom lines 20 to which the valve is connected by threaded fasteners 12c. Sensor 18' contains a conventional substance which expands with increasing temperature to extend component 18" which projects into passage 16. The substance contracts with decreasing temperature to retract component 18". Engaging the end of movable component 18" is a first elongated plunger or push rod 22. This plunger, located in passage portion 16a, is biased into engagement with component 18" by a compression coil spring 24 around the plunger, one end of the spring abutting an annular washer 26 which in turn engages a fixed annular shoulder in the passage, and the other end abutting an annular washer 28 which in turn abuts an annular collar 30 fixed on movable plunger 22. A bleed port 27 in housing 12 communicates the area between washers 26 and 28 to the outside for free air movement therebetween during compression and extension of spring 24. This biasing spring also biases plunger 22 away from engagement with the first ball valve element 32 normally retained on a valve seat 34, the valve element and valve seat collectively forming a ball valve. The inner end of slide pin 22 or plunger, i.e. the end toward the ball valve, is hollow, having an interior passage 22a which has an axial port seat 22b on the end of the plunger toward the ball valve so as to form a valving action with the ball valve element when engaging it. The other end of the plunger passage 22a has a radial port 22c which communicates to the circumferential periphery of the plunger and an annular chamber 38. This chamber is on the inner diameter of an annular sleeve-like spacer 40 which in turn has an annular chamber 42 around its outer periphery. Port 40a connects these chambers. Chamber 42 communicates through port 44 in valve housing 12, connectable by threads to an air or vacuum source 46 (shown schematically). Preferably a screen 48 is in port 44. Spacer 40 has a pair of annular seal rings 50 and 52 at its axial ends. Thus, spring 24, slide pin 22, and spacer 40 are all in passage portion 16a.
Also communicating with passage portion 16a is an outlet port 56 which is connectable to and communicant with a shutter actuator 58 (shown schematically) such as a fluid cylinder. Preferably the radiator shutter, e.g. of the type set forth in U.S. Pat. No. 3,198,298 is spring biased to the open position and fluid actuated to the closed position, the fluid actuator being an air cylinder or the like. When plunger 22 is in the position depicted in FIG. 3, the fluid from source 46 through port 44 is communicant with outlet port 56 to retain the shutter in a closed condition to inhibit cooling air flow through the radiator or the portion thereof that the shutter covers.
On the opposite side of ball valve element 32 from plunger 22 is one or more exhaust ports 60 such that, when ball valve element 32 is off its seat 34, port 56 will be communicant with these exhaust ports 60 to allow compressed air or the like to escape from shutter actuator 58 and thereby enable its spring bias control to open the shutter assembly for air flow through the raditor. Valve element 32 is normally biased against its valve seat 34 by a compression spring 64 retained as between a pair of cups 66 and 68. The spring is around a second plunger or slide pin 70, with cup 66 engaging a shoulder of the valve housing portion 12b and cup 68 being retained by an annular collar 71 around plunger 70. The inner end of plunger 70 is retained in engagement with ball 32, this end having a concave configuration to match the ball. Movement of ball 32 off its seat therefor must be against the force of biasing spring 64 by axial movement of plunger 70. These two plungers 70 and 22 straddle the ball valve, with plunger 70 constantly engaging and normally retaining the ball on its seat, and plunger 22 capable of shifting the ball off its seat.
Plunger 70 is located in the second portion 16b of passage 16. The end of plunger 70 opposite ball 32 is hollow, having passage 70a open to one axial end where a port seat 70b is located and having a second port 70c at its other end. Port 70c communicates with an annular chamber 72 around the plunger and within an annular collar-shaped spacer 74. Spacer 74 has a radial port 74a that communicates from inner chamber 72 to an outer chamber 76 around the outer periphery of spacer 74. Communicant with chamber 76 is a port 78 in housing portion 12b which is connectable to compressed air or vacuum source 80 with threaded fasteners or the like. At opposite ends of spacer 74 is a pair of annular seal rings such as O-rings 82 and 84. Air or vacuum at source 80 is able to communicate through this series of ports and passages to an outlet port 86 in housing portion 12b communicant with a fan clutch 88 preferably spring biased to the fan drive condition and shifted to the non-drive condition by fluid through this control valve.
Adjacent axial end port 70b in plunger 70 is a second ball valve including a ball valve element 90 and its valve seat 92 against which the ball valve element is normally retained by a compression coil spring 94. This spring is retained between a fixed retainer 96 held by the housing, and a cup 98 that engages ball 90. Ball 90 has passage portion 16b on the inner face thereof, and exhaust ports 100 preferably including a filter 102 on the outer face of the ball.
This control valve serves in a special manner when the engine coolant is increasing in temperature to sequentially activate the shutter system for increasing air flow through the radiator and, then sequentially, as necessary, activate the fan clutch for increasing the air propelled through the radiator by the fan system. The combination thereby enables a wide range of air flow conditions to be achieved for optimum control of the engine temperature. When the engine coolant temperature is decreasing, the control valve first deactivates the fan drive and then, as necessary, closes the shutter system to prevent the engine temperature from being lowered too far.
To assure clarity of operation of this novel mechanism, the following detailed operation description is set forth.
When in the position depicted in FIG. 3, pressurized air from source 46 communicates through port 44 of the housing, chamber 42, port 40a, chamber 38, port 22c, passage 22a, port 22b, and discharge port 56 to maintain shutter actuator 58 shifted against its spring bias to hold the shutter in its closed position, thereby minimizing air flow through the radiator of the vehicle. Also, the pressurized air in source 80 is communicant with port 78, chamber 76, port 74a, chamber 72, port 70c, passage 70a, port 70b and hence with discharge port 86 to the fan clutch 88 to retain the fan in its non-driving condition. Thus, the engine is allowed to increase in temperature with minimum air coolant flow. As the engine coolant temperature thus increases, the contents of thermoexpansion element 18 expands, thereby extending component 18" to shift plunger 22 gradually against the bias of coil sring 24.
With sufficient temperature increase to shift the plunger 22 into engagement with ball valve element 32, the communication from source 46 to shutter actuator 58 is closed off. Further movement of plunger 22 shifts ball 32 off its valve seat 34 to allow any pressurized air at shutter actuator 58 to flow out exhaust ports 60. But the continued closure of port 22b prevents exhausting of source 46 to exhaust port 60. This allows the biasing mechanism of the shutter system to open the shutters for flow of cooling air through the radiator. The amount that ball 32 is shifted from its seat will determine the rapidity and exhaust of the air from the shutter actuator and therefore opening of the shutter system. If the engine coolant temperature continues to rise, thermoresponsive element 18 will further shift plunger 22, which will shift valve 32 further, which in turn shifts second plunger 70 against its biasing spring 64 so that ultimately port 70b of plunger 70 will be closed by the ball 90 when plunger 70 engages this ball valve element. Such engagement will stop communication between pressurized air source 80 and fan clutch 88. Further shifting of the two slide pins and the straddled ball 32 will shift ball valve element 90 off its seat 92 to allow pressurized air at fan clutch 88 to flow back through port 86, passage 16b and escape out exhaust port 100. But continued closure of port 70b by ball 90 prevents exhausting of source 80 out port 100. Thus, the spring bias of the fan clutch will drive the fan to propel a greater amount of air through the radiator. If, as a result, the temperature of the engine coolant lowers, this entire mechanism will operate sequentially in reverse, with ball valve element 90 first engaging its seat, plunger 70 retracting away from the ball valve to again cause communication between source 80 and fan clutch 88, ball 32 then engaging its seat, and slide pin 22 retracting from ball 32 to reestablish the communication between source 46 and shutter actuator 58. This sequential action in one direction or another is constantly controlled for maximum cooperative effort without interference between these functions.
Conceivably sources 46 and 80 could be vacuum sources with any actual air flow occurring in the opposite direction from that which would exist if such are pressurized air sources, as would be evident to persons skilled in this field.
It is also conceivable that the control valve could be employed in other environments than for controlling engine temperatures (i.e. fan drive/air whistle alarm; shutter/fan drive override for automatic transmission, etc.). | A temperature responsive fluid control valve with sequential control functions, employing a pair of axially aligned hollow elongated plungers or slide pins, and a pair of ball valves and valve seats therefor. One ball valve is straddled by the two plungers, being biased onto its seat by the second plunger and shiftable off its seat by the first plunger. This ball valve controls a first fluid flow in response to a thermoresponsive sensor acting on the first plunger. The second ball valve is operated sequentially after the first, via the second plunger for control of a second sequential fluid flow using the same thermoresponsive sensor. | 5 |
RELATED APPLICATIONS
[0001] This application claims the benefit of priority of U.S. Provisional Applications Nos. 60/891,892 filed on Feb. 27, 2007 and 60/999,755 filed on Aug. 9, 2007, the entire contents of which application are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a nebulizer, and more particularly but not exclusively to a compact nebulizer that efficiently utilizes medication.
BACKGROUND OF THE INVENTION
[0003] The deposition efficiency in the tracheobronchial (TB) and pulmonary regions is highly dependent on particle size. Particle sizes in the range of about 1 to 5 μm, as well as the size range extending from approximately 0.005 to 0.5 μm, have a relatively high rate of deposition within the aforementioned regions. (See William Hinds, Aerosol Technology, p 241 (1999).) Various methods have typically been used to generate these therapeutic fine particles, such as air-blast nebulizers (i.e., compressed air, jet, or venturi nebulizer), pressure nebulizers, ultrasonic nebulizers, a vibrating orifice, a spinning disk, condensation devices, and inkjet technology-based nebulizers. However, despite the variety of methods used to generate therapeutic fine particles, problems remain such as wasted medication that is not dispensed and the swallowing of liquid medication by the user. Currently available nebulizers typically have residual (i.e., waste) medication of 50% or more. This waste is largely due to the fact that existing nebulizers will generate and disperse large and small particles. The large particle dispersion is not well controlled and leads to residual medication in the nebulizer and associated apparatus. Additionally, some nebulizers are relatively bulky, which unfortunately provides considerable surface area for medication deposition within the device which in turn leads to wasted unused medication. Thus, it would be an advance in the state of nebulizer art to more efficiently dispense and utilize liquid medication to reduce waste and increase patient compliance, and to protect the user of the nebulizer from swallowing liquid medication.
SUMMARY OF THE INVENTION
[0004] In one of its aspects, the present invention provides a nebulizer comprising an impactor having a curved surface and a nozzle oriented so that outflow from the nozzle engages the curved surface. The nebulizer incorporates a nebulizer tube, which may comprise a single-piece, and that may include a convergent-divergent air mixing nozzle, as well as an integral feed channel for siphoning medication. The nebulizer tube independently provides a first-level (i.e., relatively coarse) nebulization. To obtain the fine particles desired for nebulizers, the output stream from the nebulizer tube is directed towards an impactor having a curved surface at, or proximate, the impact site. When the flow strikes the impactor, very fine particles are generated. The curvature of the impactor promotes two very desirable effects. First, the portion of the flow that is not atomized into very fine particles will drain down the impactor and return to a medication reservoir disposed under the impactor, creating a “waterfall” recycling effect. Second, the impactor curvature also helps to direct the nebulized medication in a preferred direction, in this case toward the user's mouth.
[0005] In another of its aspects, the present invention also reduces the risk to the user associated with the inadvertent swallowing of unacceptably large quantities of liquid medication present in the nebulizer's reservoir. This could occur if the patient were to tilt his or her head too far back. To substantially reduce this risk, a semi-permeable membrane or other suitable material that is permeable to mist but sufficiently impermeable to liquid may be deployed to allow delivery of the nebulized mist to the user but prevent the flow of bulk liquid medication.
[0006] The present invention also provides in one of its aspects a reduction in the necessary treatment time through the generation of a dense mist of particles, in part because the particles are in the correct size range for effective deposition in the desired TB or pulmonary regions. The relatively higher density of nebulized particles may be created with the use of multiple jet impactors. Within a single nebulizer assembly, two, three, or more, high velocity jets of liquid-carrying gas may be directed at an impactor surface, creating a relatively higher density of fine droplets. Thus, the patient can inhale the full dose of medicine in a shorter time from which three benefits follow: more rapid treatment in critical situations, a financial benefit for the clinical setting (i.e., less time required from medical staff), and higher patient compliance in the home setting.
[0007] In these regards, the present invention provides a nebulizer for delivering a mist of liquid, comprising a housing and a reservoir disposed internally to the housing for containing liquid to be nebulized by the nebulizer. The nebulizer may include a monolithic nebulizer tube which has a gas channel having a first end for receiving a gas, such as compressed gas, and a second end for expelling the compressed gas and/or liquid. The gas channel may extend from a first end to a second end of the nebulizer tube. The monolithic nebulizer tube may also include a liquid feed channel comprising a first end in fluid communication with the reservoir for receiving liquid from the reservoir. Depending on the application the liquid may desirably be a liquid medication. The feed channel may include a second end in fluid communication with the gas channel. Alternatively, the feed channel may have an annular passageway at a second end of the feed channel with the annular passageway disposed about the second gas channel end. Application of compressed gas to the first end of the gas channel creates a siphon in the liquid feed channel to draw liquid into the feed channel and to expel the liquid and compressed gas from the second end of the nebulizer tube. To direct the flow of nebulized mist to an exit port of the nebulizer, a tortuous passageway may be provided between the second end of the gas channel and an exit port of the nebulizer. The tortuous passageway may be configured to remove nebulized particles larger than a selected therapeutic size from the flow of nebulized mist.
[0008] The nebulizer may further include an impactor disposed proximate the second end of the gas channel to nebulize the expelled liquid when the expelled liquid strikes the impactor. The impactor may be disposed sufficiently close the second end of the gas channel to assist in nebulizing the liquid expelled from the second end of the gas channel. The impactor may comprises a spherical, cylindrical, or mesa-like shape, or may include a ring disposed around the mesa to provide an annular channel between the ring and the mesa. The annular channel may be dimensioned to provide a fundamental resonant frequency of the annular channel tuned to generate particles of a preferred size.
[0009] In another configuration, the present invention provides a nebulizer for delivering a mist of liquid, comprising a housing having an inlet port for receiving compressed gas, such as compressed air for example, and an exit port for delivering a mist of nebulized liquid. A reservoir is disposed internally to the housing for containing liquid to be nebulized by the nebulizer. The nebulizer also includes a nebulizer tube in fluid communication with the liquid having an outlet from which the nebulized mist is provided. The outlet end of the nebulizer tube is disposed internally to the housing. The nebulizer also includes a tortuous passageway disposed within the housing between outlet end of the nebulizer tube and the exit port of the nebulizer for directing the flow of nebulized mist therethrough to the exit port.
[0010] In yet another configuration, the present invention provides a nebulizer for delivering a mist of liquid, comprising a two-piece housing having separate first and second housing portions, and a reservoir monolithic to the housing for containing liquid to be nebulized by the nebulizer. The nebulizer includes a nebulizer tube monolithic to the housing. The nebulizer tube includes a gas channel having a first end for receiving a gas, such as compressed air for example, and a second for expelling compressed gas and liquid. The gas channel extends from the first end to a second end of the nebulizer tube. The nebulizer tube also includes a liquid feed channel comprising a first end in fluid communication with the reservoir for receiving liquid from the reservoir and comprising a second end in fluid communication with the gas channel. Application of compressed gas to the first end of the gas channel creates a siphon in the liquid feed channel to draw liquid into the feed channel and to expel the liquid along with compressed gas from the second end of the nebulizer tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The foregoing summary and the following detailed description of the preferred embodiments of the present invention will be best understood when read in conjunction with the appended drawings, in which:
[0012] FIG. 1 schematically illustrates a perspective view of a first exemplary nebulizer of the present invention;
[0013] FIG. 2 schematically illustrates the nebulizer of FIG. 1 , but without the semi-permeable membrane in place;
[0014] FIG. 3 schematically illustrates a cross-sectional view of the nebulizer of FIG. 2 taken along the sectioning line 3 - 3 ;
[0015] FIGS. 4A and 4B schematically illustrate perspective views of exemplary configurations of the lower housing of a nebulizer;
[0016] FIGS. 5A and 5B schematically illustrate perspective views of exemplary configurations of the lower housing of a nebulizer of the present invention having an enlarged region for receiving liquid medication;
[0017] FIGS. 6 , 7 A, and 7 B schematically illustrate perspective views of exemplary configurations of the upper housing of the nebulizer of the present invention;
[0018] FIG. 8 schematically illustrates a cross-sectional view of a nebulizer similar to that depicted in FIG. 3 , but including the lower housing of FIG. 4B and the upper housing of FIG. 7A ;
[0019] FIG. 9 schematically illustrates the cross-sectional view of the nebulizer of FIG. 3 with the lower housing removed and with the upper housing rotated to show the internal cavity facing upward;
[0020] FIG. 10 schematically illustrates the perspective view of the nebulizer of FIG. 2 with the lower housing removed and with the upper housing rotated to show the internal cavity facing upward;
[0021] FIGS. 11 and 12 schematically illustrate a perspective and cross-sectional view taken along the sectioning line 12 - 12 , respectively, of a nebulizer tube of the present invention;
[0022] FIG. 13 schematically illustrates a perspective view of a second exemplary nebulizer of the present invention;
[0023] FIG. 14 schematically illustrates a cross-sectional view of the nebulizer of FIG. 13 taken along the sectioning line 14 - 14 ;
[0024] FIG. 15 schematically illustrates a perspective view of the lower housing of the nebulizer of FIG. 13 ;
[0025] FIG. 16 schematically illustrates a perspective view of the lower housing of the nebulizer of FIG. 13 with the nebulizer tube in place;
[0026] FIG. 17 schematically illustrates the nebulizer tube of FIG. 13 having a key for insertion in the upper housing;
[0027] FIG. 18 schematically illustrates a perspective view of the upper housing of the nebulizer of FIG. 13 having a keyway for receiving the key of the nebulizer tube;
[0028] FIG. 19 schematically illustrates a perspective view of the upper housing of the nebulizer of FIG. 13 with the nebulizer tube in place with the key of the nebulizer tube disposed in the keyway of the upper housing;
[0029] FIGS. 20A and 20B schematically illustrate perspective views of a liquid fill cap;
[0030] FIGS. 21A and 21B schematically illustrate alternative airfoil shapes for the impactor;
[0031] FIG. 22 schematically illustrates a perspective view of a third exemplary nebulizer of the present invention;
[0032] FIG. 23 schematically illustrates a cross-sectional view of the nebulizer of FIG. 22 taken along the sectioning line 23 - 23 ;
[0033] FIG. 24 schematically illustrates a perspective view of the lower housing of the nebulizer of FIG. 22 ;
[0034] FIGS. 25 , 26 , and 27 schematically illustrate perspective views of the upper housing of the nebulizer of FIG. 22 ;
[0035] FIG. 28 schematically illustrates a cross-sectional view of the upper housing of FIG. 26 taken along the sectioning line 28 - 28 , having a three-channel nebulizer tube in place of the single channel nebulizer tube of FIG. 22 ;
[0036] FIG. 29 schematically illustrates a cross-sectional view of the upper housing of the nebulizer of FIG. 26 taken along the sectioning line 29 - 29 ;
[0037] FIGS. 30 and 31 schematically illustrate a perspective and cross-sectional view taken along the sectioning line 31 - 31 , respectively, of a nebulizer tube of the present invention having three outlet channels;
[0038] FIGS. 32 and 33 schematically illustrate a perspective and cross-sectional view taken along the sectioning line 33 - 33 , respectively, of a nebulizer tube of the present invention having two outlet channels;
[0039] FIGS. 34 and 35 schematically illustrate a perspective and cross-sectional view taken along the sectioning line 35 - 35 , respectively, of a nebulizer tube of the present invention having one outlet channel;
[0040] FIG. 36 schematically illustrates a perspective view of a lower housing, similar to the housing shown in FIG. 24 , but having make-up air curtain walls;
[0041] FIG. 37 schematically illustrates a perspective view of an upper housing, similar to the housing shown in FIG. 25 , but having make-up air curtain walls;
[0042] FIG. 38 schematically illustrates a perspective view of a fourth exemplary nebulizer of the present invention having two parts with an monolithically integrated nebulizer tube;
[0043] FIG. 39 schematically illustrates a perspective view of the nebulizer of FIG. 38 with the lid open;
[0044] FIG. 40 schematically illustrates a perspective view of the nebulizer similar to that shown in FIG. 39 but having a two channel nebulizer tube;
[0045] FIG. 41 schematically illustrates a cross-sectional view taken along the sectioning line 41 - 41 of the nebulizer of FIG. 38 ;
[0046] FIG. 42 schematically illustrates a cross-sectional view taken along the sectioning line 42 - 42 of the nebulizer of FIG. 38 ;
[0047] FIG. 43 schematically illustrates a perspective view of the upper housing of the nebulizer of FIG. 38 ;
[0048] FIG. 44 schematically illustrates a cross-sectional view of the upper housing taken along the sectioning line 44 - 44 of FIG. 43 with the top cut away;
[0049] FIG. 45 schematically illustrates a perspective view of the lower housing of the nebulizer of FIG. 38 ;
[0050] FIG. 46 schematically illustrates a cross-sectional view taken along the sectioning line 46 - 46 of the lower housing of FIG. 45 ;
[0051] FIGS. 47 and 48 schematically illustrate a perspective and cross-sectional view taken along the sectioning line 48 - 48 , respectively, of a nebulizer tube of the present invention having an annular medication delivery port;
[0052] FIGS. 49 and 50 schematically illustrate a perspective and cross-sectional view taken along the sectioning line 50 - 50 , respectively, of an upper housing having a spherical impactor;
[0053] FIG. 51 schematically illustrates a fragmentary cross-sectional view of the upper housing of FIG. 49 and a lower housing assembled with the nebulizer tube of FIG. 47 disposed therein;
[0054] FIGS. 52 and 53 schematically illustrate a perspective and cross-sectional view taken along the sectioning line 53 - 53 , respectively, of an upper housing having a cylindrical impactor;
[0055] FIGS. 54 and 55 schematically illustrate a perspective and cross-sectional view taken along the sectioning line 55 - 55 , respectively, of an upper housing having a mesa-shaped impactor; and
[0056] FIGS. 56 and 57 schematically illustrate a perspective and cross-sectional view taken along the sectioning line 57 - 57 , respectively, of an upper housing having a mesa-shaped impactor with a ring disposed about the mesa to provide a resonant annular channel.
DETAILED DESCRIPTION OF THE INVENTION
[0057] Referring now to the figures, wherein like elements are numbered alike throughout, FIGS. 1 and 2 illustrate an external view of a first configuration of a nebulizer 100 of the present invention. The nebulizer 100 comprises a nebulizer tube 1 disposed within a housing 40 for receiving compressed gas, such as compressed air or nitrogen, for example, and an exit port 10 for delivering a nebulized mist to a user. The housing 40 may comprise an upper housing 2 and a lower housing 3 , which may be registered to one another by cooperation between holes 12 of the lower housing 3 and alignment posts 16 of the upper housing 2 , FIGS. 4A , 6 . The upper housing 2 may include a fill port 30 for introducing a liquid medication into the housing 40 . The fill port 30 may be shaped to readily accept the shape of standard medicine containers, which will facilitate filling of the nebulizer 100 with the correct amount of medication and reduce the possibility of spillage and waste. The fill port 30 may remain open and may also serve as an exit for nebulized liquid, or the fill port 30 may optionally include a separate funnel or duckbill-shaped cap 31 for insertion into the upper housing 2 to direct the liquid medication into the housing 40 , FIGS. 1 , 3 , 20 A, 20 B. The cap may be located inside the main body of the nebulizer to deter the cap from inadvertently coming loose and being swallowed by the user. Alternatively, the fill port cap 230 may be provided as an integral portion of the upper housing 202 , FIGS. 13 , 14 . The cap 31 , 230 may be configured so that it deflects to permit liquid to be poured into the nebulizer when a small force applied. For example, the cap 31 , 230 may deflect when a syringe is inserted for delivering liquid and may close again after the syringe is removed, or the cap 331 may be molded as part of the upper housing 302 and connected thereto via a living hinge 335 , FIGS. 22 and 23 . Moreover, the cap 31 may be provided in the form of a one-way duck-bill valve that permits the entry of liquid medication but deters the flow of nebulized mist therethrough.
[0058] To receive a liquid, such as medication, introduced through the fill port 30 , the lower housing 3 includes a reservoir 7 which may include a cylindrical sidewall 33 for containing the liquid medication within a localized region within the lower housing 3 . (While any suitable liquid may be provided in the reservoir, for illustration purposes the devices of the present application are described herein as containing a medication.)
[0059] The reservoir 7 may be dimensioned to hold at least 3 ml of liquid medication, for example. In addition, to further contain the location of the liquid medication, the reservoir 7 may include a hemispherical or other suitably shaped depression 34 into which the liquid medication may pool. Maintaining the liquid medication in a specified location assists in making the medication available to the nebulizer tube 1 , and thus aids in efficient use of the medication.
[0060] The reservoir 7 may include shapes other than cylindrical. For example, the reservoir 7 ″ may have a generally rectangular shape being bounded at the inlet and outlet end of the lower housing 3 ″ by front and rear reservoir walls 13 a , 13 b , FIG. 5A . The reservoir walls 13 a , 13 b may be straight, curved 13 a ′, or assume any other suitable shape, FIGS. 5B , 16 . In addition, in the event that liquid medication overflows the wall 33 ′ of the reservoir 7 ′, an overflow wall 13 may optionally be provided at the exit port 10 to help deter introduction of liquid medication into the user's mouth, FIG. 4B . Furthermore, one or more semi-permeable membranes 4 may be provided at the exit port 10 of the nebulizer 100 to permit mist flow while acting as an effective liquid barrier, thus creating a safety feature that prevents a user from swallowing liquid medication contained in the nebulizer 100 . In one configuration the semi-permeable membranes 4 may be used instead of the front reservoir wall 13 a . Alternatively, or additionally, an absorbent material, such as a sponge, may be incorporated into the nebulizer 100 , for example between the reservoir 7 ′ and overflow wall 13 , to deter the outflow of liquid medication into the exit port 10 . For instance, in the event that the nebulizer is tilted beyond some critical angle during use, the membrane 4 and/or absorbent material will block the flow of medication into the user's mouth while permitting the nebulized mist to flow through the membrane 4 .
[0061] For example, a foam sponge material may be used as the membrane 4 to permit mist flow while deterring liquid medication flow therethrough. In the nebulizers of the present invention, the flow of small droplets from the nebulizer 100 operates in a very low Reynold's number flow regime. The Reynold's number is a dimensionless number, a ratio of the momentum forces acting on a body to that of the viscous forces. In a low Reynold's number flow, particles tend to follow the path of the gas flow and are not likely to impact upon the solid surfaces that restrain the flow. This holds true even when that flow path is a circuitous one through the pores of a thickness of sponge material. The droplets are carried through with the flowing gas stream, and so the sponge remains dry.
[0062] Thus, in one embodiment of the present invention, the membrane 4 is provided in the form of a layer of sponge material that covers the flow through the exit port 10 and permits the nebulized mist to flow out. The sponge could comprise either a wettable or non-wettable material for the given liquid medication. (The determination of whether a material is “wetting” or “non-wetting” depends on the liquid being used. As used herein, we are most interested in the wettability of materials mainly as it pertains to the use of aqueous solutions.) If the sponge were non-wettable, a sufficiently small pore size would have enough capillary pressure to prevent the liquid medication from progress through the sponge membrane 4 . (A simple, well known equation can be used to calculate the “capillary pressure.” Capillary pressure is the pressure that would be required to force the liquid through a given-sized circular hole in a non-wetting material. The capillary pressure is dependent upon: the contact angle, the surface tension of the liquid, and the diameter of the hole.) However, most readily available sponge materials are comprised of wettable materials. If a wettable sponge material were employed as the membrane 4 , the wettable sponge material should be located so that it is not typically in contact with the bulk liquid medication in the nebulizer 100 . Otherwise, the liquid medication would undesirably be wicked into the sponge and would not be available to be delivered to the user. Nonetheless, a wettable sponge can provide useful functionality when it is strategically located so that, if the nebulizer 100 is tilted too much, the sponge acts as a barrier wicking up the large liquid drops or liquid that has sloshed due to rapid gross motions of the nebulizer 100 . For example, a 2 mm thick layer of polyethylene wettable foam having about 80% open space and pore sizes of about 0.8 mm may be used as the membrane 4 . In addition, a foam layer in the flow exit path proximate the exit port 10 provides an additional feature: a very slight back-pressure in the flow path of the gas and liquid mixture (i.e. the airborne droplets). This slight back-pressure gives the effect of a diffuser by evening out the velocity profile at the nebulizer exit port 10 so that the nebulized mist exits the nebulizer 100 at a slower average velocity and more uniform distribution across the exit port 10 . (The diffuser effect causes the velocity to be more uniform. The slight flow restriction or back pressure, due to the presence of the foam layer, will tend to slow the flow.)
[0063] Further exemplary materials for use as the membrane 4 would include films comprised of fluoropolymers (PTFE, etc.), such as DuPont Teflon® PTFE, having very small pore sizes. Films such as these are currently being produced by W. L. Gore Company under the Gore-Tex® trademark. Teflon® PTFE has a very low surface energy as it is essentially a non-polar molecule. Water is a polar molecule, and liquid water does not “wet” a Teflon® PTFE surface. Instead, liquid water forms “beaded” drops on the surface of the Teflon® PTFE; each drop has a contact angle much greater than 90 degrees. In the case of liquid water and Teflon® PTFE, a very high pressure is required to force water through small holes in the material. However, gases and water mist flow through the pores with little trouble. Gore-Tex® films are specifically created to exploit this phenomena in a number of applications. (One example is a “T” fitting that has one port covered by Gore-Tex® film. This assembly is used in some intravenous tubing, which allows gases to vent out of the tube but prevents the IV fluid from leaking through.)
[0064] The nebulizer tube 1 includes a liquid feed channel 6 having an inlet end 42 disposed in fluid communication with the reservoir 7 to receive liquid medication disposed within the lower housing 3 , FIGS. 3 , 12 . The feed channel 6 communicates with a gas channel 5 of the nebulizer tube 1 to deliver the liquid medication to the gas channel 5 to be nebulized. The gas channel 5 includes an inlet end 41 for connection to a source of compressed air and a throat 43 where the feed channel 6 connects to the gas channel 5 . The gas channel 5 may be provided in the form of a convergent channel 5 that has a cross-sectional dimension that decreases from the inlet end 41 to the throat 43 where the cross-sectional dimension may be a minimum, e.g., 15 to 20 thousandths of an inch. The feed channel 6 may also have a minimum cross-sectional dimension at the throat 43 , e.g., 15 to 20 thousandths of an inch. The nebulizer tube 1 also includes a nozzle 8 disposed in fluid communication with the throat 43 of the gas channel 5 . The nozzle 8 includes a channel cross-sectional dimension that increases away from the throat 43 towards the outlet end 44 of the nebulizer tube 1 .
[0065] The inlet end 41 of the nebulizer tube 1 may include a barb 18 to assist in securing attachment of a compressed air hose to the inlet end 41 of the nebulizer tube 1 , FIGS. 11 , 12 . A flange 19 may also be included to provide a positive stop for the air hose during initial installation. During operation, compressed air, of 25 to 45 psi for example, enters the convergent channel 5 of the nebulizer tube 1 . The air accelerates until it reaches the throat 43 of the convergent channel 5 . By virtue of the Bernoulli effect, as the flow velocity increases, its static pressure will decrease. As a result, the static pressure at the throat 43 of the convergent channel 5 will be below that of the local atmospheric pressure. Since the static pressure of the liquid is higher than the static pressure at the throat 43 of the nebulizer tube 1 , liquid is siphoned upward into the feed channel 6 as a result of a venturi effect. Subsequent to siphoning, the liquid/air mixture is rapidly expanded in the divergent section of the nozzle 8 . This rapid expansion encourages turbulent mixing and creates an effective first-level of nebulization.
[0066] The nozzle 8 is oriented so that the output flow from the nozzle 8 strikes a curved impactor 9 , which may be provided as part of the upper housing 2 . This energetic collision generates the very fine, therapeutic particles required of nebulizers. It has been determined that a sufficiently small spacing is required between the nozzle 8 and impactor 9 to generate a fine mist. A suitable nozzle to impactor spacing is 10 to 20 thousandths of an inch. The location of the nozzle 8 relative to the curved impactor 9 may be specified by an alignment boss 21 provided on the nebulizer tube 1 that mates with a complementary positioning feature 11 of the lower housing 3 to locate the nebulizer tube 1 within the housing 40 . In addition, the nebulizer tube mates with an nozzle capture feature 15 of the upper housing 2 to stabilize the tube 1 within the nebulizer 100 , FIGS. 8-10 . Additionally, or alternatively, registration of the nebulizer tube 1 to the impactor 9 may be provided by direct or indirect physical cooperation between the nebulizer tube 1 and impactor 9 . For example, referring to FIGS. 16-19 (wherein structures similar to those illustrated in FIGS. 1-12 are similarly numbered with a “200”-series reference numeral), the nebulizer tube 201 may include a registration feature, such as a boss or key 251 , for mating with a complementary structure, such as keyway 252 , on the nebulizer 209 . Engagement between the key 251 and the keyway 252 establishes the relative position between the nozzle 208 and the impactor 209 .
[0067] The impactor 9 , 209 may have a generally cylindrical shape, such as a substantially full cylinder, FIG. 6 , or a partial cylindrical impactor 17 , FIG. 7A . Such impactor shapes will generate a fine mist and will also facilitate the flow of mist toward the user's mouth. Other curved surfaces may be substituted for the cylindrical impactors 9 , 209 such as elliptical, or other suitable shape, e.g., an airfoil 60 , FIG. 21A . In addition, the curved impactor may have a cross-sectional shape which includes a flat region 62 as well as a curved region 63 , such as the airfoil 61 illustrated in FIG. 21B , for example. The airfoil impactor 60 , 61 is oriented within the housing 40 , 240 so that the tapered portion of the airfoil points in the downstream direction towards the exit port 10 , 210 of the nebulizer 100 , 200 . Such an orientation of the airfoil impactor 60 , 61 would reduce turbulence and backpressure of the air and mist as it moves out the exit port 10 , 210 of the nebulizer 100 , 200 .
[0068] In addition to creating a fine mist, the curved impactor 9 also provides at least two other desirable functions: (I) it helps direct the nebulized mist towards the user's mouth, and (ii) it facilitates a waterfall-like recycling effect. The waterfall effect arises because part of the mixture exiting the nebulizer tube 1 will strike the impactor 9 and simply drain back down into the region containing the pool of liquid, i.e., reservoir 7 . In this regard, the impactor 9 may be positioned above the reservoir 7 . Of course, a significant portion of the air/liquid mixture will exit via port 10 of the nebulizer as a mist directed toward the user's mouth. An air baffle 20 may be provided on the nebulizer tube 1 proximate the feed channel inlet end 42 , so that the high-velocity mixture striking the impactor 9 does not blow liquid away from the feed channel inlet 42 which could lead to a feed channel starvation condition. In addition, inclusion of the air baffle 20 can deter unwanted formation of large airborne droplets that might result from the surface of the liquid being agitated.
[0069] Additionally, the impactor 9 , 209 can be shaped to create a scavenging flow within the nebulizer 100 , 200 . The scavenging flow would be directed throughout the housing interior and would help prevent the accumulation of medication on the internal walls of the nebulizer 100 , 200 . In addition, curtain walls 261 may be provided in the upper housing 2 , 202 to redirect any accumulation of liquid on the upper surface of the upper housing 2 , 202 downward into the reservoir 7 , 207 . The presence of curtain walls 261 can avoid the situation of liquid running down the interior sidewall of the upper housing 2 , 202 to encounter and potentially leak out through the seam between the upper housing 2 , 202 and the lower housing 3 , 203 . The curtain walls 261 may also be positioned sufficiently close to the impactor 209 to permit fine particles to travel around the impactor 209 to the exit port 210 and to cause larger particles to strike the curtain walls 261 and then drip down into the reservoir 207 . Additionally, a filter-type material may be positioned in the nebulizer 100 , 200 to give a preferential flow direction for the nebulized mist toward the user's mouth without creating an excessive flow resistance to inhalation. Furthermore, the housing 40 , 240 and/or other components of the nebulizer 100 , 200 may be fabricated from materials that possess surface tension properties characteristic of wetting materials to create a sheeting action that will facilitate the flow of recycled materials to the reservoir 7 , 207 . For example, the material of the housing 40 may comprise plastics that are non-wetting in their original condition. Polyethylene (PE) and polypropylene (PP) are two examples. If the reservoir 7 is constructed of one of these materials, and has sufficiently steep internal shape, the liquid medication will roll down to the lowest point, which would presumably be the location from which the liquid medication is being siphoned. Many times however, in practical applications, after having been used, a surface that started out as non-wetting, can become fully or partially wetting due to the deposition of a very thin layer of dirt, minerals, or other contaminants on the surface. The surface might then act as a wettable one. For this reason, it is important to design the reservoir 7 to work well as a wettable material to start with.
[0070] The wetting angle of a wettable material is less than 90 degrees. The contact angle can be a very small angle as the edge of a liquid is pulled along a solid surface. Several characteristics of a wettable surface, together with intentional geometric features, can be used to help the functionality of the nebulizer design. An ideal nebulizer would have the capability to utilize every bit of the liquid medication contained therein. Achievement of this goal may be attempted by pulling the liquid medication from a location that is the lowest point in a depression of the reservoir 7 . The inner walls of the reservoir 7 may be sloped as much as possible, because as the liquid medication level goes down, droplets of water can remain stuck in random locations on the walls of a reservoir 7 that is made from a wettable material. These droplets would be counted as wasted medication that the nebulizer 100 is unable to use as residual content. The nebulizer design can cause the air flow to move generally downward along the walls of the reservoir 7 , which is generally a turbulent action. However the shear action downward along the reservoir wall will scrub the liquid down toward the pick up location.
[0071] The geometry of the reservoir walls, together with the wetting characteristics of the reservoir can also help to reduce the amount of residual unused medication. Internal angles or grooves that run in a direction down the side walls of the reservoir 7 can also be included. The dimensions of the angles or grooves can be relatively small as compared with the dimensions of the reservoir 7 , in which case the liquid will “wick” along the angles or grooves. Further, the design can be made to cause the liquid to preferentially move in one direction along the length of these features by gradually changing the size or shape of the groove along its length. For example, if the internal angle of the groove becomes more acute, the liquid will be preferentially pulled in that direction. Another technique for pulling the liquid toward the feed channel inlet 42 of the feed channel 6 is by make the gap between the bottom surface of the reservoir 7 and the feed channel inlet 42 sufficiently small to wick into this gap (if the surfaces are wetting materials). A further aid is to have the gap reduce in size (taper, or converge) as the liquid moves in the flow-wise direction, towards the feed channel inlet 42 . A gap that becomes smaller as it approaches the inlet to the feed channel 42 can encourage the liquid to flow in that direction.
[0072] Turning next to FIG. 22 , an additional configuration of a nebulizer 300 in accordance with the present invention is illustrated, in which the nebulizer is configured to reverse the flow of nebulized medication and then redirect the reversed flow towards the nebulizer exit port 310 . The reversal and redirection of the flow of nebulized medication can serve as a particle size filter, allowing only the smaller sized particles to reach the nebulizer exit port 310 . The three-piece nebulizer 300 includes a nebulizer tube 301 , an upper housing 302 , and a lower housing 303 along with an integral cap 331 .
[0073] Referring to the cross-sectional view of FIG. 23 , the structure of the nebulizer 300 and mechanism by which the nebulized mist is created may be understood. Compressed air enters the convergent gas channel 305 of the nebulizer tube 301 through an inlet end 341 of the nebulizer tube 301 . A barb 318 may be incorporated into the nebulizer tube 301 to aid in securing an elastomeric air hose through which compressed air is introduced into the nebulizer tube 301 . In addition, a flange 319 may be incorporated to provide a positive stop for the air hose during installation.
[0074] The air accelerates until it reaches the throat 343 (a location of minimum cross-sectional area) of the nebulizer tube 301 . By virtue of the Bernoulli effect, as the flow velocity increases, its static pressure decreases. As a result, the static pressure at the throat 343 of the nebulizer tube 301 is below that of the local atmospheric pressure. An integral liquid feed channel 306 of the nebulizer tube 301 is disposed in communication with the medication located in the reservoir 307 of the lower housing 303 . Since the static pressure of the liquid is higher than the static pressure at the throat 343 of the nebulizer tube 301 , liquid is siphoned upward though the feed channel 306 as a result of this venturi effect. Subsequent to siphoning, the liquid/air mixture is rapidly expanded in the divergent section of the nozzle 314 . This rapid expansion encourages turbulent mixing and creates an effective first-level of nebulization.
[0075] After exiting the nozzle 314 , the mixture strikes an impactor 309 which may be provided as a monolithic part of the upper housing 302 . This energetic collision generates very fine, therapeutic particles. The spacing between the nozzle 314 and the impactor 309 is selected to be sufficiently small, e.g., 20 to 40 thousandths of an inch, to generate a suitably fine mist. The impactor 309 also provides the waterfall-like recycling effect. An air baffle 320 of the nebulizer tube 301 is provided near the bottom of the feed channel 306 so that after the high-velocity mixture strikes the impactor 309 the deflected stream does not disturb the liquid near the feed channel inlet. Without the baffle 320 , it is possible that a feed tube starvation condition could be created due to liquid being blown away from the feed channel 306 . In addition, the surface of the liquid might be agitated to an extent that would produce unwanted formation of large airborne droplets. Note also, that in the event that the nebulizer is tilted forward beyond some critical angle during use, the adjoining walls 313 , 350 of the upper and lower housings 302 , 303 block the flow of medication into the user's mouth.
[0076] FIGS. 24-27 illustrate the lower and upper housings 302 , 303 from which the structures that contribute to the reversal and redirection of the nebulizer flow through the nebulizer 300 can be seen. Turning first to the lower housing 303 of FIG. 24 , the reservoir 307 may include a hemispherical or other suitably shaped depression for retaining liquid medication therein. The reservoir 307 may be surrounded by a reservoir wall 313 , such as a U-shaped wall, that is configured to cooperate with corresponding structures in the upper housing 302 to aid in confining and directing the nebulized mist. (Additionally, an alignment feature 311 is provided to position the nebulizer tube 301 within the lower housing 303 , and four holes (of which hole 312 is representative) are provided to align the upper and lower housings 302 , 303 via the mating posts 316 of the upper housing 302 , FIG. 25 .)
[0077] The upper housing 302 includes a nebulization chamber 334 in which the nebulized mist is generated, FIG. 25 . The nebulization chamber 334 is defined by a chamber wall 350 , which may have a generally cylindrical shape, and which optionally includes a shoulder 351 and an inset chamber wall portion 352 formatting with the lower housing 303 so that the shoulder 351 seats upon the upper surface of the reservoir wall 313 of the lower housing 303 and so that the inset chamber wall portion 352 extends into the cavity of the lower housing 303 defined by the reservoir wall 313 , FIGS. 23-25 . Also defining the nebulization chamber 334 is the impactor 309 , which may be provided as a straight wall that spans the cylindrical space defined by the chamber wall 350 . A chamber opening 329 is provided in the nebulization chamber wall 350 through which the nebulizer tube 301 , 501 extends, FIGS. 23 , 26 . (As described more fully below the nebulizer tubes of the present invention can include multiple channels, such as the three-channel nebulizer tube 501 depicted in FIGS. 26-28 .) As with the nebulizer configurations illustrated in FIGS. 1-19 , the upper and lower housings 302 , 303 may include analogous positioning features for registering the nebulizer tube 301 , 501 relative to the upper and lower housings 302 , 303 , such as alignment boss 321 and complementary positioning feature 311 , for example. The chamber opening 329 is dimensioned to be sufficiently large so that with the nebulizer tube 301 , 501 in place a passageway is provided to allow the nebulized mist to exit the nebulization chamber 334 through the chamber opening 329 . This geometry of the upper and lower housings 302 , 303 is designed to provide a tortuous passageway to reverse and otherwise redirect the flow through the nebulizer 300 , FIG. 27 . In this regard, the tortuous passageway may comprise a first section for directing the flow, “F”, of nebulized medication away from the outlet end of the gas channel 305 at nozzle 314 and back towards the direction of the inlet end 341 of the gas channel 305 and may comprise a second section for directing the flow, “F”, of nebulized medication to the exit port 310 of the nebulizer 300 .
[0078] Specifically, with reference to FIG. 27 , the reverse flow geometry functions as follows. The mixture containing air and medication is directed through the nebulizer tube 301 , 501 and exits the nebulizer tube 301 , 501 striking the impactor 309 . Since there is no immediate forward path toward the exit port 10 within the nebulization chamber 334 , the nebulized mist is redirected out of the nebulization chamber 334 through the chamber opening 329 towards the rear of the nebulizer 300 . By reversing the direction of the flow, particle size filtering occurs. Smaller particles that are able to quickly change direction will successfully exit the nebulization chamber 334 . However, larger particles will impact upon the internal surface of the nebulization chamber 334 and will be recycled. The larger particles may then run down the internal surface of the chamber wall 350 to be deposited in the reservoir 307 so as to create a scavenging flow to minimize medication residuals. Upon exiting the chamber opening 329 , since there is no exit port at the rear of the nebulizer 300 , the flow of mist must again reverse direction in the direction of the exit port 310 to be emitted from the nebulizer 300 . The redirection effectively serves as a particle size filter to ensure that therapeutic particles are emitted from the nebulizer 300 . Additionally, to assist in diffusion of the nebulized flow as it exits the nebulizer 300 , a taper 330 may be provided on the exterior of the nebulization chamber 334 in the form of an airfoil to diffuse the flow as the flow nears the exit port 310 . The taper 330 also reduces the velocity, turbulence, and backpressure of the air and mist as it exits the nebulizer 300 .
[0079] To further assist in directing airflow through the nebulizer to the patient, upper and lower housings 402 , 403 may be provided which have a geometry that includes a flow path for external air to be drawn in by the patient, FIGS. 36 , 37 . In this regard, the upper and lower housings 402 , 403 may be open at the end 412 opposite that of the exit port 410 , and make-up air curtain walls 470 , 474 may be included in the upper and lower housings 402 , 403 provide make-up (or bypass) air passageways 472 , 476 through the body of the housings 402 , 403 , allowing air to be drawn directly from the inlet end 412 through to the exit port 410 .
[0080] Each of the nebulizer configurations discussed so far may also utilize multi-channel nebulizer tubes 401 , 501 , rather than a single channel nebulizer tube 1 , 201 , 301 , to reduce the treatment time. For example, as shown in FIGS. 26-33 , the nebulizer 300 may utilize a two- or three-channel nebulizer tube 401 , 501 instead of the single-channel nebulizer tube 301 . The inlet gas channel 405 , 505 may be split downstream into two or three outlets 427 , 527 . Each of the outlet 527 may be fed by a separate liquid feed channel 506 , FIG. 29 . Experiments have shown that a multi-channel nebulizer tube configuration can decrease the time required to nebulize a given volume of liquid, thus minimizing the time needed to treat a patient.
[0081] In addition, still further configurations of nebulizers and nebulizer tubes are provided by the present invention. For instance, with reference to FIGS. 47-48 , a nebulizer tube 801 is provided, that may include similar structures to those of the nebulizer tube 1 of FIGS. 11-12 , such as, an air baffle 20 , an alignment boss 821 , a barb 818 , and a flange 819 . In addition, the nebulizer tube 801 includes a gas channel 805 that may be provided in the form of a convergent channel 805 that has a cross-sectional dimension that decreases from the air inlet end 841 towards the opposing outlet end 842 which terminates at outlet nozzle 811 . However, the nebulizer tube 801 includes an annular medication exit port 808 disposed in liquid communication with the liquid feed channel 806 through which liquid medication may be provided to the output end 842 of the nebulizer tube 801 . The liquid feed channel 806 may have a generally rectangular or circular cross-sectional shape and have a cross-sectional dimension of 30-90 mils. The nebulizer tube 801 is disposed within the housing which may have upper and lower housing portions 802 , 803 and which includes an impactor 809 proximate the outlet nozzle 811 and a reservoir 807 disposed in fluid communication with the feed channel 806 , FIGS. 49-51 .
[0082] In operation, a high pressure gas (typically air) enters the nebulizer tube 801 through the inlet end 841 and is accelerated to sonic velocity. The air expands as it leaves the nozzle 811 . Since the feed channel 806 is in communication with a reservoir 811 of liquid (typically medication), under the proper conditions, liquid medication is siphoned through the feed channel 806 and exits the nebulizer tube 801 via annular medication exit port 808 . Whether siphoning occurs depends on the spacing between the exterior face of the nozzle 811 and the impactor 809 . Provided that the spacing between the exterior face of the nozzle 811 and the impactor 809 is sufficiently small (for example, 20 to 80 mils, with 30 mils representing a preferred spacing), a low-pressure air zone will be formed proximal to the annular medication exit port 808 . This creates a pressure differential across the liquid that will siphon fluid from the reservoir 807 and direct it towards the impactor 809 . The energy imparted to the liquid from the gas, as well as the impaction on the impactor 809 , generates fine particles from the liquid.
[0083] Further, alternative impactor structures in addition to the spherical impactor 809 of FIGS. 49-51 may be used in the present invention. For example, a cylindrical impactor 819 provided as part of an upper housing 812 , FIGS. 52-53 , or a mesa-shaped impactor 829 provided as part of an upper housing 822 , FIGS. 54-55 , may be used to increase the efficiency of the nebulization process. The mesa-shaped impactor 829 has been demonstrated to yield a relatively-high nebulization efficiency. It is believed that the turbulence that is generated as the air flow detaches from the circular edge of the mesa enhances efficiency. The flat surface of the mesa may be roughened to further enhance nebulization. Additionally, it is observed that the impaction surface of the mesa may be flat, convex, concave, or some other non-planar structure. The edges of the mesa may incorporate jagged features to further enhance efficiency. In addition, a ring feature 840 may be added about a mesa 839 to facilitate the creation of a resonant annular channel 841 in the housing 832 , FIGS. 56-57 . The fundamental resonant frequency of the annular channel 841 may be tuned to help generate particles of a preferred size. Also, the ring 840 can create more turbulence to increase efficiencies. Moreover, each of the impactor configurations illustrated in FIGS. 49-57 may be used with any of the other nebulizer and/or nebulizer tube configurations described herein.
[0084] In yet another aspect of the present invention, a nebulizer configuration is provided in which the nebulizer body comprises only two parts, with the nebulizer tube 601 monolithically formed as a part of either the upper or the lower housing 602 , 603 , FIG. 38 . Specifically, with reference to FIGS. 38-46 a nebulizer configuration in accordance with the present invention is shown in which the nebulizer tube 601 is formed as a part of the upper housing 602 . As such, the nebulizer 600 may desirably include only two parts, the upper housing 602 and lower housing 603 . However, as with the various nebulizer configurations 100 , 200 , 300 described above, one or more semi-permeable membranes (or filters) may additionally be provided at the exit port 610 to permit mist flow while acting as an effective liquid barrier to create a safety feature that prevents the user from swallowing liquid medication contained in the nebulizer 600 . A sponge-like (or other absorbent) material may be incorporated into the nebulizer 600 as an alternative manner to obtain this feature. In the event that the nebulizer 600 is tilted beyond a critical angle during use, the membrane will block the flow of medication into the user's mouth.
[0085] The upper housing 602 may include a “living hinge” 622 that allows the impactor half of the upper housing 602 to open as a lid 620 to permit the introduction of liquid medication into a reservoir 607 of the lower housing 603 , FIG. 39 . FIG. 43 shows the upper housing 602 after the living hinge 622 is flexed into its closed functioning orientation. To assist in maintaining the liquid medication in the reservoir 607 , a medication retention flange 614 that extends over the reservoir 607 proximate the exit port 610 is provided as a part of the lower housing 603 to prevent medication from flowing out of the reservoir 607 and into the user's mouth, FIGS. 45 , 46 . The medication retention flange 614 allows the user to be inclined in bed or reclining while using this device. The reservoir 607 may be shaped to make the liquid medication available to the inlet end of the feed tube 606 of the nebulizer tube 601 . For example, the reservoir 607 may be generally V-shaped and may include a trough 611 into which the liquid medication can pool and over which the inlet end of the feed tube 606 may be positioned to receive the pooled medication, FIG. 41 . The lower end of the feed tube 606 may meet with the geometry of the reservoir 607 in the lower housing 603 such that medication in the reservoir 607 is wicked to the bottom of the feed tube 606 so that nearly all the medication can be siphoned into the air stream. (The feed tube 606 is the only feature that requires “side-action” to form the geometry.) The flat sloping walls that form the reservoir 607 allow the medication to be fully consumed even when the user is reclined at a significant angle.
[0086] The integral nebulizer tube 601 may also include a convergent channel 605 through which compressed air is introduced to the nebulizer 600 . The air accelerates until it reaches the throat 643 (minimum cross-sectional area) of the tube. By virtue of the Bernoulli effect, as the flow velocity increases, its static pressure will decrease. As a result, the static pressure at the throat 643 of the nebulizer tube 601 is below that of the local atmospheric pressure. Since the static pressure of the liquid is higher than the static pressure at the throat 643 of the nebulizer tube 601 , liquid is siphoned upward as a result of this Venturi effect. Subsequent to siphoning, the liquid/air mixture is rapidly expanded in the divergent section of a nozzle 608 of the nebulizer tube 601 . This rapid expansion encourages turbulent mixing and creates an effective first-level of nebulization. After exiting the nozzle 608 , the mixture strikes an impactor 609 which is also monolithic to the upper housing 602 , FIGS. 41 , 42 , 44 . This energetic collision generates the very fine, therapeutic particles required of nebulizers. Because the nozzle 608 and impactor 609 are both monolithic to the upper housing 602 through the living hinge 622 , the spacing between the nozzle 608 and the impactor 609 is very repeatable, FIGS. 42 , 44 . A sufficiently small spacing between the nozzle 608 and the impactor 609 is required for fine mist generation, which may be, for example, about 30 thousandths of an inch.
[0087] As with the nebulizer configuration of FIG. 22 , the nebulizer 600 may also include the “reverse flow” feature. Referring to FIG. 42 , the reverse flow feature is illustrated where the mixture of air and nebulized medication (indicated by the lines with arrowheads), after hitting the impactor 609 , is forced to flow back away from the exit port 610 , then change direction to exit the nebulizer 600 at the exit port 610 . In this regard, as with the nebulizer 300 , the nebulizer 600 includes a nebulization chamber 634 defined and surrounded by chamber walls 650 that assist in defining the flow path of the mixture of air and nebulized medication. The change of flow direction acts as a filter, removing large droplets of medication from the air stream. The desired small airborne particles change direction with the air stream, while the larger particles with significantly more inertia do not readily change direction and impact the chamber walls or fall out of the air stream to head downward into the reservoir 607 to be reused.
[0088] In addition, the nebulizer 600 may also include one or more make-up air channels 672 , which may be provided as a monolithic part of the upper housing 602 , FIGS. 42 , 43 . The make-up air channels 672 allow the user to inhale or even exhale while using the nebulizer 600 . The end 674 of the channel 672 inside the nebulizer 600 is positioned in the air stream such that the natural flow of the air stream will draw air into the nebulizer 600 rather than allowing nebulized medication to exit the make-up air channels 672 to the room. Furthermore, as with the various nebulizer configurations discussed above, the two-piece nebulizer 600 may make use of a nebulizer tube 701 that has more than one convergent/divergent gas channel and nozzle 708 , FIG. 40 . The inclusion of more than one gas channel can be achieved without significantly increasing the complexity of the mold tooling, which may be desirable because multiple gas channels can significantly reduce the time required to nebulize a certain amount of medication by drawing more medication through multiple feed tubes for mixing with high velocity air in multiple divergent nozzles 708 .
[0089] The various nebulizer configurations presented above may have a compact size permitting the nebulizers to substantially fit within the user's mouth which contributes to minimizing the amount of residual medication. The compact size is not just a matter of design choice—it has an effect on all other aspects of the nebulizer's functionality. A higher nebulization rate, within a small volume, can have negative aspects. For example, there can be interaction between the multiple jets leading to an increased probability of particle agglomeration to a size larger than that desired for effective patient treatment. However, there can be substantial benefits of making the nebulizer very compact, such as high efficiency use of the medication, which is partially dependent upon having a compact nebulizer. A compact nebulizer has a smaller wettable surface area. Thus, the inner surfaces of the nebulizer will hold less residual medicine. The location and geometry of the liquid reservoir and intake, together with the gas flow path, are also important factors affecting the amount of residual. Thus, the designs strike a balance between nebulization rate and compactness.
[0090] These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification. Accordingly, it will be recognized by those skilled in the art that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the invention. It should therefore be understood that this invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications that are within the scope and spirit of the invention as set forth in the claims. | The present invention relates generally to a nebulizer, and more particularly but not exclusively to a compact nebulizer that efficiently utilizes medication. | 0 |
STATUS OF RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Ser. No. 10/411,672, filed on Apr. 11, 2003, now U.S. Pat. No. 7,361,376, the contents hereby incorporated by reference as if set forth in its entirety.
FIELD OF THE INVENTION
Alkamide compounds having umami taste and somatosensory attributes in the oral cavity.
BACKGROUND OF THE INVENTION
The term Umami, from the Japanese word to describe savory or meaty, is the term used to describe the unique overall fullness, savory or salivatory taste of food. Materials that exhibit this taste quality generally potentiate the intensity of glutamate solutions and this is one important characteristic of umami taste. It is increasingly becoming recognized as the fifth sense of taste, the others being sour, sweet, salt and bitter. Compounds traditionally described as possessing this character are monosodium glutamate (MSG), protein hydrolysates, some amino acids and certain nucleotides and phosphates.
MSG is the most widely used material as a ‘taste enhancer’ where it synergizes the perception of ‘savory’ ingredients, but has also been alleged to cause allergic reaction to a proportion of the population. Since MSG is widely used in Asian cuisine, especially Chinese, this has been referred to as the Chinese Restaurant Syndrome. Free glutamic acid occurs in food but this also is the subject of review by The Federation of American Society for Experimental Biology.
Among other chemical compounds several nucleotides have also been described to exhibit the umami effect Adenosine 5′-(trihydrogen diphosphate), 5′-Cytidylic acid (5′-CMP), 5′-Uridylic acid (5′-UMP), 5′-Adenylic acid (5′-AMP), 5′-Guanylic acid (5′-GMP), 5′-Inosinic acid (5′-IMP) and the di-sodium salts of 5′-Guanylic acid and 5′-Inosinic acid.
Recent literature cites an extensive range of other organic compounds as taste active components of mixtures shown to give the umami taste effect. These include but are not necessarily limited to: organic acids such as succinic acid, lactic acid, saturated straight chain aliphatic acids of six, eight, fourteen, fifteen, sixteen, and seventeen carbon chain lengths, Z4,Z7, Z10,Z13,Z16,Z19-docosahexaenoic acid, Z5,Z8,Z11,Z14,Z17-eicosapentaenoic acid, Z9,Z12,Z16,Z19-octadecadienoic acid, Z9-octadecenoic acid, glutaric acid, adipic acid, suberic acid, and malonic acid. Amino acids having umami effects reported in the literature include glutamic acid, aspartic acid, threonine, alanine, valine, histidine, proline tyrosine, cystine, methionine, pyroglutamic acid, leucine, lycine, and glycine. Dipeptides possessing umami properties include Val-Glu and Glu-Asp.
Other miscellaneous compounds having umami properties include alpha-amino adipic acid, malic acid, alpha-aminobutyric acid, alpha-aminoisobutyric acid, E2,E4-hexadienal, E2,E4-heptadienal, E2,E4-octadienal, E2,E4-decadienal, Z4-heptenal, E2,Z6-nonadienal, methional, E3,E5-octadien-2-one, 1,6-hexanediamine, tetramethylpyrazine, trimethylpyrazine, cis-6-dodecen-4-olide and a number of naturally occurring amino-acids.
The discovery of alkyldienamides in a wide variety of botanicals and the use of some of these to impart flavor and/or a sensation is the subject of a huge amount of literature. Molecules of this type have also been found to exhibit biological activity, most notably anti-bacterial, anti-fungal and insecticidal activity. The most significant compounds in this class, provided with their Chemical Abstract Service number in brackets are: hydroxy-alpha-sanshool [83883-10-7], alpha-sanshool [504-97-2], hydroxy-epislon-sanshool [252193-26-3], gamma-sanshool [78886-65-4], spilanthol [25394-57-4], N-isobutyl E2,E4,8,11-dodecatetraenamide [117824-00-7 and 310461-34-8], isoaffinin [52657-13-3], pellitorine [18836-52-7] and bunganool [117568-40-8] along with a small number of geometrical isomers thereof.
Despite these disclosures there is an ongoing need for new flavor ingredients particularly those that exhibit advantageous organoleptic properties.
SUMMARY OF THE INVENTION
Our invention relates to novel compounds and a process for augmenting or imparting a taste or somatosensory effect to a foodstuff, chewing gum, medicinal product, toothpaste, alcoholic beverage, aqueous beverage or soup comprising the step of adding to a foodstuff, chewing gum, medicinal product, toothpaste, alcoholic beverage, aqueous beverage or soup a taste or sensation augmenting, enhancing or imparting quantity and concentration of at least one N-substituted unsaturated aliphatic alkyl amide defined according to the structure:
where X is selected from the group consisting of H, methyl, ethyl, n-propyl, and isopropyl;
Y is selected from the group consisting of methyl, ethyl, cyclopropyl, isopropyl, n-propyl, n-butyl, sec-butyl, isobutyl, 2-methylbutyl, allyl, cyclobutyl,
cyclopentyl, CH 2 CH(OH)CH 3 , CH(CH 3 )CH 2 OH, CH 2 C(CH 3 )OH, CH 2 CH 2 OH, CH 2 CO 2 CH 3 , geranyl, neryl;
or X and Y together form the structures:
R 3 is selected from the group consisting of methyl and H;
R 4 is selected from the group consisting of methyl and H;
R 5 is selected from the group consisting of methyl, phenyl, benzyl, ethyl, propyl, butyl, isopropyl, phenylethyl,
In a highly preferred embodiment of the invention the amides have the structure set forth below:
wherein R is methyl, ethyl, n-propyl, isopropyl, cyclopropyl, n-butyl, sec-butyl, isobutyl, cyclobutyl, CH 2 CH(CH 3 )CH 2 CH 3 , CH 2 CH(OH)CH 3 , CH(CH 3 )CH 2 OH, CH 2 C(CH 3 ) 2 OH, CH 2 CH 2 OH,
cyclopentyl or allyl; and wherein R′ is methyl, ethyl, n-propyl, n-butyl or n-pentyl and n-hexyl. As used herein these compounds will be referred to hereinafter as “alkyldienamides”.
DETAILED DESCRIPTION OF THE INVENTION
Our invention specifically relates to the novel compositions according to the formulae above, which have been described as having the following flavor characteristics:
Primary Secondary R R′ Compound characteristic characteristic CH 2 CH 2 OH n- N-(2-hydroxyethyl) E2, Z6- Tingle, melon Pepper like butyl dodecadienamide flavor warmth CH 2 CH(CH 3 )CH 2 n- N-(2-methylbutyl) E2, Z6- Fruity Salt like CH 3 butyl dodecadienamide Me N-(3,4-methylenedioxy) benzyl E2, Z6-nonadienamide Numbing Tingle CH 2 CH(CH 3 )CH 2 Me N-(2-methylbutyl) E2, Z6- Bitter Tingle CH 3 nonadienamide cyclopropyl n- N-cyclopropyl E2, Z6- Fatty Wasabi type butyl dodecadienamide mouthfeel burn cyclopropyl Me N-cyclopropyl E2, Z6- Umami Enhancement nonadienamide ethyl n- N-ethyl E2, Z6- MSG like Burning butyl dodecadienamide ethyl Me N-ethyl E2, Z6- Umami Enhancement nonadienamide isobutyl n- N-isobutyl E2, Z6- Numbing Tingle butyl dodecadienamide isobutyl Me N-isobutyl E2, Z6- Tingle/ MSG like nonadienamide numbing isopropyl n- N-isopropyl E2, Z6- Melon/cucumber Tingle butyl dodecadienamide Flavor isopropyl Me N-isopropyl E2, Z6- Cucumber taste Tingle nonadienamide Me Me N-methyl E2, Z6- Tingle Numbing nonadienamide
and uses thereof in augmenting or imparting an olfactory effect or sensation such as a taste or somatosensory effect to a foodstuff, chewing gum, medicinal product, toothpaste, alcoholic beverage, aqueous beverage or soup particularly providing a (a) umami taste, (b) tingle sensation, (c) warming/burning sensation, (d) numbing sensation, (e) cooling sensation and (f) salt effects.
More specifically, examples of the organoleptic properties for the alkyldienamides of our invention are as follows:
Compound
Taste and flavor characteristics
N-(2-hydroxypropyl) E2,Z6-
Cloying, fatty, cod liver oil, fishy.
nonadienamide
N-(2-hydroxyethyl) E2,Z6-
Strong melon flavor, tingle,
dodecadienamide
burn, pepper taste.
N-(2-methylbutyl) E2,Z6-
Slightly fruity, tingle, salty.
dodecadienamide
N-(3,4-methylenedioxy) benzyl
Numbing and tingle.
E2,Z6-nonadienamide
N-(2-methylbutyl) E2,Z6-
Metallic, bitter, tingle.
nonadienamide
N-cyclopropyl E2,Z6-
Fatty mouthfeel, tongue
dodecadienamide
burn, Wasabi like.
N-cyclopropyl E2,
Oily, tingle, strong
Z6-nonadienamide
MSG/umami mouthfeel.
N-ethyl E2,Z6-dodecadienamide
Burn, MSG effect, oily flavor, green
celery, sweet heating.
N-ethyl E2,Z6-nonadienamide
Umami character.
N-isobutyl E2,
Some tingle, anesthetic, numbing effect,
Z6-dodecadienamide
interesting cooling/tingle effect, long
lasting. The aftertaste is cooling and
refreshing.
N-isobutyl E2,
Strong tingle very long lasting, mint,
Z6-nonadienamide
oily, fizzy, tongue numbing, some MSG
effect.
N-isopropyl E2,
Oily flavor, slight tingle.
Z6-dodecadienamide
N-isopropyl E2,
Oily, cucumber, some tingle, bitter.
Z6-nonadienamide
N-methyl E2,Z6-nonadienamide
Warming, tingle.
Other compounds of the present invention include the following:
Name
Structure
N-ethyl 3-(cyclohex-3-en-1-yl) E2- propenamide
N-cyclopropyl 3-(cyclohex-3-en-1-yl) E2-propenamide
N-ethyl-4-(2,2,3-trimethylcyclopent- 3-en-1-yl) E2-butenamide
N-cyclopropyl-4-(2,2,3- trimethylcyclopent-3-en-1-yl) E2- butenamide
N-isopropyl E2, Z6-nonadienamide
N-ethyl E2, Z6-nonadienamide
N-methyl E2, Z6-nonadienamide
N-isobutyl E2, Z6-nonadienamide
N-(2-methylbutyl) E2, Z6- nonadienamide
N-cyclopropyl E2, Z6-nonadienamide
N-(2-hydroxypropyl) E2, Z6- nonadienamide
N-(3,4-methylenedioxy) benzyl E2, Z6- nonadienamide
N-allyl E2, Z6-nonadienamide
N-(carboxymethyl)methyl E2, Z6- nonadienamide
N,N-dimethyl E2, Z6-nonadienamide
N-methyl E2, Z6-dodecadienamide
N-ethyl E2, Z6-dodecadienamide
N-cyclopropyl E2, Z6-dodecadienamide
N-isopropyl E2, Z6-dodecadienamide
N-isobutyl E2, Z6-dodecadienamide
N-(2-hydroxyethyl) E2, Z6- dodecadienamide
N-(2-methylbutyl) E2, Z6- dodecadienamide
N-isobutyl 3,4-(dioxymethylene) cinnamide
Piperidyl 3,4-(dioxymethylene) cinnamide
N,N-diisopropyl 3-methyl-2- hexenamide
N,N-dimethyl 3,7-dimethyl-2,6- octadienamide
N-ethyl 5-phenyl-E2-pentenamide
N,N-ethyl 3,7-dimethyl-2,6- octadienamide
N-ethyl 5-phenyl-E2-pentenamide
The literature has not previously reported alkyldienamides having umami flavor. In addition, closely structurally related compounds such as dienals and unsaturated acids, are not specifically reported to possess umami character when tasted in isolation. In addition the ability to provide an enhanced saltiness for the product without increasing sodium level is not disclosed or suggested by the prior art. The salt enhancing properties of the compounds of the present invention are important because it allows flavorists to provide the desired salty taste profile in foods and beverages without actually having higher salt levels in the food. Therefore the consumer can have both the taste profile that they desire while without having the adverse health effects associated with increased salt levels such as hypertension.
As used herein olfactory effective amount is understood to mean the amount of compound in flavor compositions the individual component will contribute to its particular olfactory characteristics, but the flavor, taste and aroma effect on the overall composition will be the sum of the effects of each of the flavor ingredients. As used herein taste effects include salt and umami, effects. Thus the compounds of the invention can be used to alter the taste characteristics of the flavor composition by modifying the taste reaction contributed by another ingredient in the composition. The amount will vary depending on many factors including other ingredients, their relative amounts and the effect that is desired.
The level of alkyldienamides used in products is greater than 50 parts per billion, generally provided at a level of from about 50 parts per billion to about 800 parts per million in the finished product, more preferably from about 10 parts per million to about 500 parts per million by weight.
The usage level of alkyldienamides varies depending on the product in which the alkyldienamides are employed. For example, alcoholic beverages the usage level is from about 1 to about 50 parts per million, preferably from about 5 to about 30 and most preferably from about 10 to about 25 parts per million by weight. Non-alcoholic beverages are flavored at levels of from about 50 parts per billion to about 5 parts per million, preferably from about 200 parts per billion to about 1 part per million and in highly preferred situations of from about 300 to about 800 parts per billion. Snack foods can be advantageously flavored using alkyldienamides of the present invention at levels of from about 10 to about 250 parts per million, preferably from about 50 to about 200 and most preferably from about 75 to about 150 parts per million by weight.
Toothpaste can be satisfactorily flavored by using alkyldienamides at levels of from about 150 to about 500 parts per million, more preferably from about 200 to about 400 parts per million by weight.
Candy products including hard candy can be flavored at levels of from about 10 to about 200; preferably from about 25 to about 150 and more preferably from 50 to 100 parts per million by weight. Gum usage levels are from about 300 to about 800, preferably from about 450 to about 600 parts per million.
The present invention also provides a method for enhancing or modifying the salt flavor of a food through the incorporation of an organoleptically acceptable level of the compounds described herein. The compounds can be used individually or in combination with other salt enhancing compounds of the present invention. In addition, the salt enhancing materials of the present invention can be used in combination with other salt enhancing compositions known in the art, including but not limited to cetylpyridium chloride, bretylium tosylate, various polypeptides, mixtures of calcium salts of ascorbic acid, sodium chloride and potassium chloride, as described in various U.S. Pat. Nos. 4,997,672; 5,288,510; 6,541,050 and U.S. Patent Application 2003/0091721.
The salt taste enhancing compounds of the present invention may be employed to enhance the perceived salt taste of any salts used in food or beverage products. The preferred salt taste to be enhanced by the compounds of the present invention is that of sodium chloride, primarily because of the discovery that ingestion of large amounts of sodium may have adverse effects on humans and the resultant desirability of reducing salt content while retaining salt taste.
In addition, the compounds of the present invention may also be employed to enhance the perceived salt taste of known salty tasting compounds which may be used as salt substitutes. Such compounds include cationic amino acids and low molecular weight dipeptides. Specific examples of these compounds are arginine, hydrochloride, lysine hydrochloride and lysine-ornithine hydrochloride. These compounds exhibit a salty taste but are typically useful only at low concentrations since they exhibit a bitter flavor at higher concentrations. Thus, it is feasible to reduce the sodium chloride content of a food or beverage product by first formulating a food or beverage with less sodium chloride than is necessary to achieve a desired salt taste and then adding to said food or beverage the compounds of the present invention in an amount sufficient to potentiate the salt taste of said salted food or beverage to reach said desired taste. In addition, the sodium chloride content may be further reduced by substituting a salty-tasting cationic amino acid, a low molecular weight dipeptide or mixtures thereof for at least a portion of the salt.
The salt enhancing level of the compounds of the present invention range from about 100 parts per billion to about 100 parts per million; preferably from about 0.1 parts per million to about 50 parts per million; and most preferably from about 0.5 parts per million to about 10 parts per million when incorporated into the foodstuff.
The term “foodstuff” as used herein includes both solid and liquid ingestible materials for man or animals, which materials usually do, but need not, have nutritional value. Thus, foodstuffs include food products, such as, meats, gravies, soups, convenience foods, malt, alcoholic and other beverages, milk and dairy products, seafood, including fish, crustaceans, mollusks and the like, candies, vegetables, cereals, soft drinks, snacks, dog and cat foods, other veterinary products and the like.
When the alkyldienamides compounds of this invention are used in a flavoring composition, they can be combined with conventional flavoring materials or adjuvants. Such co-ingredients or flavor adjuvants are well known in the art for such use and have been extensively described in the literature. Requirements of such adjuvant materials are: (1) that they be non-reactive with the alkyldienamides of our invention; (2) that they be organoleptically compatible with the alkyldienamides derivative(s) of our invention whereby the flavor of the ultimate consumable material to which the alkyldienamides are added is not detrimentally affected by the use of the adjuvant; and (3) that they be ingestible acceptable and thus nontoxic or otherwise non-deleterious. Apart from these requirements, conventional materials can be used and broadly include other flavor materials, vehicles, stabilizers, thickeners, surface active agents, conditioners and flavor intensifiers.
Such conventional flavoring materials include saturated fatty acids, unsaturated fatty acids and amino acids; alcohols including primary and secondary alcohols, esters, carbonyl compounds including ketones, other than the alkyldienamides of our invention and aldehydes; lactones; other cyclic organic materials including benzene derivatives, acyclic compounds, heterocyclics such as furans, pyridines, pyrazines and the like; sulfur-containing compounds including thiols, sulfides, disulfides and the like; proteins; lipids, carbohydrates; so-called flavor potentiators such as monosodium glutamate; magnesium glutamate, calcium glutamate, guanylates and inosinates; natural flavoring materials such as hydrolyzates, cocoa, vanilla and caramel; essential oils and extracts such as anise oil, clove oil and the like and artificial flavoring materials such as vanillin, ethyl vanillin and the like.
Specific preferred flavor adjuvants include but are not limited to the following: anise oil; ethyl-2-methyl butyrate; vanillin; cis-3-heptenol; cis-3-hexenol; trans-2-heptenal; butyl valerate; 2,3-diethyl pyrazine; methyl cyclo-pentenolone; benzaldehyde; valerian oil; 3,4-dimethoxy-phenol; amyl acetate; amyl cinnamate; γ-butyryl lactone; furfural; trimethyl pyrazine; phenyl acetic acid; isovaleraldehyde; ethyl maltol; ethyl vanillin; ethyl valerate; ethyl butyrate; cocoa extract; coffee extract; peppermint oil; spearmint oil; clove oil; anethol; cardamom oil; wintergreen oil; cinnamic aldehyde; ethyl-2-methyl valerate; γ-hexenyl lactone; 2,4-decadienal; 2,4-heptadienal; methyl thiazole alcohol (4-methyl-5-β-hydroxyethyl thiazole); 2-methyl butanethiol; 4-mercapto-2-butanone; 3-mercapto-2-pentanone; 1-mercapto-2-propane; benzaldehyde; furfural; furfuryl alcohol; 2-mercapto propionic acid; alkyl pyrazine; methyl pyrazine; 2-ethyl-3-methyl pyrazine; tetramethyl pyrazine; polysulfides; dipropyl disulfide; methyl benzyl disulfide; alkyl thiophene; 2,3-dimethyl thiophene; 5-methyl furfural; acetyl furan; 2,4-decadienal; guiacol; phenyl acetaldehyde; β-decalactone; d-limonene; acetoin; amyl acetate; maltol; ethyl butyrate; levulinic acid; piperonal; ethyl acetate; n-octanal; n-pentanal; n-hexanal; diacetyl; monosodium glutamate; mono-potassium glutamate; sulfur-containing amino acids, e.g., cysteine; hydrolyzed vegetable protein; 2-methylfuran-3-thiol; 2-methyldihydrofuran-3-thiol; 2,5-dimethylfuran-3-thiol; hydrolyzed fish protein; tetramethyl pyrazine; propylpropenyl disulfide; propylpropenyl trisulfide; diallyl disulfide; diallyl trisulfide; dipropenyl disulfide; dipropenyl trisulfide; 4-methyl-2-[(methylthio)-ethyl]-1,3-dithiolane; 4,5-dimethyl-2-(methylthiomethyl)-1,3-dithiolane; and 4-methyl-2-(methylthiomethyl)-1,3-dithiolane. These and other flavor ingredients are provided in U.S. Pat. Nos. 6,110,520 and 6,333,180.
The alkyldienamides derivative(s) of our invention or compositions incorporating them, as mentioned above, can be combined with one or more vehicles or carriers for adding them to the particular product. Vehicles can be edible or otherwise suitable materials such as ethyl alcohol, propylene glycol, water and the like, as described above. Carriers include materials such as gum arabic, carrageenan, xanthan gum, guar gum and the like.
Alkyldienamides prepared according to our invention can be incorporated with the carriers by conventional means such as spray-drying, extrusion, drum-drying and the like. Such carriers can also include materials for coacervating the alkyldienamides of our invention to provide encapsulated products, as set forth above. When the carrier is an emulsion, the flavoring composition can also contain emulsifiers such as mono- and diglycerides or fatty acids and the like. With these carriers or vehicles, the desired physical form of the compositions can be prepared.
The quantity of alkyldienamides utilized should be sufficient to impart the desired flavor characteristic to the product, but on the other hand, the use of an excessive amount of alkyldienamides is not only wasteful and uneconomical, but in some instances, too large a quantity may unbalance the flavor or other organoleptic properties of the product consumed. The quantity used will vary depending upon the ultimate foodstuff; the amount and type of flavor initially present in the foodstuff; the further process or treatment steps to which the foodstuff will be subjected; regional and other preference factors; the type of storage, if any, to which the product will be subjected; and the preconsumption treatment such as baking, frying and so on, given to the product by the ultimate consumer. Accordingly, the terminology “effective amount” and “sufficient amount” is understood in the context of the present invention to be quantitatively adequate to alter the flavor of the foodstuff.
With reference to the novel compounds of our invention, the synthesis is effected by means of the reaction of acid with ethyl chloroformate in the presence of triethylamine and further reaction of the intermediate with amine (added either directly or in solution) according to the general scheme:
More specifically, with reference to the novel compounds of our invention, the synthesis is effected by means of the reaction of Z4-aldehydes with malonic acid under pyridine catalysis to furnish the known E2,Z6-acids. Subsequent reaction with ethyl chloroformate in the presence of triethylamine and further reaction of the intermediate with amine (added either directly or in solution) according to the scheme:
as set forth in examples herein. The acid is dissolved in dichloromethane to which ethylchloroformate is added in 1.0 to 2.0 equivalents at temperatures ranging from 0° C. to room temperature, most preferably from 10° C. to 20° C. The resulting solution is cooled to −10° C. to −30° C., and triethylamine is added in 1.0 to 2.0 equivalents such that the temperature range is below 0° C. and the mixture aged for 1 hour.
The mixture is filtered, and the filtrate cooled to 0° C. The amine is added in 1.0 to 7.0 equivalents either neat or as a solution in THF and the reaction is aged for about 1-3 hours at room temperature.
The reaction can be quenched with aqueous sodium chloride, hydrogen chloride or sodium hydroxide depending upon the need to remove residual acid or amine. The mixture is extracted into ethereal solvent or dichloromethane, washed to neutrality and solvent removed.
The crude product is purified by distillation or recrystallization depending on the physical properties.
The reaction occurs in 35-75% mole yield based on E2,Z6-acid.
The alkyldienamides of the present invention can be admixed with other flavoring agents and incorporated into foodstuffs and other products using techniques well known to those with ordinary skill in the art. Most commonly the alkyldienamides are simply admixed using the desired ingredients within the proportions stated.
The following are provided as specific embodiments of the present invention. Other modifications of this invention will be readily apparent to those skilled in the art, without departing from the scope of this invention. As used herein, both specification and following examples all percentages are weight percent unless noted to the contrary.
All U.S. patents and U.S. patent applications cited herein are incorporated by reference as if set forth in their entirety.
EXAMPLE 1
Preparation of Materials of the Present Invention
The following reaction sequence was used to prepare the specific compounds described by the NMR data set forth below:
The acid is dissolved in dichloromethane to which ethylchloroformate is added in 1.0 to 2.0 equivalents at temperatures ranging from 0° C. to room temperature, most preferably from 10° C. to 20° C. The resulting solution is cooled to −10° C. to −30° C., and triethylamine is added in 1.0 to 2.0 equivalents such that the temperature range is below 0° C. and the mixture aged for 1 hour.
The mixture is filtered, and the filtrate cooled to 0° C. The amine is added in 1.0 to 7.0 equivalents either neat or as a solution in THF and the reaction is aged for 1-3 hours at room temperature.
The reaction can be quenched with aqueous sodium chloride, hydrogen chloride or sodium hydroxide depending on the need to remove residual acid or amine. The mixture is extracted into ethereal solvent or dichloromethane, washed to neutrality and solvent removed.
The crude product is purified by distillation or recrystallization depending on the physical properties.
The amides are synthesized according to the general scheme above with the following specific examples. Equivalents set out are mole equivalents based on starting acid, yields are distilled chemical yields based on starting acid.
N-methyl 2E,6Z-nonadienamide
2E,6Z-nonadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, methylamine 1.5 eq as a 2.0M solution in THF, quench with 10% sodium chloride solution, yield=47%.
0.95 ppm (t, 3H, J=7.54 Hz, a), 2.02 ppm (quintet, 2H, J=7.33 Hz), 2.19 ppm (m, 4H, c), 2.78 & 2.85 ppm (d, 3H, J=4.81 & 4.87 Hz), 5.27-5.43 ppm (m, 2H, e), 5.90 ppm (d, 1H, J=15.36 Hz), 6.80 ppm (d, 1H, J=15.33 Hz, of t, J=6.59 Hz, g), 6.80 ppm (m, 1H).
N-ethyl 2E,6Z-nonadienamide
2E,6Z-nonadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, ethylamine 7.0 eq as a 2.0M solution in THF, quench with 10% hydrogen chloride solution, yield=60%.
0.95 ppm (t, 3H, J=7.55 Hz), 1.16 ppm (t, 3H, J=7.27 Hz), 2.03 ppm (quintet, 2H, J=7.31 Hz), 2.20 ppm (m, 4H), 3.35 ppm (quintet, 2H, J=7.04 Hz), 5.27-5.44 ppm (m, 2H), 5.84 ppm (d, 1H, J=15.32 Hz), 6.16 ppm (br. s, 1H), 6.82 ppm (d, 1H, J=15.28 Hz, of t, J=6.51 Hz).
N-ethyl 2E,6Z-dodecadienamide
2E,6Z-dodecadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, ethylamine 7.0 eq as a 2.0M solution in THF, quench with 10% hydrogen chloride solution, yield=65%.
0.89 ppm (t, 3H, J=6.86 Hz), 1.16 ppm (t, 3H, J=7.27 Hz), 1.29 ppm (m, 6H), 2.01 ppm (q, 2H, J=6.79 Hz), 2.20 ppm (m, 4H), 3.35 ppm (m, 2H), 5.30-5.44 ppm (m, 2H), 5.80 ppm (d, 1H, J=15.32 Hz), 5.87 ppm (br. s, 1H), 6.82 ppm (d, 1H, J=15.29 Hz, J=6.61 Hz).
N-isopropyl 2E,6Z-nonadienamide
2E,6Z-nonadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, isopropylamine 3.0 eq, quench with 20% sodium chloride, yield=57%.
0.95 ppm (t, 3H, J=7.53 Hz), 1.17 ppm (d, 6H, J=6.59 Hz), 2.03 ppm (quintet, 2H, J=7.36 Hz), 2.19 ppm (m, 4H), 4.14 ppm (m, 1H), 5.27-5.44 ppm (m, 2H), 5.83 ppm (d, 1H, J=15.30 Hz), 5.99 ppm (br. s, 1H), 6.81 ppm (d, 1H, J=15.27 Hz, J=6.64 Hz).
N-isopropyl 2E,6Z-dodecadienamide
2E,6Z-dodecadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, isopropylamine 3.0 eq, quench with 20% sodium chloride, yield=52%.
0.88 ppm (t, 3H, J=7.53 Hz), 1.18 ppm (d, 6H, J=6.59 Hz),1.29 ppm (m, 6H), 2.02 ppm (q, 2H, J=7.36 Hz), 2.20 ppm (m, 4H), 4.14 ppm (m, 1H), 5.27-5.44 ppm (m, 2H), 5.62 ppm (br. s, 1H), 5.78 ppm (d, 1H, J=15.30 Hz), 6.79 ppm (d, 1H, J=15.27 Hz, of t, J=6.64 Hz).
N-isobutyl 2E,6Z-nonadienamide
2E,6Z-nonadienoic acid 1 eq, ethyl chloroformate 1.2 eq, triethylamine 1.5 eq, isobutylamine 1.0 eq, quench with 10% sodium hydroxide, yield=33%.
0.92 ppm (d, 6H, J=6.74 Hz), 0.95 ppm (t, 3H, J=7.51 Hz), 1.80 ppm (septet, 1H, J=6.73 Hz), 2.03 ppm (quintet, 2H, J=7.27 Hz), 2.20 ppm (m, 4H), 3.14 ppm (t, 2H, J=6.53 Hz), 5.28-5.47 ppm (m, 2H), 5.85 ppm (d, 1H, J=15.29 Hz), 5.88 ppm (br. s, 1H), 6.82 ppm (d, 1H, J=15.27 Hz, of t, J=6.61 Hz,).
N-isobutyl 2E,6Z-dodecadienamide
2E,6Z-dodecadienoic acid 1 eq, ethyl chloroformate 1.2 eq, triethylamine 1.5 eq, isobutylamine 3.0 eq, quench with 10% hydrogen chloride solution, yield=41%.
0.88 ppm (t, 3H, J=6.99 Hz), 0.92 ppm (d, 6H, J=6.70 Hz), 1.29 ppm (m, 6H), 1.80 ppm (m, 1H, J=6.73 Hz), 2.01 ppm (q, 2H, J=6.75 Hz), 2.20 ppm (m, 4H), 3.14 ppm (t, 2H, J=6.47 Hz), 5.30-5.44 ppm (m, 2H), 5.84 ppm (d, 1H, J=15.30 Hz), 5.97 ppm (m, 1H), 6.82 ppm (d, 1H, J=15.28 Hz, of t, J=6.55 Hz).
N-(2-methylbutyl) 2E,6Z-nonadienamide
2E,6Z-nonadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, 2-methylbutylamine 3.0 eq, quench with 20% sodium chloride, yield=37%.
0.90 ppm (d, 3H, J=6.57 Hz,), 0.90 ppm (t, 3H, J=7.45 Hz), 0.96 ppm (t, 3H, J=7.55 Hz,), 1.17 ppm (m, 1H), 1.42 ppm (m, 1H), 1.58 ppm (m, 1H), 2.03 ppm (quintet, 2H, J=7.33 Hz), 2.20 ppm (m, 4H), 3.09-3.29 ppm (m, 2H), 5.28-5.44 ppm (m, 2H), 5.80 ppm (br. s, 1H), 5.82 ppm (d, 1H, J=15.34 Hz), 6.82 ppm (d, 1H, J=15.23 Hz, of t, J=6.55 Hz).
N-(2-methylbutyl) 2E,6Z-dodecadienamide
2E,6Z-dodecadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, 2-methylbutylamine 3.0 eq, quench with 20% sodium chloride, yield=45%.
0.7-0.92 ppm (m, 9H), 1.17 ppm (m, 1H), 1.29 ppm (m, 6H), 1.36 ppm (m, 1H), 1.57 ppm (m, 1H), 2.01 ppm (q, 2H, J=6.82 Hz), 2.20 ppm (m, 4H), 3.09-3.29 ppm (m, 2H), 5.30-5.44 ppm (m, 2H), 5.82 ppm (br. s, 1H), 5.83 ppm (d, 1H, J=15.27 Hz), 6.82 ppm (d, 1H, J=15.26 Hz, of t, J=6.58 Hz).
N-cyclopropyl 2E,6Z-nonadienamide
2E,6Z-nonadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, cyclopropylamine 2.0 eq, quench with 10% hydrogen chloride solution, yield=49%.
0.53 ppm (m, 2H), 0.77 ppm (m, 2H), 0.95 ppm (t, 3H, J=7.53 Hz), 2.02 ppm (quintet, 2H, J=7.37 Hz), 2.19 ppm (m, 4H), 2.77 ppm (m, 1H), 5.26-5.43 ppm (m, 2H), 5.79 ppm (d, 1H, J=15.30 Hz), 6.15 ppm (br. s, 1H), 6.82 ppm (d, 1H, J=15.30 Hz, of t, J=6.58 Hz).
N-cyclopropyl 2E,6Z-dodecadienamide
2E,6Z-dodecadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, cyclopropylamine 2.4 eq, quench with 10% hydrogen chloride solution, yield=55%.
0.53 ppm (m, 2H), 0.76 ppm (m, 2H), 0.88 ppm (t, 3H, J=6.85 Hz), 1.29 ppm (m, 6H), 2.00 ppm (q, 2H, J=6.80 Hz), 2.18 ppm (m, 4H), 2.78 ppm (m, 1H), 5.29-5.43 ppm (m, 2H), 5.83 ppm (d, 1H, J=15.34 Hz), 6.46 ppm (br. s, 1H), 6.82 ppm (d, 1H, J=15.30 Hz, of t, J=6.52 Hz).
N-(2-hydroxyethyl) 2E,6Z-dodecadienamide
2E,6Z-dodecadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, 2-ethanolamine 3.0 eq, quench with 20% sodium chloride and washed with dilute hydrogen chloride solution, yield=48%.
0.89 ppm (t, 3H, J=7.05 Hz), 1.29 ppm (m, 6H), 2.01 ppm (q, 2H, J=7.01 Hz), 2.20ppm (m, 4H), 3.47 ppm (m, 2H), 3.73 ppm (m, 2H), 4.17-4.28 ppm (br. m, 1H), 5.29-5.44 ppm (m, 2H), 5.84 ppm (d, 1H, J=15.37 Hz), 6.43-6.47 ppm (br. m, 1H), 6.84 ppm (d, 1H, J=15.31 Hz, of t, J=6.54 Hz).
N-(3,4-methylenedioxy)benzyl 2E,6Z-nonadienamide
2E,6Z-nonadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, piperonylamine 1.5 eq, quench with 10% sodium hydroxide solution, re-crystallized from hexane, yield=72%.
0.95 ppm (t, 3H, J=7.53 Hz), 2.03 ppm (quintet, 2H, J=7.37 Hz), 2.20ppm (m, 4H), 4.39 ppm (d, 2H, J=5.76 Hz), 5.27-5.44 ppm (m, 2H), 5.76 ppm (br. s, 1H), 5.78 ppm (d, 1H, J=15.38 Hz), 5.94 ppm (s, 2H), 6.75-6.79 ppm (m, 3H), 6.86 ppm (d, 1H, J=15.27 Hz, of t, J=6.59 Hz).
N-ethyl 3-(3-cyclohexenyl)-2E-propenamide
3-(3-Cyclohexenyl)-2E-propenoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, ethylamine 1.5 eq as a 2.0M solution in THF, quench with 10% sodium chloride solution, yield=39%.
1.17 ppm (t, 3H, J=7.25 Hz), 1.45 ppm (m, 1H), 1.80-1.83 ppm (m, 1H), 1.88-1.94 ppm (m, 1H), 2.09 ppm (m, 3H), 2.41 ppm (br. s, 1H), 3.36 ppm (m, 2H), 5.68 ppm (br. s, 3H), 5.77 ppm (d, 1H, J=15.40 Hz), 6.83 ppm (d, 1H,.J=15.39 Hz, of d, J=7.02 Hz).
N-cyclopropyl 3-(3-cyclohexenyl)-2E-propenamide
3-(3-Cyclohexenyl)-2E-propenoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, cyclopropylamine 1.6 eq, quench with 10% sodium chloride solution, yield=69%.
0.53 ppm (d, 2H, J=1.96 Hz), 0.79 ppm (d, 2H, J=5.59 Hz), 1.44 ppm (m, 1H), 1.82 ppm (m, 1H), 1.93 ppm (m, 1H), 2.08 ppm (m, 3H), 2.40 ppm (br. s, 1H), 2.78 ppm (m, 1H), 5.68 ppm (s, 2H), 5.73 ppm (d, 1H, J=15.58 Hz), 5.82 ppm (br. s, 1H), 6.84 ppm (d, 1H, J=15.41 Hz, of d, J=7.02 Hz).
N-allyl 2E,6Z-nonadienamide
2E,6Z-Nonadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, allylamine 1.5 eq, quench with 10% sodium chloride solution, yield=58%.
0.95 ppm (t, 3H, J=7.560Hz), 2.03 ppm (quintet, 2H, J=7.37 Hz), 2.18-2.23 ppm (m, 4H), 3.93 ppm (t, 2H, J=5.59 Hz), 5.16 ppm (d, 2H, J=17.14 Hz, of d, J=10.23 Hz), 5.30-5.43 ppm (m, 2H), 5.83-5.89 ppm (m, 1H), 5.86 ppm (d, 1H, J=14.02 Hz), 6.10 ppm (br. s, 1H), 6.81-6.86 ppm (d, 1H, J=15.29 Hz, of t, J=6.52 Hz).
N-allyl 3-methyl-2E-butenamide
3-Methyl-2E-butenoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, allylamine 1.5 eq, quench with 10% sodium chloride solution, yield=46%.
1.83 ppm (s, 3H), 2.16 ppm (s, 3H), 3.90 ppm (t, 2H, J=5.63 Hz, of d, J=1.43 Hz), 5.11 ppm (t, 1H, J=10.22 Hz, of d, J=1.35 Hz), 5.18 ppm (t, 1H, J=17.15 Hz, of d, J=1.48 Hz), 5.62 ppm (s, 1H), 5.81-5.89 ppm (m, 1H), 5.96 ppm (br. s, 1H).
N,N,3,7-tetramethyl-2E,6-octadienamide
3,7-Dimethyl-2E,6-octadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, dimethylamine 1.5 eq as a 40 wt % solution in water, quench with 10% sodium chloride solution, yield=46%.
1.61 ppm (s, 3H), 1.68 ppm (s, 3H), 1.86 ppm (2s, 3H), 2.13-2.16 ppm (m, 3H), 2.34 ppm (t, 1H, J=7.76 Hz), 2.96-3.01 ppm (m, 6H), 5.11 ppm (m, 1H), 5.78 ppm (m, 1H).
N-(carbomethoxy)methyl 2E,6Z-nonadienamide
2E,6Z-Nonadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, glycine 1.5 eq, quench with 10% sodium chloride solution, yield=62%.
0.96 ppm (t, 3H, J=7.53 Hz), 2.03 ppm (quintet, 2H, J=7.45 Hz), 2.19 ppm (t, 2H, J=6.44 Hz), 2.23 ppm (t, 2H, J=6.28 Hz), 3.75 ppm (s, 3H), 4.10 ppm (d, 2H, J=5.41 Hz), 5.31 ppm. (m, 1H), 5.39 ppm (m, 1H), 5.91 ppm (d, 1H, J=15.37 Hz), 6.60 ppm (br. s, 1H), 6.86 ppm (d, 1H, J=15.33 Hz, of t, J=6.57 Hz).
N-ethyl 4-(2,2,3-trimethyl-3-penten-1-yl)-2E-butenamide
4-(2,2,3-Trimethyl-3-penten-1-yl)-2E-butenoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, ethylamine 1.5 eq as a 2.0M solution in THF, quench with 10% sodium chloride solution, yield=22%.
0.79 ppm (s, 3H), 0.99 ppm (s, 3H), 1.17 ppm (t, 3H, J=7.27 Hz), 1.60 ppm (s, 3H), 1.81-1.92 ppm (m, 2H), 2.07-2.13 ppm (m, 1H), 2.27-2.35 ppm (m, 2H), 3.36 ppm (q, 2H, J=7.22 Hz, of d, J=7.79 Hz), 5.22 ppm (s, 1H), 5.37 ppm (br. s, 1H), 5.77 ppm (d, 1H, J=15.20 Hz), 6.83 ppm (d, 1H, J=15.19 Hz, of t, J=7.31 Hz).
N-cyclopropyl 4-(2,2,3-trimethyl-3-penten-1-yl)-2E-butenamide
4-(2,2,3-Trimethyl-3-penten-1-yl)-2E-butenoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, cyclopropylamine 1.5 eq, quench with 10% sodium chloride solution, yield=40%.
0.53 ppm (m, 90% of 2H), 0.62 ppm (m, 10% of 2H), 0.79 ppm (s, 3H), 0.80 ppm (m, 2H), 0.99 ppm (s, 3H), 1.60 ppm (s, 3H), 1.80-1.91 ppm (m 2H), 2.06-2.12 ppm (m, 1H), 2.30 ppm (m, 2H), 2.78 ppm (m, 1H), 5.21 ppm (s, 1H), 5.58 ppm (br. s, 1H), 5.74 ppm (d, 1H, J=15.20 Hz), 6.84 ppm (d, 1H, J=15.20 Hz, of t, J=7.31 Hz).
N,N-dimethyl 2E,6Z-nonadienamide
2E,6Z-Nonadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, dimethylamine 1.5 eq as a 40wt % solution in water, quench with 10% sodium chloride solution, yield=63%.
0.96 ppm (t, 3H, J=7.53 Hz), 2.04 ppm (quintet, 2H, J=7.41 Hz), 2.18-2.28 ppm (m, 4H), 2.99 ppm (s, 3H), 3.07 ppm (s, 3H), 5.29-5.43 ppm (m, 2H), 6.26 ppm (d, 1H, J=15.10 Hz), 6.82-6.88 (d, 1H, 15.09 Hz, of d, J=6.72 Hz).
N-ethyl 5-phenyl-2E-pentenamide
b 5 -Phenyl-2E-pentenoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, ethylamine 1.5 eq as a 2.0M solution in THF, quench with 10% sodium chloride solution, yield=39%.
1.15 ppm (t, 3H, J=7.27 Hz), 2.49 ppm (m, 2H), 2.75 ppm (t, 2H, J=7.80 Hz), 3.34 ppm (q, 2H, J=7.24 Hz, of d, J=1.53 Hz), 5.60 ppm (br. s, 1H), 5.77 ppm (t, 1H, J=15.28 Hz, of t, J=1.52 Hz), 6.87 ppm (t, 1H, J=15.27 Hz, of t, J=6.87 Hz), 7.16-7.20 ppm (m, 3H), 7.26-7.29 ppm (m, 2H).
N-cyclopropyl 5-phenyl-2E-pentenamide
5-Phenyl-2E-pentenoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, cyclopropylamine 1.5 eq, quench with 10% sodium chloride solution, yield=85%.
0.50-0.53 ppm (m, 2H), 0.76-0.80 ppm (m, 2H), 2.48 ppm (q, 2H, J=7.19 Hz), 2.73-2.78 ppm (m, 3H), 5.73 ppm (d, 1H, J=15.32 Hz) 5.76 ppm (br. s, 1H), 6.87 ppm (d, 1H, J=15.29 Hz, of t, J=6.91 Hz), 7.16-7.29 ppm (m, 5H).
N-ethyl 2E,6Z-dodecadienamide
2E,6Z-dodecadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, methylamine 5.0 eq as a 2.0M solution in THF, quench with 10% hydrogen chloride solution, yield 59%.
N-ethyl 3,7-dimethyl-2E,6-octadienamide
3,7-Dimethyl-2E,6-octadienoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.5 eq, ethylamine 3.05 eq as a 70 wt % solution in water, quench with 10% sodium chloride solution, yield=51%.
1.14 ppm (t, 3H, J=7.25 Hz), 1.61 ppm (d, 3H, J=8.77 Hz), 1.68 ppm (s, 3H), 1.81 ppm (s, ˜50% of 3H), 2.06-2.19 ppm (m, 3H), 2.15 ppm (s, ˜50% of 3H), 2.62 ppm (t, 1H, J=7.75 Hz), 3.31 ppm (quintet, 2H, J=7.11 Hz), 5.06-5.18 ppm (m, 1H), 5.59 ppm (s, 1H), 6.00 ppm (br. s, 1H).
N,N-diisopropyl-3-methyl-2E-hexenamide
3-Methyl-2E-hexenoic acid 1 eq, ethyl chloroformate 1.5 eq, triethylamine 1.6 eq, diisopropylamine 3.0 eq, quench with 10% hydrogen chloride solution, yield=34%.
EXAMPLE 2
Preparation of Non-alcoholic Beverage Flavor System
A non-alcoholic beverage formulation was prepared according to the following formulation:
Water
866.82 grams
High Fructose Corn Syrup 55
129.8 grams
(77° Brix)
Citric Acid
3.38 grams
The flavor applied to the beverages consisted of a blend of single fold lemon oil and distilled lime oil. The control beverage contained 35 PPM of this flavor. This control beverage exhibited the taste characteristics of a tart lemon lime flavor. Another beverage was prepared containing 35 PPM of the same flavor and 0.5 PPM of N-Ethyl E2,Z6-nonadienamide. This beverage exhibited enhanced flavor impact, increased tartness, and an increased perception of freshness as well as it being described as having a more “natural” flavor.
EXAMPLE 3
Preparation of an Alcoholic Beverage Flavor System
Flavored beverages were prepared using the following 30° Proof alcoholic base:
190° Proof food grade Ethyl
157.89 milliliters
Alcohol
High Fructose Corn Syrup 55
217.00 milliliters
(77° Brix)
Citric Acid (50% solution)
3.00 milliliters
Water
622.11 milliliters
The peach flavor applied to the beverages consisted of a blend of Gamma Decalactone, Benzaldehyde, Cis-3-hexenol, Butyric acid, 2-Methyl butyric acid, Iso butyl acetate, Linalool, and para-Mentha-8-thiol-3-one. The control beverage contained 60 PPM of the above flavor blend. This control beverage exhibited the taste characteristics of a mild candied green peach. Another beverage was prepared containing 60 PPM of the same flavor and 20 PPM of N-(3,4-methylenedioxy)benzyl E2,Z6-nonadienamide. This beverage exhibited an enhanced perception of alcohol, increased flavor impact, and a tingle effect on the tongue.
EXAMPLE 4
Preparation of a Toothpaste Product
The following separate groups of ingredients were prepared:
Group “A”
Ingredients Weight Percent glycerin 30.2 distilled water 15.3 sodium benzoate 0.1 sodium saccharin 0.2 stannous flouride 0.5
Group “B”
Ingredients Weight Percent calcium carbonate 12.5 dicalcium phosphate 37.2 (dihydrate)
Group “C”
2.0 parts by weight of sodium n-Lauroyl sarcosinate (foaming agent)
Group “D”
1.0 parts by weight of the flavor material which is a blend of peppermint oil, spearmint oil, anethole, and menthol.
Procedure:
(1) The ingredients in Group “A” were stirred and heated in a steam jacketed kettle to 160° F.
(2) Stirring was continued for an additional 3 to 5 minutes to form a homogeneous gel.
(3) The powders of Group “B” were added to the gel, while mixing until a homogeneous paste is formed.
(4) With stirring, the flavor of Group “D” was added, followed by addition immediately thereafter of the foaming agent of Group “C”.
(5) The resultant slurry was then blended for one hour.
The completed paste was then transferred to a three-roller mill, homogenized and finally tubed. The resulting toothpaste when used in a normal tooth brushing procedure yields a slightly bitter/medicinal mint flavor which exhibits moderate cooling. To this control paste 200 ppm of N-Isobutyl E2,Z6-dodecadienamide is added. This toothpaste exhibits moderate cooling without the bitterness of the control sample. In addition the sample exhibits tingle on the tongue and a slight numbing on the lips.
EXAMPLE 5
Preparation of a Chewing Gum Flavor
100 parts by weight of vehicle were mixed with 5 parts by weight of bubble gum flavor which is a blend of orange oil, amyl acetate, clove bud oil, ethyl butyrate, and methyl salicylate. To this 300 parts sucrose and 100 parts corn syrup were added. Mixing was effected in a ribbon blender with jacketed sidewalls of the type manufactured by Baker Perkins Co. The resultant chewing gum blend was then manufactured into strips 1 inch in width and 0.1 inches in thickness. These strips were cut into lengths of 3 inches each. This control gum exhibited a fruity citrus spice flavor when chewed. Another gum sample was prepared using the above recipe with the addition of 0.25 parts of N-Isobutyl E2,Z6-nonadienamide. The resulting gum had a similar taste profile to the control gum, however, it exhibited a pleasant tingle effect when chewed.
EXAMPLE 6
Preparation of Flavor for use in Hard Candy
Sugar
137 grams
Corn Syrup 42 DE
91 grams
Water
46 grams
The above ingredients were added to a stainless steel pot. With constant mixing the ingredients were brought to 295° F. The pot was removed from the heat and 0.5 grams of cinnamon bark oil was blended in. This liquid candy was then deposited into molds where it was left to cool. This recipe yielded 200 grams of finished candy. The resulting control candy exhibited a cinnamon bark type flavor with low to moderate warmth. Another candy sample was prepared using the above recipe with the addition of 100 PPM of N-Methyl E2,Z6-nonadienamide. This candy exhibited a greener flavor with less warmth, a slight numbing and a moderate level of tingle.
EXAMPLE 7
Use of the Compounds as Salt Enhancer
A trained consumer panel evaluated a series of molecules set forth below in tasting solutions and were asked to rate the perception of the salty and umami character of each taste solution. The molecules employed in the test were:
2,6-nonadienamide,N-2-propenyl-,(2E,6Z); 2,6-dodecadienamide,N-ethyl-(2E,6Z; N-isobutyl-(E2,Z6)-nonadienamide; (6Z,2E)-N-(2-hydroxyethyl)dodeca-2,6-dienamide; (6Z,2E)-n-(methylethyl)nona-2,6-dienamide; 2,6-nonadienamide,N-ethyl-,(2E,6Z); (2E)-N,N,3,7-tetramethylocta-2,6-dienamide; 2-propenamide,3-(3-cyclohexen-1-yl)-N-ethyl-,(2E); 2,6-dodecadienamide,N-cyclopropyl-,(2E,6Z); (6Z,2E)-N-(methylethyl)dodeca-2,6-dienamide; n-cyclopropyl-E2,Z6)-nonanadienamide; and 2-propenamide,3-(2-cyclohexen-1-yl)-n-cyclopropyl-,(2E)
The taste solutions presented to the panelists contained 0.3% by weight NaCl, and varying amounts of monosodium glutamate and Ribotides (a commercially available blend of disodium guanylate and disodium inosinate). The MSG content of the taste solutions varied from 0 to 0.18% by weight and the Ribotides varied from 0% to 0.013% by weight. The molecules of this invention were added to the tasting solution in amounts varying between 0 to 1.3 parts per million by weight.
The taste panel found the molecules of the invention increased the perception of saltiness as much as 40% and a smaller but still significant increase in the umami perception of up to 17%.
The panel of flavorists and food technologists were asked to evaluate a series of reduced sodium chicken broth versus a full sodium chicken broth. In this degree of difference testing, the panel was able to find a significant difference in the taste of chicken broth containing 10% less salt. The panel found the difference in the taste of the low salt sample to be pronounced when the salt was reduced by 15%.
Samples of lower salt chicken broth containing 800 parts per billion of the molecules of the invention provided above were given to this panel for evaluation. The panel could not perceive the difference between the full salt chicken broth and the chicken broth with 15% less salt containing the molecules set forth above. A sample of broth containing molecules of this invention with a 20% reduction in salt was not perceived as significantly different from the full salt broth.
A commercially available rice side dish was prepared with and without the addition of molecules listed above. These molecules were added at 5 and 10 ppm to the prepared rice mix. The rice mix was then prepared on the stove top according to the directions on the package. A panel of flavorists and food technologists were asked to rate the saltiness or the samples. The panel found that the rice samples with the addition of the molecules was significantly saltier than the unflavored reference.
The molecules of this invention were added to a range of dairy products—yogurt, sour cream, skim milk and full fat milk. The molecules were added in levels ranging from 1 to 5 ppm to the finished dairy product. A panel of flavorists and food technologists were presented the flavored and unflavored samples blind and asked to comment on the taste differences. The dairy samples containing the molecules were uniformly rated as creamier and more fatty tasting than the unflavored samples. | Compounds suitable for use as flavoring agents are disclosed. The compounds are used as flavors since they possess umami characteristics or other desirable organoleptic properties. The disclosed compounds are defined by the structure set forth below:
where X is selected from the group consisting of H, methyl, ethyl, n-propyl, and isopropyl;
Y is selected from the group consisting of methyl, ethyl, cyclopropyl, isopropyl, n-propyl, n-butyl, sec-butyl, isobutyl, 2-methylbutyl, allyl, cyclobutyl,
cyclopentyl, CH 2 CH(OH)CH 3 , CH(CH 3 )CH 2 OH, CH 2 C(CH 3 )OH, CH 2 CH 2 OH, CH 2 CO 2 CH 3 , geranyl, neryl;
or X and Y together form the structures
R 3 is selected from the group consisting of methyl and H;
R 4 is selected from the group consisting of methyl and H;
R 5 is selected from the group consisting of methyl, phenyl, benzyl, ethyl, propyl, butyl, isopropyl, phenylethyl, | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT Application Serial No. PCT/US07/85471, filed Nov. 23, 2007, which was a continuation-in-part of U.S. patent application Ser. No. 11/893,174, filed Aug. 15, 2007, which application was a continuation-in-part of U.S. patent application Ser. No. 11/626,648, filed 24 Jan. 2007, and priority of each of the above referenced applications is hereby claimed.
[0002] PCT Application Serial No. PCT/US07/85471, filed Nov. 23, 2007, is incorporated herein by reference.
[0003] U.S. patent application Ser. No. 11/893,174, filed 15 Aug. 2007, is incorporated herein by reference.
[0004] U.S. patent application Ser. No. 11/626,648, filed 24 Jan. 2007, is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0005] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0006] Not applicable
BACKGROUND
[0007] Hyperbaric and/or decompression chambers are used in many applications, and in many situations require the transfer of items either to and/or from the interior of the chambers. For example, deep sea diving, whether for pleasure or work, is associated with a serious risk of trauma to the divers. Without proper treatment, major problems from diving accidents, most commonly decompression sickness (or the “bends”) and Air Embolism, can lead to permanent disabling injuries and in some instances be fatal. Conventionally, offshore rig divers who work at great depths for considerable amounts of time must undergo decompression for extended periods time (e.g., up to two weeks). Normally the decomposition takes place in a conventional decompression chamber on the offshore rig or on a deck of a dive boat.
[0008] Dive chambers are examples of a category of pressure vessel referred to as a pressure vessel for human occupancy (“PVHO”). Once the divers are inside the vessels of the transfer system their condition must be kept stable. In keeping with this objective the problem arises of keeping the gas mixtures constant within the vessels of the transfer system. This includes both the pressures and concentrations of the compression gas, the breathing gas and the oxygen within the chamber. It is especially true for the oxygen supply within the vessel which must be replenished as it is used.
[0009] While the individual is in the decompression chamber, if medicines, supplies, food, drink, or other items are to be provided to the individual, a method and apparatus for supplying such items without substantially impacting the interior pressure and gas concentration inside the chamber needs to be provided. Additionally, it is desirable that in making this transfer that a minimum amount of interior gas pressure and/or gas concentration is lost.
[0010] One conventional method for providing access to the individual while inside the chamber is through an air lock which is independent of the entrance to the chamber. The air lock on a dive chamber can include a steel tube penetrating the chamber's wall. The steel tube can have doors called “closures” on each end.
[0011] Certain design conditions need to be addressed for an air lock or transfer portal to a decompression chamber. For example, in a portal with outer and inner doors, the outer door should be able to withstand the internal pressure of the dive chamber when the inner door is open.
[0012] In one embodiment a quick lock/quick unlock can be provided for the outer door. In one embodiment the quick lock/quick unlock for a small diameter portal can include a breech-lock type “two-ring” design familiar to those skilled in the art of quick opening closures. A two-ring style door can use a body ring welded to the body of the portal which rotatably houses a door. In one embodiment the door can have a plurality of radial extending protrusions. In one embodiment the body ring can have a plurality of enlarged openings which correspond to the plurality of radially extending protrusions of the door. In one embodiment the door can be rotated relative to the ring such that the plurality of radially extending protrusions slidable lock with the ring and prevent longitudinal movement of the door relative to the portal thereby keeping the door closed. In one embodiment the outer door can be rotated relative to the ring such that the plurality of radially extending protrusions enter the plurality of enlarged openings so that longitudinal movement of the door relative to the portal is allowable thereby allowing the door to be opened.
[0013] In one embodiment one or more of the plurality of radially extending protrusions can have a sloped section (in a rotational direction), such that when the outer door is rotated in the direction of slope the door tends to move in a longitudinal direction towards the interior of the portal. In this way the seal between the exterior door and the portal (such as an O-ring) can be more tightly sealed or energized. In one embodiment a perimeter groove in the ring can include a plurality of sloped sections such that when the outer door is rotated in a first direction the door tends to move in a longitudinal direction towards the interior of the portal causing a tighter seal to be made between the door and the portal. In one embodiment corresponding sloped areas are provided on both the plurality of radially extending protrusions of the exterior door and the plurality of sloped sections by the corresponding plurality of enlarged openings, such that both sloped portions tend to cause the door to more tightly seal against the portal when the door is rotated.
[0014] In some instances “three-ring” closures can be used on outer doors. In three-ring closures the door and body ring (first and second rings) do not rotate. Instead, a third ring (locking ring) located outside of the door and body rings itself rotates to engage mating lugs on the door and/or body rings and thereby obtain a seal. Two ring closures are preferred over three ring closures for various reasons: two ring closures are less expensive because they do not have a third ring; do not require lubrication of the sliding surfaces of this third ring; and do not have high stress areas hidden under such a third ring (which can inhibit a pre-failure detection analysis). Advantages of two ring versus three ring closures are particularly useful in competitive commercial applications such as dive chambers where they are subjected to harsh outdoor marine environments.
[0015] One hazard for conventional locks for closures is that the operator can attempt to open the air lock while the door is under pressure. As a consequence of this pressure differential, the door can be forced open very fast and the operator can be injured or the person inside the chamber can be injured by the inner door swinging open explosively.
[0016] Conventional locks for preventing two-ring closures from being opened while under pressure rely on indicators. Examples of “indicators” include pressure gages or pressure actuated spring loaded pop-up pistons. However, indicators only “notify/flag” operators, and depend on the operator recognizing and acting on the information provided by the indicators. Additionally, spring-loaded piston indicators retract when a small pressure still remains in the closure so that a false “OK” signal can be communicated. Even relatively small pressure differentials between the interior of the portals and the area where the closure is being opened can cause large forces on the closures and cause them to open fast causing injury.
[0017] Another potential problem with two-ring closures (or doors) relates to the door support allowing the door to both “swing out” (e.g., open and close) but also rotate about its axis (for locking/sealing and unlocking/unsealing). Because two distinct movements are required, a two-ring door hinge typically connects the door using a longitudinal bearing in the hinge blade which longitudinal bearing supports an axle in the center of the door. However, these bearings eventually wear, and such wear allows changes in concentric alignments of the door relative to the locking ring.
[0018] Alignment of the door relative to the locking ring is important because O-rings are preferred for sealing. O-rings (which are self-energizing gaskets) use the pressure of the fluid or gas being sealed to contribute to (or energize) their sealing effect. O-ring seals require containment in a cavity with limited gaps to prevent a form of failure referred to as “extrusion.” Extrusion failure of O-rings and the design gap sizes required to prevent it are described in O-ring design handbooks such as the “Parker O-Ring Handbook” and are familiar to those skilled in the art of O-ring joint design. For a closure where human life depends on its proper operation a concentricity misalignment of the door which leads to a gap and possible extrusion failure is unacceptable.
[0019] Conventionally available locks can be interlocks which are devices constraining the operator from opening the closure (door) until after the air locked has started to vent. Conventional interlocks for two-ring doors include threaded vent plugs in the door which vent plugs are chained to a stationary part of the vessel. These “vent-plug-on-chains interlocks” can restrict opening of the door, but they are slow and awkward.
[0020] Another problem with dive chamber air locks relates to the operation of the inner closure or door. Interior pressures of chambers are typically elevated compared to outside pressures. Because the inner door swings inwards when opening, the higher interior pressure of the dive chamber (or living space), compared to the pressure outside the chamber, causes the inner door to be pushed against the portal and pushed against a sealing O-ring (between the interior door and the portal). The force created by the higher interior pressure energizes the sealing O-ring, and seals the interior from the portal. Because of this higher interior pressure the inner door does not require a lock (or locking ring) to create a seal when in use and pressurized. However, dive chambers are not always in use and pressurized and when on ships, and when not pressurized dive chambers can be subjected to large jerking motions (such as wave action) causing the “unlocked” inner door to swing open and shut causing damage. Also, large motions can be seen during other activities of ships such as during the discharge if cargo which can cause an unlatched inner door to swing open and closed on its own. Additionally, dive chambers can be transported from one ship to another location such as by truck also subjecting the dive chamber to large jerking motions. During periods in which a dive chamber is subjected to large jerking motions, an “unsecured inner door” can bounce open and closed, which can cause damage to the inner door, O-ring, and/or portal.
[0021] Furthermore, if the inner door is somehow opened when the interior of the dive chamber is pressurized but unoccupied, a person standing outside the dive chamber would be unable to reach through the outer door and grab hold and close the inner door. However, even assuming that the interior door can be reached from the exterior, attempting to close the inner door from the exterior is very dangerous because the increased interior pressure can cause the interior door to slam shut very quickly, which slamming shut can harm the person attempting to close.
[0022] A seemingly simple solution for the interior door is to use a swing bolt latch or other clamping latch. However, swing bolts or clamping latches have the disadvantage of continuing to hold shut the inner door even where the portal pressure (or exterior pressure) is substantially greater than the interior dive chamber pressure. For example, locked swing bolts or clamping latches can trap elevated pressures inside the portal as the interior pressure of the dive chamber is reduced during a depressurization cycle. A trapped high differential pressure behind the inner door risks this door being slammed open and harming a person in the interior of the dive chamber—such as where the swing bolt or clamping latch is released (or fails) with a trapped high differential pressure behind the inner door. Such a condition could lead to an explosive release of the inner door.
[0023] Another disadvantage with conventionally available air locks (or access portals) is their lack of dealing with the time delay between: (a) starting the venting process of the interior of the portal and (b) the finishing of the venting process. Even where an interlock is used on the outer door to start venting and also “unlock” the outer door, a time lag exists between the start of the venting process to the time where the pressure differential between the interior of the portal and the exterior is at an acceptable level so that the outer door is not cause to explosively swing open.
BRIEF SUMMARY
[0024] In one embodiment is provided an interlock assembly for use with an air lock or portal fluidly connected to decompression or hyperbaric chambers. In one embodiment this air lock converts the decompression or hyperbaric chamber to a hyperbaric transfer system.
[0025] In one embodiment the decompression chamber can be cylindrical in shape with a sidewall forming the cylinder.
[0026] In one embodiment is provided an interlock air lock assembly for use with decompression chambers or hyperbaric chambers. The interlock assembly can be a portal comprising a hollow air tight vessel with open ends which are selectively closed/opened by a respective inner door and an outer door.
[0027] In one embodiment is provided a portal having a body with a sidewall extending between the opposite ends, and the inner door and the outer door having hinged assemblies that are secured to the body for pivotal movement of the doors.
[0028] In one embodiment the air lock or portal can be attached to the sidewall of the decompression or hyperbaric chamber.
[0029] In one embodiment one or both the inner door and/or the outer door can be equipped with latch assemblies for safely closing the doors to maintain an air tight environment.
[0030] In one embodiment the outer door can be also rotatable in relation to the portal. In one embodiment the outer door can be both rotatable and pivotal in relation to the portal.
[0031] In another embodiment is provided an interlock assembly that has a plurality of locking/latching safety locks which prevent an undesirable rapid venting of the decompression chamber wherein a diver and/or patient is situated.
[0032] In one embodiment the inner door is mounted at an interior end of the vessel in fluid communication with the decompression chamber when the inner door is open.
[0033] In one embodiment one or both the inner door and the outer door can be provided with seals (such as sealing O-ring fitted on the inside surface of the respective door) to facilitate the air tight engagement of the door with the body of the portal.
[0034] In one embodiment is provided a locking ring mounted at the outside edge of the vessel or portal allowing at least one locking bar to selectively extend therethrough (from the rear) to prevent undesirable rotation and opening of the outer door at a time when the vessel or portal is at an elevated pressure.
[0035] In one embodiment is provided a quick lock/quick unlock interlock system which both releases a lock against rotation of the outer door and starts venting the interior of the portal.
[0036] In one embodiment a pressure relief valve can be operatively connected to the locking member for rapidly venting pressure inside the portal when the quick lock/quick unlock is switched to an open state.
[0037] In one embodiment is provided a venting valve which is operably connected to a sliding locking member.
[0038] In one embodiment the venting valve is fluidly connected to the sidewall of the body of the air lock or portal.
[0039] In one embodiment the operative connection between the venting valve and sliding locking bar is made through a four bar linkage system which includes a slider.
[0040] In one embodiment the slider connection passes through a locking ring of the portal from the rear of the locking ring.
[0041] In one embodiment the slider connection has a first end and when it moves from the unlocked state to the locked state the first end moves away from the inner door and towards the outer door.
[0042] In one embodiment the slider connection has a first end and when it moves from the locked state to the unlocked state the first end moves away from the outer door and towards the inner door. In one embodiment the slider connection has a first end and when it moves from the unlocked state to the locked state the first end moves away from the inner door (at a time which the first end is between a plane bisecting a perimeter groove and the inner door) and towards the outer door (the first end passing through the bisecting plane).
[0043] In one embodiment the slider connection has a first end and when it moves from the locked state to the unlocked state the first end moves away from the outer door (at a time which the first end is in front of a plane bisecting a perimeter groove and the inner door) and towards the outer door (the first end passing through the bisecting plane).
[0044] In one embodiment the slider connection has a first end and when it moves to the locked condition the first end passes from behind the middle of the locking ring to in front of the locking ring.
[0045] In one embodiment the slider connection has a first end and when it moves to the unlocked condition the first end passes from in front of the middle of the locking ring to behind the middle of the locking ring.
[0046] In one embodiment the slider connection has a locking bar and the locking bar is located between the exterior of the sidewall of the portal and the outside of the locking ring.
[0047] In one embodiment a quick lock/quick unlock sensitive to the pressure differential between the interior of the portal and the exterior can be used to rotational lock the outer door.
[0048] In one embodiment the pressure sensitive quick lock/quick unlock can be a second lock in addition to an interlock quick lock/quick unlock.
[0049] In one embodiment the second lock can be operatively connected to the first lock, switching from open to closed (or from closed to open) states in a time delayed manner relative to the first lock.
[0050] In one embodiment is provided a safety lock/unlock which will generally take between about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and 60 seconds to unlock from the start of venting of the interior of the portal and the time the quick lock/quick unlock enters an unlocked state. In various embodiments ranges between any of the above referenced time delays are envisioned.
[0051] In one embodiment is provided a safety lock/unlock which will generally enter an unlocked stated when the different between the interior pressure of the portal and the exterior is below a specified safety level. In one embodiment the acceptable differential is less than about 5 psi, 4 psi, 3 psi, 2 psi, 1 psi, and/or V 2 psi (34.5, 27.6, 20.7, 13.8, 6.9, and/or 3.4 kilopascals). In various embodiments ranges between any of the above referenced pressure differentials are envisioned.
[0052] In one embodiment the amount of rotation of the outer door is limited in both first and second directions. In one embodiment this rotational limit is obtained by a slot and pin mechanism.
[0053] In one embodiment rotation of the outer door causes the door to tighten (shut more securely and seal) relative to the interior of the portal.
[0054] In one embodiment a seal is set up between the inner door and the interior of the dive chamber when the pressure of the interior of the dive chamber becomes greater than the pressure of the interior of the portal.
[0055] In one embodiment the interior door includes a latching mechanism which opens partially based on a differential higher pressure between the interior of the portal and the interior of the dive chamber. Such partial opening allows the interior of the portal to vent into the interior of the chamber.
[0056] In one embodiment the latching mechanism includes first, second, and third latching conditions, where the first latching condition is entered when the inner door seals the interior of the chamber from the interior of the portal, the second latching condition includes a partial opening of the inner door so that venting occurs from the interior of the portal to the interior of the chamber, and the third latching condition is an open condition—where the inner door is no longer constrained by the latch.
[0057] In one embodiment, when the interior pressure of the portal exceeds the interior pressure of the dive chamber the latching mechanism moves from the first latching condition to the second latching condition and allows pressure to vent from the interior of the portal to the interior of the dive chamber but restricts the extent to which the interior door can open. In one embodiment the inner door can open less than about 1/200, 1/100, 1/90, 1/80, 1/70, 1/60, 1/50, 1/40, 1/30, 1/20, 1/10, ½, 1, 1½, 2, 2½ 3, 4, 5, 6, 7, 8, 9, and 10 millimeters. In various embodiments ranges between any of the above referenced distances are envisioned.
[0058] In one embodiment the latching mechanism on the inner door includes a spring which is biased to cause the latch to move in a latched condition.
[0059] In one embodiment the latching mechanism includes a handle which has first and second sloped portions, the first sloped portion tending to be sloped towards the longitudinal centerline of the portal, and the second sloped portion tending to be sloped away from the longitudinal centerline of the portal.
[0060] In one embodiment the inner door includes a quick connect/quick disconnect mechanism for attaching to the interior end of the portal.
[0061] In one embodiment the inner door includes a floating connection with its hinge, this floating connection assisting in aligning the door with the interior opening of the portal. In one embodiment the inner door includes a centrally protruding section which can assist in aligning concentrically the inner door with the interior opening of the portal.
[0062] In one embodiment the inner door includes a venting valve for venting between the interior of the chamber and the interior of the portal. In one embodiment the venting valve can be located on the body of the air lock or portal.
[0063] In one embodiment the inner door rotates about an axis which is included in a horizontal plane.
[0064] In one embodiment the inner door rotates about an axis which is included in a vertical plane.
[0065] In one embodiment the outer door rotates about an axis which is included in a horizontal plane.
[0066] In one embodiment the outer door rotates about an axis which is included in a vertical plane.
BRIEF DESCRIPTION OF THE DRAWINGS
[0067] Reference will now be made to the drawings, wherein like parts are designated by like numerals, and wherein
[0068] FIG. 1 is a perspective view of a decompression chamber with air lock or portal.
[0069] FIG. 2 is an enlarged perspective view of the interlocking air lock or portal of FIG. 1 looking at the portal from the front of the chamber, and where a portion of the sidewall of the decompression chamber has been removed to show the inner and outer ends of the portal.
[0070] FIG. 3 is an enlarged perspective view of the interlocking air lock or portal of FIG. 2 , but now looking at the portal from the rear of the chamber and where a portion of the upper section of the portal has been removed to reveal the interior of the portal.
[0071] FIG. 4 is an enlarged perspective view of the interlocking portal of FIG. 2 , showing the quick lock/quick unlock system now placed in an unlocked state along with schematically showing the venting of the interior of the portal, and the safety or delayed lock system being pressure sensitive and moving from a locked to an unlocked state.
[0072] FIG. 5 is an enlarged perspective view of the interlocking air lock or portal of FIG. 2 with the outer door opened and schematically showing an item being placed in the interior of the portal.
[0073] FIG. 6 is an enlarged perspective view of the interlocking air lock or portal of FIG. 2 showing the item placed in the portal with the outer door closed, and the quick lock/quick unlock system now placed in a locked state, and the venting valve on the inner door opened to vent pressure from the interior of the dive chamber to the interior of the portal, and the safety or delayed locking system being pressure sensitive and moving from an unlocked state to a locked state.
[0074] FIG. 7 is an enlarged perspective view of the interlocking portal of FIG. 2 showing the inner door being opened and the item being moved from the interior of the portal to the interior of the dive chamber.
[0075] FIG. 8 is a perspective view of the interlocking air lock or portal of FIG. 2 , where a portion of the outer door and locking ring has been removed to show the body of the portal along with the quick lock/quick unlock and safety or delayed locking systems.
[0076] FIG. 9 is a perspective view of the interlocking air lock or portal of FIG. 4 with the quick lock/quick unlock locking member placed in an unlocked state and the safety or delayed locking system's locking member remaining in a locked state.
[0077] FIG. 10 is perspective view of the interlocking portal of FIG. 2 with a portion of the locking ring removed to show the interaction between the first locking rod and of one of the radial protrusions of the outer door, and also showing the interaction between the second locking rod and another of the radial protrusions.
[0078] FIG. 11 is perspective view of the interlocking portal of FIG. 2 with the outer door opened and a portion of the locking ring and outer door removed to show the body of the portal along with the quick lock/quick unlock and safety or delayed locking systems.
[0079] FIG. 12 is a sectional diagram showing the quick lock/quick unlock locking system, along with closed and open states of the handle for this locking system.
[0080] FIG. 13 is a sectional view of the locking member for the quick lock/quick unlock locking system, where it is shown in open and closed states for the locking member, but with an alternative embodiment for the outer door which outer door contains an O-ring and recess for such O-ring.
[0081] FIG. 14 is a sectional view of the safety or delayed locking system which is pressure sensitive and which is shown in a locked state.
[0082] FIG. 15 is a sectional view of the safety or delayed locking system which is pressure sensitive and which is shown in an unlocked state.
[0083] FIG. 16 is a perspective view of the interior door shown not connected to the portal with the door in an open state.
[0084] FIG. 17 is a sectional view of the latching system for the inner door shown in a locked state but where there is not a pressure differential between the interior of the dive chamber and the interior of the portal.
[0085] FIG. 18 is a sectional view of the latching system for the inner door shown in a locked state but where the interior pressure of the dive chamber is higher than the interior pressure of the portal, and the inner door is pressed closed based on the force of the larger interior dive chamber pressure.
[0086] FIG. 19 is a sectional view of the latching system for the inner door shown in a locked state, but where there is not a pressure differential between the interior of the dive chamber and the interior of the portal
[0087] FIG. 20 is a sectional view of the latching system for the inner door shown in an unlocked or open state where the interior door is opened.
DETAILED DESCRIPTION
[0088] Turning now to the drawings in more detail an airlock assembly or portal is generally designated by numeral 200 . In the following description, the terms “portal,” “airlock assembly,” interlock vessel,” and interlock assembly are used interchangeably. The portal 200 is designed to be used in a hyperbaric chamber (e.g., decompression chamber) 10 transfer system.
[0089] FIG. 1 is a perspective view of a decompression chamber 10 with air lock or portal 200 . In one embodiment a decompression chamber 10 having a fluidly connected portal 200 is included. Decompression chamber 10 can include first end 20 , second end 30 , and side wall 40 . Base 50 can be included to support chamber 10 . For entering chamber 10 a door 60 can be provided. Door 60 can be sealed with conventionally available seal 70 . Chamber 10 can have interior 80 , and sidewall 40 can separate interior 80 from the exterior 85 (or ambient environment). Preferably, door 60 opens to the interior 80 of chamber 10 .
[0090] As will be described below, portal 200 can be used to transmit one or more items from the exterior 85 to the interior 80 , while the interior 80 is at elevated pressures. Additionally, as will be described below, portal 200 can be used to transmit one or more items from the interior 80 to the exterior 85 , while the interior is at elevated pressures.
[0091] While chamber 10 is at elevated pressures with a person in the interior 80 of chamber 10 , there arises the need to quickly and easily transmit one or more items to such person, or receive one or more items from such person while maintaining chamber 10 at elevated pressures. For example, food and/or medicines may need to be provided to the person inside the chamber while the person is going through a decompression cycle while chamber 10 is maintained at elevated pressures. Such quick access is preferably obtained without substantially impacting the elevated internal 80 pressure Pc of chamber 10 . Portal 200 allows such access without substantially impacting the elevated pressure of interior 80 because the volume of interior 204 of portal 200 is typically much less than the volume of interior 80 of chamber 10 . Portal 200 is preferred to an airlock device by door 60 because such air lock device would substantially reduce the available space in interior 80 of chamber 10 , along with slowing down the time necessary to transfer one or more items (and possibly impacting the elevated pressures of interior 80 ).
[0092] FIGS. 2 through 7 show the process of an item 3000 being transmitted through portal 200 to the interior 80 of chamber 10 . FIG. 2 is an enlarged perspective view of interlocking portal 200 at the portal from the front of the chamber 10 , and where a portion of the sidewall 40 of the decompression chamber has been removed to show the front 210 and rear 220 ends of the portal. FIG. 3 is an enlarged perspective view of portal 200 , but now looking at the portal from the rear 30 of the chamber 10 and where a portion of the upper section of the portal 200 has been removed to reveal the interior 204 of portal 200 . FIG. 4 is an enlarged perspective view of portal 200 , but showing the interlocking system (lock 800 and safety lock 1000 ) now placed in an unlocked state along with schematically showing the venting of the interior 204 of the portal 200 , and the second pressure sensitive locking mechanism 1000 moving from a locked to an unlocked state. FIG. 5 is an enlarged perspective view of the interlocking portal 200 with outer door 400 opened and schematically showing an item 3000 being placed in the interior 204 of the portal 200 . FIG. 6 is an enlarged perspective view of portal 200 showing the item 3000 placed in the portal 200 with outer door 400 closed and the interlocked system (lock 800 and 1000 ) now placed in locked states, and the venting valve 1600 on the inner door 1400 opened to vent pressure from the interior 80 of the dive chamber 10 to the interior 204 of the portal 200 , and the second pressure sensitive locking mechanism 1000 moving from an unlocked state to a locked state. FIG. 7 is an enlarged perspective view portal 200 showing the inner door 1400 being opened and the item 3000 being moved from the interior 204 of the portal 200 to the interior 80 of the dive chamber 10 .
[0093] FIGS. 8 through 11 show various views of one embodiment of portal 200 . FIG. 8 is a perspective view of portal 200 , where a portion of outer door 400 and locking ring 250 has been removed to show first end 210 body 230 along with quick lock/quick unlock 800 and safety lock 1000 . FIG. 9 is a perspective view of portal 200 with quick lock/quick unlock 800 placed in a unlocked state and safety lock 1000 in a locked state. FIG. 10 is perspective view of portal 200 with a portion of locking ring 250 removed to show the interaction between the locking bar 810 and of one of the radial protrusions 510 of outer door 400 , and also showing the interaction between locking bar 1010 and another of radial protrusions 540 . FIG. 11 is perspective view of portal 200 with outer door 400 opened and a portion of locking ring 250 and outer door 400 removed to show the first end 210 of portal 200 body 230 along with quick lock/quick unlock 800 and safety lock 1000 systems.
[0094] Portal 200 can comprise body 230 with first end 210 and second end 220 . Between first and second ends 210 , 220 and body 230 can be interior 214 . Body 230 can have a continuous sidewall 240 which can be configured to form a cylindrical vessel. On first end 210 of body 230 can be an outwardly extending shoulder 211 , on which outer door 400 contacts when closed. In one embodiment portal 200 comprises an airtight body 230 closed on one end by an inner door 1400 and closed on the opposite end by an outer door 400 having two degrees of freedom for pivoting (e.g., it can pivot about two axes which are substantially perpendicular to each other).
[0095] Second end 220 of portal 200 can be in communication with interior 80 of chamber 10 , while first end 210 can extend past sidewall 40 (of chamber 10 ) and be in fluid communication with exterior 85 (or environment).
[0096] A portion of body 230 (e.g., second end 220 ) with the inner door 1400 normally extends into interior 80 of chamber 10 (the interior housing a person at elevated or hyperbaric pressures). A portion of the body 230 (e.g., first end 210 ) that has outer door 400 normally extends outside of chamber 10 . A person inside chamber 10 normally has access to inner door 1400 and can operate door 1400 to open and close the door. However, such person in interior 80 would not have access to handles operating the outer door 400 .
Outer Door
[0097] On first end 210 can be outer door 400 . Door 400 can be rotatably mounted in relation to the shoulder 211 . Also on first end 210 can be locking ring 250 which can longitudinally lock in place outer door 400 . Locking ring 250 can be attached to first end 210 and include a perimeter groove 290 along with a plurality of unlocking openings 300 . In one embodiment the plurality of unlocking openings can be symmetrically spaced about the circumference of locking ring 250 .
[0098] On second end 220 can be inner door 1400 . As will be described below outer door 400 can seal interior 214 from exterior 85 using seal 212 . As will be described below inner door 1400 can seal interior 214 from interior 80 of chamber 10 using seal 1422 .
[0099] Outer door 400 can comprise first end 410 , second end 420 , along with a plurality of locking projections 500 which detachably lock with locking ring 250 . In one embodiment door 400 can include radial projections 510 , 520 , 530 , and 540 . More or less locking projections than four can be used.
[0100] Outer door 400 can be pivotally connected to portal 200 by support bracket 700 , which support bracket can be connected to portal 200 such as by being welded to sidewall 230 . In one embodiment outer door 400 can pivot around a vertical axis, such as around hinge 710 (where hinge 710 pivotally attaches to support plate 450 to connection points 720 ). Such rotation about a vertical axis allows outer door 400 to be opened and closed and provides access to interior 204 In one embodiment outer door 400 can also rotate about a horizontal axis, such as fastener 440 . In this manner outer door 400 can both rotate about two axes which are perpendicular to each other (e.g., horizontal axis of fastener 440 which is perpendicular to vertical axis of hinge 710 ). As shown in FIG. 2 , the extent of rotation of outer door 400 about a horizontal axis can be limited. The extent of rotation of outer door 400 about a horizontal axis is limited by the movement of rotation stop 460 within rotation slot 470 (slot 470 being contained in support plate 450 and stop 460 being attached to door 400 ). Slot 470 setting up a pre-determined arc or rotation for door 400 which arc of door rotation has a length equal to that of the length of slot 470 . That is, no further horizontal rotation of outer door 400 can be made once rotation stop 460 hits either end of rotation slot 470 . As will be described above the horizontal rotation of outer door 400 allows door to be locked in locking ring and maintain a tight seal against first end 210 of body 230 . Also as will be described below rotation slot 460 can be used to rotationally position plurality of locking projections 500 in plurality of unlocking openings 300 of locking ring 250 to allow outer door 400 to detachably lock and unlock in locking ring 250 .
[0101] Locking of outer door 400 in locking ring is shown in FIGS. 5 and 6 . In FIG. 5 outer door 400 is open and in FIG. 6 outer door 400 is closed. When outer door 400 closes, a plurality of projections 500 ( 510 , 520 , 530 , and 540 ) enter a plurality of their respective unlocking openings 300 ( 310 , 320 , 330 , and 340 ) to allow door 400 to rest in locking ring 250 . Stop pin 470 is shown in contact with first end 462 of arcuate slot 460 so that door 400 has been rotated the maximum extent in a counter clockwise direction (schematically shown by arrow 2610 and 2620 ). At this maximum counter clockwise rotation plurality of projections 500 line up with plurality of unlocking openings 300 and outer door 400 can be shut. However, to shut and seal outer door 400 against body 230 , door 400 should be turned in a clockwise direction (in the opposite direction as arrows 2610 , 2620 ). Plurality of projections 500 will enter perimeter groove 290 of locking ring 250 .
[0102] In a preferred embodiment one or more of plurality of projections 500 can have an upwardly sloping surface so that as outer door 400 is rotated clockwise locking ring 250 pushing on the sloping surfaces will cause door 400 to be pushed tighter against body 230 and energizing the seal between body 230 and door 400 . In FIG. 5 sloped surface 512 is schematically shown, however, projections 520 , 530 , and 540 can each have similar sloped surfaces.
[0103] In one embodiment plurality of projections 500 extend diametrically to an extent which is slightly less than the largest diametrical extent of the plurality of unlocking openings 300 . This dimensional constraint can prevent outer door 400 from moving out of concentricity even if the center bearing (rotatively connecting door 400 to support bracket 450 ) wears or if hinge 710 is caused to become misaligned in such a way that a door concentricity error would otherwise be created.
[0104] In one embodiment one or more of plurality of projections 500 can have a beveled surface (beveled inwards from first side 410 (facing exterior 85 to second end 420 facing interior 204 ) so that, as door 400 is pushed closed (i.e., rotated on hinge 710 ) against body 230 , locking ring 250 tends to align door 400 concentrically in relation to interior 204 of body 230 . In FIG. 5 beveled surface 514 is schematically shown, however, projections 520 , 530 , and 540 can each have similar beveled surfaces. That is locking ring 250 radially pushing on the beveled surfaces will cause door 400 to be concentrically aligned in relation to interior 204 .
[0105] In a preferred embodiment one or more of plurality of projections 500 can have a second radially sloping surface 514 ′ so that, as door 400 is rotated clockwise, locking ring 250 tends to concentrically align door 400 in relation to interior 204 of body 230 . That is locking ring 250 radially pushing on the sloping surfaces will cause door 400 to be concentrically aligned in relation to interior 204 . In FIG. 5 sloped surface 514 is schematically shown, however, projections 520 , 530 , and 540 can each have similar sloped surfaces.
[0106] In certain situations outer door 400 may not be concentric (or may lose concentricity) with respect to locking ring 250 (and body 230 ). As shown in FIGS. 11 and 13 , in one embodiment outer door 400 can include one or more raised sections 412 (which interact with the edges of the locking tabs, such as edge 323 of tab 322 ) to assist and concentrically aligning inner door 400 with body 230 . In one embodiment a single raised section 412 can be provided. Where outer door 400 is out of concentricity, raised section 412 can contact edge 323 (when rotated clockwise) and cause outer door 400 to move into a concentric position. With such adjustment for concentricity, a good seal can be maintained between outer door 400 and body 230 when outer door 400 is closed or shut. This can prevent extrusion of O-ring 212 from groove 214 .
[0107] In one embodiment a seal can be included between outer door 400 and body 230 . In one embodiment ( FIGS. 12 , 14 , and 15 ) the seal can be attached to first end 210 of body 230 . In one embodiment the seal can be an O-ring 212 ′ is fitted in a dovetail-shaped groove 214 ′ formed in first end 210 of body 230 . In another embodiment (which is shown in FIG. 13 ) the O-ring 212 can be placed in a groove 214 on door 400 . To prevent O-ring 212 from falling out of the groove 214 when outer door 400 is open, the upper portion of groove 214 can be smaller than the lower portion of groove 214 . O-ring 212 can be sized to be 1½ percent smaller than the theoretical size of groove 214 so that the O-ring remains in groove 214 when door 400 is opened.
[0108] Outer door 400 can be provided with a pair of handles 600 , 610 extending from an outside surface thereof. Handles 600 , 610 allow the user to pivot door 400 about a central axis when quick lock/quick unlock 800 and lock 1000 are in unlocked states. Door 400 can be rotatively attached to support bracket 450 .
Quick Lock/Quick Unlock
[0109] FIG. 12 is a sectional diagram showing quick lock/quick unlock 800 system, along with closed 880 and open states 880 ′ of handle 880 for this locking system.
[0110] FIG. 13 is a sectional view of locking member 810 for quick lock/quick unlock 800 showing open (position of first end 820 ) and closed (position of first end 820 ′) states for locking member 810 , showing door 400 where O-ring 212 ′ and O-ring recess 214 are located in outer door 400 . As will be described below for inner door 1400 placing the seal in the door can make it easier to correct/fix problems with the groove 214 ′ for O-ring 212 ′.
[0111] A quick lock/quick unlock 800 can be operatively attached to portal 200 and set up locked and unlocked states for outer door 400 . Generally, quick lock/quick unlock 800 can comprise locking bar 810 operatively connected to valve 900 such that when valve 900 is opened locking bar 810 moves into an unlocked stated, and when valve 900 is closed, locking bar 810 moves into a locked state. Valve 900 can be secured to sidewall 240 and fluidly connect interior 204 of portal 200 with exterior 85 . Vent tube 950 of valve 900 can fluidly connect valve 900 to interior 204 . When opened, valve 900 equalizes pressure between interior 204 of portal 200 and exterior 85 of chamber 10 (which is typically atmospheric or ambient pressure). When closed, valve 900 prevents air flow between interior 204 of portal 200 and exterior thereof.
[0112] Handle 880 can be operatively connected to valve 900 , and can be used to open and close valve 900 , such as by being pivotally attached to valve 900 where rotational movement opens and closes valve 900 , such as in a ball valve. Rotation of handle 880 in a first direction can open valve 900 . Rotation of handle 880 in the opposite direction as the first direction can close valve 900 .
[0113] Handle 880 can also be operatively connected to locking bar 810 through linkage 850 . Rotation of handle 880 in the first direction can cause locking bar 810 to enter an unlocked state. Rotation of handle 880 in the opposite direction can cause locking bar 810 into a locked state. When in a locked state locking shaft can pass through (between its upper and lower diametric dimensions, and at least past the 50 percent point of its rear depth or from its second end 270 to its first end 260 ). When in a locked state, locking bar 810 will restrict rotational movement of at least one of the plurality of locking projections 500 of door 400 . That is, door 400 can be rotated until one of the plurality of locking projections comes in contact with locking bar 810 at which point further rotational movement of door 400 can be prevented. For example, locking bar 810 can enter unlocking opening 310 and resist counterclockwise rotation of door 400 . The extent of clockwise rotation of door 400 is limited by second end 464 of slot 460 coming in contact with rotation stop 470 . In this manner the rotation of door (clockwise and counterclockwise) can be limited so that plurality of locking projections 500 remain at least partially in perimeter groove 290 (and not in plurality of unlocking openings 300 ), and door 400 is kept in a locked state.
[0114] Linkage 850 can comprise handle 880 , first bar 860 , and first bar's 860 pivoting connections between handle 880 and locking bar 810 . Locking bar 810 can be slidably connected to locking ring 250 . In this manner handle 880 , linkage 850 , and locking bar 810 can be a special type of four bar system, or a crank and slider configuration. In one embodiment linkage 850 can be configured such that there is a type of dwelling between the beginning rotational movement of handle 880 to open and sliding movement of locking bar 810 to cause locking bar 810 to change into an unlocked state. For example, the pivoting connection between first bar 860 and locking bar 810 can be offset from the pivot point of handle 880 on valve 900 (such as by about 10 degrees) such that initial rotational movement of handle 880 in a first direction tends to cause locking shaft to extend out (in a more locked position) until continued movement of handle 880 in the same rotational direction finally starts to cause locking bar 810 to stroke back an enter an unlocked state. As a result, the initial movement of the handle 880 does not produce an immediate retraction of the locking bar 810 from locking ring 250 . When the handle 880 travels to about 90 degree position (shown in FIG. 4 ) in relation to its original position (shown in FIG. 2 ) first bar 860 travels about 70-80 degrees.
[0115] Locking bar 810 can be pivotally attached to first bar 860 , such that rotational movement of handle 880 transfers locking bar 810 from locked (extended) to unlocked (retracted) states. In one embodiment, to resist wear between locking bar 810 and locking ring 250 a wear/lubricating/guide sleeve can be placed in locking ring 250 .
[0116] Operatively connecting handle 880 to both venting valve 900 and locking bar 810 is beneficial in that locking shaft can only be in an unlocked stated at a time when interior 204 of portal is venting (or has vented) to exterior 85 . However, the venting of interior 204 of portal 200 will take a finite (i.e., non-zero) time and there still exists the possibility that an operator will not allow interior 204 to adequately vent, but will immediately attempt to open outer door 400 after opening handle 880 (i.e., when there still is increased pressure in interior 204 ). If this were to happen the increased pressure in interior 204 could provide a force (the difference between [interior 204 pressure and pressure of the exterior] times the cross sectional area of interior 204 ) which can cause door 400 to swing out quickly and harm the operator. Because of this risk of operator attempting to open door 400 while interior 204 has not adequately vented, a second pressure actuated lock can be provided.
Safety Pressure Lock
[0117] FIG. 14 is a sectional view of the second or safety lock 1000 system which is pressure sensitive and which is shown in a locked state. FIG. 15 is a sectional view of second or safety lock 1000 system which is pressure sensitive and which is shown in an unlocked state.
[0118] An independent safety lock 1000 can be provided for outer door 400 . Safety lock 1000 can have a locking motion similar to quick lock/quick unlock 800 (in that it uses a sliding locking bar 1010 through locking ring 250 which resists rotation of one or more of the plurality of locking projections 500 ). Safety lock 100 is intended to provide a factor of safety (beyond quick lock/quick unlock 800 ) to avoid outer door 400 being opened where a high pressure is still found in interior 204 of portal 200 .
[0119] Safety lock 1000 can have locked and unlocked states which states are dependent at least in part on the pressure of interior 204 of portal 200 . In one embodiment safety lock 1000 which will generally enter an unlocked state when the difference between interior 204 pressure of portal 200 and exterior 85 is below a specified safety pressure level. In one embodiment the acceptable differential unlocking pressure is less than or equal to about 5 psi, 4 psi, 3 psi, 2 psi, and/or 1 psi. In various embodiments ranges between any of the above referenced pressure differentials are envisioned.
[0120] Safety lock 1000 can also enter an unlocked mode in a time delayed fashion compared to the start of venting of interior 204 of portal 200 . This time delay can provide an additional factor of safety to allow an adequate quantity of excess pressure in interior 204 to be vented before outer door 400 can be opened. In one embodiment safety lock 1000 will generally take between 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and 60 seconds to enter an unlocked stated from the start of venting of interior 200 and the time the safety lock 1000 enters the unlocked state.
[0121] Safety lock 1000 can comprise locking bar 1010 which is operatively connected to piston/cylinder system 1100 . Piston/cylinder system 1100 can be fluidly connected to interior 204 of portal 200 via connecting tube 1160 . Piston/cylinder system 1100 can include cylinder 1110 having first end 1120 and second end 1130 . Cylinder 1100 can include first end 1120 and second end 1130 . On second end 1130 can be a cap 1132 which can be detachably connected to cylinder 1100 (such as by threads). Cap 1132 can be sealed with a seal such as O-ring 1134 . The interior 1140 of cylinder 1100 can be fluidly connected to interior 204 of portal through connecting tube 1160 . A restriction (such as valve 1170 ) can be used to restrict or slow down gas flow between interior 204 and interior 1140 . In one embodiment an adjustable restrictor is used which can change the amount of restriction to gas flow. For example, valve 1170 can be partially closed limiting the quantity per unit time of gas flow. As another example the internal size of tube 1160 can be sized to limit the quantity per unit time of gas flow. As another example, flow weirs/baffles can be used to restrict/slow gas flow.
[0122] Slidably connected to cylinder 1110 can be piston 1200 . Piston 1200 can have first end 1210 , and second end 1220 . First end 1210 can be detachably connected to locking bar 1010 (such as through a fastener which may be threaded). Second end 1220 can include an enlarged base and seal 1230 (which can be an o-ring).
[0123] Between second end 1220 of piston 1200 and first end 1120 of cylinder 1100 can be a biasing member 1150 (such as a helical spring) which tends to push piston towards second end 1130 of cylinder (schematically shown in FIG. 15 by arrow 2610 ).
[0124] Where interior 204 has a pressure Pc which exceeds a specified amount, such high pressure can be transmitted through tube 1160 to push against enlarged base at second end 1220 of piston 1200 , overcoming the resistance of biasing member 1150 , and pushing piston 1200 up (in the opposition direction of arrow 2610 ). Because piston 1200 is attached to locking rod 1010 , such upward movement of piston 1200 will also move up locking rod 1010 . The amount of excess pressure needed to push up piston 1200 will be a function of the cross sectional areas of enlarged base along with the resistance of biasing member 1150 (which is a function of its spring constant), frictional forces, along with the ambient pressure (which can enter interior 1140 of cylinder 1100 at first end 1120 at opening 1124 as this opening is not sealed). Alternatively, a weep hole can be placed on first end 1120 of piston.
[0125] When interior 204 is pressurized, locking rod 1010 will be in a locked state. This is because the interior 204 pressure Pc overcomes the resisting forces of movement of piston 1200 and pushes up (movement in the opposite direction of arrow 2610 ) locking bar 1010 .
[0126] Movement of locking rod 1010 in the opposite direction of arrow 2610 causes locking bar 1010 to enter a locked state. When in a locked state locking bar 1010 can pass through locking ring 250 (between its upper and lower diametric dimensions, and at least past the 50 percent point of its rear depth or from its second end 270 to its first end 260 ). When in a locked state, locking bar 1010 will restrict rotational movement of at least one of the plurality of locking projections 500 of door 400 . That is, door 400 can be rotated until one of the plurality of locking projections comes in contact with locking bar 1010 at which point further rotational movement of door 400 can be prevented. For example, locking bar 1010 can enter unlocking opening 340 and resist counterclockwise rotation of door 400 . The extent of clockwise rotation of door 400 is limited by second end 464 of slot 460 coming in contact with rotation stop 470 . In this manner the rotation of door (clockwise and counterclockwise) can be limited so that plurality of locking projections 500 remain at least partially in perimeter groove 290 (and not in plurality of unlocking openings 300 ), and door 400 is kept in a locked state at least until locking shaft enters an unlocked state.
[0127] However, when interior 204 is vented to atmosphere (exterior 80 ), such as when valve 900 is opened by handle 880 , the elevated pressure Pc which had previously pushed up piston 1200 , will gradually reduce. When Pc in interior 204 is reduced, pressure Pv in the interior 1140 of cylinder will gradually bleed into interior 204 of portal 200 . As described above this bleeding process can be slowed down by restrictions to slow down the bleeding process. As the pressure Pv decreases biasing member 1150 will push down (in the direction of arrow 2610 ) piston 1200 . Such downward movement of piston 1200 will cause a downward movement (in the direction of arrow 2510 ) of locking bar 1010 . Locking shaft will eventually move down a sufficient extent to enter an unlocked state. Because the timing of locking bar 1010 entering an unlocked state is delayed and/or because locking bar 1010 entering an unlocked state occurs only when the differential pressure between interior 204 of portal 200 and exterior 85 , safety lock provides an additional factor of safety to prevent operators from opening outer door 400 before interior 204 has been adequately depressurized.
[0128] When both quick lock/quick unlock 800 and safety lock 1000 are in unlocked states, outer door 400 can be opened by clockwise rotation (to align plurality of locking projections 500 with plurality of openings 300 ) and then swinging out outer door 400 .
Inner Door
[0129] Turning now to FIGS. 16-20 , inner door 1400 will be described in more detail. FIG. 16 is a perspective view of interior door 1400 shown not connected to portal 200 with door 1400 and where the door is in an open state. FIG. 17 is a sectional view of latching system 1900 for inner door 1400 where the latching system is shown in a locked state, but where there is not a pressure differential between interior 80 of dive chamber 10 and interior 204 of portal 200 (or where interior 204 pressure Pc′ is higher than interior 80 pressure Pc). FIG. 18 is a sectional view of latching system 1900 shown in a locked state, but where interior 80 pressure Pc of dive chamber 10 is higher than interior 204 pressure Pc′ of portal 200 (and inner door 1400 is forced closed against portal 200 body 230 based on the larger interior 80 dive chamber 10 pressure Pc). FIG. 19 is a sectional view of latching system 1900 shown in a locked state but where there is not a pressure differential between interior 80 of dive chamber 10 and interior 204 of portal 200 . FIG. 20 is a sectional view of latching system 1900 shown in an unlocked state and where interior door 1400 is opened.
[0130] As can be seen in the drawings, inner door 1400 can be mounted for pivotal movement in relation to the body 230 between (a) an open position, (b) a closed-sealed position, and (c) a plurality of partially open/closed positions. Inner door 1400 can be connected to support bracket 1402 , which bracket is secured to a hinge or pivot axle 1404 of base 1406 .
[0131] Although not shown, hinge 1404 can be attached to a base 1406 , which base can be welded to body 230 .
[0132] Alternatively, hinge 1404 can be secured to an adjustable connecting strap 1700 . Connecting strap 1700 can be adjustable and detachably connectable to second end 220 of portal 200 . Adjustability of connecting strap 1700 can be obtained through use of a connecting band secured to base 1404 through one or two adjustment mechanisms 1720 (such as threaded fasteners). As adjustment mechanisms are tightened band 1710 tightens around body 230 and a frictional connection is obtained.
[0133] Inner door 1400 itself can be adjustable concentrically by using a floating connection 1403 between door 1400 and support bracket 1402 .
[0134] Handle 1408 can be attached to the outside surface of door 1400 .
[0135] Opposite hinge 1404 can be a latch 1900 . Latch 1900 can comprise body 1905 , base 1950 , and body 1905 can be pivotally connected to base 1950 . Body 1905 can include first end 1910 , second end 1920 , base 1950 , locking cavity 2010 , and locking tip 2000 . Body 1905 can be pivotally biased to a closed position by spring 1970 (which can be a torsional spring wrapped around pivot point or pin 1960 ), which biasing is schematically indicated by arrow 1972 . In one embodiment locking cavity 2010 can detachably lock connecting bar 1500 of inner door 1400 where spring 1970 normally urges body 1905 into a closed position. Locking cavity 2010 can engage connecting member 1500 , and can have a generally hook-shaped configuration for engaging connecting member 1500 .
[0136] Outwardly sloped portion preferably forms an approximately 30 degree angle in relation to arrow 1504 when body 1905 is fully rotated in the direction of arrow 1972 . Upwardly sloped or curved section 2011 preferably forms a relatively small angle from the direction of arrow 1972 , approximately 45 degrees when body 1905 is fully latched onto connecting member 1500 .
[0137] The size and shape of locking cavity 2010 can be made to retain inner door 1400 in a normally closed position. An O-ring 1422 can be positioned in a groove 1424 formed on second end 1420 of door 1400 . O-ring 1422 can be fitted in a dovetail-shaped groove 1424 formed on second end (inner surface) 1420 of inner door 1400 . O-ring 1422 seals door 1400 against an edge of body 230 when door 1400 is closed.
[0138] In one embodiment, even when body 1905 of latch 1900 is fully rotated in the direction of arrow 1972 , locking cavity 2010 continues to allow a limited extent of possible vertical movement of connecting member 1500 (i.e., there will be a limited amount of play). This extent of possible vertical movement or play is schematically indicate d by arrows 1502 . Alternatively, an extent of possible vertical movement of connecting bar 1500 can be allowed by base 1905 giving way (e.g., rotating in a direction opposite to arrow 1972 ) a certain extent when a force in the direction of arrow 1504 is applied) on inner door 1400 (such as by a differentially higher pressure in interior 204 compared to interior 80 ), but while base 1905 remains latched and resisting (albeit partially) movement of connecting bar 1500 . The force on inner door 1400 will be transferred to connecting member 1500 , and then transferred to body 1905 causing body 1905 to rotate at least partially in the opposite direction of arrow 1972 (however, spring 1970 will continue to maintain a torsional force on body 1905 tending to make body 1905 want to rotate in the direction of arrow 1972 ). In this manner spring 1970 and latch body 1905 can allow inner door 1400 to slightly open, breaking the seal and venting the differentially higher interior 204 pressure to interior 80 without ever setting up a situation where an explosive differentially higher interior 204 pressure can be seen. After the pressure vents, body 1905 will pull door 1400 closed again. Once the interior 204 , 80 pressures equalize, inner door 1400 will again be pushed in the opposite direction of arrow 1504 by spring 1970 rotating body 1905 in the direction of arrow 1972 causing locking cavity 2010 to pull down connecting member 1500 .
[0139] This extent of possible vertical movement is envisioned to allow a break in the seal between O-ring 1422 and body 230 so that an increased pressure (relative to interior 80 ) in the interior 204 of portal 200 can vent into interior 80 of chamber 10 and not risk an excessive pushing force in the direction of arrow 1504 on inner door 1400 . In one embodiment, locking cavity 2010 can include an upwardly sloped or curved section 2011 so that an differential increase in the pressure in interior 204 (relative to interior 80 ) tends to push inner door 1400 in the direction of arrow 1504 , which tends to push connecting member 1500 in the same direction. Movement of connecting member 1500 in the direction of arrow 1504 , by contact with section 2011 , will tend to cause body 1905 to rotate in the opposite direction of arrow 1972 , and allow inner door 1400 to move slightly in the direction of arrow 1504 —at least until a seal of O-ring 1422 between inner door 1400 and body 230 is broken and interior 204 starts to vent into interior 80 . In this way only a relatively small incremental increase in pressure of interior 204 of portal 200 relative to interior 80 of vessel 10 is allowed (before venting to interior 80 starts) thereby decreasing the risk that a relatively large incremental increased pressure of interior 204 relative to interior 80 will be set up—which large pressure differential could “swing out hard” inner door 1400 and harm someone.
[0140] In one embodiment the extent of possible differential (e.g., outward or vertical) movement between inner door 1400 and body 230 can be less than about 5, 4, 3, 2, 1, ½, ¼, ⅛, 1/10, 1/20, 1/30, 1/40, 1/50, 1/60, 1/70, 1/80, 1/90, 1/100, and/or 1/200 millimeters. In one embodiment the extent of possible differential movement can be limited to the “flexing” size differential allowed by O-ring 1422 . In one embodiment the extent of possible vertical movement of the door is limited to an extent to where the sealing O-ring is between about 50 percent 1 percent compressed, 40 and 1, 30 and 1, 25 and 1, 20 and 1, 15 and 1, 10 and 1, and 5 and 1. In one embodiment the extent of possible vertical movement of the door is limited to an extent to where the sealing O-ring is between about 50 percent 5 percent compressed, 40 and 5, 30 and 5, 25 and 5, 20 and 5, 15 and 5, 10 and 5, and 5 and 2. In various embodiments ranges between any two of the above specified possible ranges can be limited for O-ring compression.
[0141] A limit on the extent of possible vertical movement will allow inner door 1400 to be transported in a “closed” position, but limit the swinging back and forth of inner door 1400 differential movements (or jerking movements) during transportation. Additionally, a limit on the extent of possible vertical movement can resist banging open and shut inner door 1400 relative to body 230 when in use, such as by jerking caused by wave movement on a ship on which chamber 10 is installed. Preferably, the limit of vertical movement is the “flexing” of O-ring 1422 because then O-ring 1422 can also reduce the amount of banging because the polymer composition of O-ring 1422 softens/dampens the shutting of door 1400 by resisting movement. Even where the limited amount of vertical movement is larger than the flexing extent of O-ring, when inner door 1400 starts to come in contact with body 230 , O-ring can contact first and start to soften (or even prevent) metal to metal contact between inner door 1400 and body 230 (which reduces or prevents banging of inner door).
[0142] In closing inner door 1400 , handle 1408 can be used to move door 1400 in the opposite direction of arrow 1972 until connecting member 1500 contacts outwardly sloped portion 2050 of body 1905 . As door 1400 is continued to be pushed closed the force of spring 1970 is overcome and body 1905 rotates in the opposite direction as arrow 1972 , at least until point 2014 is reached. As door is continued to be pushed closed in the opposite direction as arrow 1504 , spring 1970 causes body to rotate in the direction of arrow 1972 and connecting member 1500 to be “locked” inside of locking cavity 2010 .
[0143] Where interior 80 pressure in chamber 10 is greater than interior 204 pressure, such differential higher pressure relative to interior 204 of portal 200 tends to push against (create a force pushing) inner door 1400 (in the direction opposite to arrow 1504 ) causing inner door 1400 will seal against body 230 with O-ring 1422 . A seal between interior 80 and interior 204 can be maintained by O-ring 1424 because the higher interior 80 pressure pushes door 1400 against body 230 energizing the sealing effect of O-ring 1424 between door 1400 and body 230 .
[0144] To open inner door handle 1408 can be used to swing inner door 1400 in the direction of arrow 1972 . Connecting member 1500 will contact section 2011 and push up/push out section 2011 causing body 1905 to rotate in the opposite direction of arrow 1972 , allowing inner door 1400 to continue to move in the direction of arrow 1504 and pass point 2014 which is maximum extent of upwardly sloped section 2011 . After this point inner door 1400 can be opened completely. Once connecting member 1500 passes point 2014 , spring 1960 will cause body 1905 to rotate in the direction of arrow 1972 .
[0145] Alternatively, outwardly sloped portion 2050 can be used by the person in the interior to manually push body 1905 in the opposite direction of arrow 1972 , such as by using the person's thumb to push on portion 2050 at the same time as pulling up on handle 1408 . If the user wishes to open the door 1400 , the user will push on outwardly sloped portion 2050 , causing latch body 1905 to pivot away (rotate in a direction opposite of arrow 1972 ) from the connecting member 1500 , thereby allowing door 1400 to be pivoted into an open position.
[0146] In the event that an increased pressure of the interior 204 (relative to the interior 80 ) exists which is not enough to start venting interior 204 by itself, a type of manual venting occurs before latch 1900 is unlocked. That is, as handle 1408 is pulled upwardly in the direction of arrow 1504 , door 1400 will also start to move in this direction and the seal of O-ring 1422 (between door 1400 and body 230 ) will break and venting will start to occur even before connecting member 1500 comes out of locking cavity 2010 . Here, while it continues to remain in locking cavity 2010 , inner door 1400 remains “locked” but allows venting to occur before inner door 1400 is completely released by latch 1900 .
[0147] In one embodiment, handle 1408 can be located above upwardly sloped or curved section 2011 so that section 2011 can be “thumb-pressed” to manually release connecting member 1500 from locking cavity 2010 . Such a positioning also prevents finger pinching by the latch.
[0148] In certain situations inner door 1400 may not be concentric (or may lose concentricity) with respect to body 230 . In one embodiment inner door 1400 can include one or more guides to assist and concentrically aligning inner door 1400 with body 230 . In one embodiment a raised center 1430 with angled portion 1432 can be provided. Where inner door 1400 is out of concentricity, angled portion 1432 can contact body 230 and cause inner door 1400 to move into a concentric position. In one embodiment this process of being aligned concentrically is facilitated by inner door 1400 being connected to support bracket 1402 with a floating connection 1403 . Floating connection, although it maintains a nominal concentric position of inner door 1400 with respect to support bracket 1402 , inner door 1400 can move position relative to support bracket, and such relative movement can adjust the concentricity of inner door 1400 relative to body 230 . With such adjustment for concentricity, a good seal can be maintained between inner door 1400 and body 230 when inner door 1400 is closed or shut.
[0149] In one embodiment latch 1900 holds inner door 1400 “securely closed” during shipment, but yet allows (during use) inner door 1400 to temporarily (and/or partially) lift off of the seal (O-ring 1422 ) and “vent” any differential increase in pressure which may exist in portal 200 (or decrease in pressure in chamber 10 ). In the event of a pressure differential attempting to open inner door 1400 , latch 1900 allows door 1400 to “lift off” of the seal to vent the pressure. However, when the differential pressure has been equalized (by the venting), spring 1970 and sloping contact surface 2011 of locking cavity 2010 pull door 1400 “closed” again.
[0150] In one embodiment latch 1900 also allows door 1400 to be closed without manually depressing latch body 1905 (e.g., pushing on outwardly sloped portion 2050 ) because the angle of sloped portion 2050 combined with the spring action (of spring 1970 on body 1905 ) allow body to first rotate in the opposite direction of arrow 1972 (to open latch 1900 ) and then snap back in the direction of arrow 1972 against connecting member 1500 when door 1400 is pressed closed.
[0151] In one embodiment O-ring 1422 and groove 1424 are placed in inner door 1400 . Conventional methods for sealing provide for the O-ring and groove to be placed in the non-moving portion of a door/closure seal (and not the moving door). The disadvantage of this solution can be seen where the O-ring groove becomes damaged requiring machining to repair. If O-ring groove 1424 was placed in the end of body 230 and became damaged, the entire chamber 10 would need to be taken out of service so that body 230 could be re-machined (possibly requiring the cutting out of body 230 from chamber 10 ); or a very expensive in-place machining operation must be performed if it is available. Placing O-ring 1422 and groove 1424 in inner door 1400 minimizes the possibility that expensive machining on body 230 will have to be done in place. First, the sealing face (location where seal occurs between door 1400 and body 230 ) on the end body 12 is now merely flat. A flat surface is less likely to become damaged, and, if damaged, such flat surface can be repaired using inexpensive manual methods (e.g.,—a hand file). Furthermore, O-ring groove 1424 can now be easily repaired because inner door 1400 can be easily removed from portal 200 (and chamber 10 ) and taken to a machine shop.
[0152] Placing O-ring groove 1422 in inner door 1400 creates a condition that must be addressed. If inner door 1400 moves concentrically out of position relative to portal 230 , an offset can be created between O-ring groove 1424 and the flat end of body 230 which offset could allow O-ring 1422 to fail in extrusion (such as to interior 204 of portal 200 ). In one embodiment this risk is addressed by providing a guide on inner door 1400 to assist in concentrically aligning inner door 1400 with body 230 . As described above one embodiment of this adjustment guides includes an angled portion on inner door 1400 with the possible use of a floating connection 1403 between door 1400 and support bracket 1402 . Another possible solution is to have the end of tube (with the flat sealing surface) widened to compensate for possible eccentric movement of inner door 1400 .
Method of Use
[0153] FIGS. 1-6 show various steps where portal 200 is used to transmit an item 3000 to an individual located in the interior 80 of chamber 10 while chamber 10 is pressurized. FIG. 1 is a perspective view of decompression chamber 10 with interlocking portal 200 . Chamber 10 has first end 20 , second end 30 , and cylindrical wall 40 . Chamber 10 also has an interior 80 which is at an elevated pressure relative to exterior 80 . Item 3000 is to be transferred from exterior, through portal 200 , and into interior 80 where interior 80 is to remain at an elevated pressure.
[0154] FIG. 2 is an enlarged perspective view portal 200 looking at portal 200 from the front 20 of chamber 10 , and where a portion of sidewall 40 of chamber 10 has been removed to show the front 210 and rear 220 ends of portal 200 . FIG. 3 is an enlarged perspective view of portal 200 , but now looking at portal 230 from the rear 30 of chamber and where a portion of the upper section has been removed to reveal interior 204 of the portal 230 . Here, interior 204 is shown as being at pressure Pc and interior 80 of chamber is at equal pressure Pc. Exterior 85 of chamber 10 is shown as being at pressure Pa, and Pc is elevated compared to Pa—which is the normal situation for decompression (or hyperbaric) chambers during operation. Outer door 400 is sealed relative to interior 204 pressure Pc, however, elevated pressure Pc will push on outer door 400 . Locking ring 250 maintains outer door 400 shut. Outer door 400 can be opened by rotating it in a counterclockwise direction (arrow 2613 ) to align plurality of locking projections 500 with plurality of unlocking openings 300 . However, to prevent an explosive event (i.e., the high pressure Pc causing an explosive opening of door 400 ) a double safety lock system is provided for outer door 400 which includes quick lock/quick unlock 800 along with second safety lock 1000 and are both in locked states.
[0155] FIG. 4 is an enlarged perspective view of portal 230 , but showing both quick lock/quick unlock 800 and second safety lock 1000 having moved into “unlocked” states. Here, quick lock/quick unlock 800 has been placed in an unlocked state by pushing handle 880 in the direction of arrow 2504 . Handle 880 is operatively connected to first locking bar 810 (through linkage mechanism 850 ), and turning handle 880 in the direction of arrow 2504 causes bar 810 to slide backward in locking ring 250 so that shaft 880 no longer restricts rotation of locking projection 510 . Handle 880 is also operatively connected to valve 900 , so that at the same time rotation of handle 880 opens valve 900 which starts the venting process of excess pressure Pc (located inside interior 204 of portal 200 ) to exterior 80 . Inner door 1400 was previously closed (with valve 1600 shut) so that when interior 204 pressure Pc′ vents out and decreases, now pressure Pc′ becomes less than interior 80 pressure Pc inside chamber 10 . Now excess pressure Pc (compared to Pc′) pushes on inner door 1400 which energizes O-ring 1422 seal to maintain a seal between interior 80 of chamber 10 and interior 204 of portal 200 —so that interior 80 of chamber 10 will not lose (e.g., vent) its elevated pressure Pc. As described above, in a preferred embodiment locking bar 810 experiences a dwell period before it starts it sliding back in relation to rotation of handle 880 to allow vent 900 to first open and at least start venting interior 204 of portal before locking bar 810 enters an unlocked state. Additionally, locking bar 810 , when moving from locked to unlocked (and from unlocked to locked) states, respective exits and enters perimeter groove 290 of locking ring 250 (i.e., between the outer edge of locking ring 250 and the outer wall of body 230 ). Additionally, when moving from an unlocked state to a locked stated locking bar 810 moves away from inner door 1400 towards outer door 400 (and when moving from an unlocked state to a locked state, moves away from outer door 400 towards inner door 1400 ).
[0156] However, even though quick lock/quick unlock 800 may move to an unlocked state, outer door 400 still cannot be opened until safety lock 1000 also moves to an unlocked state. Safety lock 1000 is a pressure based safety lock and time delayed compared to the time in which quick lock/quick unlock 800 is placed in an unlocked state. After quick lock/quick unlock is placed in an unlocked state and interior 204 starts to vent, the interior volume 1140 of piston/cylinder 1100 will start to vent into interior 204 dropping pressure Pv (which before the start of venting of interior 2014 was the same as pressure Pc) allowing spring 1150 to push piston 1200 in the direction of arrow 2610 and move delay locking bar 1010 in the direction of arrow 2510 until delay locking bar 1010 moves to an unlocked state, no longer restricting rotational movement of outer door 400 . Additionally, when moving from an unlocked state to a locked stated delay locking bar 1010 moves away from inner door 1400 towards outer door 400 (and when moving from an unlocked state to a locked state, moves away from outer door 400 towards inner door 1400 ). Accordingly, if for some reason placing quick lock/quick unlock 800 in an unlocked state does not vent interior 204 of portal, safety lock 1000 will remain in a locked state also preventing the opening of door 400 . Furthermore, safety lock 1000 is designed such that it can only enter an unlocked state when a certain maximum interior pressure Pc′ is reached in interior 204 to prevent door 400 from being opened at a time when interior pressure Pc′ can still push and swing door 400 open in a manner which can do harm. This minimum pressure for unlocking can be achieved by using a spring 1150 of a certain stiffness compared to the cross sectional area of second end 1220 of piston 1200 . In one embodiment safety lock 1000 which will generally enter an unlocked state when the difference between interior 204 pressure of portal 200 and exterior 85 is below a specified safety pressure level. In one embodiment the acceptable differential unlocking pressure is less than or equal to about 5 psi, 4 psi, 3 psi, 2 psi, and/or 1 psi. In various embodiments ranges between any of the above referenced pressure differentials are envisioned. In one embodiment safety lock 1000 can also enter an unlocked mode in a time delayed fashion compared to the start of venting of interior 204 of portal 200 . This time delay can provide an additional factor of safety to allow an adequate quantity of excess pressure in interior 204 to be vented before outer door 400 can be opened. In one embodiment safety lock 1000 will generally take between about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and 60 seconds to enter an unlocked stated from the start of venting of interior 200 and the time the safety lock 1000 enters the unlocked state. A time delay can be obtained by providing a restriction/limiter to flow out of volume 1140 to interior 204 .
[0157] Once both quick lock/quick unlock 800 and safety lock 1000 have entered unlocked states, outer door 400 can be opened providing access to interior 204 . Because interior 204 has been fully vented to exterior 80 (through valve 900 ), interior 204 pressure Pc′ is now equal to exterior 85 pressure Pa. Door 400 can be opened by rotating it counterclockwise and then pulling it open. The seal between inner door 1400 and body 230 prevents venting from interior 80 of chamber to the outside. FIG. 5 is an enlarged perspective view of portal 200 with outer door 400 opened and schematically showing an item 3000 being placed (arrow 3010 ) in the interior 204 of the portal 230 . Now that item 3000 has been placed in the interior 204 , outer door 400 can be closed. FIG. 6 is an enlarged perspective view of portal 200 showing item 3000 placed in portal 200 with outer door 400 closed and both quick lock/quick unlock 800 and safety lock 100 having been moved into locked states. Outer door 400 is shut by swinging it closed and turning it clockwise (in the direction of arrows 2612 and 2622 ) using handles 600 , 610 . Quick lock/quick unlock 800 is placed in a locked state by pushing handle in the direction of arrow 2506 which both slides locking bar 810 in a locked state (restricting counterclockwise rotation of door 400 ), and closes valve 900 (sealing interior 204 from exterior 85 as outer door 400 is sealed with respect to body 230 by O-ring 212 ). Interior 204 has remained sealed from interior 80 of chamber because inner door 400 has continually been pushed shut because of higher interior 80 pressure Pc compared to interior 204 pressure Pc′ (which is equal to exterior 85 pressure Pa). To allow access from interior 80 to interior 204 , inner door 400 must be opened. This can be done by venting interior 80 pressure Pc into interior 204 —by opening valve 1600 . Arrows 1650 schematically indicate the venting of interior 80 pressure into interior 204 through vent opening. As this venting occurs (between interiors 80 and 204 ) the interior 204 pressure Pc′ will gradually rise to equal interior 80 pressure Pc and no longer will there be a closing force on inner door 1400 . Also as this venting occurs, the rising interior 204 pressure will cause safety lock 1000 to move into a locked state as pressure also vents into the piston/cylinder 1100 causing piston 1200 to extend and locking bar 1010 to move into a locked state.
[0158] When interior 204 pressure Pc′ equalizes with interior 80 pressure Pc, the individual inside chamber 10 can open latch 1900 , open inner door 1400 , and remove item 3000 . FIG. 7 is an enlarged perspective view of portal 200 showing inner door 1400 being opened (swung in the direction of arrow 1401 ) and item 3000 being moved from interior 204 of portal 200 to interior 80 of chamber 10 (schematically shown by arrow 3012 ). Opening latch 1900 is schematically indicated by arrow 2100 .
[0159] After removal of item 3000 , portal 200 can be readied for the next transfer. To do this valve 1600 should be shut, and inner door 1400 should be swung closed (opposite direction as arrow 1401 ) so that it is latched by latch 1900 . At this point interior 204 of portal 200 will be the same pressure Pc′ as interior 80 of chamber 80 .
[0160] To transfer an item 3000 from interior 80 to exterior 85 , the first step would have been to have the individual inside chamber 10 place item 3000 in interior 204 of portal 200 and close inner door 1400 . Then the steps previously described for opening outer door 400 would be followed for a person outside of chamber 10 to remove item 3000 from inside of portal 200 .
[0161] When venting from interior 80 of chamber 10 to interior 204 of portal 200 it is not expected that interior 80 of chamber will lose much pressure. This is because the volume of interior 80 of chamber is so much larger than the interior 204 of portal.
[0162] The following is a list of reference materials:
[0000]
LIST FOR REFERENCE NUMERALS
(Part No.)
(Description)
Reference Numeral
Description
10
decompression chamber
20
first end
30
second end
40
wall
50
base
60
door
70
seal
80
interior
85
exterior
200
portal
204
interior
210
first end
211
shoulder
212
O-ring
214
O-ring groove
216
enlarged area
218
reduced area
220
second end
230
body
240
side wall
250
locking ring
254
opening
260
first end
270
second end
280
body
284
height
290
perimeter groove
300
plurality of unlocking openings
310
first opening
312
locking tab
313
edge
320
second opening
322
locking tab
323
edge
330
third opening
332
locking tab
333
edge
340
fourth opening
342
locking tab
343
edge
400
outer door
410
first end
412
extended end
414
angled beveled end
416
outer end
418
inner end
420
second end
430
center
440
fastener
450
support plate
460
rotation slot
462
first end
464
second end
470
rotation stop
500
plurality of locking projections
510
first projection
512
sloped surface
514
beveled surface
520
second projection
530
third projection
540
fourth projection
600
handle
610
handle
700
support bracket
710
hinge
720
connection points
800
first quick lock
802
arrow
810
locking bar
812
wear/lubrication sleeve
820
first end
830
second end
850
linkage mechanism
852
pivot point
854
pivot point
856
pivot point
860
first bar
870
second bar
880
handle
900
valve
910
first end
920
second end
950
vent tube
960
first end
970
second end
1000
second delay lock
1010
delay locking bar
1012
wear/lubrication sleeve
1020
first end
1030
second end
1050
linkage mechanism
1100
piston/cylinder system
1110
cylinder
1120
first end
1124
opening on first end
1130
second end
1132
cap
1134
O-ring
1140
interior
1150
biasing member
1160
connecting tube
1170
flow control
1172
arrow
1200
piston
1210
first end
1220
second end
1230
seal
1400
inner door
1401
arrow
1402
support bracket
1403
floating connection
1404
hinge
1406
base
1408
handle
1410
first end
1420
second end
1422
O-ring
1424
O-ring groove
1426
enlarged area
1428
reduced area
1430
raised center
1432
angled portion
1434
base
1500
connecting bar
1502
arrows
1504
arrow
1600
interior venting valve
1610
handle
1620
vent opening
1630
arrow
1640
arrow
1650
arrow
1700
connecting strap
1710
band
1720
adjustment mechanism for band
1800
hinge
1810
connection points for door
1900
latch or quick lock for inner door
1905
body
1910
first end
1920
second end
1950
base
1960
pivot point
1970
spring
1972
arrow
2000
locking tip
2010
locking cavity
2011
upwardly sloped or curved section
2014
maximum extend of upwardly sloped portion
2050
outwardly sloped portion
2100
arrow
2500
arrow
2502
arrow
2510
arrow
2512
arrow
2520
arrow
2522
arrow
2530
arrow
2532
arrow
2540
arrow
2542
arrow
2550
arrow
2552
arrow
2560
arrow
2562
arrow
2570
arrow
2572
arrow
2580
arrow
2582
arrow
2590
arrow
2592
arrow
2600
arrow
2602
arrow
2610
arrow
2613
arrow
2620
arrow
3000
item
3010
arrow
3012
arrow
[0163] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
[0164] It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | An interlock vessel having an air-tight body with opposing ends. A portion of the body is designed to fit into a decompression (hyperbaric) chamber, wherein a diver or a patient undergoing a decompression treatment is positioned. The opposing ends are closed by pivotally moveable doors and locking assemblies that retain the doors in a closed position until the pressure inside the decompression chamber and the exterior of the chamber can be equalized. The outer door has two locking systems: (a) an interlock system and (b) a safety/delay locking system. Both locking assemblies are manually operated. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Section 371 National Stage Application of International Application No. PCT/GB2013/051907, filed Jul. 17, 2013, which is incorporated by reference in its entirety and published as WO 2014/016566 A2 on Jan. 30, 2014 and which claims priority of British Application No. 1213306.2, filed Jul. 26, 2012.
FIELD OF THE INVENTION
[0002] The present invention relates to a radiant burner and method.
BACKGROUND
[0003] Radiant burners are known and are typically used for treating an effluent gas stream from a manufacturing process tool used in, for example, the semiconductor or flat panel display manufacturing industry. During such manufacturing, residual perfluorinated compounds (PFCs) and other compounds exist in the effluent gas stream pumped from the process tool. PFCs are difficult to remove from the effluent gas and their release into the environment is undesirable because they are known to have relatively high greenhouse activity.
[0004] Known radiant burners use combustion to remove the PFCs and other compounds from the effluent gas stream. Typically, the effluent gas stream is a nitrogen stream containing PFCs and other compounds. A fuel gas is mixed with the effluent gas stream and that gas stream mixture is conveyed into a combustion chamber that is laterally surrounded by the exit surface of a foraminous gas burner. Fuel gas and air are simultaneously supplied to the foraminous burner to affect flameless combustion at the exit surface, with the amount of air passing through the foraminous burner being sufficient to consume not only the fuel gas supplied to the burner, but also all the combustibles in the gas stream mixture injected into the combustion chamber.
[0005] As the surface areas of the semiconductors being produced increases, the flow rate of the effluent gas also increases.
[0006] Although techniques exist for processing the effluent gas stream, they each have their own shortcomings. Accordingly, it is desired to provide an improved technique for processing an effluent gas stream.
[0007] The discussion above is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all disadvantages noted in the background.
SUMMARY
[0008] According to a first aspect, there is provided a radiant burner for treating an effluent gas stream from a manufacturing process tool, the radiant burner comprising: a combustion chamber having a porous sleeve through which combustion materials pass for combustion proximate to a combustion surface of the porous sleeve; at least one effluent nozzle for ejecting the effluent gas stream into the combustion chamber; and a perforated liner proximate to the combustion surface.
[0009] The first aspect recognizes that a problem with the increasing flow rates is that greater quantities of effluent gas need to be processed. One approach would be to increase the size of the radiant burner. However, the first aspect recognizes that a problem with this approach is that the combustion mechanisms within the radiant burner are complex and simply increasing the size of the radiant burner to match the increased flow rate of the effluent gas can lead to reduced performance of the radiant burner. Also, even if it were possible to produce a larger radiant burner with adequate performance, it is not straightforward to integrate such a larger radiant burner with existing processing equipment at the manufacturing site. Another approach would be to add further radiant burners to increase the processing capacity. However, the first aspect also recognises that a problem with this approach is that it is not straightforward to integrate such further radiant burners with existing processing equipment at the manufacturing site. The first aspect further recognizes that whilst it is possible to increase the flow rate of the effluent gas through a radiant burner, this can lead to increased combustion residues or deposits on the radiant burner caused by the non-PFC compounds, which significantly impair its performance over time.
[0010] Accordingly, a gas abatement apparatus or radiant burner is provided. The radiant burner may treat an effluent gas stream from a manufacturing process tool. The radiant burner may comprise a combustion chamber. The combustion chamber may have a porous or permeable sleeve through which combustion materials pass. The combustion materials may combust proximate to, near to or adjacent a combustion surface of the porous sleeve. One or more effluent nozzles may be provided which eject the effluent gas stream into the combustion chamber. A perforated, porous or punched liner may be provided proximate to, near to or adjacent the combustion surface. Providing a perforated liner controls the combustion materials passing into the combustion chamber to treat the effluent gas stream and also provides a surface onto which residual combustion deposits may be received. Accordingly, the liner can both improve the efficiency of the treatment of the effluent gas stream and can act as a sacrificial surface which may be replaced or cleaned either in accordance with a maintenance regime or when the performance of the radiant burner reduces. Such replacement or cleaning of the liner saves having to replace the porous sleeve or other components of the combustion chamber which cannot readily be removed or cleaned. This enables the radiant burner to operate at higher flow rates and avoids needing to increase the size of the radiant burner or needing to add further radiant burners.
[0011] In one embodiment, the perforated liner is accommodated within the combustion chamber. Accordingly, the liner may be located within the combustion chamber itself to receive the combustion residues and protect other components of the combustion chamber.
[0012] In one embodiment, the combustion materials combust in a combustion zone proximate to the combustion surface of the porous sleeve to produce combustion products and the perforated liner is located adjacent the combustion zone. Accordingly, the liner may be located adjacent, near or proximate to the combustion zone where the combustion products are generated. The exact position of the liner may vary depending on the characteristics of the combustion zone. In embodiments, the combustion products comprise, for example, oxygen.
[0013] In one embodiment, the perforated liner extends at least partially along an axial length of the combustion chamber. Accordingly, the liner may extend along the axial length of all or a part of the combustion chamber.
[0014] In one embodiment, the perforated liner is perforated with a plurality of holes. Providing holes or apertures enables the combustion products to pass from the combustion zone into the combustion chamber to mix and treat the effluent gas stream. It will be appreciated that the exact placement of the holes or apertures will affect or control the flow of the combustion products into the combustion chamber.
[0015] In one embodiment, the perforated liner comprises an expandable mesh-like structure. Providing an expandable structure provides both perforations for the products to pass from the combustion zone into the combustion chamber whilst enabling the liner to flex to enable deposits to be removed.
[0016] In one embodiment, the radiant burner comprises an actuator operable to retain the expandable mesh-like structure in a retained position within the combustion chamber and to displace at least one end of the expandable mesh-like structure to an expanded position. This enables the structure to be held in a desired position within the combustion chamber whilst expanding the structure causes deposits on the structure to be removed.
[0017] In one embodiment, the expandable mesh-like structure has a first axial length when in the retained position and second axial length when in the expanded position, wherein the second axial length is greater than the first axial length. Accordingly, a simple longitudinal extension of the structure causes flexing of the perforations and dislodges deposits.
[0018] In one embodiment, the expandable mesh-like structure has an axial length matching that of the combustion chamber when in the retained position and greater than that of the combustion chamber when in the expanded position. It will be appreciated that many embodiments include a water curtain structure adjacent the outlet of the combustion chamber into which the structure may be extended.
[0019] In one embodiment, the expandable mesh-like structure comprises a coil spring having spacers arranged to space apart adjacent turns when in the retained position. It will be appreciated that other structures are possible such as a honeycomb arrangement or woven sock, but providing a coil spring arrangement is particularly beneficial for providing a self-supporting structure which maintains its outer dimensions during axial expansion.
[0020] In one embodiment, the coil spring is formed from one of a cylindrical and a planar substrate.
[0021] In one embodiment, the spacers comprise at least one of projections from a surface of the coil spring; an annular ring, a ferrule and a wound coil surrounding a surface of the coil spring; and a pleated coil spring having adjacent turns interspaced between adjacent turns of the coil spring. The provision of these spacers controls the spacing between adjacent turns of the spring when in the retained position.
[0022] In one embodiment, dimensions and locations of the coil spring and spacers are selected to provide a selected hole density of the perforated liner. By controlling the size of the coil spring and of the spacers, and by controlling the location of the spacers on the coil spring, the size of the holes or perforations can be controlled when in the retained position.
[0023] In one embodiment, a density of the holes of the perforated liner changes along the axial length. Accordingly, the density, concentration or quantity per unit surface area of the perforations, or the ratio of aperture surface area to non-aperture surface area of the liner may vary along the axial length of the liner. This variation in the size and density of holes or apertures in the liner helps to vary the rate of flow, concentration or amount of combustion products within different parts of the combustion chamber. Varying the flow rate, concentration or amounts of combustion products within the combustion chamber can help to improve the efficiency of the effluent treatment process by providing the right amounts of combustion products at the right locations.
[0024] In one embodiment, the combustion chamber has a nozzle end proximate to the at least one effluent nozzle and an exhaust end axially distal from the at least one effluent nozzle, the density of the holes of the perforated liner decreases towards the exhaust end. Accordingly, the density or concentration of apertures in the liner may decrease along the axial length of the liner. That is to say that the amount of aperture surface area of the liner is higher towards the effluent nozzles than it is the exhaust end. This helps to increase the amount of combustion products near where the effluent gas enters the combustion chamber and decreases the amount of combustion products near the exhaust end where the quantity of untreated effluent gas is reduced.
[0025] In one embodiment, the combustion chamber has an exhaust zone extending axially proximate to the exhaust end, the density of the holes of the perforated liner increases towards the exhaust zone. Accordingly, a region of the liner near the exhaust end may have an increased or high concentration of aperture surface area in order to increase the concentration of combustion products near the exhaust end where the treatment of the effluent gas is least effective.
[0026] In one embodiment, the combustion chamber has a nozzle zone extending axially proximate to the nozzle end, the density of the holes of the perforated liner decreases towards the nozzle zone. Accordingly, a region of the liner near the nozzle end may have a decreased or low concentration of aperture surface area in order to decrease the concentration of combustion products in a region where combustion residues or deposits cause particular performance degradation or where cleaning such residues or deposits is difficult.
[0027] In one embodiment, the perforated liner is unperforated proximate to the nozzle zone.
[0028] In one embodiment, the radiant burner comprises a plurality of the nozzles positioned circumferentially around the combustion chamber and the density of the holes of the perforated liner increases circumferentially proximate to the plurality of the nozzles. Accordingly, the amount of aperture surface area of the liner may increase near the nozzles in order to deliver more combustion products in the vicinity of the effluent gas stream being ejected from the nozzles. This helps to ensure that the combustion products are concentrated in the regions where they are most needed to react with the effluent gas stream.
[0029] In one embodiment, the radiant burner comprises at least one spray nozzle for ejection of a cleaning fluid onto a cleaning zone of the perforated liner, the density of the holes of the perforated liner decreases towards the cleaning zone. Accordingly, cleaning fluids may be sprayed from the nozzle onto the liner. The density of holes in the region where the cleaning fluid impacts the liner may be decreased or even no holes are provided at all in order to prevent the cleaning fluid from passing through the liner and contacting the porous sleeve or other potentially damageable components of the radiant burner.
[0030] In one embodiment, the perforated liner comprises one of a mesh, a wire screen, a perforated sheet and a louvered sheet.
[0031] In one embodiment, the louvers of the louvered sheet are orientated to direct the combustion products within the combustion chamber. It will be appreciated that the louvers provide both a mechanism for directing the flow of the combustion products to specified regions within the combustion chamber, whilst also providing an effective bather to prevent cleaning fluid from passing through the liner.
[0032] In one embodiment, louvers of the louvered sheet are orientated to receive on a major surface the cleaning fluid from the at least one spray nozzle. Hence, it will be appreciated that the use of louvers enables perforations to be provided within the cleaning zone. It will be appreciated that that a louver is typically a long, thin, planar member; the major surface would be one of the large (typically ‘upper’ or ‘lower’) surfaces of the louver as opposed to a minor surface which would in effect be its edges.
[0033] In one embodiment, the perforated liner is axially displaceable between an accommodated position where the perforated liner is accommodated within the combustion chamber and an unaccommodated position where the perforated liner protrudes from the combustion chamber. Accordingly, the liner may be movable within the combustion chamber to protrude from the combustion chamber to facilitate cleaning. It will be appreciated that such displacement may be provided in addition to or instead of providing the spray nozzle.
[0034] In one embodiment, the perforated liner fully extends from the combustion chamber in the unaccommodated position. Fully removing of the liner from the combustion chamber further helps to aid its cleaning or replacement.
[0035] In one embodiment, the radiant burner comprises a cleaning tank for holding a cleaning fluid and wherein the perforated liner extends into the cleaning tank in the unaccommodated position Immersing the liner within the cleaning tank helps to remove the combustion residues and clean the liner.
[0036] In one embodiment, the radiant burner comprises means for agitating the perforated liner in the cleaning tank. It will be appreciated that agitating further helps to clean the liner.
[0037] In one embodiment, the perforated liner comprises an aperture for receiving an associated one of the effluent nozzles, displacement of the perforated liner causing movement of the aperture with respect to the associated one of the effluent nozzles to dislodge any effluent treatment deposit located on an outer surface thereof. Accordingly, the act of displacing the liner may facilitate the removal of combustion deposits or residues that may have been deposited on the nozzles, which may in time otherwise reduce the performance of these nozzles.
[0038] In one embodiment, the perforated liner is metallic. Providing a metallic liner enables increased mechanical and thermal shock stress to be applied when performing the cleaning compared to that which would be possible when trying to clean the porous sleeve or other components of the combustion chamber.
[0039] In one embodiment, the perforated liner comprises nickel.
[0040] In one embodiment, the combustion zone and the perforated liner are cylindrical.
[0041] According to a second aspect, there is provided a method of treating an effluent gas stream from a manufacturing process tool, the method comprising the steps of: passing combustion materials through a porous sleeve of a combustion chamber for combustion proximate to a combustion surface of the porous sleeve; ejecting the effluent gas stream from at least one effluent nozzle into the combustion chamber; and providing a perforated liner proximate to the combustion surface.
[0042] In one embodiment, the perforated liner is accommodated within the combustion chamber.
[0043] In one embodiment, the combustion materials combust in a combustion zone proximate to the combustion surface of the porous sleeve to produce combustion products and the perforated liner is located adjacent the combustion zone.
[0044] In one embodiment, the perforated liner extends at least partially along an axial length of the combustion chamber.
[0045] In one embodiment, the perforated liner is perforated with a plurality of holes.
[0046] In one embodiment, the perforated liner comprises an expandable mesh-like structure.
[0047] In one embodiment, the method comprises retaining the expandable mesh-like structure in a retained position within the combustion chamber and displacing at least one end of the expandable mesh-like structure to an expanded position.
[0048] In one embodiment, the expandable mesh-like structure has a first axial length when in the retained position and second axial length when in the expanded position, wherein the second axial length is greater than the first axial length.
[0049] In one embodiment, the expandable mesh-like structure has an axial length matching that of the combustion chamber when in the retained position and greater than that of the combustion chamber when in the expanded position.
[0050] In one embodiment, the expandable mesh-like structure comprises a coil spring having spacers arranged to space apart adjacent turns when in the retained position.
[0051] In one embodiment, the coil spring is formed from one of a cylindrical and a planar substrate.
[0052] In one embodiment, the spacers comprise at least one of projections from a surface of the coil spring; an annular ring, a ferrule and a wound coil surrounding a surface of the coil spring; and a pleated coil spring having adjacent turns interspaced between adjacent turns of the coil spring.
[0053] In one embodiment, the method comprises selecting dimensions and locations of the coil spring and spacers to provide a selected hole density of the perforated liner.
[0054] In one embodiment, a density of the holes of the perforated liner changes along the axial length.
[0055] In one embodiment, the combustion chamber has a nozzle end proximate to the at least one effluent nozzle and an exhaust end axially distal from the at least one effluent nozzle, the density of the holes of the perforated liner decreases towards the exhaust end.
[0056] In one embodiment, the combustion chamber has an exhaust zone extending axially proximate to the exhaust end, the density of the holes of the perforated liner increases towards the exhaust zone.
[0057] In one embodiment, the combustion chamber has a nozzle zone extending axially proximate to the nozzle end, the density of the holes of the perforated liner decreases towards the nozzle zone.
[0058] In one embodiment, the perforated liner is unperforated proximate to the nozzle zone.
[0059] In one embodiment, the step of ejecting comprises ejecting from a plurality of the nozzles positioned circumferentially around the combustion chamber and wherein the density of the holes of the perforated liner increases circumferentially proximate to the plurality of the nozzles.
[0060] In one embodiment, the method comprises the step of ejecting a cleaning fluid from at least one spray nozzle for onto a cleaning zone of the perforated liner and wherein the density of the holes of the perforated liner decreases towards the cleaning zone.
[0061] In one embodiment, the perforated liner comprises one of a mesh, a wire screen, a perforated sheet and a louvered sheet.
[0062] In one embodiment, the louvers of the louvered sheet are orientated to direct the combustion products within the combustion chamber.
[0063] In one embodiment, the louvers of the louvered sheet are orientated to receive on a major surface the cleaning fluid from the at least one spray nozzle.
[0064] In one embodiment, the method comprises the step of axially displacing the perforated liner between an accommodated position where the perforated liner is accommodated within the combustion chamber and an unaccommodated position where the perforated liner protrudes from the combustion chamber.
[0065] In one embodiment, the perforated liner fully extends from the combustion chamber in the unaccommodated position.
[0066] In one embodiment, the step of axially extending comprises extending the perforated liner into a cleaning tank holding a cleaning fluid.
[0067] In one embodiment, the method comprises the step of agitating the perforated liner in the cleaning tank.
[0068] In one embodiment, the perforated liner comprises an aperture for receiving an associated one of the effluent nozzles and the method comprises the step of displacing the perforated liner to cause movement of the aperture with respect to the associated one of the effluent nozzles to dislodge any effluent treatment deposit located on an outer surface thereof.
[0069] In one embodiment, the perforated liner is metallic.
[0070] In one embodiment, the perforated liner comprises nickel.
[0071] In one embodiment, the combustion chamber and the perforated liner are cylindrical.
[0072] According to a third aspect, there is provided a perforated liner for a radiant burner for treating an effluent gas stream from a manufacturing process tool, the radiant burner comprising a combustion chamber having a porous sleeve through which combustion materials pass for combustion proximate to a combustion surface of the porous sleeve; at least one effluent nozzle for ejecting the effluent gas stream into the combustion chamber, the perforated liner being shaped and configured for placement proximate to the combustion surface.
[0073] In one embodiment, the perforated liner is shaped and configured for accommodation within the combustion chamber.
[0074] In one embodiment, the combustion materials combust in a combustion zone proximate to the combustion surface of the porous sleeve to produce combustion products and the perforated liner is shaped and configured for location adjacent the combustion zone.
[0075] In one embodiment, the perforated liner is dimensioned to extend at least partially along an axial length of the combustion chamber.
[0076] In one embodiment, the perforated liner is perforated with a plurality of holes.
[0077] In one embodiment, the perforated liner comprises an expandable mesh-like structure.
[0078] In one embodiment, the expandable mesh-like structure has a first axial length when in a retained position and second axial length when in an expanded position, wherein the second axial length is greater than the first axial length.
[0079] In one embodiment, the expandable mesh-like structure has an axial length matching that of the combustion chamber when in the retained position and greater than that of the combustion chamber when in the expanded position.
[0080] In one embodiment, the expandable mesh-like structure comprises a coil spring having spacers arranged to space apart adjacent turns when in the retained position.
[0081] In one embodiment, the coil spring is formed from one of a cylindrical and a planar substrate.
[0082] In one embodiment, the spacers comprise at least one of projections from a surface of the coil spring; an annular ring, a ferrule and a wound coil surrounding a surface of the coil spring; and a pleated coil spring having adjacent turns interspaced between adjacent turns of the coil spring.
[0083] In one embodiment, dimensions and locations of the coil spring and spacers are selected to provide a selected hole density of the perforated liner.
[0084] In one embodiment, a density of the holes changes along the axial length.
[0085] In one embodiment, the density of the holes decreases towards an exhaust end.
[0086] In one embodiment, the density of the holes increases towards an exhaust zone.
[0087] In one embodiment, the density of the holes of the perforated liner decreases towards a nozzle zone.
[0088] In one embodiment, the perforated liner is unperforated proximate to the nozzle zone.
[0089] In one embodiment, the density of the holes of the perforated liner increases circumferentially proximate a plurality of nozzle regions.
[0090] In one embodiment, the density of the holes of the perforated liner decreases towards a cleaning zone.
[0091] In one embodiment, the perforated liner comprises one of a mesh, a wire screen, a perforated sheet and a louvered sheet.
[0092] In one embodiment, the louvers are orientated to direct the combustion products within the combustion chamber.
[0093] In one embodiment, the louvers are orientated to receive on a major surface the cleaning fluid from the at least one spray nozzle.
[0094] In one embodiment, the liner comprises an aperture for receiving an associated effluent nozzle.
[0095] In one embodiment, the perforated liner is metallic.
[0096] In one embodiment, the perforated liner comprises nickel.
[0097] In one embodiment, the perforated liner is cylindrical.
[0098] According to a fourth aspect, there is provided a radiant burner perforated liner for treating an effluent gas stream from a manufacturing process tool, the radiant burner comprising a combustion chamber having a porous sleeve through which combustion materials pass for combustion proximate to a combustion surface of the porous sleeve; at least one effluent nozzle for ejecting the effluent gas stream into the combustion chamber, the perforated liner being shaped and configured for placement proximate to the combustion surface.
[0099] Further particular and preferred aspects are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with features of the independent claims as appropriate, and in combinations other than those explicitly set out in the claims.
[0100] Where an apparatus feature is described as being operable to provide a function, it will be appreciated that this includes an apparatus feature which provides that function or which is adapted or configured to provide that function.
[0101] The Summary is provided to introduce a selection of concepts in a simplified form that are further described in the Detail Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0102] Embodiments of the present invention will now be described further, with reference to the accompanying drawings, in which:
[0103] FIG. 1 illustrates a radiant burner according to one embodiment;
[0104] FIG. 2 is an enlarged view of the interface between a liner and nozzle shown in FIG. 1 ;
[0105] FIGS. 3 to 5 illustrate regions of differing perforation density according to embodiments;
[0106] FIGS. 6 and 7 illustrate displacement of the liner according to one embodiment;
[0107] FIGS. 8 and 9 illustrates a radiant burner according to one embodiment;
[0108] FIGS. 10A to 10C illustrate a structure which is coiled to provide the turns of a coil spring according to embodiments;
[0109] FIG. 11 illustrates side view of a portion of turns of a coil spring according to one embodiment; and
[0110] FIG. 12 illustrates a structure which is coiled to provide the turns of a coil spring according to one embodiment.
DETAILED DESCRIPTION
Overview
[0111] Before discussing the embodiments in any more detail, first an overview will be provided. As mentioned above, the conditions within the combustion chamber of a radiant burner may be such that combustion residues deposit on surfaces within the combustion chamber due to changes in flow rate of effluent gases into the combustion chamber. These residues affect the performance of the combustion chamber typically by preventing flow of the combustion materials through a burner element and by blocking nozzles providing the effluent gas stream. In addition, the residues can potentially affect the chemistry of the combustion within the combustion chamber.
[0112] Providing a perforated or porous liner within the combustion chamber protects the burner element and/or nozzles from such combustion deposits since the combustion residues deposit on the liner, which can be cleaned more conveniently and in any of a variety of different ways than is possible for the burner element or the nozzles. For example, the liner may be mechanically cleaned using a scraper, by spraying water onto the liner or by expanding the liner to change the shape of the perforations and dislodge the deposits. Such cleaning would typically not be possible or would damage the burner element. This cleaning may be performed in-situ or by removing the liner from the combustion chamber. Again, this is something that is not easy to do with the burner element or the nozzles. This approach makes it easier and faster to clean the radiant burner.
[0113] Also, the mechanical arrangement of the liner may be configured to adjust the combustion properties of the combustion chamber. For example, the perforations or apertures within the liner may be sized and distributed to affect the concentration and flow of the combustion gases within the combustion chamber. Also, the size and location of the perforations may be configured to prevent or reduce the likelihood of any cleaning material being used to clean the liner from contacting and potentially damaging the combustion element.
[0114] Hence, it can be seen that the arrangement of a liner helps to improve the performance of the radiant burner.
Radiant Burner—General Configuration and Operation
[0115] FIG. 1 illustrates a radiant burner, generally 8 according to one embodiment. The radiant burner 8 treats an effluent gas stream pumped from a manufacturing process tool such as a semiconductor or flat panel display process tool typically by means of a vacuum pumping system. The effluent stream is received at inlets 10 . The effluent stream is conveyed from the inlet 10 to a nozzle 12 which injects the effluent stream into a cylindrical combustion chamber 14 . In this embodiment, the radiant burner 8 comprises four inlets 10 arranged circumferentially, each conveying an effluent stream pumped from a respective tool by a respective vacuum pumping system. Alternatively, the effluent stream from a single processed tool may be split into a plurality of streams, each one of which is conveyed to a respective inlet 10 . Each nozzle 12 is located within a respective bore 16 formed in a ceramic top plate 18 which defines an upper or inlet surface of the combustion chamber 14 .
[0116] The combustion chamber 14 has sidewalls defined by an exit surface 21 of a foraminous burner element 20 such as that described in EP 0 694 735. The burner element 20 is cylindrical and is retained within a cylindrical outer shell 24 . A plenum volume 22 is defined between an entry surface 23 of the burner element 20 and the cylindrical outer shell 24 . A mixture of fuel gas, such as natural gas or a hydrocarbon, and air is introduced into the plenum volume 22 via one or more inlet nozzles [not shown]. The mixture of fuel gas and air passes from the entry surface 23 of the burner element 20 to the exit surface 21 of the burner element 20 for combustion within the combustion chamber 14 .
[0117] The ratio of the mixture of fuel gas and air is varied to vary the temperature within the combustion chamber 14 to that which is appropriate for the effluent gas stream to be treated. Also, the rate at which the mixture of fuel gas and air is introduced into the plenum volume 22 is adjusted so that the mixture will burn without visible flame at the exit surface 21 of the burner element 20 . The exhaust 15 of the combustion chamber 40 is open to enable the combustion products to be output from the radiant burner 8 .
[0118] Accordingly, it can be seen that the effluent gas received through the inlets 10 and provided by the nozzles 12 to the combustion chamber 14 is combusted within the combustion chamber 14 which is heated by the mixture of fuel gas and air which combusts near the exit surface 21 of the burner element 20 . Such combustion causes heating of the chamber 14 and provides combustion products, such as oxygen, typically within a range of 7.5% to 10.5% depending on the air/fuel mixture [CH 4 , C 3 H 8 , C4H 10 ], provided to the combustion chamber 14 . This heat and the combustion products react with the effluent gas stream within the combustion chamber 14 to clean the effluent gas stream. For example, SiH 4 and NH 3 may be provided within the effluent gas stream, which reacts with O 2 within the combustion chamber 14 to generate SiO 2 , N 2 , H 2 O, NO x . Similarly, N 2 , CH 4 , C 2 F 6 may be provided within the effluent gas stream, which reacts with O 2 within the combustion chamber 14 to generate CO 2 , HF, H 2 O.
Perforated Liner—Fixed Arrangement
[0119] Provided within the combustion chamber 14 is a liner 40 . In this embodiment, the liner 40 is cylindrical and it is received within the combustion chamber 14 adjacent the exit surface 21 of the burner elements 20 . The combustion of the mixture of fuel gas and air occurs within a combustion zone 25 adjacent the exit surface 21 of the burner element 20 . In this embodiment, the outer surface 44 of the liner 40 is positioned adjacent the combustion zone 25 so that combustion products pass through perforations of the liner 40 and enter the combustion chamber 14 . However, it will be appreciated that the exact location of the liner 40 with respect to the exit surface 21 of the burner element 20 and the combustion zone 25 may be varied to vary the conditions within the combustion chamber 14 .
[0120] The liner 40 is perforated to enable the combustion products to pass from the combustion zone 25 into the combustion chamber 14 . The size and distribution of these perforations are selected to facilitate the distribution and flow of combustion products from the combustion zone 25 into the combustion chamber 14 , as will be described in more detail below. Also, the size and distribution of the perforations can be varied to protect the burner elements 20 from damage during cleaning of the liner 40 . It will be appreciated that the perforations can be provided in a variety of different ways; for example, the liner 40 may be punched or rolled to create apertures at the correct locations or may even be louvered.
[0121] In this embodiment, the liner 40 is formed of two parts; namely a cylindrical section and a top plate section. The cylindrical section and the top plate section 46 are affixed. The top plate 46 has a radially outer circumferential flange which is clamped between an upper section 60 and a lower section 62 of the radiant burner 8 . This retains the liner 40 in place within the combustion chamber 14 .
Spray Nozzle
[0122] In order to clean the fixed liner, a further bore 30 in the ceramic top plate 18 is provided through which a spray nozzle 32 extends at the inlet end of the combustion chamber 14 . The spray nozzle 32 is supplied with a cleaning fluid, such as water, from an accumulator which operates to dispense a selected or fixed amount of fluid, such as water, from the spray nozzle 32 at a selected pressure. The geometry of the spray nozzle 32 defines a spray pattern for the cleaning fluid. In this example, a 120° ejection nozzle is provided which directs the fluid in a 120° cone having an angular tolerance which causes cleaning fluids to impact on an impact zone 34 of the liner 40 .
[0123] The mechanical impact, vaporisation and/or thermal shock of the cleaning fluid contacting the inner surface of the hot liner 40 causes combustion residues deposited on the liner 40 to become detached.
Nozzle Cleaning
[0124] As can be seen in more detail in FIG. 2 , the top plate 46 comprises apertures, each of which receives a respective nozzle 12 . The apertures are defined by upstanding edges 48 of the top plate which may be toleranced to provide an interference fit with an outer surface 13 of the nozzles 12 . The presence of the upstanding edges 48 of the top plate 46 enables any combustion residues deposited on the outer surface 13 of the nozzles 12 to be scraped off when the liner 40 is removed from the combustion chamber 14 .
[0125] In the embodiment shown in FIG. 1 , removal of the liner 40 is achieved by separating the upper section 60 and lower section 62 of the radiant burner 8 . However, in embodiments described in more detail below, the liner 40 may be displaced from the combustion chamber 14 without separating the upper section 60 and lower section 62 .
Perforated Liner—Displaceable Arrangement
[0126] FIG. 6 illustrates a displaceable arrangement according to one embodiment where the spray nozzle 32 is omitted. In order to clean the liner 14 , it is displaced from the exhaust 15 of the combustion chamber 14 for cleaning. Typically, the liner 40 is displaced into a water bath 90 . Immersing the liner 40 in the water bath causes a mechanical impact, vaporisation and/or thermal shock which dislodges combustion residues. The liner 40 may then be agitated within the water bath or the water bath itself may be agitated to facilitate cleaning.
[0127] In particular, the perforated liner 42 is retained by a fixing 80 coupled with an actuator 82 which is shown in the accommodated or retracted position. Coupled with the cylindrical outer shell 24 is a lower chamber, generally 92 . The lower chamber 92 provides for cooling of the processed effluent gases exiting the combustion chamber 14 . The processed effluent gases enter a cylindrical tube 83 , flow through an aperture 85 and out of an outlet 88 . The cylindrical tube 83 has a water curtain which flows in the direction A and is fed by a water curtain feed 84 . A cooling spray 86 is directed towards the aperture 85 the water curtain. The cooling spray 86 helps to cool the processed effluent gases and to trap particulate material. The water bath 90 is maintained at the lower portion of the container 92 .
[0128] FIG. 7 shows the perforated liner 42 in the unaccommodated or protruding position. The perforated liner 42 is displaced by the actuator 82 into the water bath 90 . The immersion of the perforated liner 42 within the water bath 90 causes residues deposits to be removed. Reciprocating the actuator 82 helps to agitate the liner 42 within the water bath 90 . The actuator 82 may be retracted to displaced the perforated liner 42 and accommodate this back within the combustion chamber 14 . Displacement of the perforated liner 42 helps to remove any residue deposits on the nozzles 12 .
[0129] It will be appreciated that for such an arrangement, the circumferential flange 50 is omitted and the liner 40 is instead retained within the combustion chamber 14 by the fixing 80 and actuator 82 . The displacement mechanism can then return the liner 40 to the accommodated position as shown in FIG. 1 .
[0130] The displacement of the liner 40 causes combustion residue on the outer surface 13 of the nozzles 12 to be removed.
[0131] In both the fixed and displaceable arrangements, a mechanical scrapper may be inserted which contacts with the inner surface 42 of the liner 40 and provides mechanical cleaning. Alternatively, or additionally, the mechanical scraper may be located in the water bath 90 and may engage the liner 40 during displacement of the liner 40 to the unaccommodated position.
Perforated Liner—Expandable Mesh Arrangement
[0132] FIGS. 8 and 9 illustrate a radiant burner according to one embodiment. This embodiment incorporates all the features of the embodiments mentioned above and below, but this embodiment omits the provision of the spray nozzle 32 and the actuator 82 . Instead, as will become clear from the description below, a modified actuator 82 A is provided which operates to expand a liner 42 A in order to remove deposits. However, it will be appreciated that further embodiments may also include the spray nozzle 32 to eject cleaning fluid onto the liner 42 A and/or the actuator 82 to displace the liner 42 A in a similar manner to that mentioned above.
[0133] In this embodiment, the liner 42 A is cylindrical and it is received within the combustion chamber 14 adjacent the exit surface of the burner elements. The combustion of the mixture of fuel gas and air occurs within a combustion zone adjacent the exit surface of the burner element. In this embodiment, the outer surface of the liner 42 A is positioned adjacent the combustion zone so that combustion products pass through perforations of the liner 42 A and enter the combustion chamber 14 A. However, it will be appreciated that the exact location of the liner 42 A with respect to the exit surface of the burner element and the combustion zone may be varied to vary the conditions within the combustion chamber 14 A.
[0134] The liner 42 A is an expandable mesh which is perforated to enable the combustion products to pass from the combustion zone into the combustion chamber 14 A. The size and distribution of these perforations is selected to facilitate the distribution and flow of combustion products from the combustion zone into the combustion chamber 14 A, as will be described in more detail below. Also, the size and distribution of the perforations can be varied to protect the burner elements from damage during cleaning of the liner 42 A for those embodiments which incorporate the spray nozzle. It will be appreciated that the perforations can be provided in a variety of different ways; for example, the liner 42 A may be formed from a coil spring as will be explained in more detail below or may even be a woven sock.
[0135] In this embodiment, the liner 42 A is formed of two parts; namely a cylindrical section and a top plate section. The cylindrical section and the top plate section are affixed. The top plate has a radially outer circumferential flange which is clamped between an upper section and a lower section of the radiant burner. This retains the liner 42 A in place within the combustion chamber 14 A.
[0136] In an alternative embodiment, where the liner 42 A is also displaced from the exhaust of the combustion chamber 14 A for cleaning in the manner described above, the liner 42 A is retained by a fixing coupled with the actuator 82 in addition to the modified actuator 82 A. This enables the liner 42 A to be both expanded as well as immersed and/or manually scraped as mentioned above.
[0137] The modified actuator 82 A is coupled with the end 42 B opposing the top plate section. When it is desired to remove deposits from the liner 42 A, the modified actuator 82 A actuates to extend the length of the liner 42 Aa in the direction B shown in FIG. 9 . The top plate section retains the liner 42 A in place as the end 42 B is displaced. The modified actuator 82 A is connected with the end 42 B using an annular ring. The extension of the liner 42 causes the perforations of the liner 42 A to extend and flex, thus dislodging any deposits. Once the liner 42 A has been extended by the required amount, the modified actuator 82 A reverses the expansion and restores the liner 42 A back to its retained position, as shown in FIG. 8 .
[0138] Typically, the expansion will seek to expand the size of the perforations by around a half and will require the axial length of the liner 42 A to be extended by typically between one third and two thirds of its axial length in the retained position.
[0139] An advantage of this arrangement is that through a simple mechanical displacement, deposits can be dislodged. This displacement can be performed relatively quickly compared to the displacement technique shown in FIG. 7 and has a reduced effect on the conditions within the combustion chamber 14 A compared to any of the techniques mentioned above.
[0140] As mentioned above, one embodiment the liner 42 A comprises a coil spring. FIGS. 10A to 10C illustrate the structure which is coiled to provide the turns of such a coil spring. A substrate 100 A; 100 B is provided. The substrate may be cylindrical, having a generally circular cross-section or may be planar, having a generally rectilinear cross-section.
[0141] Spacers 102 A; 102 B; 102 C are provided either surrounding or protruding from the substrate 100 A; 100 B. In particular, the spacer 102 A comprises a smaller-diameter substrate (such as a wire) wound around the outside of the substrate 100 A; 100 B. The spacer 102 B comprises projections which extend from the surface of the substrate 100 A; 100 B. The Spacer 102 C comprises an annular ring or a ferrule provided on the outer surface of the substrate 100 A; 100 B.
[0142] The diameter of the substrate 100 A; 100 B, is denoted by the distance D. The distance between one outer surface of the substrate 100 A; 100 B and an outer surface of the spacer 102 A; 102 B; 102 C is denoted by the distance d. The length of the spacers 102 A; 102 B; 102 C is denoted by the distance l. The distance between adjacent spacers is denoted by the distance L. The distances d, D, l and L determine the size and geometry of the perforations 104 when the liner 42 A is in the retained position, as shown in FIG. 11 . Typically, the distance D will be around 1.5 to 2 mm, whilst the distance d will be typically around 2 to 2.5 mm Typically, the distances l and L are selected in order to avoid spacers on adjacent turns of the coil spring from contacting. However, it will also be appreciated that it is possible to adjust these so that they to contact, if required.
[0143] Also, it will be appreciated that by varying the distances d, D, l and L, along the length of the substrate, it is possible to vary the density of perforations within the liner 42 A when in the retained position, as will be described in more detail below.
[0144] FIG. 12 illustrates an alternative coil ring structure according to one embodiment. In this embodiment, the substrate 100 A; 100 B is provided. However, rather than providing spacers which surround the substrate 100 A; 100 B, instead, a separate spacer structure 102 D is provided which is itself formed into a coil spring and turns of that coil spring are interleaved between adjacent turns of the substrate 100 A; 100 B. In particular, the spacer 102 C comprises a pleated substrate which undulates with a reciprocating, sinusoidal or sawtooth profile, which is then wound into a coil spring. The spacing provided by the undulations provides the perforations when in the retained position.
Liner Perforations—Combustion Product General Flow Control
[0145] In order to control the introduction of combustion products from the combustion zone 25 into the combustion chamber 14 , the size and distribution of perforations is varied as shown in FIG. 3 . To improve clarity, the cylindrical portion is shown as a rectangular net.
[0146] As can be seen, in a region 70 which is adjacent the ceramic top plate 18 , no or a lower density of perforations is provided. Optionally, in a region 74 which is adjacent the exhaust 15 of the combustion chamber 14 , a higher density of perforations is provided. In a region 72 between the regions 70 and 74 , the density of perforations changes from a higher density of perforations towards the region 70 to a lower density of perforations towards the region 74 .
[0147] Providing a higher density of perforations in the region 72 close to the nozzles 12 helps to increase the distribution of combustion products in the region where the effluent gas stream combusts within the combustion chamber 14 . Generally reducing the density of perforations towards the outlet 15 reduces the amount of combustion products as the amount of untreated effluent gas stream reduces.
[0148] Providing the region 74 with a high density of perforations also increases the density of combustion products in the vicinity of the outlet 15 where combustion is likely to be less efficient. Reducing the density of perforations in the region 70 helps to decrease the distribution of combustion products in the region where the effluent gas stream undergoes little combustion within the combustion chamber 14 .
Liner Perforations—Combustion Product Flow—Nozzle Optimisation
[0149] In order to control the introduction of combustion products from the combustion zone 25 into the combustion chamber 14 , the size and distribution of perforations is varied as shown in FIG. 4 . To improve clarity, the cylindrical portion is shown as a rectangular net.
[0150] In the embodiment shown in FIG. 1 , there are provided four nozzles 12 equally spaced circumferentially. The relative positions of those nozzles 12 are indicated schematically in FIG. 4 . In order to concentrate the presence of combustion products in the vicinity of each of those nozzles 12 , the density of perforations in the regions 12 a is increased compared to the density of perforations in the regions 12 b.
[0151] It will be appreciated that depending on the particular number and configuration of the nozzles 12 , the precise location of the regions 12 a and 12 b will vary to match.
Liner Perforations—Spray Protection
[0152] In order to prevent damage to the burner element 20 , the size and distribution of perforations is varied as shown in FIG. 5 . To improve clarity, the cylindrical portion is shown as a rectangular net.
[0153] As can be seen, a region 34 of no or a low density of perforations is provided. This prevents or reduces the likelihood of any cleaning fluid ejected from the spray nozzle from passing through the liner 40 and contacting and causing damage to the burner element 20 .
[0154] It will be appreciated that in embodiments utilising louvers rather than perforations, the presence of the zone 34 is not required.
Liner Perforations—Density Combinations
[0155] In order to provide combustion product control and spray protection, the densities shown in FIGS. 3 , 4 and/or 5 may be combined to arrive at an appropriate density profile for the perforated liner. In particular, the zones 70 and 74 may, for example, be omitted.
[0156] As mentioned above, the processing of effluent gases such as silane, chloro-silanes and organo-silane produces solid by-products such as SiO 2 and Si 3 N 4 . These tend to deposit on surfaces within the radiant burner. The rate of deposit is sufficient that, typically, turbulent flame burners are instead used for processing of such gases which are typically produced during photovoltaic solar and flat panel display processes.
[0157] In embodiments, a perforated screen is interposed between the burner element and the combustion chamber. For example, a 6 inch diameter screen is mounted within a 7 inch diameter burner element. The burner is fired in a conventional way, with the perforated screen forming a gas purged radiant boundary to the combustion chamber. The screen may be capped with a metallic plate which is perforated to allow for various head fixtures to protrude, for example a pilot burner, process nozzles, thermocouple, etc. This provides for a sacrificial surface, covering the areas ordinarily prone to deposition, but made of substantially more robust material than the base parts [which are currently ceramic fibre for the head insulation and composite metal fibre/ceramic fibre for the burner elements]. Providing a perforated screen provides surfaces that can be cleaned. In one embodiment, the parts are cleaned by impacting water droplets from a high pressure spray nozzle. In another embodiment, the liner is mounted on an actuator, allowing it to be translated out of the burner and dipped into a tank of water immediately below the burner.
[0158] The screen may be a simple perforated sheet which is rolled and welded, or may be punched with louvers such that the combustion bi-products are directed downwards, but any water spray or steam [if admitted through the top of the combustion chamber] is prevented from coming into contact with the surface of the burner. Alternatively, a knitted wire braided wire screen may be employed.
[0159] The liner needs to be able to withstand the high temperature oxidizing conditions of the combustion chamber and also to withstand the high thermal shock of cleaning events. Accordingly, the liner may include inconnel 600 or similar alloys. Alternatively, mild steel may be used with a heavy high phosphorus electrode-less nickel plating. When heated to braising temperatures in a vacuum furnace [800° c. 250° c.] the nickel coating flows into the surface of the mild steel and the phosphorus is subsequently burned out, leaving a non-porous coating of essentially pure nickel which has a melting point of approximately 1440° c. and a coating melting point of 800° c. to 1200° c., depending on phosphorus content.
[0160] As mentioned above, embodiments provide for the combustive abatement of process gases such as silane chloro-silanes and organo-silanes produces solid by-products such as SiO2, Si3N4. These tend to deposit on surfaces within the abatement system, for example on the head ceramic, and burner liner of radiant burners.
[0161] Despite offering the best abatement performance (in terms of fuel use per litre of gas treated to a defined destruction or removal efficiency level) such burners have been superseded by inferior turbulent flame burners for the harshest photovoltaic solar and flat panel display processes. However, embodiments provide an arrangement that provides for the abatement of such processes, combining the efficiency and performance of the radiant burner with the mean time between service of a simpler turbulent flame device.
[0162] In one embodiment, a perforated screen is interposed between the radiant burner and the combustion chamber. For example a 6″ diameter screen is mounted in a 7″ diameter burner. The burner is fired in the conventional way, with the perforated screen forming a gas purged radiant boundary to the combustion chamber. The screen may be capped with a metallic plate perforated to allow for the various head fixtures to protrude—for example pilot burner, process nozzles, thermocouple, etc. This provides for a sacrificial surface, covering the areas ordinarily prone to deposition, but made of a substantially more robust material than the base parts (currently ceramic fibre for the head insulation and composite metal fibre/ceramic fibre for the burner liner)
[0163] In another embodiment, the screen is an expanding screen rolled from wire, with spacers along the wire to keep the turns of the wire at a mutual separation which defines the openness of the screen. To clean the screen, it is expanded by translating the lower end of the screen downwards (the upper end requires to be fixed.) The screen may be similar to a cross filter but the spacing of the wire would require to be say 1 mm on a wire of a similar size. This method is particularly applicable to a concentric burner, where the water spray/steam clean method is impractical.
[0164] Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiment and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention as defined by the appended claims and their equivalents.
[0165] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. | A radiant burner and method are disclosed. The radiant burner is for treating an effluent gas stream from a manufacturing process tool and comprises: a combustion chamber having a porous sleeve through which combustion materials pass for combustion proximate to a combustion surface of the porous sleeve; at least one effluent nozzle for ejecting the effluent gas stream into the combustion chamber; and a perforated liner proximate to the combustion surface. Providing a perforated liner controls the combustion materials passing into the combustion chamber to treat the effluent gas stream and also provides a surface onto which residual combustion deposits may be received. Accordingly, the liner can both improve the efficiency of the treatment of the effluent gas stream and can act as a sacrificial surface which may be replaced or cleaned either in accordance with a maintenance regime or when the performance of the radiant burner reduces. | 5 |
FIELD OF THE INVENTION
[0001] The invention is directed to underwater acoustic communications, and more particularly to a double differentially coded spread spectrum (DD-SS) method for underwater acoustic communications.
BACKGROUND OF THE INVENTION
[0002] Reliable long-range acoustic communications (LRAC) is an enabling technology for numerous applications of manned and unmanned underwater systems. For example, with the capability of communicating at long ranges of several hundreds or even thousands kilometers, it will become possible to remotely command and control unmanned underwater vehicles that are otherwise unreachable. As another example, underwater systems will be able to rely on such capability to establish a wide-area undersea network to complete missions in a collaborative fashion. As an active area of research, LRAC has received a tremendous amount of attention for the past two decades. A number of LRAC schemes have been proposed and tested by sea-going experiments. However, most research and experiments done so far have concentrated on the fixed LRAC cases where both the source and the receiver are moored (see e.g., M. Stojanovic, J. A. Catipovic, and J. G. Proakis, “Adaptive multichannel combining and equalization for underwater acoustic communications,” Journal of the Acoustical Society of America, vol. 94, no. 3, pp. 1621-1631, 2000; V. Capellano, “Performance improvements of a 50 km acoustic transmission through adaptive equalization and spatial diversity,” in OCEANS, October 1997, pp. 569-573; L. Freitag and M. Stojanovic, “Basin-scale acoustic communication: A feasibility study using tomography m-sequences,” in OCEANS, 2001. MTS/IEEE Conference and Exhibition, vol. 4. IEEE, 2001, pp. 2256-2261; A. Plaisant, “Long range acoustic communications,” in OCEANS, October 1998, pp. 569-573; and H. Song, W. Kuperman, and W. Hodgkiss, “Basin-scale time reversal communications,” The Journal of the Acoustical Society of America, vol. 125, p. 212, 2009).
[0003] In mobile LRAC applications the source and/or the receiver move at a significant speed. LRAC is made difficult by a number of factors, including (but not limited to) low signal-to-noise ratios (SNRs) mainly caused by large transmission losses, significant Doppler shifts induced by relative source-receiver motion as well as environmental factors such as internal waves, and severe inter-symbol interference (ISI) due to large channel delay spread. While these performance-limiting factors exist in both fixed and mobile LRAC, they tend to be more pronounced and therefore more difficult to be dealt with in the mobile cases, making an already challenging LRAC problem even more challenging. While many of the existing LRAC schemes developed for the fixed cases might in theory work well in the mobile cases, only a few have been actually tested at sea-going experiments. Examples include single-carrier communications with linear channel equalization reported in H. Song, S. Cho, T. Kang, W. Hodgkiss, and J. Preston, “Long-range acoustic communication in deep water using a towed array,” The Journal of the Acoustical Society of America, vol. 129, no. 3, pp. EL71-EL75, 2011, and orthogonal frequency division multiplexing (OFDM) reported in T. Kang, H. Song, and W. Hodgkiss, “Long-range multi-carrier acoustic communication in deep water using a towed horizontal array,” The Journal of the Acoustical Society of America, vol. 131, no. 6, pp. 4664-4671, 2012.
[0004] Disadvantages of these prior art approaches include the need of complicated receiver processing such as phase/Doppler tracking and correction, channel estimation and tracking, channel equalization, and frequent performance outage due to unpredictable environmental fluctuations. It is therefore desirable to provide a method that minimizes such disadvantages.
BRIEF SUMMARY OF THE INVENTION
[0005] According to the invention, a method for mobile underwater acoustic communications includes double differentially (DD) encoding a communication signal to produce a DD-encoded communication signal, applying direct sequence spread spectrum (SS) to the DD-encoded signal to produce a DD-SS communication output signal, and transmitting the DD-SS communication output signal.
[0006] By combining direct sequence SS with DD coding, the DD-SS method provides elegant solutions to many challenging problems faced by mobile LRAC. The invention is extremely simple as it does not require any complicated signal processing such as channel estimation, channel equalization, phase and Doppler tracking and correction.
[0007] The invention i) increases the SNR via processing gain, ii) eliminates the ISI through multipath suppression, and iii) enables bandwidth efficiency improvement via data multiplexing. And, the use of DD coding and decoding forgoes the need of explicit phase/Doppler tracking and correction at symbol detection. Together with traditional beamforming, DD-SS offers an effective means of dealing with those performance-limiting factors with simple receiver processing. More importantly, because neither channel estimation nor Doppler/phase tracking is involved, the performance of DD-SS is inherently robust against unpredictable fluctuations in underwater communication environments, making it particularly suitable for the mobile LRAC cases. Experimental data show that the DD-SS invention obtains an uncoded bit error rate (BER) of less than 4% at a data rate of 6.4 bits/s for a bandwidth of 200 Hz and at a range of 550 km.
[0008] The invention provides high performance reliability, since the receiver processing does not require knowledge of channels, and low computational complexity since no complicated channel estimation and equalization is needed. The invention provides high bandwidth efficiency since no overhead is required for channel estimation or for phase/Doppler tracking, and data multiplexing is available for better bandwidth efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic diagram of a DD-SS transmitter according to the invention;
[0010] FIG. 2 is a schematic diagram of a DD-SS receiver according to the invention;
[0011] FIG. 3 is a schematic representation of an LRAC10 experiment conducted in deep water off the Southern California Coast according to the invention;
[0012] FIGS. 4A-B are graphs showing snapshots of channel impulse responses according to the invention;
[0013] FIG. 5 shows the spectrogram of the signal received at the first array element (top figure) and the spectrogram of the received signal after beamforming (bottom figure) according to the invention;
[0014] FIG. 6 are graphs of the input to DS despreading (top figure) and the output after DS despreading (bottom figure) according to the invention;
[0015] FIG. 7 are graphs of the magnitude and unwrapped phase of the peaks at the output of DS despreading according to the invention; and
[0016] FIGS. 8A-B are scatter plots of the normalized output of the DD decoder for the BPSK case and the 4-PSK case, respectively, according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The DD-SS Transmitter
[0018] Design of Transmitted Signal:
[0019] FIG. 1 illustrates a system diagram of a DD-SS transmitter in accordance with the invention. The transmitter is designed to generate a transmitted signal that not only suits for long-range propagation through underwater acoustic channels but also enables simple detection at the receiver (as will be discussed further below).
[0020] Assume that A1) all information symbols are phase-modulated with unit magnitude, i.e., |d[n]|=1 ∀n. At the transmitter, information symbols d[n]'s are first demultiplexed into M independent data sequences:
[0000] d i [n]:=d[nM+i], i= 0 , . . . ,M− 1,
[0021] which are then forwarded to the corresponding branches of DD encoding and DS spreading.
[0022] At each (say, the ith) branch, data symbols d i [n] are first DD encoded into coded symbols u i [n] by using two recursions:
[0000] u i [n]=u i [n− 1 ]v i [n], n= 0,1, . . .
[0000] u i [−1]=1 (1)
[0000] and
[0000] v i [n]=v i [n− 1 ]d i [n], n= 0,1, . . .
[0000] v i [−1]=1. (2)
[0023] These two recursions reveal that DD coding is nothing but a repetition of single differential (SD) coding. It is well known that SD coding makes possible to forgo phase tracking at symbol detection. By repeating SD coding, DD coding enables symbol detection without the need of tracking not only phase shifts but also Doppler shifts, as we will discuss later. Note that under assumption A1, there will be no divergence in signal power due to recursions. After DD coding, each coded symbol u i [n] is then DS spread by the spread waveform
[0000]
c
i
(
t
)
:=
∑
k
=
0
G
-
1
c
i
,
k
φ
(
t
-
kT
c
)
(
3
)
[0024] to generate the spread spectrum signal x i (t), as:
[0000]
x
i
(
t
)
=
∑
n
=
0
∞
u
i
[
n
]
c
i
(
t
-
nT
s
)
[0025] where T s is the symbol interval. In (3), c i =[c i,1 , . . . , c i,G ] represents the spread code used for the generation of c i (t), T c =T s /G is the chip interval, and φ(t) denotes the chip pulse function.
[0026] In DD-SS, DS spreading is employed to i) increase the SNR via processing gain, ii) eliminate the ISI through multipath suppression, and iii) enable bandwidth efficiency improvement via data multiplexing. To serve these purposes, it is desirable to design spreading codes such that the corresponding spreading waveforms are both orthogonal and shift-orthogonal, i.e.,
[0000]
r
ij
(
τ
)
:=
∫
c
i
(
t
)
c
j
(
t
-
τ
)
t
=
{
1
,
i
=
j
and
τ
=
0
0
,
otherwise
(
4
)
[0027] After DS spreading, the summation of the M spread spectrum signals is pulse-shaped and then modulated onto carrier frequency f c . The transmitted signal in passband is thus given by:
[0000] {tilde over (x)} ( t )= Re{x ( t ) e j2πf c i } (5)
[0028] Where x(t)=Σ i=0 M-1 Σ n=0 ∞ u i [n]c i (t−nT s ) is the baseband equivalent of {tilde over (x)}(t). Note that in writing {tilde over (x)}(t), we have absorbed the effect of pulse shaping into φ(t).
[0029] The spectrum of {tilde over (x)}(t) is determined by φ(t), T c and f c . To make {tilde over (x)}(t) suitable for propagation through a physical channel with a bandwidth range [f 1 ,f h ], we choose f c =(f 1 +f h )/2, φ(t) as a root raised cosine function with a roll-off factor β and T c =(β+1)/(f h −f l ). Under these choices, it is not difficult to find that the DS-SS supports a data rate:
[0000]
R
b
=
M
log
2
C
G
×
B
1
+
β
bits
/
sec
,
(
6
)
[0030] where B:=f h −f l denotes the signal bandwidth, and |C| is the size of the signal constellation C to which information symbols belong. Clearly, one can control the data rate by selecting different values of signaling parameters M, |C| and G.
[0031] Formulation of Received Signals:
[0032] The transmitted signal, after propagating through the underwater channel, is received by an array of N r equally spaced receiver elements. To model the N r received signals, the following two commonly-used channel assumptions are made:
[0033] A2) The channel between the source and the receiver array is a linear time-varying (LTV) multipath channel of N p resolvable paths, with impulse response given by
[0000]
h
(
t
,
τ
)
=
∑
p
=
1
N
p
A
p
(
t
)
δ
(
τ
-
τ
p
(
t
)
)
(
7
)
[0034] where A p (t) and τ p (t) denote the time-varying path amplitude and delay of the pth path, respectively.
[0035] A3) The N r received signals are plane-wave arrivals. Therefore, any two of them are related by a time offset.
[0036] Under these assumptions, the Nr received signals can be expressed as:
[0000]
r
~
m
(
t
)
=
s
~
(
t
-
m
d
c
cos
θ
r
)
+
w
~
m
(
t
)
,
m
=
0
,
…
,
N
r
-
1.
(
8
)
[0037] where d is the spacing between two adjacent receiver elements, c is the speed of sound, and θ r denotes the angle of arrival (AOA), {tilde over (w)} m (t) captures the additive noise, and
[0000]
s
~
(
t
)
=
∑
p
=
1
N
p
A
p
(
t
)
x
~
(
t
-
τ
p
(
t
)
)
(
9
)
[0038] is the noise-free received signal at the first receiver element. It is noted that assumptions A2 and A3 have also been used in deriving the data model of M. Simon and D. Divsalar, “On the implementation and performance of single and double differential detection schemes,” Communications, IEEE Transactions on, vol. 40, no. 2, pp. 278-291, February 1992. How accurate this model is will be tested by at-sea experiments. Next, we describe how to recover information symbols from {tilde over (r)} m (t).
[0039] The DD-SS Receiver
[0040] Long-range communications through underwater acoustic channels is challenging and is expected to suffer from a variety of severe signal distortions. Each of those distortions could make symbol detection highly unreliable or even impossible. For reliable symbol recovery, it is thus critical to remove them prior to symbol detection. In this section, we discuss how this can be done by using a receiver processing scheme plotted in FIG. 2 . The proposed receiver processing consists of several steps, with each step targeting at a particular signal distortion. In what follows, we describe these steps in details, under the following assumptions:
[0041] A4) Among the N p channel paths in (7), one (say, the qth) path dominates the others in terms of having a much larger path amplitude.
[0042] A5) Both path amplitudes A p (t) and path delays τ p (t) vary with time slowly such that they remain approximately constant within the symbol interval T s .
[0043] Assumption A4 can be justified by recognizing the fact that there usually exists a direct path between the transmitter and the receiver array in LRAC in deep water. As compared to reflected paths, a direct path suffers from less attenuation and thus has a much large magnitude. This fact will be verified by analyzing experimental data.
[0044] Beamforming:
[0045] In LRAC, the received signals are expected to have extremely low SNRs due to large transmission losses and high noise levels from the towing receiver ship. Beamforming constitutes the first step taken to ensure adequate SNRs for symbol detection. Recalling that all signal parts in {tilde over (r)} m *s are related by time shifts, beamforming amounts to forming the beamformed signal as:
[0000]
r
~
(
t
)
=
∑
m
=
0
N
r
-
1
r
~
m
(
t
-
m
d
c
cos
θ
^
r
)
(
10
)
[0046] where {circumflex over (θ)} r stands for an estimate of the AOA θ r . By combining the signal parts coherently and the noise parts incoherently, this so-called delay-and-sum beamformer has a potential of increasing the SNR by 10 log Nr dB. In this work, the estimated AOA is obtained by searching for a {circumflex over (θ)} r such that the beamformed signal {tilde over (r)}(t) achieves its maximum possible power. To reduce computational complexity, such search is done in frequency domain by using fast Fourier transform (FFT).
[0047] DS Despreading:
[0048] Before information symbols can be detected, one needs to obtain decision statistics of coded symbols (say, u[m] for some l and m) from the baseband equivalent of {tilde over (r)}(t) which, using (10), (8) and (9), can be written as:
[0000]
r
(
t
)
=
∑
p
=
1
N
p
A
p
(
t
)
jϕ
p
(
)
c
i
(
t
-
mT
s
-
τ
p
(
t
)
)
u
i
[
m
]
+
∑
i
≠
1
M
-
1
∑
p
=
1
N
p
∑
n
≠
m
∞
A
p
(
t
)
jϕ
p
(
)
c
i
(
t
-
nT
s
-
τ
p
(
t
)
)
u
i
[
n
]
+
w
(
t
)
(
11
)
[0049] where φ p (t):=−2πf c τ p (t) is introduced to capture the phase of the pth path, and w(t) represents the baseband noise. As evident in (11), r(t) consists of N p signal terms (in the first summation) caused by multipath propagation, a number of interference terms (in the second summation) due to data multiplexing, and a noise term. Among the N p signal terms, under assumption A4, the qth term is dominant and provides the most reliable decision statistics for u l [m]. Considering this, we perform DS despreading to extract this term from r(t) by computing:
[0000] y l [m]=∫r ( t ) c l ( t−mT s −τ q ( t )) dt, (12)
[0050] where y l [m] denotes the decision statistics of u l [m]. In the ideal case where spreading waveforms satisfy (4), it can be shown that, under assumption A5,
[0000] y l [m]=A q [m]e jφ q [m] u l [m]+w l [m] (13)
[0051] where A q [m]=A q (mT s ), φ q [m]=φ q (mT s ) and W l [m] denotes the noise. Regarding (12) and (13), two remarks are due:
[0052] Remark 1) In the case where spreading waveforms satisfy (4), DS spreading improves reliability of y l [m] by i) reducing the noise power level by 10 logG dB via processing gain and ii) eliminating interfering terms caused by multipath propagation and data multiplexing completely. In practice, ideal spreading waveforms might not be available. However, it is not difficult to construct spreading waveforms with r ij (τ)τ0 for i≠j or τ≠0. In this case, DS spreading is capable of suppressing those interfering terms effectively. As a result, y l [m] is expected to enjoy a reasonably high SNR. In the remainder of this paper, we absorb into the noise term w l [m] all residual interference caused by the use of non-ideal spreading waveforms.
[0053] Remark 2) The operation of DS despreading in (12) requires knowledge of τ q (t). To avoid such requirement, (12) can be alternatively implemented by first matched filtering r(t) with a filter c l (−t), and then searching at the output for a peak within the interval [mT s ,(m+1)T s ].
[0054] DD Decoding:
[0055] Given decision statistics y l [m]'s, DD decoding is performed to recover information symbols d l [m], under the following assumption:
[0056] A6) The path phase φ q [m] vary linearly within the interval of three consecutive information symbols, i.e., φ q [m+1]−φ q [m]=φ q [m]−φ q [m−1].
[0057] Under this assumption, the Doppler shift of the dominant path is allowed to change slowly as long as it remains approximately constant within three consecutive symbol intervals. Recall that the dominant path in mobile LRAC is most likely the direct path. Under Assumption A6, the source ship and/or receiver ship are thus allowed to change its speed or direction without affecting symbol detection.
[0058] To perform DD decoding, we first form:
[0000]
z
l
[
m
]
=
(
y
l
[
m
]
y
l
*
[
m
-
1
]
)
·
(
y
1
[
m
-
1
]
y
l
*
[
m
-
2
]
)
*
y
l
[
m
]
y
l
*
[
m
-
1
]
·
y
l
[
m
-
1
]
y
l
*
[
m
-
2
]
,
(
14
)
[0059] with superscript * standing for conjugation and ∥ denoting the magnitude of a complex number, and then make decision on d l [m] as:
[0000] {circumflex over (d)} l [m ]=det( z l [m ]) (15)
[0060] with det(•) representing a PSK detector. By combining (13), (1) and (2), it can be readily verified that z l [m]=d l [m] when w l [m]=0. In other words, the proposed receiver processing is capable of achieving perfect symbol recovery at least in the noise-free case. It is worth pointing out that this has been accomplished without any complicated receiver processing such as channel estimation and tracking, channel equalization and Doppler tracking and correction. This, on the one hand, reduces receiver complexity considerably, and on the other hand, makes the performance robust against unpredictable changes in communication environments.
[0061] The design of the DD-SS receiver has been based on a number of channel assumptions that may or may not hold valid in practice. To test the performance of DD-SS, we participated LRAC10 and collected the received data. In the next section, we report the performance results we have obtained by analyzing experimental data.
[0062] LRAC 10: Experimental Demonstration
[0063] Experiment Setting:
[0064] As illustrated in FIG. 3 , the LRAC10 experiment was conducted in deep water off the Southern California Coast in September 2010. Two research ships from Scripps Institution of Oceanography were involved. The source ship (R/V New Horizon) towed a J-15 source at a speed of 2-3 knots around the region centered at location (34° N, 129° W). The source was deployed at a depth of about 75 m with a source level of approximately 172 dB μPa@1 m. The receiving ship (R/V Melville) towed a HLA (Five Octave Research Array or FORA) mostly at a speed of 3.5 knots at a depth of about 200 m. The 189-m long ultra-low frequency (ULF) sub-aperture of the FORA was used for reception. The sub-aperture consisted of N r =64 receiver elements equally spaced at d=3 m.
[0065] To test DD-SS, two DD-SS signals were transmitted using a bandwidth of B=200 Hz ranging between f l =100 Hz and f h =300 Hz. The two DD-SS signals were generated by using the scheme described in Section II with different signaling parameters. The first signal (referred to as BPSK signal) employed BPSK modulation (i.e., C={1,−1}) and no data multiplexing (i.e., M=1), and carries information of 439 bits. The BPSK signal was used as a baseline signal to test feasibility of the DD-SS system. The second signal (referred to as 4-PSK signal) employed 4-PSK modulation (i.e., C={1,1 j,−1,−1 j}) and data multiplexing of order M=2, and it carries information of 474 symbols or 1896 bits. The use of the 4-PSK signal was intended to investigate how performance and data rate are traded off in DD-SS. To generate spreading waveforms in both signals, we choose Kasami codes of length G=63 (see L. Welch, “Lower bounds on the maximum cross correlation of signals (corresp.),” Information Theory, IEEE Transactions on, vol. 20, no. 3, pp. 397-399, May 1974) as spreading codes, and a root raised cosine function with a roll-off factor β=1 as the pulse shaping function. As per (6), the data rates corresponding to the two signals are 1.6 bits/sec and 6.4 bits/sec, respectively.
[0066] In our test, we were only interested in uncoded error performance. No error correcting codes was used in either signal. To facilitate signal discovery at the receiver array, a linear frequency modulated (LFM) signal was sent before the DD-SS signal. The two signals were separated by a guard time of 3 seconds to avoid interference.
[0067] In LRAC10, the two DD-SS signals were transmitted at different hours and consequently, they were received at different locations: the BPSK signal at location A (33.38° N, 126.32° W) and the 4-PSK signal at location B (32.28° N, 124.06° W). At the two locations, the corresponding source-receiver ranges are 297 km and 557 km, and the headings of the receiver ship are 110° and 182° from the North, respectively, as indicated in FIG. 3 .
[0068] Experimental Results:
[0069] As the first step in beamforming, we acquire an estimate of the AOA by searching for an AOA that maximizes the power of the corresponding beamformed signal. The estimated AOA (measured from the forward endfire direction) turns out to be 167° for the BPSK case and 112° for the 4-PSK case. Both estimated AOAs are consistent with the theoretical ones that have been computed based on the location and heading data of the source and the receiver array.
[0070] Because such computation assumes a direct path between the source and the receiver array, it thus can be implied that a dominant direct path exists between the source and the receiver array, as stated in assumption A4. This implication is further confirmed by FIGS. 4( a ) and 4 ( b ) where two snapshots of the channel impulse response are plotted for the two signal cases. The two snapshots are obtained by correlating the beamformed received signal with the corresponding transmitted LFM signal.
[0071] To see how beamforming improves the input SNR, we compare the spectrogram of the received signal at the first array element (i.e., {tilde over (r)} 1 (t)) with that of the beamformed signal r(t) in the BPSK case. As shown in FIG. 5 , the BPSK signal is hardly visible before beamforming. By computing the powers of the received signal within the intervals of the LFM signal and the guard time, the SNRs of {tilde over (r)} 1 (t) and r(t) are estimated to be −20 dB and −5 dB, respectively. In other words, beamforming helps improve the input SNR by 15 dB, which is only 3 dB less than the theoretical value 10 log 64=18 dB. Such difference is likely due to the noise correlation. It is important to point out that after beamforming, the input SNR at −5 dB is still not high enough for reliable symbol recovery. To some extent, this justifies the need of DS spread/despreading in DD-SS.
[0072] The importance of DS spreading and despreading can be better appreciated by comparing the input and output signals of DS despreading. FIG. 6 plots two 3-second long signals, the top one is a part of the input signal of DS despreading in the BPSK case, and the bottom one is the corresponding output signal. Clearly, DS despreading helps suppress interference and noise, and therefore improves reliability of symbol recovery.
[0073] The operation of DD decoding is based on the phase of the signal peaks after DS despreading. As evident in FIG. 7 , the magnitude of the signal peaks tends to change quite randomly. Since DD decoding does not rely on the magnitude information, randomness in the magnitude will thus have no effect on its performance. On the other hand, although the phase variation is not linear overall, as shown in FIG. 7 , it is quite linear within the duration of three consecutive peaks, as we assumed in assumption A6. Therefore, DD decoding is expected to yield good performance.
[0074] FIGS. 8( a ) and 8 ( b ) plot the normalized output (i.e., z l [m] in (14)) of the DD decoder for the two signal cases. The corresponding BER is 0% for the BPSK case and 4% for the 4-PSK case. For the 4-PSK case, error-free communications can be easily achieved by incorporating error-correcting channel coding with a slight reduction of data rate. In a word, our experimental data shows that DD-SS is at least capable of achieving excellent uncoded error performance (less than 4%) at a data rate of 6.4 bits/s for a bandwidth of 200 Hz and at a range of 550 km.
[0075] The invention therefore provides a novel LRAC scheme that is specially designed for the mobile cases. Its approach is different than prior art LRAC schemes. Instead of relying on complicated receiver processing to compensate various distortions to the communication signal, the invention utilizes the communication signal itself to make it easier to compensate those distortions at the receiver. The invention utilizes both direct sequence (DS) spread spectrum (SS) and double differential (DD) coding, and is termed direct sequence spread spectrum (DD-SS).
[0076] Obviously many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that the scope of the invention should be determined by referring to the following appended claims. | A method for mobile underwater acoustic communications includes double differentially (DD) encoding a communication signal to produce a DD-encoded communication signal, applying direct sequence spread spectrum (SS) to the DD-encoded signal to produce a DD-SS communication output signal, and transmitting the DD-SS communication output signal. The method i) increases the SNR via processing gain, ii) eliminates the ISI through multipath suppression, and iii) enables bandwidth efficiency improvement via data multiplexing. The method is shown capable of facilitating simple receiver processing and offering performance robustness against unpredictable channel fluctuations. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority under 35 U.S.C. 119 and 35 U.S.C. 365 to Korean Patent Application No. 2010-0086825 (filed on Sep. 6, 2010), which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Technical Field
The present disclosure relates to an outdoor unit for an air conditioner.
2. Description of the Related Art
Generally, the air conditioner is an apparatus for cooling or heating air based on a refrigeration cycle including a compressor, a condenser, an evaporator and an expansion member.
One of the condenser and the evaporator that is placed outdoors is heat-exchanged with outside air and the heat exchanger placed outdoors is called an outdoor unit.
The heat exchanger situated inside the outdoor unit and an outdoor fan suctioning outdoor air to the inside of the outdoor unit and discharging to the outside of the outdoor unit are mounted.
For a general outdoor unit, the outdoor fan is mounted in the rear of the discharge port and the heat exchanger performing a function of the condenser or the evaporator is placed in the rear of the outdoor fan.
A grille is formed in the discharge port of the outdoor unit, such that the introduction of foreign substance from the outside or the entrance of person's hands is prevented. Since the discharge port of an existing outdoor unit is maintained in opened condition regardless of whether or not the operation of the outdoor, when the outdoor unit is not operating, there is a disadvantage that the foreign substance is introduced into the inside of the outdoor unit via the discharge port. Particularly, in the desert regions, small particles of sand is introduced into the inside of the outdoor unit to degrade the operating performance of the outdoor unit.
SUMMARY OF THE INVENTION
The disclosure proposed to improve above disadvantage is to provide opening and closing structure of the discharge port of the outdoor unit in which the discharge port of the outdoor unit is closed when not operating the outdoor unit and is opened only when operating the outdoor unit.
An outdoor unit for an air conditioner according to an exemplary embodiment of the disclosure to achieve above objects, comprising: a case forming shape and having a suction port suctioning outside air and a discharge port discharging the suctioned air; a heat exchanger accommodated inside the case; a fan that is accommodated inside the case and forcibly circulate air; and a louver assembly rotatably mounted in the case so as to selectively open and close the discharge port.
An outdoor unit for an air conditioner according to an exemplary embodiment of the disclosure including above configuration may obtain the same effects as below.
First, since the discharge port of the outdoor unit is opened only when operating the outdoor unit, the introduction of the foreign substance may be prevented via the discharge port when not operating the outdoor unit.
Further, when the discharge port of the outdoor unit is selectively closed by the louvers and the louvers close the discharge port of the outdoor unit, an advertisement or a picture may be attached to the surface of the louver, such that there is an advantage that may beautifully design a shape of the outdoor unit. In other words, there is a advantage that may use the front of the outdoor unit as an advertising board.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of an outdoor unit showing a condition in which a discharge port is opened, as an outdoor unit for an air conditioner according to an exemplary embodiment of the disclosure.
FIG. 2 is a front perspective view of an outdoor unit showing a condition in which a discharge port is closed.
FIG. 3 show a louver structure according to a first embodiment of the disclosure, as a cross-sectional view taken along line I-I of FIG. 2 .
FIG. 4 shows schematically a louver driving mechanism according to a second embodiment of the disclosure.
FIG. 5 shows a portion of the rear of the outdoor unit case equipped with the louver driving mechanism.
FIG. 6 shows schematically a form in which the louver is connected to the louver driving mechanism.
FIG. 7 is a front view of the outdoor unit showing schematically the louver driving mechanism according to a third embodiment of the disclosure.
FIG. 8 is a cross-sectional view showing a process in which the louvers close the discharge port of the outdoor unit, as a cross section view taken along line II-II of FIG. 7 .
FIG. 9 is a cross-sectional view showing a condition when the louvers close perfectly the discharge port of the outdoor unit.
FIG. 10 shows the louver structure according to a fourth embodiment of the disclosure
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, an outdoor unit of an air conditioner in an exemplary embodiment of the disclosure will be described in detail with reference to the drawings.
FIG. 1 is a front perspective view of an outdoor unit showing a condition in which a discharge port is opened, as an outdoor unit for an air conditioner according to an exemplary embodiment of the disclosure and FIG. 2 is a front perspective view of an outdoor unit showing a condition in which a discharge port is closed.
In FIG. 1 and FIG. 2 , an outdoor unit 10 for an air conditioner of an exemplary embodiment of the disclosure includes a case 11 forming a shape, a heat exchanger (not shown) accommodated inside the case, and a fan 14 (refer to FIG. 3 ) arranged in front of the heat exchanger.
In detail, an discharge port 111 is formed in a front of the outdoor unit 10 and a suction port (not shown) is formed in a side of the outdoor unit 10 . Further, a discharge grille 12 is formed in the discharge port 111 and blocks putting your hands or entering bulky foreign substance from the outside. The discharge grille 12 may be composed by a combination of a plurality of ribs extending in all directions from a center of the discharge port 111 and a plurality of circular ribs having a diameter different from each other. However, it is revealed that the discharge grille 12 is not limited to the same structure as above. In addition, the discharge grille 12 is fixed to the front of the case 11 i.e. an edge of the discharge port 111 . Alternatively, the discharge grille 12 may be made in one body with the case 11 .
In addition, a plurality of louvers 13 can be installed rotatably in the front of the discharge grille 12 . When not driving the outdoor unit 10 , the upright louvers 13 close perfectly the discharge ports 111 , and the outdoor unit 10 rotates frontward during its driving process to allow the discharge port 111 to be opened.
Hereinafter, the structure and operations of the louvers 13 will be described in detail with reference to drawings.
FIG. 3 shows a louver structure according to a first embodiment of the disclosure, as a cross-sectional view taken along line I-I of FIG. 2 .
In FIG. 3 , the plurality of louvers 13 can be placed horizontally or vertically. In addition, the louvers 13 close perfectly the discharge port 111 under condition parallel to the front of the case 11 .
In detail, both ends of each of the plurality of louvers 13 are rotatably connected to the edge of the discharge port 111 . First, it is described that the plurality of louvers 13 are placed in the horizontal direction and arranged adjacently to each other in the vertical direction.
When the plurality of louvers 13 are placed in the horizontal direction, a rotation axis may be protruded from both side ends of each louver 13 . In addition, the rotation axis may be formed in the top end of the side end of the louvers 13 . According to such a structure, when the fan 14 is driven and the suctioned outdoor air is discharged to the discharge port 111 , the louvers 13 rotate frontward by air pressure to be discharged above. Further, if the fan 14 is stopped, each of the louvers 13 returns to its original position by gravity to maintain an upright condition. When the louvers 13 is in the upright condition, the discharge port 111 is completely closed. Therefore, there is a advantage that a separate driving mechanism rotating the louvers 13 is not needed.
In addition, since the discharge grille 12 is arranged in the rear of the louvers 13 , when the fan 14 is stopped, a phenomenon that the louvers 13 rotate inside the outdoor unit 10 can be prevented by wind blowing into the inside of the outdoor unit 10 from the outside of the outdoor unit 10 .
On the other hand, when the louvers 13 are vertically combined to the discharge port 111 , since it is impossible to rotate due to gravity of the louvers 13 , the rotation axis of the louvers 13 is equipped with elastic members such as a torsion spring at this time. In other word, when wind pressure generated by driving of the fan 14 acts to the louvers 13 , the louvers 13 rotate frontward. Then, when the fan 14 is stopped, the louvers 13 may return to its original position by force of restoration of the elastic member (refer to FIG. 10 ).
Alternatively, the driving mechanism to allow the louvers 13 to rotate selectively will be applied. The description about this will be described with reference to the drawings below.
FIG. 4 shows schematically a louver driving mechanism according to a second embodiment of the disclosure, FIG. 5 shows a portion of the rear of the outdoor unit case equipped with the louver driving mechanism and FIG. 6 shows schematically a form in which the louvers are connected to the louver driving mechanism.
In FIG. 4 to FIG. 6 , A connection bar 22 is extended to one or both ends of the louvers 13 and a pinions 21 is mounted in the end of the connection bar 22 . In addition, a racks 20 may be arranged in the front or rear of the pinions 21 . Further, the pinions 21 may be gear-coupled with the racks 20 . The racks 20 is formed with lengths that may be gear-coupled with both of the pinions 21 connected to uppermost louvers 13 and the pinions 21 connected to lowermost louvers 13 . Further, the racks 20 may be mounted inside the case 11 to enable reciprocal movement along the length of the racks 20 .
Further, a driving motor M may be connected to any one of the pinions 21 connected to the louvers 13 , for example, the lowermost or uppermost pinions 21 .
According to such a configuration, when the driving motor M is operated, the pinions 21 connected to the driving motor M rotates. Further, the racks 20 engaged with the pinions 21 is moved upward or downward on the drawings. Therefore, another pinions gear-coupled with the rack 20 rotate together, too, such that the entire louvers 13 rotate at the same rotational speed and the discharge port 111 is opened or closed selectively.
On the other hand, another mechanism in addition to the rack and pinion structure may be applied as a method for rotating simultaneously a plurality of the pinion 21 connected to the louvers 13 , respectively. For example, time belt type belts may be applied instead of the rack 20 . In other words, gear teeth are formed in inner principal plan of the belt and the plurality of pinions 21 may be engaged with the gear teeth formed in inner principal plan of the belt. Further, when the driving motor is connected to the uppermost or the lowermost pinion 21 , another pinions 21 also rotate at the same speed according to the rotation of the belt.
Further, in addition to the time belt type belt, a chain type sprocket assembly may be applied.
The pinion described above is called “a first power delivery member” and the rack, the time belt or the sprocket assembly is called “a second power delivery member”.
FIG. 7 is a front view of the outdoor unit showing schematically the louver driving mechanism according to a third embodiment of the disclosure, FIG. 8 is a cross-sectional view showing a process in which the louvers close the discharge port of the outdoor unit, as a cross section view taken along line II-II of FIG. 7 and FIG. 9 is a cross-sectional view showing a condition when the louvers close perfectly the discharge port of the outdoor unit.
Referring to FIG. 7 to FIG. 9 , the discharge port 111 of the outdoor unit 10 according to the disclosure may be selectively closed by the plurality of louvers 13 extending in all directions. The plurality of louvers 13 may be arranged to be overlapped with each other. In other word, a portion of one louver may be arranged to be vertically overlapped with a portion of another louver (refer to FIG. 8 ).
Specifically, the driving motor may be mounted in the center of the discharge grille 12 and the louver assembly having a fan type may be mounted in the front of the discharge grille 12 . In other words, the louver assembly, in which the plurality of louvers 13 having the fan type are connected to each other, is mounted and the inner end of the louver 13 connected to its edge is connected to the rotation axis of the motor M. According to this configuration, as shown in FIG. 7 and FIG. 8 , when the driving motor M is rotated to rotate the louvers 13 connected to the edge, the discharge port 111 is closed while unfolding the plurality of louvers 13 in a fan type.
Further, the discharge port 111 may be perfectly closed by unfolding one louver assembly circularly and as shown in FIG. 7 , short louver assemblies are provided in combined type to enable the discharge port 111 to be closed. For example, the discharge port 111 is to be quartered and four louver assemblies may be circularly surrounded in the inside of the discharge port 111 . Further, each louver 13 situated at the edge are connected to the rotation axis of the driving motor M. In this condition, when the driving motor M rotates, four louver assemblies cover by ¼ of the discharge port 111 area to perfectly close the discharge port 111 in total.
On the other hand, one side of each louver 13 is convexly rounded as shown in FIG. 8 and FIG. 9 and the other side is concavely rounded. Then, when the louver assembly is in fully unfolded condition as shown in FIG. 9 , there is no gap between adjacent louvers. In other words, the plurality of louvers may be arranged in one column side by side without overlapping with each other.
In addition, when the louver assembly is in the folding process, one of the louvers 13 is smoothly sled along the side of the adjacent louvers 13 so as to be positioned on the rear of the adjacent louvers 13 .
FIG. 10 shows the louver structure according to a fourth embodiment of the disclosure.
In the FIG. 10 , the louvers 13 according to the fourth embodiment of the disclosure may be rotatably coupled with the discharge port 111 vertically.
The louvers 13 are provided with the rotation axis 17 forming the rotation center of the louvers 13 . An elastic member 18 providing force of restitution to the louvers 13 is coupled with the rotation axis 17 . The elastic member 18 includes a torsion spring.
When the fan 14 rotates, the louvers 13 overcome the elastic force of the elastic member 18 so as to rotate with one direction. Further, the discharge port 111 is opened and air of the inside of the outdoor unit 10 is discharged outside.
On the other hand, when the driving of the fan 14 is stopped, the louvers 13 rotate at its original position by force of restoration of the elastic member 18 so as to close the discharge port 111 .
In summary, when wind pressure generated by driving of the fan 14 acts to the louvers 13 , the louvers 13 rotates frontward. Then, when the fan 14 is stopped, the louvers 13 may return to its original position by force of restoration of the elastic member.
In such a configuration, opening and closing of the louvers 13 may be easily achieved by a simple configuration. | An outdoor unit for an air conditioner according to an exemplary embodiment of the disclosure, comprising: a case forming shape and having a suction port suctioning outside air and a discharge port discharging the suctioned air; a heat exchanger accommodated inside the case; a fan that is accommodated inside the case and forcibly circulate air; and a louver assembly revolvably mounted in the case so as to selectively open and close the discharge port. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates generally to electronic appliance controllers and, more particularly, to an appliance electronic control system which tends to maintain a constant total cycle time, and thus an accurate "Time Remaining" display, notwithstanding variations in the actual time required for a water fill operation.
The subject invention may be implemented as a part of an appliance electronic control system which is disclosed in concurrently-filed application Ser. No. 07/968,991, filed Oct. 30, 1992, by Thomas R. Payne and Steven A. Rice, entitled "Reconfigurable Appliance Electronic Control System with Automatic Model Determination, Internally Restructurable Control and Flexible Programmable Test Modes", and concurrently-filed application Ser. No. 07/969,139, filed Oct. 30, 1992, by Thomas R. Payne, William W. Wead and Steven A. Rice, entitled "Appliance Electronic Control System with Programmable Parameters Including Programmable and Reconfigurable Fuzzy Logic Controller", the entire disclosures of which are hereby expressly incorporated by reference.
Application Ser. No. 07/968,991 discloses a microcontroller-based electronic control system which is able to handle a variety of different appliances which are members of a family of commercial laundry products In a particular embodiment disclosed, the appliance electronic control system is applicable to each of a two-speed clothes washer, a one-speed clothes washer, an electronic dryer and a gas dryer.
A desirable feature in such appliances is a "Time Remaining" display which indicates cycle time remaining based on the state of a count down timer maintained by the controller. In a commercial, coin-operated laundry environment, a dryer cycle is entirely time driven, so little difficulty is involved in maintaining an accurate "Time Remaining" display The controller simply initializes the count down timer with the total cycle time, and then decrements the count down timer at regular predetermined intervals.
However, a clothes washer is both time and event driven, such that an accurate measure of cycle time remaining is more difficult to achieve. Thus, in the case of a washing machine, in order to initialize the count down timer, the control system must sum the time requirements of the various portions of the cycle, referred to herein as operational modes. These operational modes include wash water fill time, soak time, wash agitate time, spin time, rinse fill time, rinse agitate time, final spin time, and several pauses that occur between these operational modes. The pauses are required in order to allow the machine to come to a complete stop upon completion of one operational mode and the commencement of another operational mode in certain situations. In particular, a washing machine would likely be damaged if an attempt were made to switch instantaneously from an agitate mode to a spin mode, since a change in motor direction is involved.
The operational mode times just mentioned are under the direct control of the controller, with the exception of wash water fill and rinse water fill. Since the cessation of water fill is event driven, based on closing of a water level sensor switch or equivalent, rather than time driven, the actual time required to fill is known only after the water fill has occurred. This prevents an accurate initializing of the count down timer and thus prevents an accurate display of time remaining in the wash cycle.
In the past, this problem has been addressed by simply stopping the timer during water filling operations. However, when such an approach is employed, the displayed "Time Remaining" has little actual meaning since the operational cycle is not complete after the number of displayed minutes.
Another approach in the context of an electronically-controlled washing machine is to maintain a history of each particular machine to learn the actual fill times for that particular machine. This may be accomplished using a data filtering technique whereby a running average is kept for the fill time, and running average data is used in a time calculation for determining nominal fill time. This approach would offer a great deal of accuracy in estimating cycle time and thus in displaying "Time Remaining", but the displayed time may be different for different machines. It is considered less desirable by many users, especially in commercial laundry applications, to have a number of machines sitting side by side with different displayed cycle times.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a washing machine electronic control system which includes a "Time Remaining" display which is accurate notwithstanding variations in the actual time required for water filling operations.
It is a related object of the invention to provide a washing machine electronic control system which achieves a nominal total cycle time notwithstanding variations in actual time required for a water filling operation.
It is another object of the invention to provide a washing machine electronic control system which prevents excessive flooding in the event a water level sensor malfunctions.
When a conventional electromechanical timer having cams is employed to control a washing machine, there is a practical minimum duration for any operation, which is related to timer motor speed and cam construction. Pause intervals are typically thirty seconds, although much shorter pause intervals, for example seven seconds, would be sufficient to allow the washing machine motor to come to a complete stop before switching from one operational mode to another, for example, from agitate to spin.
In accordance with an overall aspect of the invention it is recognized that, when controlling the same washing machine with an electronic control capable of establishing time intervals of virtually any duration, it is possible to reduce the length of time of the pause intervals to the minimum needed to stop one type of motion and to start another type of motion, for example. However, if longer pauses remain in the operational cycle, they provide a means of compensating for actual fill times which differ from a nominal fill time.
During design, a nominal or characteristic fill time is determined, which may, for example, be calculated from the midrange of specified flow values for the particular water valve assembly employed. To some extent, water valve assemblies are able to maintain a constant flow even with variations in water pressure. However, this constant flow operation is by no means perfect, and variations in fill time accordingly do occur.
Total cycle time is determined in advance, and used to initialize a cycle timer which drives the "Time Remaining" display. When calculating total cycle time, the value of the nominal or characteristic fill time, for example three minutes for each fill, is included in the sum of the time durations of the operational modes. Rather than thirty seconds for the pause intervals, a nominal pause interval of, for example, fifteen seconds is established.
The first time the machine fills, the actual time for the filling operation is measured. If the machine takes, for example, less than three minutes to fill, the pause intervals are lengthened to compensate for the unused time allocated for the fill. If the machine takes, for example, more than three minutes to fill, the pause intervals are shortened to compensate for the extra time required for the fill.
It will be appreciated there is a limit to the compensation which can be achieved employing this approach. Thus, int he case of long fill time durations (slow fills), the pause intervals cannot be shortened to less than zero seconds. In the case of short fill time durations (fast fills), in principle the pause intervals could be lengthened as much as would be required to achieve full compensation; however, it is considered undesirable to have excessively long pause durations and an arbitrary limit, for example, thirty seconds, is established. In actual implementation, the pause intervals should not be shortened to less than a predetermined minimum which protects the mechanical components when changing from agitate to spin, for example seven seconds. To preserve a thirty-second range for compensation, rather than a thirty second maximum limit for pause durations, the maximum limit may be lengthened to thirty seven seconds.
In cases where the actual fill times exceed the compensation capability, one-time adjustment of the "Time Remaining" count down timer occurs upon completion of the second fill operation. Thus after the second fill is complete, the control determines the difference between the compensation required and the compensation that can actually be achieved by adjusting the duration of any remaining pause intervals. The timer is then "jumped" either forward of backward to reflect this amount of time.
In accordance with a more particular aspect of the invention, a washing machine electronic control system includes a count down timer and a time remaining display indicating cycle time remaining based on the state of the count down timer.
The electronic control system additionally includes control elements for effecting an operational cycle comprising a plurality of operational modes established in a sequence. The operational modes include at least one fill operation having a duration defined by the actual time required for a predetermined amount of liquid to enter a washing machine, and at least one pause interval. Typically, the operational cycle includes first and second fill operations, and first, second and third pause intervals. The first and second pause intervals comprise at least one initial pause interval and occur prior to the second fill operation, and the third pause interval comprises a subsequent pause interval, and occurs after the second fill operation. The operational cycle has a nominal total cycle time which includes a nominal fill time for each of the fill operations, and a nominal time duration for each of the pause intervals.
The control elements are operable to maintain the time remaining display by initializing the count down timer to a state representing the nominal total cycle time, and by decrementing the count down timer at regular predetermined intervals.
The control elements are additionally operable to measure the duration of the at least one fill operation, and to adjust the duration of the at least one pause interval to the extent possible to compensate for any difference between the duration of the at least one fill operation and the nominal fill time so as to tend to achieve the nominal total cycle time.
In embodiments providing for at least first and second pause intervals, the control elements are further operable, in the event the difference between the duration of the at least one fill operation, and the nominal fill time exceeds compensation that can be achieved by adjusting the duration of the first pause interval, to adjust the duration of the second pause interval to the extent possible to compensate for any remaining difference between the duration of the at least one fill operation and the nominal fill time so as to tend to achieve the nominal total cycle time.
In embodiments providing for first and second fill operations, the control elements are further operable to measure the duration of the second fill operation and to adjust the duration of the subsequent pause interval to the extent possible to compensate for any difference between the combined durations of the first and second fill operations and twice the nominal fill time to the extent not previously compensated for so as to tend to achieve the nominal total cycle time.
In situations where sufficient compensation cannot be achieved by adjusting the durations of pause intervals, then the state of the count down timer is adjusted, by way of a one-time correction, to a state which represents actual cycle time remaining.
In accordance with another aspect of the invention, the control system prevents excessive flooding in the event a liquid level sensor malfunctions, where the liquid level sensor is normally used to sense when the predetermined amount of liquid has entered the machine. A flood timer is maintained to track actual fill time during a filling operation, and actual fill time as tracked by the flood timer is periodically compared to a predetermined maximum value. Operation is terminated in the event the actual fill time exceeds the predetermined value.
BRIEF DESCRIPTION OF THE DRAWINGS
While the novel features of the invention are set forth with particularity in the appended claims, the invention, both as to organization and content, will be better understood and appreciated from the following detailed description, taken in conjunction with the drawings, in which:
FIG. 1 is a schematic diagram of an appliance electronic control system connected for controlling a clothes washing machine;
FIG. 2 is a flowchart representing a routine to periodically decrement the cycle timer represented by the variable Time Remaining at predetermined intervals; and
FIGS. 3A, 3B and 3C are a flowchart representing a control program.
DETAILED DESCRIPTION
Referring initially to FIG. 1, an appliance electronic control system 20 includes a suitably programmed microcontroller 22, for example, a Motorola 6805. Within the microcontroller 22 are memory elements 23 in the form of RAM memory, as well as ROM program memory. The microcontroller 22 includes input/output port lines, generally designated 24, which output signals for activating various functional elements within a clothes washing machine 26 and which receive various inputs. The microcontroller input/output lines 24 are connected to the functional elements within the washing machine 26 as shown in FIG. 1, in some cases directly, and in other cases through relays, in this case five relays respectively designated RL1, RL2, RL3, RL4 and RL5. For water level sensing, the control system 20 includes an opto-isolator 28 for interfacing 120 volts AC from a water level sensor 29 to an input of the microcontroller 22. The water level sensor 29 responds to incoming water filling a washing machine tub 30 reaching a predetermined level.
For powering the microcontroller 22 and other elements, a DC power supply 31 is included, which receives 120 volts AC from conductors L1 and N.
Included within the washing machine 26 are a number of conventional mechanical and electromechanical elements, including a motor 32, a start relay 34, a motor speed control winding 36, a lid switch 38, and hot and cold water valve solenoids 40 and 42. The motor 32 is connected through a conventional mechanical transmission (not shown) to drive an agitator 43, and reverses direction to effect either a spin or an agitate operation, in cooperation with the transmission, in a well-known manner. For user control, a selector switch 44 is provided, the state of which is sensed by the microcontroller 22 through selected ones of the input/output lines 24.
From FIG. 1, it can be seen that relay RL1 controls energization of the motor 32. Relay RL2 controls motor direction (agitate or spin). Relay RL3 controls motor speed. Relays RL4 and RL5 respectively control the hot and cold water solenoids 40 and 42.
Also connected to and driven by the microcontroller 22 is a user display 46 which, among other things, indicates cycle Time Remaining, based on a count down cycle timer, for example within the RAM memory 23, and maintained by software within the microcontroller 22.
In this regard, included within the microcontroller 22 memory 23 is a memory location 48 storing a variable Time Remaining, which implements the count down cycle timer. Alternatively, a hardware register may be employed. In either event, it will be appreciated that the cycle timer is a counter which, during operation, has a counter state which is intended to reflect time remaining in a cycle.
Considering exemplary programming within the microcontroller 22, FIG. 2 is a flowchart of a routine 50 which maintains the FIG. 1 cycle timer 48. It will be appreciated that FIG. 2 represents a process which executes concurrently with the remainder of the programming described hereinbelow, and somewhat independently. The FIG. 2 routine is executed at regular predetermined intervals, for example every 1/120 second, and has a single step, that of Box 52, where the cycle timer 48 is decremented by an appropriate amount, for example 1/120 second, whereupon the routine exits at 54.
Any one of a variety of known microcontroller techniques may be employed to implement the periodic calling of the FIG. 2 routine. As one example, the FIG. 2 routine may be an interrupt routine. However, in the approach of the above-incorporated concurrently-filed application Ser. No. 07/968,991, the FIG. 1 Maintain Cycle Timer routine 50 is included as part of a program main loop which executes entirely through every 1/120 second. The program main loop includes an initial program step which waits for a zero crossing of the 60 HZ 120 VAC input power line, and then allows the entire program main loop to execute, whereupon execution again waits for the next zero crossing of the AC power line.
FIGS. 3A, 3B and 3C illustrate a simplified flowchart for a wash cycle which includes the fill time compensation of the invention. What are effectively the same flowchart steps implemented in a slightly different manner are disclosed in the above-incorporated concurrently-filed application Ser. No. 07/968,991. Although the results are the same, a fundamental difference in approach is that the flowchart of FIGS. 3A, 3B and 3C herein implies a sequential series of operations through a washing machine cycle, whereas, in the more comprehensive flowchart of the above-identified application Ser. No. 07/968,991, the entire routine is executed 120 times a second, and, during each time through, certain operations are executed or not depending upon the status of various flags which are maintained.
In overview, the Wash Cycle routine 60 of FIGS. 3A, 3B and 3C effects an operational cycle including a plurality of operational modes established in a predetermined sequence. By way of example, the following TABLE depicts the operational modes of a typical wash cycle, and the duration of each:
TABLE______________________________________Operational Mode Duration______________________________________WASH FILL 3 minutes nominalSOAK 2 minutes fixedWASH AGITATE 11.75 minutes fixedFIRST PAUSE 15 + 7 seconds nominalFIRST SPIN 3.5 minutes fixedSECOND PAUSE 15 + 7 seconds nominalRINSE FILL 3 minutes nominalRINSE AGITATE 2 minutes fixedTHIRD PAUSE 15 + 7 seconds nominalFINAL SPIN 5.5 minutes fixed______________________________________
From the foregoing TABLE, it will be seen that most of the operational modes are of a fixed time duration, with the exception of the two fill operations, which have a nominal duration of three minutes each, and the three pause intervals which have nominal durations of fifteen seconds plus seven seconds each. In accordance with the invention, differences between the actual duration of the fill operations and the nominal fill time is compensated for, to the extent possible, by adjusting the durations of the pause intervals. Accordingly, the initial setting of the Time Remaining cycle timer accurately reflects the total cycle time, and accurately reflects "Time Remaining" as a wash cycle proceeds. It will be appreciated that, in accordance with the disclosure of the above-incorporated concurrently-filed application Ser. No. 07/969,139, the "fixed" time durations in the foregoing TABLE are subject to programming for various durations. Nevertheless, ordinarily at the beginning of a particular machine operational cycle these durations are fixed for that particular cycle.
In FIG. 3A, the first execution step is in Box 62 where the count down timer 48 is initialized to a state representing the nominal total cycle time by summing the durations of the operational modes of the wash cycle, such as in the TABLE example above, and storing the result as the variable Time Remaining. (Thereafter the FIG. 2 routine decrements the variable Time Remaining at predetermined intervals.)
Next, in a series of steps beginning with Box 64 and ending with Box 78, a wash fill operation of three minutes nominal duration is performed, while measuring the actual duration. In particular, a variable Fill Time, here used as a timer variable, is utilized to track the actual time required for the fill operation. The timer variable Fill Time is reset at Box 64. A timer variable Flood Timer, a safety feature to prevent excessive flooding from malfunctioning water level sensors, is reset at Box 66, and likewise subsequently tracks actual fill time. In Box 68, signals are output to actuate either or both of the hot and cold water solenoids 40 and 52. During the filling operation, a loop is executed in which the value of the timer variable Flood Timer is repeatedly checked against a predetermined value, sixteen minutes, at decision Box 70. If the value of the timer variable Flood Timer exceeds sixteen minutes, all machine functions are stopped; the water solenoids 40 and 52 are turned off, and the machine is placed into an error mode at Box 72. This error mode persists until additional coinage sufficient for a vend is deposited, the machine is placed into diagnostics mode, or the machine experiences a power outage. If it is determined that the machine has not been filling for over sixteen minutes, the timer variables Flood Timer and Fill Time are incremented at Box 74 and a full condition is checked for at decision Box 76 which interrogates the state of the input from the FIG. 1 level sensor 29. If the full condition does not exist, the program loops back to decision Box 70 where the status of the timer variable Flood Timer is again checked. If the full condition exists at decision Box 76, the water solenoids are turned off at box 78.
In the absence of an error condition, the actual duration of the wash fill is determined by the time it takes a predetermined amount of water to enter the washing machine to eventually actuate the water level sensor 29, and at this point is indicated by the value of the timer variable Fill Time.
In the specific example disclosed herein, an actual wash fill duration within the range of 3 minutes ±15 seconds can be completely compensated for by adjusting the duration of the first pause interval as is described below. An actual wash fill duration within the range of 3 minutes ±30 seconds can be completely compensated for by adjusting the durations of the first and second pause intervals. An actual wash fill duration outside the range of 3 minutes ±15 seconds but within the range 3 minutes ±30 seconds is compensated for by adjusting the duration of the first pause interval to the extent possible, and subsequently adjusting the duration of the second pause interval to compensate for the remaining difference between the duration of the wash fill operation and the nominal fill time.
In Box 84 a soak operation occurs, followed by wash agitate in Box 86 where the motor 32 is energized in the direction which causes agitation. Both the soak and the wash agitate operations occur for fixed time durations.
From the TABLE hereinabove, it will be seen that the next operation is the first pause interval, which has a nominal duration of fifteen plus seven seconds. However, in accordance with the invention, to compensate for fill time variations the duration of the first pause interval is adjusted to the extent possible to accommodate variations in the fill time from the three minute nominal fill time.
Considering first the situation where compensation can be completely effected, in decision Box 88 the variable Fill Time is compared with three minutes fifteen seconds and, if Fill Time is not greater than three minutes fifteen seconds, execution proceeds to decision Box 90, where the variable Fill Time is compared to two minutes forty five seconds. If the variable Fill Time is not less than two minutes forty five seconds, then it follows that the actual fill time is within the range of three minutes ±fifteen seconds whereupon, in Box 92, the first pause interval is caused to occur with a duration equal to three minutes fifteen seconds plus seven seconds minus the variable Fill Time. Thus, in Box 92, the resultant duration of the first pause interval is within the range of from zero plus seven to thirty plus seven seconds. Then, in Box 94, the variable Fill Time is reset to three minutes.
Considering now a situation where the actual fill time was greater than three minutes fifteen seconds (slow fill), in decision Box 88 the answer is yes, whereupon execution proceeds to Box 96 where a predetermined absolute minimum pause interval is established, int his example seven seconds. Then, in Box 98, the variable Fill Time is adjusted by subtracting fifteen seconds, since fifteen seconds of the long fill time have been compensated for in Box 96.
Conversely, if the fill was relatively fast such that the fill time in Box 90 is determined to be less than two minutes forty five seconds, then in Box 100 a pause interval of an arbitrary maximum is established, in this example thirty plus seven seconds. Then, in Box 102, the variable Fill Time is increased by adding the fifteen seconds which were compensated for in Box 100.
After the first pause, of whatever length, execution proceeds to Box 110 where a first spin of fixed duration is effected.
Next, in order to adjust the duration of the second pause interval to compensate for any remaining difference between the duration of the first fill operation and the nominal fill time, to the extent possible, execution proceeds to decision Box 112 to determine whether the value of the variable Fill Time (after adjustment in either Box 94, 98 or 102) is greater than three minutes fifteen seconds. If not, execution proceeds to decision Box 114 which asks whether the variable Fill Time is less than two minutes forty five seconds. If not, then Box 116, which may be compared to Box 92, adjusts the duration of the second pause interval to compensate for the remaining difference in the fill time, and in Box 118 the value of the variable Fill Time is set to three minutes.
In the same manner as discussed above with reference to Boxes 96, 98, 100 and 102, in the event the fill was slow and the value of the variable Fill Time is still greater than three minutes fifteen seconds, in Box 120 a minimum duration pause of seven seconds is established, and in Box 122 the value of the variable fill time is adjusted.
Conversely, in the event of a fast fill, in decision Box 114 the value of the variable Fill Time may be less than two minutes 45 seconds, in which case execution proceeds to Box 124 where a pause of maximum duration, e.g. thirty plus seven seconds, is established, and in Box 126 the value of the variable Fill Time is increased by fifteen seconds.
In any event, execution then proceeds to Box 130. The steps of Boxes 130, 132, 134, 136, 138, 140 and 142 perform a rinse fill operation of three minutes nominal duration, with the timer variable Flood Timer as a safety device, in generally the same manner as described above with reference to Boxes 66, 68, 70, 72, 74, 76 and 78. Just as in the case of the wash fill, the actual duration of the rinse fill may be greater or less than the nominal three minute fill time.
In a variation of the approach of Boxes 66, 68, 70, 72, 74, 76 and 78, in the sequence beginning with Box 130 the timer variable Fill Time is not reset. The value of the variable Fill Time is simply increased by an amount which reflects the actual duration of the rinse fill. Employing this approach, rather than resetting the variable Fill Timer, allows the total fill variation time to be tracked with one timer.
Upon completion of the rinse fill, cycle timer correction, if needed, is carried out. This amounts to a one time adjustment of the cycle timer 48 in the event either extremely fast fills or extremely slow fills have occurred.
Thus, decision Boxes 150 and 152 serve to recognize this condition, and cause the cycle timer 48 to be jumped, forward or backward as is appropriate, and additionally to adjust the value of the variable Fill Time to control the actual duration of the third pause interval.
More particularly, in the event of extremely slow fills, where the adjustments of Boxes 96, 98, 120 and 122 were insufficient, in decision Box 150 it is determined that the value of the variable Fill Time is greater than six minutes fifteen seconds. The comparison value six minutes fifteen seconds is used because six minutes is twice the three minute nominal fill time for the wash fill and the rinse fill, and fifteen seconds is the nominal duration of the third pause interval. Under these conditions, execution proceeds to Box 154 where the cycle timer 48 variable Time Remaining is increased, in a one-time adjustment, to indicate to the user the actual cycle time remaining. As indicated, the cycle timer is increased by a value equal to the variable Fill Time minus six minutes fifteen seconds. Then, in Box 156, the value of the variable Fill Time is reset to six minutes fifteen seconds.
Conversely, in the event of extremely fast filling operations where the adjustments of Boxes 100, 102, 124 and 126 were insufficient, in decision Box 152 the value of the Variable Fill Time is less than five minutes forty five seconds, in which case execution proceeds to Box 158 where the cycle timer 48 which reflects time remaining is decreased to indicate to the user the actual time remaining in the wash cycle. As indicated in Box 158, the cycle timer is decreased by an amount equal to five minutes forty five seconds minus the value of the variable Fill Time. Then, in Box 160, the value of the variable Fill Time is set to five minutes forty five seconds.
In any event, an agitate operation is effected in Box 162.
Box 164 establishes the third pause interval. The third pause interval have a nominal duration of fifteen plus seven seconds. However, the actual duration of the third pause interval is between seven and thirty plus seven seconds, being determined by subtracting the value of the variable Fill Time from the constant 6.25 minutes.
The final spin occurs in Box 166, and the wash cycle ends at Box 168.
While specific embodiments of the invention have been illustrated and described herein, it is realized that numerous modifications and changes will occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit and scope of the invention. | An appliance electronic control system which tends to maintain a constant total cycle time, and thus an accurate "Time Remaining" display, notwithstanding variations in the actual time required for a water fill operation. The control system includes a count down timer and a time remaining display indicating cycle time remaining based on the state of the count down timer. The count down timer is initialized to a state representing nominal total cycle time, which includes the sum of a nominal fill time for water filling operations, a nominal time duration for each of several pause intervals, and the time durations of operational modes under the direct control of the control system, such as agitate time and spin time. During operation, the count down timer is decremented at regular predetermined intervals. The first time the machine fills, the actual time for the filling operation is measured. If the machine takes time less than the nominal fill time to fill (fast fill), the pause intervals are lengthened to compensate for the unused time allocated for the fill. If the machine takes more time than the nominal fill time to fill (slow fill), the pause intervals are shortened to compensate for the extra time required for the fill. In situations where the actual fill time exceeds the compensation capability, a one-time adjustment of the "Time Remaining" count down timer occurs at an appropriate point in the cycle. A safety feature to prevent excessive flooding due to faulty water level sensors is included. | 3 |
FIELD OF THE INVENTION
The present invention relates to processes for controlling the torque developed between opposing rolls in a calendering operation. More particularly, the present method relates to the control of torque in a calendering system that is suitable for use with a paper making and/or converting operation.
BACKGROUND OF THE INVENTION
It is known to those of skill in the art that a calender or calender stack is a series of rolls, usually steel or cast iron, mounted horizontally and/or stacked vertically. During machine calendering in a paper processing application, the dry paper passes between the rolls under pressure, thereby improving the surface smoothness of the paper caused by, for example, imperfections in felt marks, cockle lumps, fibrils, and the like. Additionally, such a calender stack can improve the gloss and create a more uniform caliper and porosity. These improvements can make the paper better suited for printing and decrease manufacturing problems during printing and rewinding operations. As would be known to those of skill in the art, a typical loading range between opposed rolls generally varies from 0 N/cm (Gap) to 85,000 N/cm (0 lbs. per linear inch (Gap)-1,000 lbs. per linear inch).
Some known calendering systems are provided with a steel roll and a roll having a rubberized coating. In such systems, the steel roll is known as the king roll and it may be located in the top or bottom position of the calender. The king roll may be larger or smaller than the other rolls in the calender stack and may be crowned (i.e., has a larger or smaller diameter in the center of the roll as compared to the ends) in order to permit even pressure being applied to a substrate passing between opposing loaded roll faces. However, one of skill in the art will realize that the king roll and/or the queen roll can be crowned and/or provided with variable crown capability. A variable crown can be achieved using various methods including, a pressurized oil filled roll where the oil pressure controls the degree of crowning, internal hydraulic shoes that press against the roll shell to control the degree of crowning, or roll bending. The roll in mateable engagement with the king roll is known as the queen roll. In certain operations, the queen roll can be provided with a rubberized coating in order to increase the engagement of the surface of the queen roll with the surface of the king roll.
In conventional calendering operations, as the two rolls come in contact, one or both surfaces of the king roll and/or queen roll deform. In operations where the queen roll is provided with a rubberized coating, such a coating will be provided on the queen roll in about ½-inch to 1-inch (1.27 cm to 2.54 cm) in thickness. As the surface of the rubberized queen roll deforms, the rubberized coating deforms in order to pass through the nip formed between the king roll and queen roll. This cover flows to conform to the nip surface. Such conformation can result in shear forces being formed across the area of contact between the two rolls.
A second mechanism that can create shear forces across a nip in a calendering operation exists when one roll of the calender attempts to drive the second roll. As one roll attempts to speed up or slow down, it forces the rubberized coating deposited upon the second roll to deform in such a way as to force the second roll to speed up or slow down. In doing so, the interaction between the first and second rolls of the calender create a shear force that is transmitted through a substrate disposed therebetween. This shear force cannot be avoided in a calendering operation with only one driven roll. These forces can be generated by rolls of a calender system having steel rolls and/or rolls having no coating disposed thereon due to frictional forces caused by roll deformation.
When the rolls forming the calender nip are separately driven and are forced together, they are provided with the capability of transferring forces across the nip to drive each roll. If the rolls tend towards asynchronous behavior (i.e., the rolls are not surface speed matched in the nip), a net torque is developed between the rolls with associated forces across the nip, and the resulting calendering operations can become unpredictable. The nip torque imbalance creates a shear force across a material passing between the rolls of the nip that is greater than the shear forces caused by the roll deformation alone. This shear force can damage a substrate placed between the rolls of a calender system.
A known method for controlling the shear force developed across the nip in a calendering operation provides for an operator to manually set the torques between multiple drives to minimize the shear force transmitted through the substrate. The most common means to manually manipulate the torque division between the multiple drives are 1) through torque division to multiple motors of a common speed controller output, 2) operating one drive to control speed and one to provide a constant torque or 3) operating one speed controller as a lead, or master, speed controller and the second as a droop, or current compounded, speed controller.
Such systems may be suitable for use in situations where constant loading of the rolls of a calender system is utilized. However, some processes require variable calender loading as the product (such as paper) passes between the calender rolls. In variable calender loading systems where total motor torque loads can change, manual adjustments such as those used in constant loading processes, are not suitable. This is because an operator of a variable calender system would be required to provide continual (if not continuous) adjustments to the motor torques to maintain the desired minimum level of shear force in the nip.
Thus, it would be useful to provide for a method to control torque in a calendering system that keeps one roll torque (or current) at a desired value while a second roll (preferably rubber covered) is nipped against the first roll. Such a mechanism would effectively change the torque on the second roll to affect a change of the torque utilized by the first roll. Such a process would control the amount of shear forces developed across a substrate passing between the calender rolls. This can minimize the shear damage to the substrate and improve the tensile loss during a calender, combiner, or embosser/laminator operation. This can effectively reduce web losses through reduced substrate damage by minimizing shear forces transmitted across the substrate.
SUMMARY OF THE INVENTION
The present invention provides for a method for controlling a calendering system having a first roll and a second roll. The first roll is provided with a first roll torque controller and a first roll speed controller. The method comprises the steps of: (a) setting the first roll at a desired process speed with the first roll speed controller; (b) determining a target torque of the first roll; (c) contactingly engaging the first and second rolls; (d) measuring an actual torque of the first roll; (e) comparing the target torque and the actual torque; and, (f) adjusting a speed of the first roll with the first roll torque controller to maintain the target torque of the first roll according to the comparison of the target torque and the actual torque.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an exemplary process for controlling torque (or current) in a calendering system in accordance with the present invention;
FIG. 2 is a block diagram of an alternative embodiment of a torque (or current) control process;
FIG. 2A is a block diagram of a further embodiment of a torque (or current) control process;
FIG. 2B is a block diagram of a further embodiment of a torque (or current) control process;
FIG. 3 is a block diagram of a further embodiment of a torque (or current) control process;
FIG. 4 is a block diagram of a further embodiment of a torque (or current) control process; and,
FIG. 5 is a block diagram of a further embodiment of a torque (or current) control process.
DETAILED DESCRIPTION OF THE INVENTION
Provided herein are seven exemplary, but non-limiting embodiments on methods to affect the torque of the queen roll of a calendering system that, in turn, can cause a predictable change in the king roll torque of the calendering system. Six of the exemplary, but non-limiting, systems described herein utilize a process controller in concert with speed controllers and/or torque controllers in order to effectuate control of the forces generated between calendering rolls during a calendering operation. The seventh exemplary embodiment described herein does not require the use of a process controller in order to effectuate system control. However, it should be easily recognized and understood that the following systems could also be utilized in any apparatus, process, and/or situation where one roll is required to apply pressure to another. This would include processes utilizing multiple nip and/or gap combinations having at least two calendering rolls. These exemplary processes described herein could be utilized in combiner processes, embossing processes, laminating processes, processes using pressure rolls, and combinations thereof.
In a typical DC motor system, it should be realized that armature current draw is directly proportional to the torque produced by the motor. However, it should be realized by one of skill in the art that in AC motor systems that motor current (or total current) is not directly proportional to torque. Thus, by convention, torque is the preferred term used herein. However, one of skill in the art will understand that torque and current should be understood to be used interchangeably herein when describing exemplary DC motor systems. Additionally, some AC drives (i.e., vector-controlled AC drives, etc.), a “torque producing” component of current is proportional to torque, and is available for control. This component of such an AC drive could be treated as a DC motor current in control of motor torque.
FIG. 1 depicts a block diagram of an exemplary process 90 for controlling torque in a calendering system 42 . The calendering system 42 is generally provided with a first roll 12 (also referred to herein as king roll 12 ) and a second roll 14 (also referred to herein as queen roll 14 ). The first roll 12 is generally rotated by mechanical connection to first roll motor drive 18 which is operatively connected to first roll motor 16 . Similarly, the second roll 14 is generally rotated by mechanical connection to second roll motor drive 22 which is operatively connected to second roll motor 20 .
Generally, first roll motor 16 cooperatively associated with first roll 12 is controlled by a manipulation of the first roll 12 speed by first roll speed controller 28 and first roll torque controller 24 . This manipulation can be provided by first roll motor speed sensor 38 to provide feedback to first roll speed controller 28 and then provide a torque (or current) correction to first roll torque controller 24 . The torque correction provided by first roll torque controller 24 can either increase or decrease the torque provided by first roll motor 16 to either increase or decrease the speed of first roll 12 .
As with first roll motor 16 , second roll motor 20 cooperatively associated with second roll 14 is controlled by a measurement of second roll 14 speed by second roll motor speed sensor 36 that provides feedback to second roll speed controller 30 that then provides a torque, or current, correction to second roll torque controller 26 . The torque, or current, correction provided by second roll torque controller 26 can either increase or decrease the torque (current) provided by second roll motor 20 to either increase or decrease the surface speed of second roll 14 .
In accordance with the present invention, the motors associated with the rolls of a calendering process are preferably provided with load sharing. In other words, both motors are speed controlled all the time. However, the second roll speed controller 30 associated with the second roll 14 of the calendering system 42 can have its speed reference 44 adjusted to compensate for the reaction of second roll 14 to nip load changes between first roll 12 and second roll 14 . It was surprisingly found that cooperative coupling of first roll torque controller 24 with second roll speed controller 30 and/or second roll torque controller 26 can reduce or even prevent the development of a resultant torque between first roll 12 and second roll 14 that produces transmittable shear forces upon a web material 40 moving in a machine direction MD and disposed between first roll 12 and second roll 14 . Thus, in accordance with the present invention, it is desirable to keep the first roll 12 torque constant in order to provide for the second roll 14 torque to produce the work energy going into a rubber coating disposed upon the second roll 14 that is being deformed due to contact with the first roll 12 . In other words, the desired torque from the first roll motor drive 18 is affected by the torque applied to the second roll motor drive 22 .
As shown in FIG. 1 , establishment of the correct torque from the second roll motor drive 22 can be provided by process controller 34 . When first roll 12 and second roll 14 are in non-contacting engagement (i.e., first roll 12 and second roll 14 are in an ‘un-nipped’ or ‘gapped’ state), process controller 34 is disengaged and the speed of second roll 14 is adjusted independently of first roll 12 by second roll speed controller 30 through second roll torque controller 26 .
The desired speed of first roll 12 can be determined by the operators to achieve process objectives, such as production rate and sheet control, from the calender system 42 . Additionally, the desired speed of first roll 12 can be determined by any downstream processing needs for web material 40 . If the web material 40 remains tight at the in-running nip and is breaking, the surface speed of the first roll 12 can be reduced by adjusting what is known to those of skill in the art as the calender draw. If the web material 40 at the in-running nip is too loose, as determined by the web material 40 sagging and weaving, the calender draw can be adjusted to speed up the first roll 12 .
A calender system 42 useful with the present invention can be operated with the first roll 12 and second roll 14 in non-contacting engagement or in contacting or mating engagement (i.e., providing a ‘nip’ therebetween). In any regard, the calender system 42 should be started and first roll 12 and second roll 14 accelerated to operating speed. Such start-up and acceleration can be done in either a ‘nipped’ or ‘gapped’ configuration. In a ‘nipped’ configuration, the first roll 12 sets the calender system 42 speed. Because the surface of the second roll 14 tends to deform, the second roll 14 speed should not be used as a process reference. In a ‘gapped’ mode, both the first roll 12 and second roll 14 run at the same speed to create a nip without damaging the web material 40 disposed therebetween when contact occurs between first roll 12 and second roll 14 .
The target first roll 12 torque (current) value is determined by providing a gap between the first roll 12 and second roll 14 and operating the calender system 42 with, or without, web material 40 disposed therebetween. The torque (current) produced by first motor 16 during this gapped condition is the torque required to maintain the first roll 12 at the necessary calendering system 42 speed. The first roll 12 in this configuration is not doing any work on its surface, on or upon any material disposed between first roll 12 and second roll 14 , or upon the surface of second roll 14 . This value provides a possible target torque for the first roll 12 that can minimize any torque transfer between the first roll 12 and second roll 14 .
At any time in the calendering process, the first roll 12 and second roll 14 can be matingly engaged. As is known to one of skill in the art, such mating engagement can occur by the provision of air pressure to inflate airbags or air cylinders that produce a force to load the first roll 12 and second roll 14 of calendering system 42 together. In another instance, hydraulic oil pressure can be utilized to operate hydraulic cylinders cooperatively associated to each of first roll 12 and second roll 14 of calendering system 42 to produce the force to load the first roll 12 and second roll 14 together. In yet another embodiment, a jack screw, driven either manually or with a motor, can be utilized to produce the force necessary to load the first roll 12 and second roll 14 together. In any regard, each of these processes, and others known to those of skill in the art, can give a measured degree of loading, either by actual loading pressures, weights of first roll 12 and second roll 14 and load or relief pressure levels, or by movement of the first roll 12 relative to the surface of the second roll 14 .
The actual first roll 12 torque is obtained from the first roll motor 16 by way of a torque sensor preferably in electrical communication with first roll torque controller 24 as a measured or calculated value. All motors are preferably provided with measures of torque that can be extracted and used by any controllers or computers external to the first roll motor 16 .
When first roll 12 and second roll 14 are in contacting engagement, process controller 34 dynamically compares the in situ output from first roll torque controller 24 ultimately supplied to first roll 12 through any associated gearing ratios in first roll motor drive 18 to a target torque desired by an operator of, or process requirement for, calendering system 42 . In other words, when the target torque and actual torque have been determined, the next step is to compare and determine the error as a function of target torque and actual torque. This error is then used by an algorithm associated with process controller 34 to produce an output value that is used to change the speed of second roll 14 to regulate the first roll 12 torque. The process controller 34 incorporates an integral term that is a coefficient multiplied by the time integral of the error value and adds this product to the proportional term (another coefficient multiplied by the error) to form an output of the proportional plus integral controller. For a constant error, the proportional term remains constant, and the integral term increases with time (assuming constant coefficients). This integral increases the output of the proportional plus integral controller until the calendering system 42 responds accordingly and makes the error zero.
As would be appreciated by one of skill in the art, the values of torque for first roll 12 and second roll 14 , in either the ‘gapped’ state or the ‘nipped’ state, can be stored as an array. These torque values may be stored with a registration value according to the acquisition frequency of the values. Compilation of the torque values for the first roll 12 and second roll 14 values can be used to develop a torque profile. This profile may then be used together with the profiles of similar web material 40 to determine a typical torque profile for the particular type of web material 40 involved in the analysis. Any of these profiles may be used to alter the control scheme to adjust the torque profile applied by calendering system 42 to subsequent web material 40 . The profiles can be used to predict when changes in the web material 40 may occur within the web material 40 in order to allow for compensatory changes in the control algorithm.
The profiles may also be used as data to support the use of intelligent or model-based control schemes to affect the manufacture of web material 40 . As an example, a neural network may take as inputs the operating conditions known during the process of manufacturing web material 40 that correspond to each portion of the web material 40 and associate those known conditions with the torque(s) required by the same portion of the web material 40 provided by the web material 40 history. The neural network may then predict changes necessary to the manufacturing and calendering conditions to yield a desired torque profile for web material 40 . The neural network may then control the manufacturing and calendering processes to dynamically implement the predicted torque changes. The neural network may associate known manufacturing and calendering conditions with the torque values these conditions produced, as provided by the torque history. These associations may form the basis for predictions by the neural network of the operating conditions that will yield a desired torque profile in subsequent web material 40 .
Referring again to FIG. 1 , an exemplary, but non-limiting, process to influence the torque in the first roll 12 can use a process controller 34 to manipulate the second roll speed controller speed reference 44 through a subtractor 46 (a subtractor 46 may also be known in the art as a summer having appropriate polarity). This can dynamically change the speed of the second roll 14 through the second roll speed controller 30 . As shown, second roll speed controller 30 can be influenced by the output of a process controller 34 , operating as a proportional plus integral controller, through the second roll speed controller speed reference 44 to the speed controller 30 The proportional plus integral controller operates as described supra. Process controller 34 can monitor (either continuously or by sampling) the output of actual torque signal of the first roll torque controller 24 and send a correction to the second roll speed controller speed reference 44 .
In a gapped condition, both speed control systems for first roll 12 and second roll 14 preferably operate independently and the process controller 34 is turned off. When the calender system 42 operates in a “nipped” condition, the process controller 34 is turned on in order to provide a load share control for exemplary process 90 . This can be accomplished by setting the initial output value for the process controller 34 .
The first value the process controller 34 sends to the second roll speed controller speed reference 44 is zero, in order to keep the same target speed for the second roll speed controller 30 . At the same time, the process controller 34 minimum and maximum output limits are set at the initial value of zero and can increase steadily (i.e., ramp) to their final values.
When the calender system 42 changes from a “nipped” condition to a “gapped” condition, the process controller 34 is turned off with its limits set to the initial values. The transition from “gapped” condition to “nipped” condition and back to “gapped” condition can be accomplished by a switching mechanism 93 . An exemplary switching mechanism 93 can utilize a physical switch that senses the distance, loading pressure, and/or force necessary to contact the first roll 12 and second roll 14 . Alternatively, an exemplary switching mechanism 93 can provide for a measurement of the distance moved compared to an operator entered point of contact of first roll 12 with second roll 14 .
Speed Controller Droop
When a typical DC motor is operated with a constant armature voltage, the speed of the motor changes as the load is increased. This speed/load characteristic of a motor is known to those of skill in the art as droop. A positive droop indicates a decrease in motor speed. A negative droop indicates an increase in motor speed. A similar function can be duplicated in a speed controller by feeding a portion of the output from the speed controller to the input of the speed controller in a feedback loop. This is known to those of skill in the art as droop or current compounding.
As used herein, a controller can consist of operations consisting of input, comparison, processing algorithms, output functions, and combinations thereof. In operation, a controller can utilize any or all of these functions to define an output. A droop controller can be as simple as a single input, multiplier algorithm, or an output.
FIG. 2 depicts a block diagram of an alternate embodiment of an exemplary process 10 for controlling torque in a calendering system 42 . Here the torque in the first roll 12 is influenced by use of a droop controller 32 to control droop (i.e., current compounding) to either dynamically increase or decrease the output of second roll speed controller 30 . As shown, second roll speed controller 30 can be influenced by the output of the process controller 34 operating as a proportional plus integral controller through the droop controller 32 as described supra.
Droop controller 32 monitors (either continuously or by sampling) the output signal of the second roll speed controller 30 and sends a small portion of this output back to the input of second roll speed controller 30 to supplement the speed signal feedback input to second roll speed controller 30 . This process can effectively reduce the effect of the integral term output from process controller 34 and provide for the second roll speed controller 30 to allow a small error in the speed signal feedback. As would be realized by one of skill in the art, increasing the droop of the second roll speed controller 30 can effectively “soften” the second roll speed controller 30 and allow for the first roll motor 16 to increase its torque output to first roll 12 . Decreasing droop causes the second roll speed controller 30 to provide more torque to the second roll 14 by second roll motor 20 thereby decreasing the torque supplied by the first roll motor 16 to the first roll 12 . It should be understood that one of skill in the art could use both positive and negative feedback to create the range of droop suitable for use with the present invention.
In a gapped condition, both speed control systems for first roll 12 and second roll 14 operate independently and the process controller 34 is turned off. The droop controller 32 is provided with a manually entered value at this time. When the calender system 42 operates in a “nipped” condition, the process controller 34 is turned on in order to provide a load share control for exemplary process 10 . This can be accomplished by setting the initial torque value for the process controller 34 .
The first value the process controller 34 sends to the droop controller 32 is the same value as the manually entered droop value used during the “gapped” condition prior to going to a “nipped” condition. At the same time, the process controller 34 minimum and maximum output limits are set at the initial value and can increase steadily (i.e., ramp) to their final values. The resulting droop value is then sent to the droop controller 32 that has an input supplied by process controller 34 when a nipped condition is sensed.
When the calender system 42 changes from a “nipped” condition to a “gapped” condition, the process controller 34 is turned off with its limits set to the initial values. In other words, the original operator entered manual droop value is used in the droop controller 32 . The transition from “gapped” condition to “nipped” condition and back to “gapped” condition can be accomplished by the use of switching mechanism 93 as described supra.
As described (i.e., separate controllers and power supplies for each motor, regardless of whether AC or DC current is utilized for each motor), the two speed controllers act as described supra. This is because each roll motor speed controller 28 , 30 can act on the total power applied to each roll motor 16 , 20 independently from the other roll motor speed controller 28 , 30 .
Second Roll Motor Field Adjustment
FIG. 2A depicts a block diagram of an alternative exemplary process 10 A for controlling torque in a calendering system 42 (i.e., to the speed controller droop system described supra). In this alternative process, another type of drive, known to those of skill in the art as a common power supply DC drive, one motor (usually the first roll motor 16 ) of a calendering system 42 is driven and controlled from a main power supply and/or a field current controller. The second motor (usually the second roll motor 20 ) is driven from the main power supply but controlled by the field current supplied from a field current controller 50 to second roll motor 20 . Increasing field current causes the second roll motor 20 to slow down. Decreasing the field current causes the second roll motor 20 to speed up. Alternatively, both first roll motor 16 and second roll motor 20 can be controlled by their respective fields.
A second roll speed controller 30 based on a process of adjusting the field current to second roll motor 20 can be arranged so that the increasing output from second roll speed controller 30 subtracts from a constant value of field current and reduces the field current of second roll motor 20 , causing the second roll motor 20 to speed up in order to minimize the error feedback provided to second roll speed controller 30 . Droop controller 32 acts as previously described for FIG. 1 supra, when the second roll speed controller 30 changes the field current to affect a change in speed of second roll motor 20 and second roll 14 . While nipped, if the second roll speed controller 30 seeks to increase the speed of second roll motor 20 , the output of second roll speed controller 30 is increased and the corresponding droop value from droop controller 32 feeds some of the signal back to the input of the second roll speed controller 30 to reduce its effect. The controller action can change a direct acting controller (i.e., the output of second roll speed controller 30 increases for an increased set point) into a reverse acting controller (i.e., field current reference 48 decreases for an increase of the set point for second roll speed controller 30 ). One of skill in the art should understand that such a reverse acting controller that provides an input to second roll speed controller 30 to the field current reference 44 can be used herein with appropriately selected limits, initial values, and droop polarity.
In a gapped condition (first roll 12 /second roll 14 separated), both speed control systems for first roll 12 and second roll 14 operate independently and the process controller 34 is turned off. The droop controller 32 is provided with a manually entered value at this time. When the calender system 42 operates in a “nipped” condition (first roll 12 /second roll 14 contacting), the process controller 34 is turned on in order to provide a load share control for process 10 A. This can be accomplished by setting the initial value of the process controller 34 .
The first value the process controller 34 sends to the droop controller 32 is the same value as the manually entered droop value used during the “gapped” condition prior to going to a “nipped” condition. At the same time, the process controller 34 minimum and maximum output limits are set at the initial value and can increase steadily (i.e., ramp) to the final values as discussed supra. The resulting droop value is then applied to the droop controller 32 that also has an input supplied by the output of process controller 34 when a nipped condition is sensed.
When the calender system 42 changes from a “nipped” condition to a “gapped” condition, the process controller 34 is turned off with its limits set to their initial values. In other words, the original operator entered manual droop value is used in the droop controller 32 . The transition from a “gapped” condition to a “nipped” condition and back to a “gapped” condition can be accomplished by the use of a switching mechanism 93 as described supra.
Speed Reference Manipulation on Speed Controller with Droop FIG. 2B depicts a block diagram of an exemplary but non-limiting alternative embodiment of a process 10 B for controlling torque in a calendering system 42 . In this process 10 B, process controller 34 is capable of manipulating the second roll speed controller speed reference 44 through a subtractor 46 . Additionally, the output from subtractor 46 that becomes the input to second roll speed controller 30 can then be further compensated with the use of a manually manipulated droop controller 32 as described supra. This alternative process can provide for the recognized benefits inured with both the speed reference control scheme as described with respect to FIG. 1 with the benefits of a speed controller droop control scheme as described in association with FIG. 2 . The gapped to nipped to gapped transitions of calendering system 42 can be identical to those as described supra. Additionally, the droop value manually entered into droop controller 32 can be determined by the operator to benefit the process of web material 40 by calender system 42 while the calender system 42 transitions from gap to nip to gap.
Similarly, it should be evident to one of skill in the art that the features of the speed reference manipulation of a drooped speed controller as described with regard to FIG. 2B can also be applied to the second roll motor field adjustment process as described with reference to FIG. 2A . Such an exemplary system would provide a combination of the benefits realized from each of the systems if utilized individually. In any regard, one of skill in the art would understand that the various embodiments of the calender control processes described herein can be combined in virtually any manner to provide the control scheme required for the particular calendering process utilized and to realize any combined benefits cooperatively associated thereto.
Torque (Current) Division Between the First Roll and Second Roll
FIG. 3 depicts a block diagram of an alternative embodiment of an exemplary, but non-limiting, process 60 for controlling torque in a calendering system 42 . In this method of control for calendering system 42 , when a gapped condition exists between first roll 12 and second roll 14 , the first roll speed controller 28 manipulates the first roll torque controller 24 and the second roll speed controller 30 manipulates the second roll torque controller 26 independently. However, when a nipped condition exists between first roll 12 and second roll 14 , the first roll speed controller 28 manipulates both the first roll torque controller 24 and the second roll torque controller 26 . In this process 60 , the output torque signal of the first roll speed controller 28 is preferably divided and scaled between the first roll motor torque controller 24 and second roll motor torque controller 26 by a function 66 that collectively adds up to 100% through torque division multipliers 62 , 64 . By way of non-limiting example, the output of first roll speed controller 28 provides a portion of its output therefrom to one motor (e.g., X percentage of the output from first roll speed controller 28 to the first roll motor 16 from first roll torque (current) division multiplier 64 ) and the remainder to the other motor (e.g., 100% minus X percentage of the output from first roll speed controller 28 to the second roll motor 20 from second roll torque (current) division multiplier 62 ). It should be clear to those of skill in the art that in a gapped condition, both portions of the function can equal the same number, typically operator-entered.
To implement such an exemplary controller system, one of skill in the art will understand that the output of the process controller 34 can be used to adjust the first roll load share multiplier 64 . If the torque supplied to first roll motor 16 driving first roll 12 must be increased, the output of first roll load share multiplier 64 should be increased and the corresponding output of the second roll load share multiplier 62 should be decreased. However, if the torque supplied to first roll motor 16 driving first roll 12 must be decreased, then the output of first roll load share multiplier 64 should be decreased and the corresponding output of the second roll load share multiplier 62 should be increased.
In a gapped condition (first roll 12 /second roll 14 separated), both speed control systems for first roll 12 and second roll 14 operate independently and the process controller 34 is turned off. The torque (current) division multipliers 62 , 64 can be provided with manually entered values. When the calender system 42 operates in a “nipped” condition (first roll 12 /second roll 14 contacting), the process controller 34 is turned on in order to provide a load share control for exemplary process 60 . This can be accomplished by setting the initial value of the process controller 34 .
The first value the process controller 34 sends to the torque (current) division multipliers 62 , 64 is the same value as the manually entered torque (current) division multiplier 62 , 64 values used during the “gapped” condition prior to going to a “nipped” condition. At the same time, the process controller 34 minimum and maximum output limits are set at the initial value and can increase steadily (i.e., ramp) to their final values. Concurrently, the output of the first roll speed controller 28 to the input of second roll torque division multiplier 62 should preferably be increased by the difference in the outputs of the second roll speed controller 30 and the properly scaled output of the first roll speed controller 28 at the time of transition from nip to gap to account for potential differences in load torques for the two different rolls.
When the calender system 42 changes from a “nipped” condition to a “gapped” condition, the process controller 34 is turned off with its limits set to their initial values. Next, the second roll speed controller 30 is turned on with its initial value set to a value that will maintain the input of second roll torque controller 26 through the second roll torque division multiplier 62 at the transition. Additionally, the original operator entered current division values are used in the torque (current) division multipliers 62 , 64 . In the nipped condition and immediately prior to the gapped condition, the first roll speed controller torque command may not be fast enough to provide the proper torque signal to the first and second roll torque controllers 24 , 26 . A feed-forward control that relates torque-to-nip conditions (i.e., a nip force—the amount of loading pressure or nip width) can be useful to prevent too much torque from being applied to the nip and the over-speeding of either roll motor 16 , 20 when the calender achieves a gap condition between the rolls 12 , 14 . First roll speed controller 28 proportional gain scheduling based upon the first roll torque division multiplier 64 may be desirable in order to keep the speed response of the first roll motor 16 constant over the range of operation and improve response to fast changing calender system 42 load conditions. A transition from a “gapped” condition to a “nipped” condition and back to a “gapped” condition can be controlled by the use of a switching mechanism 93 as described supra.
It should be understood by those of skill in the art that the implementation of the torque division multipliers 62 , 64 can be based on percent, per unit, or any other desired base multiplier. Further, it should be clear that a variation of this embodiment may require no particular change in the first roll torque division multiplier 64 . If this is the case, the output of the first roll torque division multiplier 64 can remain constant, and all control can be accomplished by the process controller 34 by properly adjusting the second roll torque division multiplier 62 to accomplish the desired torque control. The method described herein does not create a base for percent, per unit, or any fixed ratio for calculations.
Torque Target Set Point for Queen Roll Drive
FIG. 4 depicts a block diagram of an alternative, but non-limiting, embodiment of a process 70 for controlling torque in a calendering system 42 . As shown, a first roll speed controller 28 controls the torque controller 24 for first roll motor 16 . Second roll motor 20 is controlled by second roll torque controller 26 when a nipped condition exists between first roll 12 and second roll 14 . The first roll speed controller 28 produces the torque necessary to control the speed of first roll motor 16 thereby controlling the speed of first roll 12 . The second roll torque controller 26 produces the torque required to accommodate the set point torque for the second roll motor 20 . In nipped configuration the output of process controller 34 provides the torque set point for the second roll torque controller 26 . If the signal from first roll motor torque controller 24 indicates that the torque from the first roll motor 16 should be increased, the second roll motor torque controller 26 set point is decreased by process controller 34 . However, if the first roll motor 16 torque needs to be decreased, the second roll motor torque controller 26 set point is increased by process controller 34 . This can be accomplished by the process controller 34 output subtracting from a constant value to provide the appropriate signal change to the second roll motor 20 torque loop. The controller action can change a direct acting controller (i.e., the output of process controller 34 increases for an increased set point) into a reverse acting controller (i.e., the set point for torque controller 26 decreases for an increase of the set point for process controller 34 ). One of skill in the art should understand that such a reverse acting controller can be used herein with appropriately selected limits and initial values. In a gapped condition, preferably both speed controllers independently control their respective motors.
As described supra, in a gapped condition (first roll 12 /second roll 14 separated), both speed control systems for first roll 12 and second roll 14 operate independently and the process controller 34 is turned off. In this embodiment, second roll speed controller 30 provides the set-point for the second roll torque controller 26 . When the exemplary process 70 for controlling calender system 42 operates in a “nipped” condition (first roll 12 /second roll 14 contacting), the process controller 34 is turned on in order to provide load share control. This can be accomplished by setting the torque initial value of the process controller 34 .
After the calender system 42 switches to a “nipped” condition, the process controller 34 outputs a first value so that the set-point to the second roll torque controller 26 is the same value as the recent average value from the second roll speed controller 30 during the “gapped” condition prior to going to a “nipped” condition. This initial value is the difference of the maximum torque minus the recent average value from the second roll speed controller 30 . At the same time, the process controller 34 minimum and maximum output limits are set at their initial values and can increase steadily (i.e., ramp) to their final values. Additionally, the second roll speed controller 30 is turned off.
When the calender system 42 changes from a “nipped” condition to a “gapped” condition, the process controller 34 is turned off. The second roll speed controller 30 is turned on with its initial value set at the same value as the recent average output from the process controller 34 subtracted from the maximum torque. This is also known to those of skill in the art as a ‘bumpless’ transfer. The transition from a “gapped” condition to a “nipped” condition and back to a “gapped” condition can be accomplished by the use of a switching mechanism as described supra.
Torque Target Set Point for King Roll Drive
FIG. 5 depicts a block diagram of an alternative embodiment of a process 80 for controlling torque in a calendering system 42 . In this exemplary, but non-limiting process, when the first roll 12 and second roll 14 are nipped, the second roll motor speed controller 30 controls the second roll motor torque controller 26 for the second roll motor 20 . Similarly, first roll 12 is controlled by a separate first roll torque controller 24 . Here, the second roll motor speed controller 30 could produce the torque required to control the speed of first roll 12 through second roll 14 . The first roll motor torque controller 24 for the first roll motor 16 produces the target torque required by the set point.
It was surprisingly found in this exemplary embodiment that no process controller is required. Since the first roll motor 16 maintains a constant torque set at the target torque level, the second roll torque controller 26 produces the torque the second roll motor 20 requires to drive the entire calender 42 at the desired process speed. In order to use the second roll motor speed controller 30 during nip conditions, the speed feedback from the first roll motor 16 is used as the second motor speed controller 30 feedback. During gap conditions, each roll motor 16 , 20 will utilize its respective speed controller 28 , 30 and its respective roll motor speed sensor 38 , 36 .
Similar to the exemplary processes described supra, the exemplary process 80 for controlling calender system 42 can operate in both a “gapped” and “nipped” configuration. However, the process 80 was found through simulation to minimize the shear forces disposed across a web substrate 40 in a calender system 42 without the need for a process controller. In a gapped condition, both speed control systems for first roll 12 and second roll 14 operate independently. In this configuration, the first roll speed controller 28 provides the set-point for the first roll torque controller 24 and the second roll speed controller 30 provides the set-point for the second roll torque controller 26 .
When the process operates in a “nipped” condition, the first roll speed controller 28 is turned off and the first roll torque controller 24 receives its set-point from a manually entered set-point determined by the process operators. The set-point can be based on minimum torque for minimum shear or related to any other process requirements (including, but not limited to, a torque table, and the like). Concurrently, the second roll speed controller 30 switches its feedback from the second roll speed sensor 36 to the first roll speed sensor 38 .
This transition of the second roll speed controller 30 feedback from the second roll motor speed sensor 36 to the first roll motor speed sensor 38 can be accomplished by the use of a transition controller 82 . In a preferred embodiment, the transition controller 82 is provided with a transition control algorithm. The transition control algorithm preferably conditions the transition controller 82 input and output signals to create a smooth transition from second roll motor speed sensor 36 to first roll speed sensor 38 . The transition control algorithm can include averaging functions, filtering functions, ramp functions, scaling functions, switch functions, and combinations thereof as required in order to switch the scaled feedbacks from one source to another. Scaling, conditioning, and switching both the speed feedbacks and references may be necessary for some installations depending on how the speed reference is scaled. When the calender system 42 changes from a “nipped” condition to “gapped” condition, the first roll speed controller 28 then is turned on and the second roll speed controller 30 is switched to operate from the second roll speed sensor 36 signal. The same signal conditioning algorithms may need to be applied to both the speed reference and any controller feedbacks to create a smooth transition to “gap” operation.
In a gapped condition, the first roll speed controller 28 transition to “on” is preferably accomplished by setting the first roll speed controller 28 initial value to the target torque set-point value for first roll 12 . The limits for first roll speed controller 28 start at this initial value and are steadily increased (i.e., ramped) to the final maximum and minimum values. However, it would also be possible to provide only the final maximum, only the final minimum, or even provide no limits to the first roll speed controller 28 depending upon any process parameters required for the system during a transition. The second motor speed controller 30 is also transitioned from the first motor speed sensor 38 signal to the second motor speed sensor 36 signal during the time the first roll speed controller 28 is turned “on”. This transition can be accomplished by the use of a transition controller 82 that smoothly transitions the first motor speed sensor 38 and the second motor speed sensor 36 scaled values during the “nipped” condition and transitions the second roll speed controller 30 from the first motor speed sensor 38 to the second motor speed sensor 36 after a “gapped” condition is sensed.
The transitions of the feedback from one motor to the other should be performed on the properly scaled values considering motor operating speeds in rpm, roll diameters and gear ratios. It should be readily realized that a smooth transition requires such properly scaled values. Additionally, transitions from a “gapped” condition to a “nipped” condition and back to a “gapped” condition can be determined by a switching mechanism as described supra.
In all embodiments described above, the implementation control strategy should account for acceleration, known load disturbance torques, and motor power and torque limits to adjust the target torque set-points. Additionally, one of skill in the art should easily recognize that any system for controlling the torque in a calendering system 42 should be tuned in order to control interactions between the first roll and second roll of any of the exemplary processes described herein. Further, the control methodologies and techniques described herein can be coupled with, and/or be included into, control schemes, including known ‘position’ controller processes, to produce the result desired.
All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this written document conflicts with any meaning or definition of the term in a document incorporated by reference, the meaning or definition assigned to the term in this written document shall govern.
Any dimensions and/or calculated values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension and/or value is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | A method for controlling a calendering system having a first roll and a second roll is disclosed. The first roll has a first roll torque controller and a first roll speed controller. An exemplary method comprises the steps of: (a) setting said first roll at a desired process speed with said first roll speed controller; (b) determining a target torque of said first roll; (c) contactingly engaging said first and second rolls; (d) measuring an actual torque of said first roll; (e) comparing said target torque and said actual torque; and, (f) adjusting a speed of said first roll with said first roll torque controller to maintain said target torque of said first roll according to said comparison of said target torque and said actual torque. | 3 |
This application claims the benefit of Provisional Application No. 60/474,127, filed May 29, 2003.
FIELD OF THE INVENTION
The present invention relates generally to semiconductor devices, and more, particularly, to power MOSFET devices.
BACKGROUND OF THE INVENTION
Power MOSFET devices are employed in applications such as automobile electrical systems, power supplies, and power management applications. Such devices should sustain high voltage in the off-state while having a low voltage drop and high current flow in the on-state.
FIG. 1 illustrates a typical structure for an N-channel power MOSFET. An N-epitaxial silicon layer 1 formed over an N + silicon substrate 2 contains p-body regions 5 a and 6 a , and N+ source regions 7 and 8 for two MOSFET cells in the device. P-body regions 5 and 6 may also include deep p-body regions 5 b and 6 b . A source-body electrode 12 extends across certain surface portions of epitaxial layer 1 to contact the source and body regions. The N-type drain for both cells is formed by the portion of N-epitaxial layer 1 extending to the upper semiconductor surface in FIG. 1 . A drain electrode is provided at the bottom of N+ substrate 2 . An insulated gate electrode 18 typically of polysilicon lies primarily over the body and portions of the drain of the device, separated from the body and drain by a thin layer of dielectric, often silicon dioxide. A channel is formed between the source and drain at the surface of the body region when the appropriate positive voltage is applied to the gate with respect to the source and body electrode.
The on-resistance of the conventional MOSFET shown in FIG. 1 is determined largely by the drift zone resistance in epitaxial layer 1 . The drift zone resistance is in turn determined by the doping and the layer thickness of epitaxial layer 1 . However, to increase the breakdown voltage of the device, the doping concentration of epitaxial layer 1 must be reduced while the layer thickness is increased. Curve 20 in FIG. 2 shows the on-resistance per unit area as a function of the breakdown voltage for a conventional MOSFET. Unfortunately, as curve 20 shows, the on-resistance of the device increases rapidly as its breakdown voltage increases. This rapid increase in resistance presents a problem when the MOSFET is to be operated at higher voltages, particularly at voltages greater than a few hundred volts.
FIG. 3 shows a MOSFET that is designed to operate at higher voltages with a reduced on-resistance. This MOSFET is disclosed in paper No. 26.2 in the Proceedings of the IEDM, 1998, p. 683. This MOSFET is similar to the conventional MOSFET shown in FIG. 2 except that it includes p-type doped regions 40 and 42 which extend from beneath the body regions 5 and 6 into the drift region of the device. The p-type doped regions 40 and 42 define columns in the drift region that are separated by n-type doped columns, which are defined by the portions of the epitaxial layer 1 adjacent the p-doped regions 40 and 42 . The alternating columns of opposite doping type cause the reverse voltage to be built up not only in the vertical direction, as in a conventional MOSFET, but in the horizontal direction as well. As a result, this device can achieve the same reverse voltage as in the conventional device with a reduced layer thickness of epitaxial layer 1 and with increased doping concentration in the drift zone. Curve 25 in FIG. 2 shows the on-resistance per unit area as a function of the breakdown voltage of the MOSFET shown in FIG. 3 . Clearly, at higher operating voltages, the on-resistance of this device is substantially reduced relative to the device shown in FIG. 1 , essentially increasing linearly with the breakdown voltage.
The improved operating characteristics of the device shown in FIG. 3 are based on charge compensation in the drift region of the transistor. That is, the doping in the drift region is substantially increased, e.g., by an order of magnitude or more, and the additional charge is counterbalanced by the addition of columns of opposite doping type. The blocking voltage of the transistor thus remains unaltered. The charge compensating columns do not contribute to the current conduction when the device is in its on state. These desirable properties of the transistor depend critically on the degree of charge compensation that is achieved between adjacent columns of opposite doping type. Unfortunately, non-uniformities in the dopant gradient of the columns can be difficult to avoid as a result of limitations in the control of process parameters during their fabrication. For example, diffusion across the interface between the columns and the substrate and the interface between the columns and the p-body region will give rise to changes in the dopant concentration of the portions of the columns near those interfaces.
The structure shown in FIG. 3 can be fabricated with a process sequence that includes multiple epitaxial deposition steps, each followed by the introduction of the appropriate dopant. Unfortunately, epitaxial deposition steps are expensive to perform and thus this structure is expensive to manufacture. Another technique for fabricating these devices is shown in co-pending U.S. application Ser. No. 09/970,972, in which a trench is successively etched to different depths. A dopant material is implanted and diffused through the bottom of the trench after each etching step to form a series of doped regions (so-called “floating islands”) that collectively function like the p-type doped regions 40 and 42 seen in FIG. 3 . However, the on-resistance of a device that uses the floating island technique is not as low as an identical device that uses continuous columns.
Accordingly, it would be desirable to provide a method of fabricating the MOSFET structure shown in FIG. 3 that requires a minimum number of deposition steps so that it can be produced less expensively while also allowing sufficient control of process parameters so that lightly doped columns that extend almost through a layer of deposited can be formed.
SUMMARY OF THE INVENTION
A method of manufacturing a semiconductor device is disclosed and starts with a semiconductor substrate having a heavily doped N region of at the bottom main surface and a lightly doped N region at the top main surface. There are a plurality of trenches in the substrate, with each trench having a first extending portion extending from the top main surface towards the heavily doped region. Each trench has two sidewall surfaces in parallel alignment with each other. A blocking layer is formed on the sidewalls and the bottom of each trench. Then a P type dopant is obliquely implanting into the sidewall surfaces to form P type doped regions. The blocking layer is then removed. The bottom of the trenches is then etched to remove any implanted P type dopants. The implants are diffused and the trenches are filled.
The body and the source regions are then formed after the gate dielectric and the gate conductor are formed. The body region consists of an implanted P body region on top of each of the diffused P type doped regions to form the body regions and implanted N+regions within the body regions to form source regions. Above the gate dielectric region is a gate conductor that extends over the P-type body and the N + source regions of two adjoining trenches. A source conductor is connected to the P-type body and the N + source region.
The un-doped sidewalls will typically be doped with N type dopant. The trenches may have the shape of a dog bone, a rectangle, a rectangle with rounded ends or a cross with the P type dopant being implanted into the ends of the dog bone, a rectangle, or a rectangle with rounded ends, and in opposite sides of the cross.
Rectangular-shaped trenches may be arranged in an array of rows and columns with the ends of the trenches in the column being implanted with P type dopants and the ends of the trenches in the rows being implanted with N type dopants. Cross-shaped trenches may be implanted with P-type dopant along one set of axes, and with N-type dopant along a second set of axes at 90° to the first set.
The angle of the implant can be selected so that the bottom of the trenches are not implanted.
The technique may be used to manufacture the termination regions by varying the shape, the depth and width of the trenches, in conjunction with the implant angle.
The identification of the type of doping use herein only refers to that shown in the particular embodiment. Those skilled in the art know that similar results may be achieved by using P type dopant instead of N type and visa versa. The use of the particular type of dopant in the description of the embodiments should in no way limit the scope of the claims.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a sectional view of a prior art conventional MOSFET;
FIG. 2 is a chart showing breakdown voltage the on resistances and current;
FIG. 3 is a sectional view of a prior art superjunction transistor;
FIGS. 4–14 illustrate the process steps used to manufacture the disclosed semiconductor device;
FIGS. 15 , 23 , 24 and 25 illustrate the different shapes that can be used to manufacture the disclosed semiconductor device;
FIGS. 16 , 18 , and 19 illustrate the different arrangements of the trenches to achieve the disclosed device;
FIG. 17 is a sectional view of the disclosed device illustrating the source region;
FIGS. 20 , 26 and 27 illustrate possible termination arrangements of the semiconductor device;
FIG. 21 shows a top view of the termination region; and
FIG. 22 is a sectional view of FIG. 21 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
A technique for forming lightly doped columns that extend almost through a layer of deposited epitaxial semiconductor material is best understood by referring to FIGS. 4–18 while reading the description below. This technique uses trenches etched into the silicon to form lightly doped columns. One type of trenches has a dimension in a first direction that is greater than the dimension in a second direction that is perpendicular to the first direction and is generally rectangular shaped, while a second type is cross-shaped. FIG. 16 shows the top view of a series of generally rectangular shaped trenches 35 following two separate implantation steps that have doped the two narrow walls 31 and 33 of the trenches 35 . FIGS. 9 and 10 show the technique that is used to perform the two implantation steps. The two separate implantation steps are performed at an angle with respect to the surface of the substrate that allows the dopant to be implanted into just the two narrow “end” sidewalls 31 and 33 . The presence of a layer of material such as silicon dioxide or silicon nitride (or a sandwich of such materials) prevents the ions that are being implanted from reaching the semiconductor sidewalls 37 that are along the long axis of each trench. Following the implantation step, any dopant that has been implanted in the bottom of the trench may be removed by etching the trench deeper, and then the dopant may be diffused until the desired dopant distribution is obtained. The trench is then filled using an oxidation or deposition step.
The shape of the trench is not limited to just being rectangular. Many other possible trench shapes such as dog-bones 235 , or rectangles with rounded ends 135 , ( FIG. 15 ), or crosses are also possible. The profile of the implanted dopant is slightly different, allowing the optimization of the shape of the implanted region. Both of the tench geometries avoid placing dopant atoms near a corner, which might result in better control of the resulting dopant profile.
The pattern of trenches across the surface of the device may also be varied to obtain the best performance. Examples of trench placement are shown in FIG. 16 which shows a square array, FIG. 18 which shows a staggard array 110 and FIG. 19 which illustrates an array 133 of rows and columns. The number and locations of the trenches is important because it affects overall device efficiency.
One fabrication sequence for the doped columns will now be discussed.
Referring to FIG. 4 a lightly doped epitaxial layer 1 is deposited on a heavily doped substrate 2 . Then as shown in FIG. 5 a blocking layer 41 of silicon dioxide is either grown or deposited on the top surface of the epitaxial. The blocking layer has a desired thickness of between 400 and 2,000 A°. In FIG. 6 the blocking layer 41 is masked by a mask 43 to facilitate the its etching. Following the etching of the blocking layer 41 , trenches 45 are etched into the epitaxial layer 1 as illustrated in FIG. 7 . A blocking layer 47 is grown or deposited on all of the sidewalls and bottoms of each trench 45 as is shown in FIG. 8 . The thickness of blocking layer 47 is between 200 and 2000 A°.
Referring to FIG. 9 , a first implant of boron ions is performed in the narrow end 33 at an angle alpha that in conjunction with the thickness of the blocking layer 47 will limit the penetration of the dopant in to the epitaxial 1 . The thickness of the blocking layer 41 is sufficient enough to prevent the penetration of the dopant into the tops of the columns 21 . The result is implanted ions 51 in the column 21 at the small side 33 . Generally to prevent the penetrations of the ions in the bottom of the trench alpha should be equal to the tangent G, the depth of the trench ti T, the width of the trench.
In FIG. 10 a second implant using the same dopant species is performed at the other small side 31 of the trenches 45 at an angle beta that is traditional equal to alpha minus 90 degrees leaving implanted ions 52 in the small side 31 as is shown in FIGS. 10 and 11 .
The implants are performed parallel to the long axis, the F side, of the geometry that is used, so no dopant penetrates through the oxide on these sidewalls because of the large angle away from being perpendicular.
In FIG. 12 the trench is etched to remove the blocking layer 47 and any implanted ions at the bottom of the trenches to a depth H shown generally at 53 .
In FIG. 13 a diffusion step is performed to create P-type doped regions 55 and 57 . The trenches 45 are filled with an insulator such as silicon dioxide in FIG. 14 . The trenches can have many different shapes such as the square shape 100 of FIG. 15 a , the elongated shape 101 of FIG. 15 b , or the dog bone shape 103 of FIG. 15 c . No dopant is introduced on the walls at the long sides of the structure for any of the geometries.
The FIG. 15 shown the location of the implanted dopant 36 and 38 following the first and second implants as shown in FIGS. 9 and 10 .
After dopant implantation and diffusion to form the doped columns, the trenches are filled. Typically a dielectric will be used, though it is possible to fill it with polysilicon and re-crystalize the polysilicon, or to fill the trench with single crystal silicon using epitaxial deposition. Once the surface is planarized, the active region that includes the body, gate dielectric and conductor, and the source regions should be placed anywhere there is no trench present to provide channel regions for carrier flow. For the array 104 of FIG. 16 , active regions can be anywhere in the rows and columns between the trenches. Depending on the dimensions of the trench, polygonal, cellular or stripe geometries are all feasible. A striped geometry might run parallel to the long axis of the trenches (top row of figure). A cellular geometry might enclose each trench as sown on the bottom row 16 b of the FIG. 16 . If a cell is formed at each end of the trench (middle row of FIG. 16 ), the source injects carriers around 3 sides, but not at the fourth side. The cross section for either cellular version is the same through the doped column and is shown in FIG. 17 .
The Use of Trenches Having Different Orientations in Combination with Implants with Dopants Having Different Conductivity Types is illustrated in FIG. 19 .
The creation of the active region includes the steps of implanting the P type source body region 5 on top of the P columns 36 and 38 . A source 7 of N type dopant is then implanted on top of the source body regions 5 . A gate oxide 6 is deposited and the gate electrode 18 is formed in the gate oxide between the rows 108 and 148 over the sources 7 . Finally, the source electrode is connected to the source and source body region of each device.
A variation of the technique that was previously discussed uses the implantation of dopants of both conductivity types in the active region of the device. In this variation, the second dopant type is implanted at an angle of 90° and 270° to the first dopant implant, as shown in FIG. 19 . It provides the needed amount of dopant compensation and/or charge balance to obtain a high breakdown voltage. Where the structures 11 have N-type dopants implanted at regions 136 and 138 and P-type dopants implanted at regions 36 and 38 . A second set of rectangular trenches 35 that are perpendicular to the first set of trenches 35 provide this capability are shown in FIG. 19 . While geometries that allow the doping of the walls of a single trench with dopants of both conductivity types is shown in FIG. 23 . Unwanted doping of the top region of any sidewall which could occur when two dopants are implanted at 90° to each other can be prevented by using a blocking layer having a greater thickness along the top part of the sidewall than previously shown.
A Compatible Termination Structure
A formation of a termination at the device perimeter that is compatible with the sequence used in the fabrication of the super-junction structure at the center of the device is often a challenge.
In the present embodiment however, it is possible to form a compatible termination structure by either using the same process sequence, or by adding one more implant to the existing process sequence. These two possibilities are discussed in greater detail below.
A Compatible Termination Structure that Requires no Additional Process Steps
This termination structure is best understood by referring to FIGS. 21 and 22 . The FIG. 20 shows a top view and FIGS. 21 and 22 shows a side view of trenches 35 , 121 an 122 at the termination having different lengths, device 207 , dotted line trenched 201 and device 209 and/or having both different lengths and widths trenches 207 , 211 and 200 —and different width trenches 207 , 201 and 205 . The trench length directly determines the depth along the sidewall that is implanted on the two walls at the ends of each trench while the trench width directly affects the total charge introduced in these two sidewall. By varying the trench length and width, both the depth of the junctions formed by the introduced dopant and the total dopant amount that is introduced can be optimized. By also controlling the number and the locations of the trenches that are etched in the termination region, as shown in FIG. 20 , the positions as well as the depths of the diffused p-type junctions in the termination region can be optimized to produce the highest breakdown voltage.
It is also possible to etch trenches that are not generally rectangular in shape (such as crosses 214 , squares 215 or circles 216 of FIGS. 24 and 25 ) that may also have different dimensions to etch trenches that are generally rectangular in shape, but with their axes along a line that is different from that of the trenches etched in the active region of the device. Examples of these trenches are shown in FIG. 26 .
A Compatible Termination Structure that Requires an Additional Implant Step
The termination structure uses a second implant step with a dopant having the same conductivity type as that of the region containing the trenches. This additional implant provides dopant that can either partially compensate the dopant from the first implant, or provide charge to balance the dopant introduced by the first implant. By etching a second set of trenches 123 that are generally rectangular shaped, and that have their major axis at an angle offset to the axis of the first set of trenches and by varying the dimensions of the trenches as discussed above, it is possible to control both the location and the amount of dopant introduced. Examples of possible termination trenches of this type are shown in FIG. 26 . It is also possible to etch trenches that are not generally rectangular in shape (such as squares or trenches) that may also have different dimensions or to etch trenches that are generally rectangular in shape with their axes along a line that is different from that of the trenches etched in the active region of the device as is shown in FIGS. 19 and 27 . Implanting the first dopant type along one set of axes and the second dopant type along another set of axes that is 90° to the first set of axes provides the needed amount of dopant compensation and/or charge balance to obtain a high breakdown voltage. | A method of manufacturing a semiconductor device is disclosed and starts with a semiconductor substrate having a heavily doped N region of at the bottom main surface and having a lightly doped N region at the top main surface. There are a plurality of trenches in the substrate, with each trench having a first extending portion extending from said top main surface towards the heavily doped region. Each trench has two sidewall surfaces in parallel alignment with each other. A blocking layer is formed on the sidewalls and the bottom of each trench. Then a P type dopant is obliquely implanting into the sidewall surfaces to form P type doped regions. The blocking layer is then removed. The bottom of the trenches is then etched to remove any implanted P type dopants. The implants are diffused and the trenches are filled. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a wheel angular acceleration sensor for a vehicle anti-lock control device, and particularly, to an improvement in a wheel angular acceleration sensor comprising a flywheel rotatably and slidably supported on an output shaft rotated in association with a wheel braked by a wheel brake, a friction clutch plate which normally transmits a driving torque of the output shaft to the flywheel and which allows overrun rotation of the flywheel when the wheel is about to lock at the braking, and a cam mechanism responsive to the overrun rotation of the flywheel to impart axial displacement thereto, said friction clutch plate and said cam mechanism being interposed in series between said output shaft and said flywheel, said axial displacement of the flywheel being outputted as a signal for controlling a braking force of the wheel brake.
2. Description of the Prior Art
Such a wheel angular acceleration sensor has been already known as described, for example, in Japanese Patent Publication Kokai No. 58-126241.
In conventional angular acceleration sensor, a friction clutch plate is disposed parallel with a plane perpendicularly crossing the axis of an output shaft and is not tiltable relative to that plane. This sometimes brings forth inconveniences in that if a machining error is present in a cam mechanism, when the cam mechanism is operated, an unbalanced load may be exerted between driving and driven cam plates to apply a thrust obliquely, i.e., in an inclined direction relative to the axis of the output shaft, from the cam mechanism to a flywheel to impair smooth axial displacement of the flywheel, and than an unbalanced load may be exerted also to a frictional surface of the friction clutch plate to vary the slip characteristic of the friction clutch plate.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a wheel angular acceleration sensor of the mentioned type which overcomes these drawbacks as noted above.
For achieving the above-described object, the present invention is characterized in that between the output shaft and the friction clutch plate is interposed an aligning plate for connecting the output shaft and the friction clutch plate in a rotating direction. The aligning plate being provided at one side thereof with a pair of first fulcrum projections placed in abutment with the output shaft so as to enable the tilting of the aligning plate around a first axis perpendicularly crossing an axis of the output shaft and at the other side with a pair of second fulcrum projections abutting against the friction clutch plate so as to enable the tilting of the aligning plate around a second axis perpendicularly crossing both the axis of the output shaft and the first axis.
With this arrangement, when an unbalanced load is exerted to the cam mechanism and the friction clutch plate due to any machining error at the time of generation of a thrust of the cam mechanism, the aligning plate accordingly tilts around the first and second axes perpendicularly crossing the axis of the output shaft and perpendicularly crossing each other, negating the unbalanced load. Accordingly, the flywheel can smoothly displace in the axial direction and the slip characteristic of the friction clutch plate can be stabilized to allow a control signal for the braking force to appear accurately.
Particularly, since the tilting of the aligning plate by the first and second fulcrum projections involves only a very small frictional resistance, unbalanced load can positively be deleted. Moreover, since such aligning plate can be formed to have a very small axial width, the axial length of the acceleration sensor hardly increases, thus not impairing the compactness of the sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 through 6 show a first embodiment of the present invention.
FIG. 1 is a schematic plan view of a motorcycle provided with a braking system having an antilock control device;
FIG. 2 is a longitudinal sectional side view showing essential parts of the braking system;
FIG. 3 is a sectional view taken on line III--III of FIG. 2;
FIG. 4 is a longitudinal sectional view in an enlarged scale of the antilock control device shown in FIG. 3;
FIG. 5 is a sectional view taken on line V--V of FIG. 2;
FIG. 6 is an exploded perspective view showing essential parts of a wheel angular acceleration sensor;
FIG. 7 is a longitudinal sectional view showing a modified example of a pressing ring of the wheel angular acceleration sensor.
FIGS. 8 through 10 show a second embodiment of the invention wherein
FIG. 8 is a longitudinal sectional view showing parts around the aligning plate of the wheel angular acceleration sensor;
FIG. 9 is a sectional view taken on line IX--IX of FIG. 8;
FIG. 10 is an exploded perspective view showing essential parts of the wheel angular acceleration sensor.
FIG. 11 shows a third embodiment of the present invention and is a longitudinal sectional view of essential parts of the wheel angular acceleration sensor.
FIGS. 12 through 18 shows a fourth embodiment of the invention in which
FIG. 12 is a sectional view showing essential parts of a braking system similar to that shown in FIG. 3 of the first embodiment;
FIG. 13 is a longitudinal sectional view in an enlarged scale of the antilock control device shown in FIG. 12;
FIG. 14 is an enlarged sectional view showing portions around an accelerating device and a cam shaft;
FIG. 15 is a sectional view taken on line XV--XV of FIG. 13;
FIG. 16 is a sectional view taken on line XVI--XVI of FIG. 15;
FIG. 17 is an exploded perspective view showing essential parts of a wheel angular acceleration sensor; and
FIG. 18 is a sectional view taken on line XVIII--XVIII of FIG. 17.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described with reference to the drawings.
A first embodiment of the present invention shown in FIGS. 1 through 6 will be first described. Referring to FIG. 1, a motorcycle 1 comprises a pair of left and right front wheel brakes 3f, 3f for braking a front wheel 2f, and a rear wheel brake 3r for braking a rear wheel 2r, the front wheel brakes 3f, 3f being actuated by output hydraulic oil pressure of a front master cylinder 5f operated by a brake lever 4, the rear wheel brake 2r being actuated by output hydraulic oil pressure of a rear master cylinder 5r operated by a brake pedal 6. Particularly braking hydraulic oil pressure of the front wheel brakes 3f, 3f are controlled by an antilock control device 7.
Referring to FIGS. 2 and 3, a hub 8 of the front wheel 2f is rotatably supported on an axle 10 through a pair of bearings 11, 11', the axle 10 having its opposite ends detachably secured to lower ends of a pair of left and right front forks 9, 9 by means of holders 121 and bolts and nuts 122. The pair of front wheel brakes 3f, 3f disposed on both sides of the front wheel 2f each comprise a brake disk 12 secured to an end face of the hub 8 and a brake caliper 14 supported on the front fork 9 through a bracket 13 in a state straddling the brake disk 12. When output hydraulic oil pressure of the front master cylinder 5f is supplied to an input port 14a of the brake caliper 14, the brake caliper 14 actuates to grip the brake disk 12 to apply a braking force to the front wheel 2f.
The antilock control device 7 is interposed in a hydraulic oil pressure conduit 15 as a braking oil passage connecting between an output port 5fa of the front master cylinder 5f and an input port 14a of each brake caliper 14.
The antilock control device 7 comprises, as principal elements, a hydraulic oil pressure pump 16 operable during braking, a modulator 17 having a control hydraulic oil pressure chamber 18, into which is introduced a discharge pressure of the pump 16, and provided halfway of the conduit 15, a normally closed pressure-discharge valve 20 provided in a communication passage between the chamber 18 and an oil tank 19, and an inertia type wheel angular acceleration sensor 21 for detecting angular deceleration in excess of a predetermined value of the front wheel 2f thereby to open the pressure-discharge valve 20, as shown in FIGS. 2 and 5, these elements being encased in a casing 22.
The casing 22 is constructed such that open ends of a cup-like inner casing 22a and an outer casing 22b are threadedly coupled to each other. The outer casing 22b is integrally formed at an end wall thereof with a radially outwardly extending portion 22c, the casing 22 except said extending portion 22c being disposed so as to be settled in a recess portion 8a formed in the left end of the hub 8. The outer casing 22b has a center portion of its end wall supported on the left end of a tubular shaft 24 fitted around the outer periphery of the axle 10 and is connected to the front fork 9 by a stop means so as not to be rotated around the axle 10. Any suitable stop means can be used but a bolt 25 (see FIG. 2) for securing the bracket 13 to the front fork 9, for example, is suitable.
The hydraulic oil pressure pump 16 comprises a cam shaft 26 disposed parallel to the axle 10, a push rod 27 disposed with the inner end thereof opposed to an eccentric cam 26a formed on the cam shaft 26, a pump piston 28 in abutment with the outer end of the push rod 27, an operating piston 29 in abutment with the outer end of the pump piston 28, and a return spring 30 for urging the push rod 27 in a direction of moving it away from the eccentric cam 26a.
The push rod 27 and the pump piston 28 are slidably fitted in a first cylinder bore 33 formed in the extension 22c to define an inlet chamber 31 and an outlet chamber 32 in the outer peripheries thereof. A plug 34 is fitted in the outer end of the first cylinder bore 33 so as to define a pump chamber 35 between the plug 34 and the pump piston 28, and the aforesaid operating piston 29 is slidably fitted in the plug 34 so as to define a hydraulic oil pressure chamber 36.
The inlet chamber 31 is brought into communication with an oil tank 19 through a conduit 37 and brought into communication with a pump chamber 35 through an intake valve 38. The pump chamber 35 is brought into communication with the outlet chamber 32 through one-way seal member 39 having the function of a discharge valve. The hydraulic oil pressure chamber 36 is connected to an upstream pipe 15a of the conduit 15 so that the chamber 36 may always come into communication with an output port 5fa of the front master cylinder 5f.
As shown in FIG. 5, the cam shaft 26 is supported on the end wall of the outer casing 22b through bearings 40, 40' and is driven by the front wheel 2f through the later-described accelerating gear unit 45.
The cam shaft 26 has a meter driving gear 49 secured to the outer end thereof, and the gear 49 is meshed with a driven gear 50 connected to an input shaft of a speedometer 51 of the motorcycle.
The modulator 17 comprises a pressure reducing piston 46, a fixed piston 47 for receiving one end of the pressure reducing piston 46 to control the limit of backward movement thereof, and a return spring 48 for urging the pressure reducing piston 46 in a direction to abut against the fixed piston 47, both pistons 46 and 47 being slidably fitted in a second cylidner bore 52 formed in the extending portion 22c adjacent the first cylinder bore 33.
In the second cylinder bore 52 the pressure reducing piston 46 defines a control hydraulic oil pressure chamber 18 between the piston 46 and the inner end wall of the second cylinder bore 52 and defines an output hydraulic oil pressure chamber 55 between the piston 46 and the fixed piston 47, and the fixed piston 47 defines an input hydraulic oil pressure chamber 54 around the outer periphery thereof. This input hydraulic oil pressure chamber 54 is brought into communication with the hydraulic oil pressure chamber 36 of the hydraulic oil pressure pump 16 through an oil passage 56, the output hydraulic oil pressure chamber 55 is connected to a downstream pipe 15b of the conduit 15 so that the chamber 55 may always come into communication with the input port 14a of the front wheel brakes 3f, 3f, and the control hydraulic oil pressure chamber 18 is brought into communication with the outlet chamber 32 of the pump 16 through an oil passage 57.
The fixed piston 47 includes a valve chamber 58 always communicating with the input hydraulic oil pressure chamber 54, and a valve hole 59 for bringing the valve chamber 58 into communication with the output hydraulic oil pressure chamber 55, the valve chamber 58 encasing therein a valve body 60 capable of opening and closing the valve hole 59 and a valve spring 61 for urging the valve body 60 toward the closed side. A valve opening rod 62 for pressing the valve body 60 to the open side is projected at one end of the pressure reducing piston 46, the rod 62 maintaining the valve body 60 on open side when the piston 46 is positioned at its limit of backward movement.
An outward opening of the second cylidner bore 52 is closed by an end plate 63 secured to the extending portion 22c, and the fixed piston 47 is always held at a position in abutment with the end plate 63 by the spring force of the return spring 48 or by the oil pressure introduced into the input and output hydraulic oil pressure chambers 54 and 55.
The hydraulic oil pressure pump 16 and the modulator 17 are arranged at the rear of the front fork 9 similarly to the brake caliper 14.
The pressure discharge valve 20 comprises a valve seat member 65 fitted in a stepped cylinder bore 64 of the outer casing 22b and a valve body 67 slidably fitted in the valve seat member 65 to open and close a valve hole 66 in the member 65. The valve seat member 65 defines an inlet chamber 68 at a small diameter portion of the stepped cylinder bore 64 and an outlet chamber 69 at a large diameter portion thereof, both the chambers 68 and 69 being brought into communication with each other through the valve hole 66. The inlet chamber 68 is brought into communication with the control hydraulic oil pressure chamber 18 of the modulator 17 through an oil passage 70, and the outlet chamber 69 is brought into communication with the inlet chamber 31 of the hydraulic oil pressure pump 16 through an oil passage 71. After all, the outlet chamber 69 is in communication with the oil tank 19.
The wheel angular acceleration sensor 21 comprises a flywheel 72 rotated by the front wheel 2f through the accelerating gear unit 45, a cam mechanism 73 for converting overrun rotation of the flywheel 72 into axial displacement, and an output lever mechanism 74 responsive to the axial displacement of the flywheel 72 to actuate the pressure discharge valve 20, these elements being disposed within the casing 22.
The accelerating gear unit 45 comprises a cuplike input mebmer 75 disposed within the casing 22 while orienting the open end thereof at the outer casing 22b, a ring gear 76 formed in the open end of the input member 75, a first planetary gear 78 1 secured to the inner end of the cam shaft 26 to engage the rear gear 76, one or more second planetary gears 78 2 supported through a bearing 111 on a support shaft 77 projected on the end wall of the outer casing 22b to engage the ring gear 76, a sun gear 79 simultaneously meshed with the first and second planetary gears 78 1 and 78 2 , and an output shaft 42 spline-coupled at 112 to the sun gear 79 and rotatably supported on the cylindrical shaft 24.
The secondary planetary gear 78 2 is provided so that the engagement between the first planetary gear 78 1 and the ring gear 76 and sun gear 79 is made properly to maintain the coaxial state between the ring gear 76 and the sun gear 79 to secure a positive power transmission by the accelerating gear unit 45. In the case the ring gear 76 and the sun gear 79 are sufficiently high in supporting rigidity, the secondary planetary gear 78 2 can be excluded.
The input member 75 is formed at the center portion of the end wall thereof with an outwardly projecting boss 75a, which is in turn rotatably supported on the cylndrical shaft 24 through a bearing 123 and a seal member 124.
An inner peripheral portion of a coupling plate 125 is secured to the end of the boss 75a by means of a screw 120. A plurality of engaging holes 126 are bored and arrayed on a circumference in the outer peripheral portion of the coupling plate 125, and a plurality of plastic coupling pins 127 are correspondingly provided on the end face of the hub 8 of the front wheel 2f so that when the cylindrical shaft 24 is fitted on the axle 10, the coupling pins 125 are fitted into the engaging holes 126 of the coupling plate 125 to connect the input member 75 to the hub 8. Accordingly, the coupling plate 125 and the coupling pins 127 constitute a coupling 128.
The coupling pins 127 are formed into taper shape so as to provide smooth fitting thereof into the engaging holes 126, and also have the function of a shear pin which shears upon reception of a rotating torque in excess of a predetermined value.
The boss 75a of input member 75 extends through the inner casing 22a of the casing 22, and a seal member 129 is interposed therebetween to seal the casing 22. The provision of the seal member 129 is effective to minimize the slip speed of the lip portion of the seal member 129 thus prolonging the service life thereof.
The output shaft 42 comprises a small diameter end portion 42a on one end spline-coupled at 112 to the sun gear 79, a large diameter end portion 42b on the opposite end, a shaft portion 42c for connecting both the ends 42a and 42b, and a flange 42d extending radially outwardly from the outer end of the large diameter end portion 42b. The small diameter end portion 42a is arranged at a position adjacent the outer casing 22b. The shaft portion 42c and the large diameter end portion 42b are rotatably supported on the cylindrical shaft 24 through a needle bearing 41 and a ball bearing 131, respectively.
The shaft portion 42c rotatably supports the flywheel 72, which is in turn connected to the flange 42d through the cam mechanism 73, a friction clutch plate 87 and an aligning plate 138.
The cam mechanism 73 comprises an annular driving cam plate 82 encircling the output shaft 42, a driven cam plate 83 integrally formed on the flywheel 72 and opposed to the driving cam plate 82, and a plurality of thrust balls 84 (only one of which is shown) in engagement with a plurality of cam recessed portions 82a, 83a of both the cam plates 82 and 83. In a normal case where the driving cam plate 82 assumes a position on the driving side with respect to the driven cam plate 83, the thrust balls 84 are engaged in deepest portions of the recessed portions 82a and 83a to merely transmit the rotating torque of the driving cam plate 82 to the driven cam plate 83, generating no relative rotation between the cam plates 82 and 83 whereas conversely, when the driven cam plate 83 overruns relative to the driving cam plate 82, relative rotation between the cam plates 82 and 83 occurs so that the thrust balls 84 roll and climb the inclined bottom surfaces of the recessed portions 82a and 83a of both plates to apply the thrust to both the cam plates 82 and 83, whereby the driven cam plate 82 is caused to axially displace away from the driving cam plate 82.
The friction clutch plate 87 is formed annularly and arranged so as to encircle the large diameter end portion 42b of the output shaft 42 of the driving cam plate 82, and a friction lining 87a in engagement with the back of the driving cam plate 82 is provided on the front surface of the plate 87.
As shown in FIG. 6, the aligning plate 138 has at one side a pair of first flucrum projections 139, 139 in abutment with the flange 42d to enable the tilting of the plate 138 around a first axis y perpendicularly crossing an axis x of the output shaft 42 and has at the other side a pair of second fulcrum projections 140, 140 in abutment with the back of the friction clutch plate 87 to enable the tilting of the plate 138 around a second axis z perpendicularly crossing both the axis x of the output shaft and the first axis y. On the outer periphery of the aligning plate 138 are bent a pair of first transmission pawls 141, 141 projected axially toward the flange 42d adjacent the first fulcrum projections 139, 139 and a pair of second transmission pawls 142, 142 axially projected toward the friction clutch plate 87 adjacent the second fulcrum projections 140, 140. The first transmission pawls 141, 141 are engaged with a pair of notches 143, 143 formed in the outer periphery of the flange 42d, the second transmission pawls 142, 142 being engaged with a pair of notches 144, 144 formed in the outer periphery of the friction clutch plate 87. With this, the aligning plate 138 connects the flange 42d and the friction clutch plate 87 in the rotating direction. In this case, minimum plays for allowing the tilting of the aligning plate 138 around the first and second axes y and z is provided between the respective corresponding transmission pawls 141, 142 and notches 143, 144.
The flywheel 72 has a boss 72a extending to the side opposite the cam mechanism 73, and a pressing ring 89 adapted to actuate the output lever mechanism 74 is mounted on the boss 72a through a release bearing 88 comprising a radial ball bearing.
The output lever mechanism 74 comprises a support shaft 90 projected from the inner end face of the outer casing 22b at an intermediate position between the axle 10 and the pressure discharge valve 20, and a lever 91 supported pivotally in an axial direction of the axle 10 at a neck 90a on the foremost end of the support shaft 90. The lever 91 comprises a long first arm 91a extending from the support shaft 90 while bypassing the output shaft 42 and a short second arm 91b extending from the support shaft 90 toward the pressure discharge valve 20, the first arm 91a being formed at its intermediate portion with an abutting portion 93, in the form of a crest, for abutment with the outer surface of the pressing ring 89.
A return spring 94 is compressed between the foremost end of the first arm 91 and the outer casing 22b, and the foremost end of the second arm 91b is arranged so as to be able to press the outer end of the valve body 67 of the pressure discharge valve 20.
The force of the return spring 94 acts on the lever 91 to press the abutment portion 93 of the first arm 91a against the pressing ring 89 and normally press the valve body 67 of the pressure discharge valve 20 to maintain its closed position. The pressing force received by the pressing ring 89 from the return spring 94 acts on the flywheel 72, the cam mechanism 73, the friction clutch plate 87 and the aligning plate 138 to urge these against the flange 42d whereby a force is applied to both the cam plates 82 and 83 so as to approach toward each other and a friction engaging force is applied to the friction clutch plate 87 and the driving cam plate 82.
The aforesaid friction engaging forces is set to such level that when the rotating torque in excess of a predetermined value acts between the friction clutch plate 87 and the flywheel 72, the friction clutch plate 87 gives rise to a slip.
A guide rod 85 extending through the return spring 94 and the levr 91 is fixedly mounted on the outer casing 22b to prevent falling of the return spring 94 and to control the pivotal route of the lever 91.
The support shaft 90 is designed as an adjustable type so that the fulcrum position of the lever 91 can be adjusted to assure the abutment state of the abutment portion 93 of the lever 91 against the pressing ring 89 and the closed state of the pressure discharge valve 20 by the second arm 91b. More specifically, the support shaft 90 has a thread portion 90b screwed into the outer casing 22b and projecting externally thereof, and a lock nut 92 is threadedly engaged with the outer end of the thread portion 90b. Accordingly, when the lock nut 92 is loosened and the thread portion 90b is turned suitably, the effective length of the support shaft 90 increases and decreases and therefore the position of the neck 90a thereof, i.e., the fulcrum position of the lever 91 can be adjusted. After the adjustment has been made, the lock nut 92 is fastened whereby the support shaft 90 is secured to the outer casing 22b.
The thread portion 90b and the lock nut 92 are faced externally of the casing 22 so that maintenance therefor can be easily performed by special tools. That is, the lock nut 92 is formed into a circular shape and is formed at its end with a tool groove 95 which can be merely engaged with a special screw driver that bypasses the outer end of the thread portion 90b. Tool groove 96 on the thread portion 90b can be a conventional one with which a conventioanl screw driver engages.
An O-ring 97 for sealing the outer casing 22b is attached to a portion of the support shaft 90 which extends through the outer casing 22b.
If, as in a modified example shown in FIG. 7, the pressing ring 89 is formed at its inner end with an outwardly oriented flange 89a and an abutment portion 93 of the lever 91 is brought into abutment with the flange 89a, the spacing between the flywheel 72 and the lever 91 can be reduced to effectively make the sensor 21 compact.
Next, the operation of the above-described embodiment will be described. In mounting the antilock control device 7 on the front wheel 2f, one end of the cylindrical shaft 24 is fitted into the outer casing 22b which has already incorporated therein the hydraulic oil pressure pump 16, the modulator 17, the pressure discharge valve 20, the output lever mechanism 74 and the planetary gears 78 1 ,78 2 . The output shaft 42 provided with the sun gear 79 is mounted on the cylindrical shaft 24, and the flywheel 72, the cam mechanism 73, the friction clutch plate 87, the aligning plate 138, etc. are mounted on the output shaft 42, after which the input member 75 is fitted into the other end of the cylindrical shaft 24 and the inner casing 22a is screwed to the outer casing 22b and thereafter the coupling plate 125 of the coupling 128 is fixed to the input member 75 by means of screws. In this manner, the antilock control device 7 is assembled as a single assembly separately from the front wheel 2f.
Then, when the cylindrical shaft 24 of the antilock control device 7 is fitted to the axle 10 supporting the hub 8 of the front wheel 2f and the device 7 is housed within the recess 8a of the hub 8, the engaging holes 126 of the coupling plate 125 are immediately engaged by the coupling pins 127 of the hub 8.
Thereafter, both ends of the axle 10 are secured to the lower ends of the pair of front forks 9, 9 by means of the holders 121 and bolts and nuts 122.
In the manner as described above, the assembling of the antilock control device 7 and the mounting of the device 7 on the front wheel 2f are easily carried out. Moreover, the axle 10 firmly supports the casing 22, and the hub 8 encases the principal parts of the device 7 in a compact manner.
During the travelling of the vehicle, the rotation of the front wheel 2f is transmitted to the input member 75 through the coupling 128 from the hub 8, and then to the output shaft 42 while being increased in speed by the ring gear 76, the first and second planetary gears 78 1 , 78 2 and the sun gear 79, and transmitted to the flywheel 72 throught the first transmission pawls 141, the aligning plate 138, the second transmission pawls 142, the friction clutch plate 87 and the cam mechanism 73 from the flange 42d and therefore, the flywheel 72 is rotated at a higher speed than the front wheel 2f. Thus, the flywheel 72 is able to have a great rotational inertia force. At that time, even if the pressing ring 89 and the lever 91 are in abutment with each other, the rotation of the flywheel 72 is not at all impaired by the lever 91 due to the provision of the release bearing 88.
At the same time, the cam shaft 26 and the speedometer 51 are also driven by the rotation of the first planetary gear 78 1 .
If an overload is being applied to the input member 75 for some reason during the driving as described above, the coupling pins 127 of the coupling 128 are sheared to cut off the transmission from the hub 8 to the input member 75, and therefore it is possible to prevent the accelerating gear unit 45 or the sensor 21 from suffering from overload.
When the front master cylinder 5f is operated to brake the front wheel 2f, the output oil pressure thereof is transmitted to the front wheel brakes 3f, 3f through the upsteam pipe 15a of the hydraulic oil pressure conduit 15, the hydraulic oil pressure chamber 36 of the hydraulic oil pressure pump 16, the input hydraulic oil pressure chamber 54 of the modulator 17, the valve chamber 58, the valve hole 59, the output hydraulic oil pressure chamber 55 and the downstream pipe 15b of the hydraulic oil pressure conduit 15 in said order, actuating these to apply a braking force to the front wheel 2f.
On the other hand, in the hydraulic oil pressure pump 16, since the output oil pressure of the front master cylinder 5f is introduced into the hydraulic oil pressure chamber 36, the pressing action of said hydraulic oil pressure on the operating piston 29 and the lifting action of the eccentric cam 26a on the push rod 27 cause the reciprocating action of the pump piston 28. Then, in the suction stroke in which the pump piston 28 moves toward the push rod 27, the intake valve 38 is opened so that oil in the oil tank 19 is taken into the pump chamber 35 through the inlet chamber 31 from the conduit 37. In the exhaust stroke in which the pump piston 28 moves toward the operating piston 29, the one-way seal member 39 deforms to open the valve so that the oil in the pump chamber 35 is fed under pressure to the outlet chamber 32 and further to the control hydraulic pressure chamber 18 of the modulator 17 through the oil passage 57. Then, when the pressure in the outlet chamber 32 and the control hydraulic oil pressure chamber 18 increases to a predetermined value, the pump piston 28 is held at the position in abutment with the plug 34 due to the pressure of the outlet chamber 32.
Incidentally, since the control hydraulic oil pressure chamber 18 of the modulator 17 has originally been cut off its communication with the oil tank 19 by the closing of the pressure discharge valve 20, oil pressure supplied to the chamber 18 from the pump 16 directly exerts on the pressure reducing pistion 46 to urge the piston toward a retracted position, and the valve body 60 is held in the open state by the valve opening rod 62 to allow passage of output oil pressure from the front master cylinder 5f.
Accordingly, in a normal braking state, the braking force applied to the front wheel brakes 3f, 3f is proportional to the output oil pressure of the front master cylinder 5f.
When an angular deceleration occurs in the front wheel 2f following the braking operation, the flywheel 72 which has sensed such angular deceleration is caused to make overrun rotation with respect to the output shaft 42 due to the inertia force thereof. The angular moment of the flywheel 72 at that time gives rise to a relative rotation between the cam plates 82, 83, and the flywheel 72 is subjected to axial displacement due to the thrust generated by the rolling of the thrust balls 84 whereby the pressing ring 89 is caused to forcibly move the lever 91. However, in a stage where no possibility is present to lock the front wheel 2f, the angular deceleration of the front wheel 2f is so low as not to oscillate the lever 91.
However, when the front wheel 2f is about to lock due to an excessively great braking force or lowering in coefficient of friction of the road surface, the angular deceleration of the front wheel 2f rapidly increases to exceed a predetermined value so that the pressing force of the pressing ring 89 exceeds a set level and the lever 91 oscillates around the support shaft 90 while compressing the return spring 94. Therefore, the second arm 91b of the lever 91 oscillates so as to move away from the valve body 67, as a result of which the pressure discharge valve 20 assumes an open position.
When, after the flywheel 72 has been displaced axially, the rotating torque due to the inertia of the flywheel 72 exceeds a predetermined transmission torque of the friction clutch plate 87, a slip occurs between the driving cam plate 82 and the friction clutch palte 87 and the flywheel 72 continues its overrun rotation with respect to the output shaft 42 whereby the overload can be prevented from acting on the cam mechanism 73 and the like.
Incidentally, when, at the time of the thrust being generated due to the relative rotation of the driving and driven cam plates 82, 83, an unbalanced load is exerted between both the cam plates 82, 83 due to any machining error in the plurality of cam recessed portions 82a, 83a and the thrust balls 84, etc., three members of the driving cam plate 82, the friction clutch plate 87 and the aligning plate 138 unitarily tilt around the first axis y on the abutment point between the first fulcrum projections 139, 139 of the aligning plate 138 and the flange 42d of the output shaft 42, or two members, the driving cam plate 82 and the friction clutch plate 87, unitarily tilt around the second axis z on the abutment point between the second fulcrum projections 140, 140 of the aligning plate 138 and the friction clutch plate 87, whereby such unbalanced load can be immediately corrected into a proper thrust load acting along the axis x of the output shaft 42. Thus, the axial displacement of the flywheel 72, that is, its sliding can be carried out smoothly, and in addition, the frictional engaging force between the friction clutch plate 87 and the driving cam plate 82 can be uniformly controlled at any parts to stabilize the slip characteristic of the friction clutch plate 87.
When the pressure discharge valve 20 is opened, oil pressure of the control oil chamber 18 is discharged to the oil tank 19 through the oil passage 70, the inlet chamber 68, the valve hole 66, the outlet chamber 69, the oil passage 71, the inlet chamber 31 of the hydraulic oil pressure pump 16 and the conduit 37, and therefore, the pressure reducing piston 46 is moved toward the control hydraulic oil pressure chamber 18 against the force of the return spring 48 due to the oil pressure in the output hydrualic oil pressure chamber 55 to thereby withdraw the valve opening rod 62. The valve body 60 shifts to the closed side to interrupt communication between the input and output oil chambers 54, 55 and increase the volume of the output hydraulic oil pressure chamber 55. As the result, the braking oil pressure acting on the front wheel brakes 3f, 3f lowers to reduce the braking force of the front wheel 2f, thus avoiding the locking phenomenon of the front wheel 2f. Then, since the pressing force of the pressing ring 89 to the lever 91 is released as the rotation of the front wheel 2f accelerates, the lever 91 pivots and returns to its original position with the repulsion force of the return spring 94 to close the pressure discharge valve 20. When the valve 20 is closed, the pressure oil discharged from the hydraulic oil prssure pump 16 is immediately sealed in the control hydraulic oil pressure chamber 18 whereby the pressure reducing piston 46 is moved back toward the output hydraulic oil pressure chamber 55 to increase pressure in the chamber 55 to restore the braking force. Such operation is repeatedly carried out at high speeds, whereby the front wheel 2f can be braked efficiently.
FIGS. 8 through 10 show a second embodiment according to the present invention, which is different from the previous embodiment in the connecting construction between the output shaft 42 and the aligning plate 138.
More specifically, the annular aligning plate 138 is formed with a pair of semi-circular cylindrical first fulcrum projections 139, 139 projecting in a radially center direction from the inner peripheral edge along the first axis y. These projections are engaged with recessed grooves 146, 146 formed on the outer peripheral surface of the larger diameter end portion 42d of the output shaft 42 to extend along the axis of shaft 42. The first fulcrum projections 139 each has a cylindrical surface placed in abutment with a stop ring 147 of a circular section which is secured to the outer periphery of the large diameter portion 42b so as to transverse the recessed grooves 146, 146. Thus axial movement of the plate 138 is limited by abutment against the ring 147.
It is to be noted in this case that if an axial dead end is provided at one end of each of the recessed grooves 146, 146 and the first fulcrum projections 139,139 are supported by them, the aforesaid stop ring 147 can be omitted. This construction is realized by the fourth embodiment of FIGS. 12-18 to be described later.
According to the second embodiment, the rotating torque of the output shaft 42 can be transmitted to the aligning plate 138 through the frist fulcrum projections 139, 139, and the aligning plate 138 can be tilted around the first axis y on the abutment point between the first fulcrum projections 139, 139 and the stop ring 147. Accordingly, the first fulcrum projections 139, 139 are also to have the function of the first transmission pawls 141, 141 of the first embodiment. Therefore, the flange 42d in the first embodiment can be deleted to effectively simplify the construction.
Other structures in the second embodiment are similar to those of the first embodiment, and parts in the former corresponding to those of the first embodiment are indicated by the same reference numerals.
FIG. 11 shows a third embodiment according to the present invention, which is different from the first embodiment in that the pressing ring 89 and the lever 91 are normally held in a non-contact state.
More specifically, a cylindrical retainer 150 is fitted to the boss 72a of the flywheel 72 projected on the side of the sun gear 79, the retainer 150 having at the outer end thereof a radially inwardly oriented flange 150a abutting against the end face of the boss 72a. Between the outwardly oriented flange 150b formed at the inner end of the retainer 150 and the seat plate 150 superposed on the end of the sun gear 79 is compressed a return spring 152 for the flywheel 72, the resilient force of the return spring 152 urging the flywheel 72 always toward the cam mechanism 73 through the retainer 150.
The pressing ring 89 is relatively rotatably fitted around the boss 72a between the outwardly oriented flange 150b of the retainer 150 and the disk portion 72b of the flywheel 72, and a predetermined small spacing 153 is normally formed between the pressing ring 89 and the lever 91 of the output lever mechanism 74.
When the thrust is applied to the flywheel 72 by the operation of the cam mechanism 73, the flywheel 72 is moved leftward, and the pressing ring 89 comes into abutment with the abutment portion 93 of the lever 91 to forcibly move the lever 91.
According to this embodiment, the non-contact state between the pressing ring 89 and the lever 91 is normally maintained, and therefore, the flywheel 72 can be rotated without being resisted by the lever 91 even if no release bearing is provided between the flywheel 72 and the pressing ring 89. The return spring 152 for the flywheel 72 can be ensured a sufficient length to set its spring constant small, and in addition, the boss 72a of the flywheel 72 can have a sufficient length to stabilize the sliding of the flywheel 72.
Other structures in this embodiment are substantially similar to those of the first embodiment, and parts in this embodiment corresponding to those of the first embodiment are indicated at the same reference numerals.
FIGS. 12 through 18 show a fourth embodiment of the present invention, which is different from the above-described first embodiment in the construction of a coupling for connecting the hub 8 with the input member 75, in the construction of an aligning plate and associated elements, and in the construction to support the flywheel 72 on the output shaft 42.
More accurately, in the fourth embodiment, the boss 75a of the input member 75 projected integrally from the center of the end wall to the hub side is connected to the hub 8 of the front wheel 2f through a coupling 200.
As shwon in FIGS. 13, 15 and 16, the coupling 200 comprises a driving coupling plate 202 secured to the end face of the hub 8 by means of a plurality of pressure pins 201 and a driven coupling plate 203 secured to the end face of the boss 75a of the flywheel 75 by means of a plurality of bolts 204. The driving coupling plate 202 is provided with a plurality of transmission tongues 205, 205, . . . which are cut-erected toward the driven coupling plate 203 to extend in the circumferential direction and which are given resiliency. Each of said transmission tongues 205 is formed at one end thereof with a semispherical convex portion 206 protruded toward the driven coupling plate 203. On the other hand, the driven coupling plate 203 is formed with a plurality of concave portions 207, 207, . . . which extend radially on the surface opposed to the driving coupling plate 202, said convex portions 206, 206, . . . being resiliently engaged in said concave portions 207, 207, . . . respectively. Thus, when an excessively great torque is applied between both the coupling plates 202 and 203, the covex portions 206, 206, . . . are disengaged from the concave portions 207, 207, . . . against the spring force of the transmission tongues 205 to release the connection between both the coupling plates 202 and 203 to prevent the transmission of an excessively great torque.
The driven coupling plate 203 has a boss 203a fitted on the outer peripheries of the boss 75a and hub 8, and the interior of the casing 22 is closed by seal members 228 and 229 interposed between the boss 203a and the hub 8 and inner case 22a.
Turning again to FIG. 13, the output shaft 42 comprises a small diameter end portion 42a spline-connected to a sun gear 79, a large diameter end portion 42b on an opposite side to the portion 42a, a shaft portion 42c for connecting these end portions 42a and 42b, the output shaft 42 having no flange 42d provided in the first embodiment. The small diameter end portion 42a is arranged directed toward the outer case 22b, and the shaft portion 42c and the large diameter end portion 42b are rotatably supported on the cylindrical shaft 24 through the needle bearing 41 and ball bearing 131, respectively.
The flywheel 72 is rotatably and slidably supported on the shaft portion 42c through a slide type ball bearing 210. The ball bearing 210 comprises a retainer 211 for retaining a number of balls in plural rows and an outer race 212, said outer race 212 being press-fitted into the boss 72a of the flywheel 72. The flywheel 72 is connected to the large diameter end portion 42b of the output shaft 42 through the cam mechanism 73, a friction clutch plate 287 and an aligning plate 238.
The annular aligning plate 238 has, as shown in FIG. 17, the same construction as that of the aligning plate 138 of the second embodiment shown in FIG. 10. More specifically, the aligning plate 238 is provided with a pair of semicylindrical first fulcrum projections 239, 239 to enable the tilting of the aligning plate 238 around a first axis y perpendicularly crossing an axis x of the output shaft 42, a pair of semi-cylindrical second fulcrum projections 240, 240 to enable the tilting of the aligning plate 238 around a second axis z perpendicularly crossing the axes x and y, respectively, and a pair of transmission pawls 242, 242 in engagement with a pair of notches 144, 144 formed in the outer periphery of the friction clutch plate 87.
On the other hand, a pair of recessed grooves 246, 246 formed in the outer peripheral surface of the large diameter end portion 42b of the output shaft 42 each has an axial dead end 247, the first fulcrum projection 239 of the aligning plate 238 being engaged with the dead end 247.
In FIG. 13, the outer race 212 of the slide type ball bearing 210 projects lengthwise from the boss 72a of the flywheel 72 to the side opposite the cam mechanism 73 in the axial direction, and a release bearing 88 whose inner race is formed by said projecting outer race of bearing 210 is provided adjacent to the flywheel 72.
A pressing ring 89 adapted to actuate the output lever mechanism 74 is fitted around the outer periphery of the outer race of the release bearing 88.
In this embodiment, the lever 91 of the output lever mechanism 74 has an appropriate gap g given against the fulcrum portion on the support shaft 90, i.e., the base portion of the neck 90a in order to secure the state of abutment with the pressing ring 89 by the abutting portion 93 of the level 91 and the closed state of the pressure discharge valve 20 caused by the second arm 91b.
Accordingly, in the fourth embodiment, since the flywheel 72 is supported on the output shaft 42 through the slide type ball bearing 210, rotation and sliding movement thereof on the output shaft 42 are effected very smoothly, so that the operating characteristic thereof remains almost unchanged even if the lubricating state should be varied, thus making it possible to precisely respond to certain angular deceleration speed of the front wheel 2f. | A wheel angular acceleration sensor for a vehicle anti-lock control device wherein the tendency of the wheel going toward a locked state resulting from an excessively great braking force of the brake applied thereto is detected by overrun rotation of the flywheel and the overrun rotation is converted into an axial displacement of the flywheel by the cam mechanism to output it as a signal for controlling the braking force, the sensor having an aligning mechanism interposed between an output shaft rotated in association with the wheel and the cam mechanism as well as a friction clutch plate for allowing the overrun rotation of the flywheel, whereby when a deflected load is exerted on the cam mechanism or the friction clutch plate due to an error in machining or the like at the time of occurrence of a thrust at the cam mechanism, the aligning mechanism works to overcome the deflected load, allowing the flywheel to displace smoothly and accurately in the axial direction. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved process for the production of woven polypropylene fabrics. More specificlaly, it relates to improved efficiency in the production of polypropylene carpet backing.
2. Description of the Prior Art
The additive used in the preferred embodiment of this invention is marketed by Badische-Aniline-Soda-Fabrik (BASF) under the trade name of Lufilen E 100. The Lufilen additive is primarily sold as a delustering agent for use in polyester spinning processes to deluster the product. It has been found that although this additive performs its intended purpose as a delustering agent very poorly in the production of polypropylene tapes which are subsequently woven into carpet backing, this additive unexpectedly has a remarkable effect on the efficiency of downstream operations such as weaving and burling. Accordingly, it is an object of this invention to provide better efficiency in a process for the production of woven polypropylene fabrics.
This and other objects will be readily apparent upon reading the specification.
SUMMARY OF THE INVENTION
Broadly, the invention resides in an improved process for producing polypropylene fabrics wherein polypropylene resin is extruded into flat ribbon yarns which are subsequently woven into fabrics, the improvement comprising the addition of 0.5 to 5 weight percent of an additive to the resin prior to extrusion, said additive containing fine silica particles, whereby greatly improved production efficiency is achieved with relatively little effect on the luster of the ribbon yarns. It has unexpectedly been discovered that the use of such an additive increases weaving efficiency, reduces burling time, decreases the frequency of weaving faults such as lost picks and broken picks, and allows the use of larger weft yarn packages. Although the silica particles are believed to be the active ingredient, it is preferable that the additive contain a large amount of low density polyethylene.
More specifically, the amount of low density polyethylene in the additive can range from 70 to 90 weight percent.
Still more specifically, the amount of silica particles in the additive can range from 10 to 30 weight percent.
Still more specifically, the silica particles can substantially range in size from 0.5 to 30 microns.
In a further aspect, the invention resides in an improved process for producing polypropylene fabrics wherein polypropylene resin is extruded into flat ribbon yarns which are subsequently woven into fabrics, the improvement comprising the addition of 0.5 to 5 weight percent of an additive to the resin prior to extrusion, said additive containing low density polyethylene, fine silica particles, and a stabilizer, such as N-n-hexadecylacetoacetamide, whereby greatly improved production efficiency is achieved with relatively little effect on the luster of the ribbon yarns.
Specifically, the amount of low density polyethylene in the additive can range from 70 to 90 weight percent. The amount of N-n-hexadecylacetoacetamide in the additive can range from 0.5 to 5 weight percent. And the amount of silica particles in the additive can range from 10 to 30 weight percent.
More specifically, the silica particles can substantially range in size from 0.5 to 30 microns.
In a preferred aspect, the invention resides in an improved process for producing polypropylene fabrics wherein polypropylene resin is extruded into flat ribbon yarns which are subsequently woven into fabrics, the improvement comprising the addition of about 1 weight percent of an additive to the resin prior to extrusion, said additive containing about 79 weight percent polyethylene having a density of about 0.92 grams per cubic centimeter, about 20 weight percent silica particles substantially having a size range from 1 to 20 microns, and about 1 weight percent N-n-hexadecylacetoacetamide, whereby greatly improved production efficiency is achieved with relatively little effect on the luster of the ribbon yarns.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the production of polypropylene carpet backing, polypropylene resin is extruded into thin sheets or webs which are continuously slit into ribbons as the web leaves the extruder. These ribbons are passed through an oven and simultaneously stretched to provide proper orientation and thickness. The ribbons are then ready for subsequent weaving operations.
During weaving, the warp yarns, which run in the machine direction, are fed to the loom from a large cylinder called the loom beam. Each loom beam feeds from 100 to several thousand ends, depending upon the width of the loom and the desired closeness of the weave. The weft or fill yarns, which run in the cross-machine direction, are fed to the loom from small packages located beside the loom. In the Sulzer loom, the end of each fill yarn package is automatically grasped by a small shuttle which is mechanically propelled through the shed to the other side of the loom. The fill yarn is then cut and the shuttle returns to repeat the process. Each pass of the shuttle is termed a "pick". Occasionally the shuttle may break the fill yarn while passing through the shed. This is called a "broken pick". Also, the shuttle may fail to grasp the end of the fill yarn from the package and travel through the shed without any fill yarn at all. This is termed a "lost pick".
After the weaving operation, the woven fabric is subjected to burling and mending to cure defects. The burling consists of removing knots and loose threads, whereas the mending eliminates holes, missed warp yarns and filling picks, as well as other defects.
It has unexpectedly been found that the addition of 1 weight percent Lufilen E 100, sold by BASF as a delustering agent, results in improved efficiency of the downstream process. An analysis of the Lufilen showed that it contains about 79 weight percent polyethylene, said polyethylene having a density of 0.92 grams per cubic centimeter. It also contains about 20 weight percent very fine silica particles, predominately ranging in size from about 1 to 20 microns, and also about 1 weight percent N-n-hexadecylacetoacetamide. It is believed that the amide is present as an antioxidant for the polyethylene and is not responsible for the improved process efficiency which results from the use of Lufilen. Accordingly it is believed that the benefits of this invention may be achieved by use of an additive containing only low density polyethylene and fine silica particles, and the scope of this invention should not be limited to the scope of the preferred embodiment, which is set forth only as an illustration.
The results of the addition of 1 weight percent Lufilen to the fill yarn resin, producing a fill yarn having a 1050 denier, are set forth in the Table below. The Lufilen was added only to the fill yarns because the fill yarns have a greater influence on weaving efficiency than do the warp yarns.
TABLE______________________________________ Without With Change Lufilen Lufilen (Percent)______________________________________Lost Picks from10,000 Square Meters 35.0 26.0 -25.7Broken Picks from10,000 Square Meters 676 107 -84.2Burling Time inMinutes for 10,000Square Meters 399 257 -35.6Weaver Efficiency.sup.1 (Percent) 92.9 95.9 +3.0Total Weave RoomEfficiency.sup.2 (Percent) 83.3 91.2 +7.9______________________________________ .sup.1 "Weave Efficiency" is the percentage of loom capacity each weaver is utilizing. .sup.2 "Total Weave Room Efficiency" is the percentage of full capacity a which the entire weave room is operating.
The use of the Lufilen additive produced ribbon yarns which were smoother, softer, and showed less fibrillation. As is readily seen from the table, the improvements resulting in the downstream operations are remarkable and totally unexpected. The number of lost picks decreased more than 25%, the number of broken picks decreased more than 84%, the amount of burling time decreased more than 35%, the individual weaver efficiency increased 3%, and the total weave room efficiency increased almost 8%. Because of this increased efficiency and decreased loom stoppage, the number of looms per weaver has been increased from 10 to 12.
The amount of the additive which can be used will of course vary with the economics of the specific process in which it is used. A reasonable range would be from 0.5 to 5 weight percent, with 1 weight percent being preferred.
Accordingly, it will be obvious to those skilled in the art that many variations may be made from the preferred embodiment without departing from the scope of this invention. | Efficiency in the production of woven polypropylene fabrics is greatly improved through the use of an additive comprising fine silica particles. Addition of the abovesaid additive to the resin prior to extrusion of the ribbon yarns increases weaving efficiency, reduces burling time, decreases the frequency of weaving faults such as lost or broken picks, and permits the use of larger weft yarn packages. | 3 |
FIELD OF THE INVENTION
The present invention relates to a stable high ginsenoside-yielding callus line of Panax quinquefolium (American ginseng) developed from root explants and a process for the development of these callus lines. More particularly, the invented callus line has a distinct morphological marker of purple pigmentation and saponin yield comparable in quantity and quality to that of normal roots.
The invention provides a viable alternate option to boosting the industrial production of ginseng saponins (ginsenosides) which are in high demand in market as important ingredients of health tonics and anti-aging drug preparations.
BACKGROUND
Ginsenosides (triterpene glycosides) extracted from roots of 4-7 years old plants of ginseng (common name for Panax species) are important constituents of herbal health care products today. Owing to their strong immuno-modulatory, adaptogenic and aphrodisiac actions, ginseng saponins are widely prescribed in several conditions of health disorders such as anaemia, diabetes, asthma, neuroaesthemia, dyspepsia, convulsion and even in cancer and AIDS. Priced at 750-1000 US $ per kg and with an annual global production of 35-40 thousand tons, Panax roots are the fourth largest selling herbal healthcare product today. Korea, China and Japan have the major share in the global supply of ginseng roots. [Indian pharmaceutical companies import about 400-500 tons of Panax root powder annually.] The chief source of ginseng roots are P. ginseng (Korean panax), P. quinquefolium (American panax) and P. notoginseng (Chinese panax). The Indian congeners i.e. P. pseudoginseng and P. sikkimensis Ban., growing wild in the sub-Himalayan zones (Darjeeling, Sikkim, Arunachal Pradesh etc.) though found to be on par in saponin quality and content with their oriental counterparts, have not yet been commercially exploited. Traditional field cultivation of Panax sp. is very slow and labour intensive. It takes 18-22 months for the seed to germinate (following 2-3 stratification cycles to break seed dormancy) and an extended gestation period of 3-5 years for the crop to mature and provide economic root biomass yield and quality of saponins. Tissue culture based strategies for rapid propagation (micro-cloning) and in vitro ginsenoside production in Panax, therefore, hold immense promise and potential.
PRIOR ART REFERENCES
These are many reports on tissue culture studies particularly, in vitro ginsenoside production in cell suspension cultures, of Korean ginseng— P.ginseng [Boitechnology in Agriculture & Forestry Vol. 4(1) (Ed) Y. P. S. Bajaj pp 484-500 (1988); Cell Culture and Somatic Cell Genetics of Plants Vol. 5 (Ed) I. K. Visil (1988)pp. 213-234, J. Biotechnol 52:121-126 Process Biochem, 33:69-74 (1998)]. The maximum ginsenoside level detected in cell culture of ginseng has been reported to be 16 mg/g. dry wt. (Agri Cell Rep., February, 1994). Possibility of ginsenoside production in genetically transformed hairy roots has also been indicated in P.ginseng [P1. Cell Rep. 12: 681-686; (1993), Ibid 15: 555-560) (1996), Phytochemistry 49:1929-1934 (1998)]. In contrast there have been very few reports concerning P. quinquefolium cell and tissue cultures [Phytochemistry 35: 1221-1225, (1994), Process Biochem., 33:69-74 (1998)]. The applicants, during their research, had earlier shown that callus and cell suspension cultures of P. quinquefolium are also capable of producing characteristic ginsenosides in vitro [Phytochemistry 35:1221-1225 (1994)]. The crude ginsenoside content (i.e. 0.56% and 0.65% for callus and cell cultures, respectively) and ratio of Rb and Rg group of ginsenosides of these wild line cultures were found to vary with their age (days after subculture) during a 5 week culture cycle. The possibility of isolating high ginsenoside yielding lines of P. quinquefolium , specifically rich in different ginsenoside fractions, was first hypothesized by the applicants in this report. The present invention is an outcome of the continued efforts made by the applicants in this direction and accordingly, the applicants have now developed a high-yielding callus line with a crude ginsenoside level as high as 1.21% f.wt. that matches well with that in 3-4 years old roots of field grown plants [Shoyakugaku Zosshi 32:96 (1978), J. Herb Spices & Med. P1. 3:41-50 (1995)]. Recent market trends show that because of extremely high price of wild roots of P. ginseng , the demand for P. quinquefolium has increased dramatically and is 5-10 times more expensive than its oriental counterparts [P1. Med. 61:466-469 (1996)].
The novelties of the inventions are as follows:
(a) The invention for the first time, provides a stable high-ginsenoside yielding callus line of P. quinquefolium whose saponin content is comparable in yield and quality to that of field grown plants,
(b) The procedure outlines the formulation of a callus culture maintenance medium [modified MS medium with double the amount of organic adjuvants+200 mg/l myoinositol+2, 4-D (1.0 mg/l)+Kinetin (0.25 mg/l)] for callus maintenance and multiplication and incubation environment such as continuous light (3000 Lux) and temperature 28±2° C. that support sustained growth and stable ginsenoside yield for over four and half years,
(c) The invention has resulted in identifying the parameters, such as inoculum age, inoculum to medium ratio, tissue harvesting schedule, media pH, and extraction, TLC densitometry and HPLC analysis of the crude ginsenoside, that are required for further scaling up of the isolated line,
(d) The isolated callus line has a morphologically distinguishable feature, characteristic DNA profile and a stable chemical fingerprint. FIG. 1 depicts the characteristic purple pigmentation in the callus cells of the isolated line in comparison to pale white non-pigmented wild line counterpart. The morphological appearance is as nearly true as is reasonably possible to make the same in coloured illustration of this marker character,
(e) The isolated callus line has been shown to grow and accumulate ginsenoside in amounts and quality on medium having cheap market grade sugar as energy source in comparison to the conventionally employed costly analytical grade sucrose. This is a vital step towards cost reduction strategies for commercial utilisation of such tissue culture lines,
(f) The isolated callus line has all the desired attributes that enable it to be exploited on a commercial basis.
Objects
The main object of the present invention is to provide a stable high ginsenoside-yielding callus line of Panax quinquefolium (American ginseng), developed from root explants and a process for the development of said callus lines, obviating the drawbacks of the earlier methods.
Another object of the present invention is to isolate a callus line with saponin yield comparable in quantity and quality to that of normal roots so as to devise an in vitro process for the production of these health care compounds on a commercially feasible scale.
Still another object of the present invention is to identify in vitro growth conditions and other experimental parameters for commercialisation and in vitro production of Panax quinquefolium.
Yet another object of the present invention is to reduce the cost of ginsenoside production in vitro by use of cheaper carbohydrate sources.
One more object of the present invention is to identify morphological marker(s), genetic marker (DNA fingerprint) and chemical fingerprint of the isolated high-yielding line.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The file of this patent contains at least one photograph executed in color. Copies of this patent with color photographs will be provided by the Patent and Trademark Office upon request and payment of the necessary fee.
FIG. 1 is a photograph that represents a mild callus line of Panax quinquefolium.
FIG. 2 is a photograph that depicts the characteristic purple pigmentation in the callus line of the invention
FIG. 3 is a photograph that represents the DNA profile of the selected callus line of Panax quinquefolium.
DETAILED DESCRIPTION
Accordingly, the present invention provides a stable high ginsenoside—yielding callus line of Panax quinquefolium (American ginseng) from root explant having:
(a) purple pigmentation,
(b) growth Index of 204.8 to 246.01 in about 45 days of culture,
(c) ginsenoside yield of 0.94 to 1.33% f.wt. in about 45 days of culture,
(d) yield of Rb group of ginsenosides 49 to 55% from the crude extract in about 45 days of culture,
(e) yield of Rg group of ginsenoside of 35-49% from crude extract in about 45 days of culture, and
(f) characteristic DNA profile wherein the lanes 1, 2, 3, 4, 5, and 6 as represented in FIG. 3, wherein the PCR amplified fragments produced by the template megabase genomic DNA with the primers 5′ CGCAGTACTC 3′ (SEQ ID NO: 1), 5′ GTCCTACTCG 3′ (SEQ ID NO: 2), 5° CTACACAGGC 3′ (SEQ ID NO: 3), 5′ GTCCTTAGCG 3′ (SEQ ID NO: 4), 5′ GTCCTCAACG 3′ (SEQ ID NO: 5), 5′ CTACTACCGC 3′ (SEQ ID NO: 6), respectively, are shown and Lane Mw shows the standard size markers of a ladder at 100 bp intervals from 1000 bp downwards.
In an embodiment, the invention provides a method for the development of a stable high ginsenoside-yielding callus line from root explants, comprising the steps of:
(a) establishing of the aseptic callus cultures from root explants on basal medium modified after Murashige and Skoog medium to obtain primary callus,
(b) transferring the primary calli to medium II for optimal growth,
(c) multiplying and maintaining the callus for more than 2 years by regular sub-culturing in medium II every six to seven weeks under temperature 28±2° C., 1000-2000 lux light intensity and 70 to 80% relative humidity;
(d) obtaining the fragile and pale white calli,
(e) isolating the high yielding purple pigmented callus occurring as spontaneous variant from 20 th sub-culture,
(f) enriching the isolated purple pigmented variant through selection and cell aggregate cloning in at least seven subsequent sub-cultures, and
(g) proliferating the enriched callus line by using culture Medium III and incubating the callus culture in continuous light of 3000-4000 lux intensity to obtain high yielding callus line.
In an embodiment of the invention the root explants are obtained from at least 3 years old Panax quinquefolium plants.
In yet another embodiment, the roots are cut into 2-7 mm long small explant pieces which are washed thoroughly in water at least 4 times to remove dirt and contaminants.
In a further embodiment, the root explants are sterilized by treatment with centrimide for a period of about 5-10 minutes and with mercuric chloride for about 10-30 seconds.
In another embodiment of the invention, the medium used in step (a) is the basal medium modified after Murashige and Skoog's (1962) medium supplemented with 2-4 mg/l glycine, 200 mg/l myoinositol, 10 mg/l thiamine hydrochloride, 10 mg/l pyridoxine hydrochloride and 5 mg/l nicotinic acid.
In a further embodiment, Medium II used in step (b) is obtained by addition of 2,4-dichlorophenoxyacetic acid (0.5-2.0 mg/l) and kinetin (0.25-0.50 mg/l) to the basal medium for optimal callus induction.
In an another embodiment, Medium III used in step (g) comprises nutrient salts of basal medium, 200 mg/l myoinositol, 2.0-4.0 glycine, 0.5-1.0 mg/l nicotinic acid, 0.5-2.0 mg/l pyridoxine HCl and 0.2-0.4 mg/l thiamine HCl, 2,4-D (0.1-0.5 mg/l) and Kinetin (0.25-0.50 mg/l) for optimal growth of the selected line.
In yet another embodiment of the present invention, chemical extraction of the ginsenosides from freshly harvested callus (5 to 45 days or 1 to 5 months old) was done with methanol (100%, 4 times), redissolving the dried extract in water soluble portion and finally extracting this water portion with n-Butanol saturated with water (4 times), collecting the n-Butanol fraction, centrifuging it and collecting the supernatant, drying it under vacuum.
In yet another embodiment of the present invention, the selected callus line is genetically characterised through molecular marker patterns generated using the cell line genomic DNA as template in the randomly primed polymerase chain reaction (RP-PCR) assays.
In yet another embodiment of the present invention the content and quality of various ginsenoside fractions may be monitored and identified by TLC densitometry and HPLC.
In still another embodiment of the present invention carbohydrate sources used may be selected from sucrose, market grade sugar, molasses treated with EDTA and charcoal.
The callus line of the invention has faster growth rate (Growth index=204.80-246.01) giving rise to increased (about 7.5 folds) biomass production than in non-selected wild line (Growth index=21.40-36.56) in about 45 days of culture.
It also has increased crude ginsenoside yield. It is about 4 times more in selected callus line (0.94-1.33%f.wt) in comparison to that of wild line (0.24-0.37%) in about 45 days of culture. The applicants observed increased yields of Rb and Rg group of ginsenosides. After about 45 days of culture the crude extract has 49-55% of ginsenosides of the Rb group and 35-49% of ginsenosides of the Rg group in the selected line as compared to 6-8% Rb group and 33-45% Rg group of ginsenosides in the wild line.
Brief methodology of the present process includes:
(a) Establishment of aseptic callus cultures of the wild line and selection of the high ginsenoside—yielding line.
The wild line utilised in this study was generated as reported by the applicants earlier (Phytochemistry 35: 1221-1225, 1994). Briefly, the roots of a 3 years old P. quinquefolium plant grown at CIMAP (Central Institute of Medicinal and Aromatic Plants, Lucknow, India) experimental Farm at Bonnera (Jammu and Kashmir; 3500 altitude) were cut into small explant pieces (2-7 mm long). The explants were washed in water 4-5 times to ensure that all dirt was removed. The explant surface was sterilized with centrimide (10 min) and 0.1% HgCl 2 (10 seconds) and horizontally implanted onto the agar-gelled medium. The basal medium (BM) used during the course of the present invention was of Murashige and Skoog (1962; Physiol. Plant, 15:473-497); and consisted of (in mg/l) NH 4 NO 3 (1650), KNO 3 (1900), KH 2 PO 4 (170), MgSO 4 .7H 2 O (370), CaCl 2 .2H 2 O (440), ZnSO 4 .7H 2 O (8.60), H 3 BO 3 (6.20), MnSO 4 .4H 2 O (22.30), KI (0.83), CuSO 4 .5H 2 O (0.025), CoCl 2 .6H 2 O (0.025), Na 2 MoO 4 .2H 2 O (0.25), Na 2 EDTA (37.25), FeSO 4 .7H 2 O (27.85), glycine (2.0), nicotinic acid (0.50), pyridoxine HCI (0.50), thiamine HCI (0.10), myoinositol (100), sucrose (30,000) and agar (7,000). Keeping in view the high demands for nutrients and organic manure by Panax species during field cultivation, the basal medium (BM) used in this study was modified after Murashige and Skoog (Physiol. Plant. 15: 473-497) by incorporating into MS medium 200 mg/l of myo-inositol, 10 mg/l each of thiamine hydrochloride and pyridoxine HCI and 5 mg/l of nicotinic acid (Medium I). Optimal callus induction occurred when basal medium (BM) was further fortified with 2,4-dichlorophenoxyacetic acid (0.5-1.5 mg/l) and kinetin (0.25-0.50 mg/l) (Medium II). The induced calli were multiplied by regular sub-culturing onto the fresh medium every 6-7 weeks under 2000 Lux light intensity, 28±2° C. temperature and 70-80% relative humidity. The high-yielding callus line was isolated from the wild line (pale-white in appearance) as a spontaneously occurring variant in the form of purple pigmented sector in the 20 th subculture cycle. The variant sector was excised and subjected to repeated selection for seven subsequent subculture cycles. The selected line proliferated better when Medium II was replaced with a different callus maintenance medium comprising of nutrient salts of BM,200 mg/l myoinositol, 2.0-4.0 mg/l glycine, 0.5-1.0 mg/l nicotinic acid, 0.5-2.0 mg/l pyridoxine HCI, 0.2-0.4 mg/l thiamine HCl, 0.1-0.5 mg/l 2,4-D and 0.25-0.50 mg/l Kinetin (Medium III). Through this “cell-enrichment” selection technique the pigmented line (FIG. 2) was isolated with stable morphology, characteristic DNA profile (FIG. 3) and fast growth in vitro, and was further subjected to chemical analysis. The selected line requires continuous light of high intensity (3000-4000 lux) for its optimum proliferation and growth in culture.
(b) Growth kinetic studies of the wild and the selected lines.
For the in vitro growth and other culture conditions for improved ginsenoside yield and quality, the calli of the isolated line was subcultured under different nutrient/incubation regimes (treatments) and their Growth index (GI) was calculated as a function of time by following formula. G. I = F.Wt. at the time of harvest - Initial inoculum Initial inoculum × 100
A minimum of 24 replicated cultures/treatment were used for data analysis and the data is expressed as mean performance±SD of all the replicates. All experiments were repeated at least 3 times.
(a) Molecular characterisation of the selected line.
The selected line was genetically characterised through molecular marker patterns generated using the cell line genomic DNA as template in the randomly primed polymerase chain reaction (RP-PCR) assays. The amplification reaction mixture in a final volume of 25 μl, contained 400 μM each of dNTP, 1.0 mM MgCl 2 , 10.0 pmoles of primer, 0.25 units of Taq polymerase and 2.5 μl Taq buffer (Bangalore Genei, India), 50.0 ng template DNA. After a single pre-PCR cycle of 94° C. (5 min), 35° C. (1.5 min) and 10° C. (15 min), the reaction mixture contents were cycled to 40 times with each cycle consisting of a sequence of 94° C. (1.5 min), 35° (1.5 min) and 72° C. (1.0 min) and were finally given an extension completion incubation of 72° C. for 5 min in a PCR machine (Perkin Elmer Model 2400). At the end of the PCR run, amplification products were separated electrophoretically on a 1.4% agarose in 1×TAE buffer. A mixture of 1000 to 100 base pairs (bp) of ladder of 10 double stranded (ds) DNA fragments were co-electrophoresed to gauge the size (bp) of the amplification products.
(d) Extraction of the crude ginsenoside
Extraction of crude ginsenoside from callus samples was done according to the procedure reported earlier by us [Phytochemistry 35: 1221-1225 (1994)]. The method which was essentially modified after Furuya et al. [Chem. Pharm. Bull. 21:98 (1973)] is briefly explained in the following flow chart:
(e) TLC analysis of crude ginsenoside extract.
The crude ginsenosides were redissolved in HPLC grade methanol, centrifuged at 8000 rpm for 15 minutes and supematant collected. The crude sample was first spotted on 60 F 254 E-merck pre-coated TLC plates and chromatographed, alongwith known amount of authentic ginsenoside samples using a solvent phase consisting of CHCl 3 :MeOH:H 2 O (13:7:2). The ginsenoside fractions were visualized by spraying the plates with 10% (v/v) H 2 SO 4 followed by heating at 100° C. for 10 minutes. Scanning for quantification of these spots was carried out on a dual wavelength densitometer (Shimadzu) at 530 and 700 nm.
(f) HPLC analysis of crude ginsenoside extract.
HPLC of the crude ginsenoside mixture was carried out according to a modified procedure of Solidati and Sticher (P1. Med. 1980 38:348-357). The analysis was performed on a C 18 waters μ Bondapack column (150×3.9 mm) using CH 3 CN:H 2 O:9:16 (flow rate=0.5 ml/minute) as mobile phase for ginsenosides Rb 1 , Rb 2 , Rc, Rd, Rf and Ro. The Rt values for these were found to be 7.98, 8.81, 10.63, 13.45, 18.98 and 20.82, respectively. For ginsensoside Re and Rg1 separation, mobile phase used was CH 3 CN:H 2 O:11:39 (the respective Rt values for these were 21.88 and 23.19, respectively). Detection was done at λ max=203 nm. While all other authentic ginsenoside fractions were procurred from Carl Roth (Germany), ginsenoside Ro was generously gifted by Prof. O. Tankaka (Japan).
The following examples further illustrate the comparison of biomass yield and ginsenoside productivity and effect of inoculum density, harvesting schedule and efficacy of different carbohydrate source on these in wild and selected callus lines of the present invention and should not be construed to limit the scope of the invention:
EXAMPLE 1
Growth kinetics and ginsenoside productivity and quality of the subject callus lines:
Growth characteristics of the selected line was studied and compared with that of the wild line (control) over a culture span of 45 days. Specific growth rates, crude ginsenoside contents and quality were monitored at 10 days interval and the results are depicted in Table 1. The higher biomass and ginsenoside productivity of the selected line became evident from the 25 th day of incubation and continued up to 45 th day of culture. The wild line accumulated highest biomass and crude ginsenosides around the 25 th and the 35 th day of culture, whereas corresponding values in case of the selected line were acquired on around 40-50 days of culture. The biomass production in terms of growth index is about 7.5 times more in selected line (232.7) in comparison to the wild line (30.2) after 45 days of culture (Table 1). The crude ginsenoside content on fresh weight basis is about 4 times in the selected line (1.21%) in comparison to that of wild line (0.29%). For ginsenoside quality in terms of Rb: Rg fractions, wild line cultures at around 25-30 days were the best, the selected line-again exhibited best profile around 40 days of culture when as high as 53% and 43% of Rb and Rg groups of ginsenosides were produced.
The selected callus line has depicted high stability in terms of its in vitro growth (GI=210.8-292.09), crude ginsenoside content (1.09-1.27% f.wt.) and ginsenoside quality (Rb: Rg ratio=1.12-1.30) for over 20 subculture generations during more than three years tested (Table 2). The Panax cultures in general, showed slightly better growth in winter months (November-February) than in summer months (April-August).
EXAMPLE 2
Effect of inoculum density and harvesting schedule on ginsenoside production and quality:
Harvesting schedule and the amount of initial inoculum for increase productivity of the selected line were studied taking four initial inoculum densities (10-40% w/v), the best growth and saponin yields were obtained when 2-3 months old calli were used at 25-30% initial density (i.e., 10-15 g innoculum/40 ml of the medium). Besides, a 30-35 day culture cycle should be followed if both Rb (particularly Rb 2 ) and Rg (mainly Rg, and Re) groups of ginsenosides are to be extracted (Table 3). The culture span can be reduced to 5-10 days if interest lies more in Rb 1 and Rb 2 fractions which became very low beyond 40-45 days of incubation. For Rg group of saponins the cultures should be harvested after 3-4 months when Rg1+Re are the major fractions of the ginsenoside pool.
EXAMPLE 3
Comparison of different carbohydrate sources on growth and ginsenoside content in the subject line:
Different carbohydrate energy sources in the medium were tried to observe the efficacy of cheaper substitute for costly sucrose (Table 4). In order to cost economise the in vitro procedure developed in this study, the conventionally used carbon source-sucrose (Rs 250 per kg), which is the most costly ingredient of the nutrient medium, was tried to be substituted with alternate cheaper sources like market grade sugar (Rs. 14-16/kg) and molasses (Rs 1.0 per liter) which is a waste byproduct of sugar industries. While efficacy of market grade sugar was evaluated at 1-4% (w/v) concentration in the callus maintenance medium, molasses was subjected to certain pretreatment (prior to use) to remove inhibitory compounds. For this, 25% (wlv) molasses solution was soaked with activated charcoal (2 g/l) for 2 hours, boiled for 30 minutes and left overnight. It was then filtered (Whatman No.1) and centrifuged. The supernatant was diluted with water (x 50 times) and used 0.3% (v/v) in experiments. Alternately 5% of the molasses (w/v) solution was titrated with 10% (w/v) Na 2 -EDTA to precipitate EDTA-chalets, kept in the refrigerator overnight, centrifuged and diluted 50 times as above, before using 0.3% (v/v) in the medium. The wild and selected callus lines were grown on medium supplemented with 3% (w/v) sucrose (control), market grade sugar (3% w/v) and charcoal or EDTA treated molasses. The results obtained for biomass yield and crude ginsenoside content after 10 days interval upto 50 days of incubation indicated that while molasses could not sustain callus growth, market grade sugar which is about 15 times cheaper than Analar grade sucrose can be used as a sole energy source for both wild and the selected lines. In fact market grade sugar-containing medium supported 10-15% more biomass gain than sucrose in case of the selected line (Table 4). The crude ginsenoside content in the sugar containing medium also remained as high as in sucrose supplemented medium. HPLC analysis of the saponins also did not indicate any inhibitory effect of sugar on levels of various ginsenoside fractions.
EXAMPLE 4
Effect of supplementation of sodium acetate in the medium on ginsenoside yield:
One of the probable precursors sodium acetate was incorporated in the medium at concentration ranging from 5-50 mg/l. Sodium acetate has been used by other workers (P1. Med. 47:200-204) as a putative precursor for saponin biogenesis. The selected as well as non-selected lines of P. quinquefolium (our study) however showed a sharp fall in ginsenoside content (0.06-0.18% f.wt.) at various levels of sodium acetate. Which probably is not an appropriate precursor to be used in such feeding experiments with P. quinquefolium calli.
The above mentioned examples clearly indicate that present invention provides a high ginsenoside-yielding purple pigmented callus line of P. quinquefolium that can synthesize and accumulate ginsenosides (both in content and quality) that are produced in field grown roots of this plant species. To the best of our knowledge this is the first line of its kind and has all the attributes necessary for the commercial scaling and utilization.
The following tables, i.e., Tables 1 to 4, provide comparisons of biomass yield and production of different ginsenosides, stability of the selected line, effect of culture duration at the time of harvest on quantitative and qualitative spectrum of ginsenosides in the wild and selected callus lines of P. quinquefolium , and comparison of the efficacy of different carbohydrate energy sources (supplemented in callus maintenance medium) on biomass yield and crude ginsenoside content of wild and selected callus lines of P. quinquefolium , respectively.
TABLE 1
Comparison of change in biomass yield and production of different
ginsenosides as a function of culture age in wild and
selected callus lines of P. quinquefolium *
Days
Crude
Ginsenoside
after
ginsenoside
fractions
Inocu-
Callus
Growth
Content (%
Rh
Rg
Ro
Rb:Rg
lation
Line
Index
f. wt)
group
group
group
Group
5
W
23.5**
0.10
35.43
38.00
2.40
0.93
S
22.3
0.32
41.23
29.98
1.89
1.37
15
W
11.9
0.39
3.91
22.84
1.37
0.04
S
24.1
0.46
17.03
7.83
1.26
0.61
25
W
32.2
0.56
56.64
51.18
4.50
1.11
S
175.9
0.80
38.20
38.29
3.21
0.99
35
W
40.8
0.26
2.94
45.41
8.60
0.07
S
216.2
0.97
44.92
39.42
3.82
1.14
45
W
30.2
0.29
7.15
40.87
tr
0.18
S
232.7
1.21
53.82
43.47
4.60
1.24
*Inoculum size = 25% (10 g/40 ml medium)
**Each value represents the mean of three analysis done at 6, 12 and 18 months of total culture age (4 replicates/analysis)
W Wild line
S Selected line
tr Trace amounts.
TABLE 2
Stability of the selected line in terms of growth index, crude
ginsenoside content and ratio of Rb and Rg ginsenoside over a
period of three years.
Crude
ginseno-
Ginsenoside quality (% of
Total culture
side
crude Ginsenoside)
age (months) /
Growth
Content
Rb
Rg
Rb
time of harvest
Index*
(% f. wt.)
Group
group
Group:
8
280.20**
1.18
58.82
43.47
1.24
(December, 95)
14
210.80***
1.23
31.13
45.65
1.12
(June, 96)
20
290.60
1.14
50.04
39.09
1.28
(December, 96)
26
239.68
1.22
49.21
37.85
1.30
(June, 97)
32
292.09
1.09
9.08
40.90
1.20
(December, 97)
38
248.58
1.27
52.23
40.48
1.29
(June, 98)
*Panax callus cultures show slightly faster growth in winter months than in summer
**Data were collected after 45-50 days of growth in the respective passage.
***All data represent mean of 4 pooled replicates of 6 cultures each
TABLE 3
Effect of culture duration at the time of harvest on quantitative and
qualitative spectrum of ginsenosides in the wild and selected callus
lines of P. quinquefolium *
Culture
Crude
Ginsenoside Fractions (month)***
Duration
Callus
ginsenoside
(% of the crude)
(months)
Line
(% f. wt.)
Rb1
Rb2
Rc
Rd
Rf
Rg1 + Re
1
W
0.28***
7.02
13.85
tr
tr
0.92
40.41
S
0.82
10.81
35.60
0.87
0.92
40.41
2
W
0.43
7.15
tr
tr
tr
Tr
37.00
S
0.98
18.09
18.36
2.04
43.17
3
W
0.41
Tr
4.46
0.93
0.87
4.21
37.82
S
1.18
3.49
1.18
tr
tr
tr
57.91
4
W
0.56
0.09
tr
tr
tr
Tr
65.45
S
1.38
2.41
1.12
tr
tr
0.98
63.39
5
W
0.36
1.89
7.08
tr
tr
0.24
62.40
S
0.77
3.82
2.02
0.93
tr
2.14
51.21
*Inoculum size = 30% (15 g/50 ml medium)
**Inoculum age = 7-8 weeks after subculture of 14 month old calli
***Each value represent mean of 24 replicates pooled into 3 samples for analysis
W Wild line
S Selected line
tr Trace amounts
TABLE 4
Comparison of the efficacy of different carbohydrate energy sources
(supplemented in callus maintenance medium) on biomass yield and crude
ginsenoside content of wild and selected callus lines of P. quinquefolium *
Culture
age at
Crude
Carbohydrate
Amount
harvest
Callus
Growth
insenoside
Source
used
(days)
line
Index
(% f. wt.)
Sucrose
3% (w/v)
20
W
17.82**
0.48
S
36.13
0.59
40
W
40.71
0.31
S
198.23
0.99
Market grade
3% (w/v)
20
W
34.58
0.62
sugar
S
216.12
0.97
40
W
46.01
0.49
S
272.13
1.19
Molasses after
0.3% (w/v)
20
W
2.16
0.02
Charcoal
S
8.13
0.13
pretreatment
40
W
—
—
S
—
—
Molasses after
0.3% (w/v)
20
S
—
—
EDTA
Pretreatment
W
—
—
The main advantages of the present invention are:
1. The subject callus line in this study is capable of producing ginsenoside (within 30-50 days) in yield and quality comparable to that of 3-5 years old roots of field-grown plants.
2. It has resulted in the generation of a viable alternative source (callus line) for the commercial production of ginsenosides of P. quinquefolium.
3. The invention assumes significance considering the worldwide demand for Panax saponins and the problems associated with Panax cultivation on account of its prolonged seed dormancy and long gestation period from planting to harvest (4-7 years).
4. The cultural procedure and conditions used for this invention are fully defined and reproducible.
5. The invention provides an efficient means for ginsenoside production on large scale, irrespective of geographic locations and climatic conditions.
6. Market grade sugar can be used to replace sucrose in the medium, etc., that would contribute towards the cost reduction of the process.
6
1
10
DNA
Artificial sequence
primer
1
cgcagtactc 10
2
10
DNA
Artificial sequence
primer
2
gtcctactcg 10
3
10
DNA
Artificial sequence
primer
3
ctacacaggc 10
4
10
DNA
Artificial sequence
primer
4
gtccttagcg 10
5
10
DNA
Artificial sequence
primer
5
gtcctcaacg 10
6
10
DNA
Artificial sequence
primer
6
ctactaccgc 10 | The invention provides stable high ginsenoside-yielding callus lines of Panax quinquefolium (American Ginseng). The callus lines are useful in the industrial production of ginsenosides for use in a variety of ginseng preparations. | 2 |
BACKGROUND
1. Field of Invention
This invention relates to muzzle brake devices used on firearms to reduce felt recoil to the shooter.
2. Prior Art
A muzzle brake also called by other names i.e. compensator, recoil reducer is designed to vent and/or redirect recoil producing gases upon the discharge of a firearm to reduce felt recoil to the shooter. Since the muzzle brake receives and redirects the expelling gases from the barrel it must be firmly attached to the barrel. First, if the muzzle brake is not firmly attached the gas pressure at the end of the barrel can eject it from the barrel by shear force. Secondly, it the muzzle brake becomes loose from repeated firing it can also be ejected off the barrel with a bullet strike. For these reasons muzzle brakes are attached either by: (1) threading the barrel and the muzzle brake, (2) the barrel is designed/grooved for accepting a particular muzzle brake i.e. military rifle, (3) the barrel diameter and muzzle brake diameter are equal and thus a perfect fit and secured like a barrel band with set screws. However none of the disclosed patents allow for one single muzzle brake to be used on firearms without threaded barrels, barrels with a front sight, or different diameter barrels (meaning one single muzzle brake will fit on more than one size barrel). The following disclosed patents range from actual muzzle brakes to attachments for firearm accessories.
U.S. Pat. No. 7,032,339 by Bounds, U.S. Pat. No. 6,820,530 by Vais, U.S. Pat. No. 4,436,017 by Mohlin, and U.S. Pat. No. 2,852,983 by Netzer, all illustrate a screw-on type muzzle brake onto a similarly threaded barrel. These inventions met the requirement of rigid attachment to the barrel however one major drawback is that all require a barrel to be threaded. The firearm is permanently altered and if the front sight is too close to the front of the barrel it will need to be removed before the barrel can be threaded. Altering the barrel by threading it alters the value of the firearm. The second drawback is the cost for threading the barrel. Also Mohlin uses a wear ring in the front of the muzzle brake that can be replaced when it becomes worn but is not designed to be used for different calibers or different positions of the projectile passing through the exit hole due to multiple barrel sizes.
U.S. Pat. No. D449,668 by Gangl illustrates a slide-on type muzzle brake. For this design to work the inner portion that houses the barrel must be the same diameter as the barrel for a snug fit. Due to this design one muzzle brake cannot be used on multiple firearms because different firearms have different barrel diameters. Another drawback of this design is that the expelled gases are partially redirected and there is no forward pull of the firearm by gases hitting the end of the muzzle brake. The brake is strictly flow through.
U.S. Pat. No. 3,191,330 by Olson illustrates a bolt-on type firearm accessory attached to the barrel of a firearm. The design however is for a vibration damper. The side clamp as designed could not withstand the force of muzzle blast if it were used to attach a muzzle brake.
U.S. Pat. No. 2,073,755 by Poate illustrates a bolt-on type firearm accessory attached to the barrel of a firearm. The design however is for an attachment to a tripod or carriage. The side clamp is semi-cylindrical on each inside portion of the clamp and because of this shape the clamp is then restricted to one barrel size only.
U.S. Pat. No. 1,390,658 by Towson illustrates a slide-on type muzzle brake. The design allows for the muzzle brake to slide onto the barrel and hook the front sight which holds the device onto the barrel. The drawback is that the muzzle brake must fit the barrel with close tolerance including the front sight. In other words the device must be designed specifically for each barrel with a front sight for diameter and front sight location and size. Secondly on barrels without a front sight this design will not work.
One muzzle brake on the market (www.brownells.com—“adjustable muzzle brake”) is a slip-on type but it cannot be used on firearms that have a front sight within 1″ of the muzzle. Also each muzzle brake will fit only one barrel size meaning that over 20 different sizes are built to fit a group of firearms.
DRAWINGS
Figures
FIG. 1 shows a side orthographic view of the device.
FIG. 2 shows an upright orthographic view of the device.
FIG. 3 shows an orthographic view of the muzzle brake end of the device with a detachable orifice as another embodiment.
FIG. 4 shows an orthographic view with hidden lines of FIG. 3 .
DRAWINGS - Reference Numerals
1
bolt
2
upper clamp assembly
2a
upper clamp
2b
upper clamp
2c
upper clamp
2d
upper clamp
5
lower clamp assembly
5a
base
5b
bolt receptor
5c
bolt receptor
6
muzzle brake tube
7
muzzle brake tube entry aperture
8
muzzle brake tube exit aperture
9
muzzle brake tube orifice
10
orifice bolt
11
cushion plate
12
firearm barrel
DETAILED DESCRIPTION
FIG. 1 - 3 —Preferred Embodiment
One embodiment of the device is illustrated in FIG. 1 (side orthographic view), and FIG. 2 (upright orthographic view). The device has a muzzle brake tube 6 which is open on both ends comprised of a rigid material like steel, etc. and shown shaped as a square tube but the shape could also be rectangular or round. Approximately centered along the horizontal axis of tube 6 are two oblong shaped holes at opposite ends of each other and perpendicular to the open ends of tube 6 . One of the two holes is the muzzle brake tube entry aperture 7 and the other hole is the muzzle brake tube exit aperture 8 . The oblong shape of both aperture 7 and aperture 8 is oblong along the vertical axis in FIG. 1 .
Rigidly attached to muzzle brake tube 6 at the point of muzzle brake tube entry aperture 7 is the lower clamp assembly 5 shown in FIGS. 1-2 . Tube 6 is attached to assembly 5 such that muzzle brake tube entry aperture 7 , aperture 8 and assembly 5 are aligned along the longitudinal axis of assembly 5 . Assembly 5 can be a single milled piece or 3 separate pieces welded together consisting of a base 5 a of rigid angled material such as steel, etc. and two bolt receptors 5 b and 5 c of rigid material such as steel, etc. parallel and rigidly attached. Both bolt receptors 5 b and 5 c have threaded holes. The base 5 a can be an angled piece of equal thickness material as shown in FIGS. 1-2 or a milled piece of square or rectangular stock with the angle cut on the inside portion that will contact barrel 12 . Base 5 a is lined with a soft protective material such as rubber, etc. to serve as a barrier between base 5 a and barrel 12 .
Above barrel 12 in FIG. 1 is cushion plate 11 consists of a rigid material with a liner identical to the liner on base 5 a . The length of plate 11 is commensurate with the clamping action of assembly 5 and the width is commensurate with the width of assembly 5 as shown if FIGS. 1-2 .
Above cushion plate 11 in FIG. 1 is upper clamp assembly 2 consisting of a rigid material with unthreaded holes that line up with lower clamp assembly 5 . Upper clamp assembly 2 is made of upper clamps 2 a - 2 d . Assembly 2 can be made of one solid piece rather than a series of clamps. Through each hole in upper clamp assembly 2 a bolt 1 is threadable into lower clamp assembly 5 .
Operation— FIGS. 1-2
The upper clamp assembly 2 and each corresponding bolt 1 are removed from lower clamp assembly 5 prior to assembly to a firearm. Be sure that base 5 a and cushion plate 11 liners are intact and if not they should be replaced before continuing assembly.
As shown in FIG. 1 place barrel 12 into base 5 a and slide it up to muzzle brake tube entry aperture 7 . Next put cushion plate 11 with the liner facing barrel 12 and line up holes with the rear holes of assembly 5 . Insert a bolt 1 through each hole in upper clamp assembly 2 , through the two holes of cushion plate 11 , and thread each bolt 1 into assembly 5 .
Arrange barrel 12 so that it is horizontal with muzzle brake tube 6 before tightening each bolt 1 and after alignment is made then tighten bolt 1 in each clamp securely. Depending on the model of firearm barrel 12 may have a front sight that extends into the area of assembly 2 and this is not a problem but rather an aid in securing the device to barrel 12 . Since assembly 2 is a series of upper clamps 2 a - 2 d the difference in height of a front sight is independently accommodated with each clamp. The front sight will act as a wedge anchor for the muzzle brake once tightened.
The wedge shape of base 2 a allows for perfect centering of firearm barrel 12 regardless of diameter. The shape of base 5 a being “V” shaped is particularly important because the shape aligns the barrel along the longitudinal axis of the muzzle brake regardless of diameter or taper. The oblong shapes of muzzle brake tube entry aperture 7 and muzzle brake tube exit aperture 8 accommodate different caliber bullets and different size barrel 12 avoiding bullet strike. The oblong shape of aperture hole 8 and aperture hole 9 are particularly important because the shape allows easy projectile clearance with various barrel diameters and tapers. The oblong shape does let some gas escape through however most is caught on the inside wall of the device and in fact the larger the caliber bullet and the higher the pressure of the gas the more efficient the device operates. Before firing double check alignment by looking down the end of the barrel through the device to see that the bullet path will not hit muzzle brake tube 6 .
The side exhaust ports on the muzzle brake tube 6 are sufficiently large to minimize any ambient noise or pressure caused by the device. The recoil reduction and forward pull of a firearm caused by the device during firing is efficient and has been tested on rifles up to and including a .458 Winchester Magnum with full power loads.
Additional Embodiment
FIGS. 3 - 4
FIG. 3 shows an additional embodiment of an isolated view of muzzle brake tube 6 with added components of a muzzle brake tube orifice 9 and orifice bolt 10 . Orifice 9 has a more restrictive exit hole than the muzzle brake tube exit aperture 8 and two threaded holes that line up with two unthreaded holes in tube 6 . Orifice 9 is composed of a less rigid material like aluminum of a size that fits inside of tube 6 and still makes a seal of aperture 8 . Bolt 10 fits into each bolt hole in tube 6 and orifice 9 and is long enough to penetrate both components and does not extend into the open area of tube 6 .
Operation of Additional Embodiment
The assembly of the device on barrel 12 is the same and the only difference is choosing the correct muzzle brake tube orifice 9 that matches barrel 12 size and caliber of the bullet. Orifice 9 opening as installed must be clear of the bullet path and is checked by looking down the end of the barrel through the device for proper alignment. Orifice bolt 10 is then tightened on both sides of orifice 9 until tight.
The reason for using orifice 9 is to further increase efficiency of the device. Orifice 9 is made of a less rigid material because in the event of a bullet strike due to incompetent installation no harm will occur to the shooter or the muzzle brake.
Advantages
From the description above a number of advantages are shown:
(a) The muzzle brake is bolted on the firearm for ease of installation (b) The materials used are common and little if any complicated machining needs to be done depending on method of manufacture. (c) The large tube on the muzzle brake is efficient at reducing felt recoil. (d) The muzzle brake will center the barrel along the longitudinal axis because of the “V” shape of the base where the barrel rests. (e) The muzzle brake allows the projectile to pass through the tube aperture 7 and tube aperture 8 even in barrels of various diameters and tapers because the holes are oblong.
CONCLUSION, RAMIFICATIONS AND SCOPE
The reader will note that the device in its various embodiments does solve the problem of a universal and detachable muzzle brake that does not require alteration of the firearm to accommodate its use and can be used on barrels with different diameters and tapers. The muzzle brake is no less efficient than other muzzle brakes that must be threaded to the barrel or require some special adaptation on the firearm barrel to attach a muzzle brake. In addition the muzzle brake has additional advantages:
(a) Using the bolt-on method of attaching the device to the barrel forgoes the need and cost of threading the barrel of the firearm. (b) Thread-on muzzle brakes require more precision because of barrel size matching with the thread-on muzzle brake but no expertise is required to install the bolt-on muzzle brake. (c) Firearm owners are generally uneasy about altering the barrel to accommodate a thread-on muzzle brake so the simple bolt-on type muzzle brake is preferable. (d) Slip-on type muzzle brakes have the same problem of matching barrel size and cannot be used on different firearms whereby the bolt-on muzzle brake does not have this limitation. (e) Slip-on types cannot be used when the front sight is close to the end of the barrel however, the bolt-on muzzle brake does not have this limitation.
Thus none of the prior art can be considered a multiple barrel, multiple caliber muzzle brake allowing use on a wide range of firearms from a single muzzle brake. Although the description above contains many specificities these should not be considered as limiting the scope of the embodiment but merely as illustrations of the some of the currently preferred embodiments. For example the muzzle brake tube can be rectangular, square, or round; the base of lower clamp assembly can be milled from square stock by simple cutting the notch and drilling the holes, etc.
Thus the scope of the embodiment should be determined by the appended claims or equivalent rather than the above examples. | A bolt-on muzzle brake having an angled base ( 5 ), clamps ( 2 ) to secure it to a firearm barrel ( 12 ), and a tube ( 6 ) at the end of the angled base ( 5 ) that redirects the recoil producing gases. The muzzle brake can be attached to a barrel without threading it on the barrel. The muzzle brake can also be attached to multiple sized barrels, different caliber barrels, and barrels with front sights all with the same muzzle brake. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an obturating device for tubes, flasks, and the like containers, the opening and closing of which are controlled by a rotation of a casing forming an outer face of the obturating device.
Tubes, flasks and the like containers used for conditioning products are conventionally provided with a closing cap which is removed upon using the container.
Obturating devices have however already been made for enabling to use the product contained therein without having to remove the closing cap. The present invention relates to a device of the type which is of a simple manufacturing and is easy to handle.
OBJECT OF THE INVENTION
The object of the invention is to provide an obturating device with a valve-cap and casing, and in which a rotation of the casing by a quarter of circumference enables to close or to open the hole of the container.
SUMMARY OF THE INVENTION
According to the invention, the obturating device for tubes, flasks and the like containers comprises a valve-cap with a plate, said plate having a secondary component protruding at the upper part, blades protruding in the middle of an outlet passage for the liquid in order to maintain the secondary component, said plate downwardly extending into a fitting skirt for a neck of the container, said fitting skirt comprising an outer periphery with two diametrically opposed side notches, said valve-cap being associated with a casing which comprises a plate having a central hole and an outer fitting skirt with two symmetrically opposed orientating inner ramps, said ramps being used as a bearing member for the side notches of the valve-cap, whereby opening and closing of the device are respectively made by rotating the casing.
Several other characteristic features of the invention will become more apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are shown by way of non limiting examples in the accompanying drawings, wherein:
FIG. 1 is a vertical cross-section of the obturating device in an opened position;
FIG. 2 is a vertical cross-section of the obturating device in a closed position;
FIG. 3 is a partial cross-section of the device substantially taken along line III--III of FIG. 1;
FIG. 4 is a partial vertical cross-section view of the casing showng an inner ramp;
FIGS. 5, 6 and 7 shows variants of the obturating device;
FIG. 8 is a vertical cross-section of a variant of embodiment of the obturating device in an opened position, the inner valve-cap being fixed to a neck of the flask;
FIG. 9 shows the obturating device of FIG. 8 in a closed position;
FIG. 10 is a vertical cross-section showing in a closed position the obturating device placed upside-down and comprising a dosing means;
FIG. 11 shows the same device as that of FIG. 10 in an opened position;
FIG. 12 shows two half cross-sections of the obturating device in a particular application;
FIGS. 13-15 are partial perspective views showing means for controlling a fluid output in various particular positions;
FIG. 16 shows two vertical half cross-sections of the obturating device of the preceding figures provided with complementary means.
DETAILED DESCRIPTION OF THE INVENTION
The obturating device according to the invention is formed of two parts: a valve-cap 1 is mounted on a neck 22 of a flask 15 and a casing 9 covers the valve-cap 1 and the neck 22.
The valve-cap 1 comprises a cylindrical plate 4 over-topped with a plug 5. The plug 5 is maintained by radial blades 6 in the middle of an outlet passage 11 provided in the casing 9 for a fluid contained in the flask 5. The plate 4 downwardly extends into a fitting skirt 4a having, on its outer periphery two diametrically opposed side notches 2 and 3. The casing 9 has a central hole 11 which is opened or closed according to whether the plug 5 of the valve-cap 1 obturates the central hole 11 or not.
The casing 9 extended into an outer fitting skirt 12 in the inner wall of which are formed opening ramps 16 and 21 in which can slide the above mentioned diametrically side opposed notches 2 and 3 of the valve-cap 1.
On the other hand, the casing 9 is provided with an inner tightness skirt 10 which is applied against a tightness skirt 8 of the valve-cap 1. The valve-cap 1 has itself a second tightness skirt 7 which is applied against the inner edge of the neck 22 of the flask 15.
As shown in the drawings, while the tightness skirt 3 of the valve cap 1 is cylindrical in shape, the inner tightness skirt 10 of the caasing is slightly downwardly tapered and is therefore substantially in the extension of the tightness skirt 8 of the valve cap. Samely the second tightness skirt 7 is also slightly downwardly tapered so as to be substantially in the extension of the cylindrical shaped neck 22 of the flask 15. Such cooperation of a cylindrical and a tapered parts improves tightness between the parts and furthermore enables an easier and better flow of the product along these parts.
In the embodiment of FIGS. 1, 2, 5, 6 and 7, the casing 9 is positioned in height on the neck 22 of the flask 15 by means of a horizontal plain ring 13 which can rotate in a groove 14 which is also horizontal and provided in the neck 22.
In the present embodiment, the valve-cap 1 raises or falls to respectively open or close the hole 11 of the casing by means of its opposed notches 2 and 3 bearingly rotating on the opposed ramps 16 and 21 when the casing is rotated.
According to FIG. 4, the notch 2 of the valve-cap 1 is introduced in the ramp 16 of the casing 9 through a vertical passage.
FIG. 5 shows, in an opening position, an obturating device in which the casing 9 has an upper plate 23 which is a cup-shaped at 23a, instead of being bulged as in FIGS. 1 and 2.
In the embodiment of FIG. 6, the obturating device shown in an opened position, is provided with a casing 9 having a flat upper plate 23 with a protruding pierced end part 24.
In FIG. 7, the outlet portion of the obturating device has a long tapered shape as shown at 25.
In the variant of embodiment of FIGS. 8 and 9, the valve-cap 1 is fixed on the neck 22 of the flask 15 by means of an horizontal plane ring 18 inserted in a groove 17 formed in the neck 22. The opposed notches 2 and 3 of the valve-cap 1 slide in opposed ramps 19 and 20 of the casing 9. By a rotation of the casing 9, the casing 9 raises or falls with respect to the fixed valve-cap 1, in order to open (FIG. 8) or close (FIG. 9) the hole 11 provided in the casing 9.
In a preferred embodiment of the invention, closing and opening of the obturating device are made by a rotation of a quarter of a circumference of the casing 9 by suitably designing the opposed and cooperating notches and ramps provided respectively in the valve-cap and in the casing.
In FIGS. 10 and 11, a rotation of the casing 9 by a quarter of circumference causes the inner valve-cap 1 to raise and to fall, respectively: When the valve-cap 1 raises, it opens the hole 11 of the casing, and when the valve-cap 1 falls, it closes the hole 11.
The obturating device also comprises a dosing means which comprises, besides the casing 9 and the valve-cap 1 as hereinabove described, a foot-valve 26 and an air intake tube 126. In this case, and as shown, the obturating device must be used up-side-down.
The radial blades 6 of the valve-cap 1 are extended and support a collar 29 forming a plain ring 29a. The plain ring 29a when it is mounted, is engaged in an upper groove 26a of the foot-valve 26 which is itself provided on its outer periphery with a flexible bearing member 27 and a central skirt 28 surrounding the air intake tube 126.
The flexible bearing member 27 of the valve-cap 1 is applied, in a closed position of the obturating device, against an inner protrusion or seat 15a of the neck of the tube or flask 15 (see FIG. 11). In an open position, a communication is made betwee the inside of the tube or flask 15 and the head of the valve-cap 1 (see FIG. 10).
For assembling together the parts of the obturating device of FIGS. 10-11, the foot-valve 26 is engaged on the collar 29 of the valve-cap 1 by means of the groove 26a of the foot-valve 26 engaged on the plain-ring 29a of the collar 29.
The air intake tube 126 is forced in the central skirt 28 of the foot-valve 26. The whole unit placed in the casing 9 is engaged on the flask 15.
The dosing means being fixed with the obturating device works together with the obturating device.
The flask being placed up-side-down as shown in FIG. 10, the product contained in the flask goes down within the valve-cap 1. Then by rotating the casing 9 in the opening direction of FIG. 11, the outlet hole 11 for the product is opened together while closing the foot-valve 26 which confines a dose of the product within the valve-cap 1. By a pressure movement exerted by the user on the flask which is then flexible, or by mere gravity, this dose is ejected.
By turning the casing 9 in the closing direction of FIG. 10, the outlet hole 11 for the product is closed and the foot-valve 26 is opened to form a new dose within the valve-cap 1.
The extruded and thin walled air intake tube 126 has two main functions:
upon forming the dose within the valve-cap 1, the tube 126 enables air confined in the valve-cap 1 to raise up to the bottom of the flask, the flask being maintained up-side-down.
in relation with a pressure exerted by the user on the flask or by mere gravity the tube 126 will channel air from the bottom of the flask to the valve-cap 1 for ejecting the dose.
In FIG. 12, and as in the preceding embodiments, the device comprises a valve-cap 1 mounted on a neck 22 of a flask 15 and a rotating casing 9 covering the valve-cap 1 and the neck 22. The valve-cap 1 forms an annular top portion 4 from which are formed the blades or cross-members 6 protruding in the outlet passage of the liquid contained in the flask 15. Outerly, the valve-cap 1 is downwardly extended in a fitting skirt 4a having an outer periphery provided with diametrically opposed side notches 2, 3.
The casing 9 has a central hole 11, and forms an outer fitting skirt 12 with an inner wall having ramps in which can slide the diametrically opposed side notches 2, 3 of the valve-cap 1.
The casing 9 also forms an inner tightness skirt 10 which is applied against a tightness skirt 8 of the valve-cap 1 and from the bottom of which are extended the blades or cross-members 6.
The valve-cap 1 innerly forms grooves 30 engaged with ribs 31 externally formed on a supplemental port forming a sleeve 32. The sleeve 32 forms at its bottom portion two collars 33, 34 encasing an annular protrusion 35 of the flask 15. In order to prevent a rotation of the sleeve 32 with respect to the flask 15, grooves and ribs 36, 37 are advantageously provided. Moreover, a pad 38 of the flask enters a groove 39 of the collar 34 for axially locking the sleeve 32.
The collar 33 is outerly provided with a groove 40 for the horizontal plain ring 13 of the casing 9 which can therefore be rotated without sliding. In this manner, the valve-cap 1 raises or falls when the casing is rotated by moving the opposed notches 2 and 3 in the ramps provided in the fitting skirt 12 of the casing 9.
When not in use, and as shown in the left-hand side of FIG. 12, the flask 15 is closed by a membrane-shaped lid 43, made for example in aluminium or in plastics material, for perfectly isolating the product contained in the flask 15.
Some at least of the radial blades 6 form, at their lower part, a cutting edge 41 and carry, at their upper part, a plug 42 for closing the central hole 11 in a quite similar manner as in the preceding embodiments.
When is desired to use the product contained in the flask 15, it suffices to rotate the casing 9 in the direction for which the ramps of the skirt 12 act on the notches 2, 3 to make the valve-cap 1 to go down, with the valve-cap 1 being axially guided by the grooves 30 and ribs 31. The going-down movement of the valve-cap 1 causes a going-down movement of the blades or cross-members 6 so that the cutting edges 41 will cut the lid 43 and camber the lid 43 as this is shown at 43a on the right hand side of FIG. 12. Simultaneously, the plug 42 is lowered so that the hole 11 is freed to enable the product contained in the flask 15 to be outwardly directed by following the tightness skirts 8 and 10. The flask 15 can then be closed by means of the obturation device by rotating the casing 9 in an opposed direction.
It is also possible that the blades or crossmembers 6 suppport other secondary components than the plug 42 of the various embodiments and cutting edges 41. The plug 42 could, for example, be substituted by a small stick or brush, the cutting edges 41 being either maintained or not.
FIGS. 13-15 show that the skirt 12 of the casing 9 of anyone of the preceding embodiments have marking elements formed by a protruding rod 44, a notch 45 of a small width and a notch 46 of a greater width. Besides, the flask 15 has a mark 47 shown by an arrow.
By making the protruding rod 44 to coincide with the mark 47 of the flask 15, the casing 9 is placed for ensuring a proper closing of the flask 15 by cooperating with the plug 42 of the obturating device, as for example illustrated by the plug 42 as shown on the right hand side of FIG. 12.
Making the smaller width notch 45 to coincide with the mark 47, corresponds to a position for which the valve-cap 1 is only slightly moved and, consequently, the output of liquid is small between the plug and the mouth of the casing 9.
Finally, making the greater width notch 46 to coincide with the mark 47, corresponds to the position of full-output of the liquid illustrated for example on the right hand side of FIG. 12.
Other intermediary positions can be provided without departing from the scope of the invention.
Samely, one or a plurality of centering studs 48 (FIG. 12) can be provided on the flask 15 to correspond to recesses 48a of the casing 9 in order to form hard points corresponding to positions of the notches 45 and 46.
According to FIG. 16, the top portion 23 of the plate 4 of the valve-cap 1 is provided with fins 49, 50 which are preferably aligned vertically with the notches 2, 3. The fins 49, 50 are chosen of a sufficient thickness to resist to lateral thrusts without deformation.
The bottom portion of the casing 9 comprises a flexible pawl 51 suitably placed with respect to the upper end of one of the ramps 16, 21 in which are placed the notches 2, 3.
When the casing 9 is in a closing position (screwing direction), the flexible pawl 51 is placed behind one of the fins 49 or 50, which locks the casing 9 with respect to the valve-cap 1; such a locking action being sufficient for preventing a rotation of the casing 9 under effect of vibrations caused for example by transportation of the flask 15. Flexibility of the pawl 51 is however sufficient for being temporarily distorted, which enables the pawl 51 to overpass the abutment formed by one of the fins 49, 50 during the movements (unscrewing direction) made for opening the flask 15. The two above described locking and unlocking positions are shown on the right part and the left part, respectively of FIG. 16. | The obturating device for tubes, flasks and the like containers of fluids, comprises a valve-cap with a plate, said plate having an upper part with a secondary component protruding at said upper part, blades protruding in middle of an outlet passage for the fluid in order to maintain the secondary component, said plate downwardly extending into a fitting skirt for a neck of the container. The fitting skirt comprises an outer periphery with two diametrically opposed notches with said valve-cap being associated with a casing which comprises a plate having a central hole and an outer fitting skirt with two symmetrically opposed orientating inner ramps. The ramps are used as a bearing member for the notches of the valve-cap. | 1 |
BACKGROUND
This relates generally to data centers.
Data centers are centers where a number of servers reside to implement data processing. For example, a number of servers may be provided to send and receive information to support various websites and other data intensive operations.
Power management has become an increasingly active research area for modern computing systems. While most of this interest focuses on mobile platforms, more recently it has become clear that power management is also of critical importance in enterprise environments. Trends towards consolidation and higher density, enabled by virtualization in new small form factor server blades, and the traditional drive for higher performance have led to increased power and cooling requirements in data centers. These characteristics elevate ownership costs and put more pressure on rack and enclosure densities, demanding new approaches to data center management that can enable more power efficient execution of enterprise workloads.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic depiction of one embodiment of the present invention; and
FIG. 2 is a flow diagram showing one implementation of a component-based attribute prediction in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
Data centers commonly exhibit platform heterogeneity. This heterogeneity stems from the architectural and management capability variations of the underlying platforms in a data center. This heterogeneity may arise from a number of sources, but may simply be the result of the fact that, over time, progressively advanced platforms may be acquired with increasingly improved power conservation and other characteristics. Thus, one heterogeneity that exists is due to the fact that the data center may include a large number of platforms that were purchased at different times with different capabilities and different technology levels.
In accordance with one embodiment, an allocator efficiently allocates workloads to the best fitting platforms to improve the power efficiency of the whole data center. The allocation may be performed by employing analytical prediction layers that can accurately predict workload power/performance across platform architectures and power management capabilities.
Modern data centers incorporate a variety of platforms with different power/performance tradeoffs. This is due to the incremental replacement and growth cycles, typical of data centers. The platforms in data centers not only vary in terms of their performance and power profile, but they also provide different degrees of power management capabilities. While some systems, especially older generation platforms, only provide rudimentary power management features, such as system sleep states or processor performance states, newer platforms include a richer set of power management functionality, including memory power and thermal control, enhanced processor power management, and aggressive idle states.
In addition, as data centers environments embrace and deploy virtualization solutions, enterprise workloads become significantly more diverse and heterogeneous too, placing a wide range of requirements on the underlying infrastructure. Taking advantage of this heterogeneity and platform power management capability at the data center level enables increased energy efficiency in the enterprise.
Workload to resource allocation is currently primarily focused on balancing the demand across the resources. These existing methods base their decisions on utilization information or stripe workloads across resources in a round robin fashion. However, energy efficiency of the whole data center may be improved by allocating the heterogeneous resources based on their power/performance tradeoffs. By matching workload requirements and execution behavior to the underlying power characteristics of physical resources and their power management capabilities, significant improvements in data center energy efficiency may be achieved.
This power-aware allocation policy is composed of a performance estimation layer that guides an allocation layer. The performance estimation layer uses derived workload and platform descriptors to predict workload behavior on different platforms of the data center. As used herein, “workload” is any task or group of tasks to be handled by a platform. Then, the allocator feeds these estimates into its allocation policies and determines the most energy efficient platform for the given workload and performance level. In this way, the workloads are deployed into different platforms under devised energy efficiency criteria.
Referring to FIG. 1 , a plurality of platforms 12 may be scheduled to handle a number of workloads W 1 -Wn. A control or allocator 14 may include a plurality of components. The control may be implemented in hardware or software and may be part of one or more platforms 12 or may be a dedicated unit. The workload profile 18 is based on information about the platforms 12 and about the workloads W 1 -Wn. The workload profile 18 is developed by having platforms specify their power consumption characteristics. As used herein, power consumption characteristics encompass rated power consumption, types of thermal management solutions, such as fans, coolers, and heat sinks, environmental conditions, such as local platform ambient temperature, and power management capabilities and features. At the same time, workloads may provide their execution characteristics through online or offline profiling on a subset of platforms.
The workload profile is then used to develop resource descriptors 20 and workload descriptors 22 . Partial resource and workload descriptors are constructed through online or offline profiling. The descriptors provide power performance characteristics for a subset of workload and physical resources. Next, a performance estimation 24 is undertaken. It may use blocking factor (BF) or regression analyses. Specifically statistical or analytical models are used to predict workload power/performance characteristics across all platforms. The prediction is derived from partial resource and workload descriptors, generated through online or offline profiling. The use of either analytical, such as best fit, or statistical, such as regression, approaches may depend on the usage model.
The performance estimation is used to derive the allocation policy 26 . The allocation policy matches workload and resource characteristics provided by descriptors to increase power efficiency of the underlying hardware platforms. As a result, the workloads W 1 -Wn are matched to specific platforms 12 .
Performing intelligent mappings between applications and underlying platforms for execution may involve a variety of information. The platform descriptors may be made up of component declarations and component parameters. For example, the processor component on a server may be declared and described with parameters such as architecture family and frequency. Similarly, workload descriptors may consist of attribute declarations and component-based attribute values. In particular, attribute values, defined in these descriptors, may be associated with component metadata outlining the type of component to which they apply. For example, a workload descriptor may declare cache misses per instruction (MPI) as an attribute. The value of this attribute depends upon the parameters of the memory component assumed, such as the size of the cache. Therefore, any definitions of this attribute are associated with: (1) a component type which correlates to a declaration in a platform descriptor and (2) a list of component parameters that restrict where this value should be applied. If the parameter list is empty, the attribute value can be applied to all platforms. This approach allows an attribute to be defined multiple times, with varying degrees of applicability to a particular component instantiation for a platform.
Given the use of descriptors as an input to the allocation scheme, the issue arises as to where the information is obtained. Platform component parameters may be obtained via basic input/output system mechanisms in the platform, currently used by traditional management systems to obtain hardware information. Workload descriptor attribute values are more complicated since they vary across systems. One approach is to make values available via workload profiling across all types of platforms. This approach may be viable for data centers where the applications are known a priori and there is a limited amount of heterogeneity. On the other hand, for service oriented data centers, where workloads may be submitted at runtime, the descriptor attribute values may be determined online. For scalability, in many data center environments that may involve measuring attribute values on a small set of platforms and then predicting the remaining values.
The attribute values may be defined conditioned upon component descriptions. This allows efficient estimation of attribute values when necessary by profiling workloads on a subset of systems wherein the global heterogeneity can be captured in the component permutations of the smaller set. This approach may be termed “component-based attribute prediction.” As an example, performance of a central processing unit bound workload can be represented as a function of its central processing unit and memory behavior:
CPI=CPI core +MPI *Latency* BF
Where CPI is cycles per instruction, MPI is memory accesses per instruction, latency is memory access latency, and BF is processor blocking factor. The first part of this equation reflects micro-architecture execution characteristics, while the second part of the equation represents performance of a memory subsystem. This type of performance characterization can be used for cross-platform performance prediction. In other words, if workload performance is available for all the components in the platform, its performance can be accurately predicted as a combination of component level performance parameters, even though the workload has not been profiled on the platform.
FIG. 2 provides an example in which a workload is profiled on two systems, S and D, each with a processor (CPU) and memory (MEM) having CPI values that have different processor and memory architectures. Component attributes obtained in this profiling are then used to predict workload performance on two other systems, W and I, where W has processor architecture similar to that of system S and the memory architecture is similar to that of system D. I has a processor architecture from system D and a memory architecture from system S.
Once workload and resource descriptors are obtained, the allocation policy distributes the workload to reduce the overall power consumption, while meeting performance requirements of each workload.
References throughout this specification to “one embodiment” or “an embodiment” mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one implementation encompassed within the present invention. Thus, appearances of the phrase “one embodiment” or “in an embodiment” are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be instituted in other suitable forms other than the particular embodiment illustrated and all such forms may be encompassed within the claims of the present application.
While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention. | A data center may be operated to achieve reduced power consumption by matching workloads to specific platforms. Attributes of the platforms may be compiled and those attributes may be used to allocate workloads to specific platforms. The attributes may include performance attributes, as well as power consumption attributes. | 8 |
[0001] This application claims priority from U.S. Provisional Application Serial No. 60/182,040, which is incorporated in its entirety herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to an access opening closure device for allowing articles to pass through an otherwise impervious wall. More specifically, the present disclosure relates to an access opening closure device for use in prisons and hospital psychiatric wards which allows an article to be passed through a cell or hospital room door without exposing a guard or hospital attendant to possible injury or battery by the prisoner or patient.
[0004] 2. Background of Related Art
[0005] Prison cell and hospital room doors for confining dangerous inmates or patients which are fitted with an access opening to allow passage of food or medication without the necessity of opening the locked door are well known. The access opening may also be used to handcuff an inmate before unlocking the door. Typically, the access opening is small in relation to the door and is covered by a portal which may be closed to close the access opening. One problem associated with the above-described access opening/portal arrangement is that once the portal is opened, the confined inmate or patient has direct access to the area outside the confined space. Due to the violent nature of some confined inmates and/or patients, prison guards and hospital attendants are exposed to possible danger from the confined inmate or patient when direct access is available.
[0006] Accordingly, what is needed is an access opening closure device of simple construction which can be used in association with existing doors having access openings and is operable to allow passage of articles through the access opening without allowing an inmate or patient direct access from the confined space to the area outside of the confined space.
SUMMARY
[0007] An access opening closure device is provided for use in prisons, hospital psychiatric wards and the like is disclosed. The closure device includes a housing defining a receptacle, an access door and a top cover. The top cover is preferably formed from a transparent material and is movably supported on the housing to open or close a top opening in the housing. The access door is preferably formed from stainless steel and is movably supported on the housing to open or close a rear opening in the housing. A bracket assembly is secured to the housing about the rear opening. The bracket assembly is adapted to secure the housing about an access opening in a door, e.g., a prison cell door. The device also includes three locks. A first lock is positioned to retain the top cover in a closed position. A second lock is positioned to retain the access door in its closed position and a third lock is positioned to retain the access door in its open position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Various preferred embodiments of the access opening closure device are described herein with reference to the drawings, wherein:
[0009] [0009]FIG. 1 is a perspective view of one embodiment of the presently disclosed access opening closure device;
[0010] [0010]FIG. 2 is a perspective view of the access opening closure device shown in FIG. 1 with the top cover in its open position and its access door in its closed position;
[0011] [0011]FIG. 3 is a partial cross-sectional view taken along section lines 3 - 3 of FIG. 1;
[0012] [0012]FIG. 4 is a perspective view of the access opening closure device shown in FIG. 1 with the top cover in a closed position and the access door in an open position;
[0013] [0013]FIG. 5 is a partial cutaway view taken along section lines 5 - 5 of FIG. 4;
[0014] [0014]FIG. 6 is a perspective view of another embodiment of the present disclosed access opening closure device; and
[0015] [0015]FIG. 7 illustrates a partial cutaway, cross-sectional view of an alternate embodiment of access door 14 and lock 44 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0016] Preferred embodiments of the presently disclosed access opening closure device will now be described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views.
[0017] [0017]FIGS. 1 and 2, illustrate an access opening closure device, shown generally as 10 . Briefly, closure device 10 includes a housing 12 , an access door 14 and a top cover 16 . Housing 12 has a bottom wall 18 , a pair of side walls 20 and 22 and a front wall 24 which defines a receptacle 25 for receiving food, medication or the like. A plurality of drain holes 29 (FIG. 2) are formed through the bottom wall 18 to allow fluid to drain therefrom. Side walls 20 and 22 have a height that increases from front end 26 to rear end 28 of housing 12 . Alternately, the side walls can be rectangular. In extreme cases, when a prisoner or patient must be subdued before the guard enters the cell, the reduced height of front end 26 compared to rear end 28 of housing 12 enables the guard to spray a subduing agent, such as pepper spray or mace, directly into the cell. Preferably, housing 12 is constructed from stainless steel, although other materials having the requisite strength requirements can also be used.
[0018] Referring also to FIG. 3, top cover 16 is pivotably attached to the top of front wall 24 via hinge assembly 29 . Preferably, hinge assembly 29 is fastened to cover 16 and front wall 24 by screws 27 . However, other fastening techniques may also be used including adhesives, welding, etc. Top cover 16 is pivotable from a first closed position enclosing housing 12 to a second open position uncovering housing 12 . Preferably, cover 16 is constructed from a durable, transparent material such as Lexa® which permits viewing of the contents of receptacle 25 when top cover 16 is in the closed position. Alternately, other materials having the requisite strength requirements can also be used including stainless steel, aluminum or fire safe material having the requisite strength requirements.
[0019] A series of brackets including a top bracket 30 , a side bracket 32 and a bottom bracket 34 are secured to the rear end of housing 12 by welding. Alternately, the series of brackets can be secured to housing 12 using other known fastening procedures. Each of the brackets includes a smooth concavity 33 for slidably receiving access door 14 . The concavities formed in top and bottom brackets 30 and 34 define a guide track along which door i 4 may be slid between open and closed positions. As illustrated in FIGS. 1 and 2, the guide track is formed in top and bottom brackets 30 and 32 at a position adjacent the back side 31 of the brackets which is to be positioned against the prison cell or hospital room door 35 . By forming the guide track in this manner, access door 14 can be positioned close to door 35 while retaining the required thickness for strength. Side bracket 32 also includes a concavity (not shown) into which the forward end 36 of door 14 is positioned when door 14 is closed. Each of the brackets also includes a series of holes dimensioned to receive screws. The screws facilitate securement of the housing about an access port in door 35 .
[0020] Access door 14 is slidably positioned along the guide track formed between top and bottom brackets 30 and 34 . Door 14 includes a handle 40 to facilitate opening and closing of the door. Preferably, the top and bottom edges 37 and 38 of door 14 are radiused to permit door 14 to slide freely along the guide track. Door 14 is movable from a closed to an open position to permit access into housing 12 from within the confined space. A stop 41 (FIG. 2) is fastened to one side of access door 14 . Stop 41 is positioned to engage side wall 22 when access door 14 is in the open position to prevent door 14 from sliding out of the guide track. Preferably, sliding door 14 is constructed from stainless steel. However, other materials having the requisite strength requirements may also be used.
[0021] A pair of locks 42 and 44 are secured adjacent to access door 14 . Preferably, locks 42 and 44 are secured to top bracket 30 via screws. Alternately, locks 42 and 44 can be secured to door 35 and/or other fastening techniques may be used to secure the locks in place. Referring to FIG. 4, each lock includes a spring biased projection 54 and 55 which is urged downwardly towards the bottom frame. A catch 56 is secured to access door 14 and is positioned to engage projection 54 of lock 42 . When projection 54 is positioned within catch 56 , access door 14 is locked in a closed position. Projection 54 of lock 42 can be lifted from catch 56 by rotating key 58 .
[0022] Lock 44 is positioned above top edge 37 of access door 14 . A pair of recesses 48 and 50 formed in top edge 37 are positioned to receive projection 55 of lock 44 . When projection 55 is biased into recess 48 , access door 14 is locked in an open position. When projection 55 is biased into recess 50 , access door 14 is locked in a half-open position. The combination of locks 42 and 44 prevents access door 14 from being slammed between its open and closed positions.
[0023] A lock 66 is also provided on top cover 16 . Lock 66 includes a spring biased projection 68 which is receivable in a catch 20 to lock top cover 16 in the closed position. Catch 70 can be secured to top bracket 30 . Alternately, catch 70 can be secured to other support structures, such as door 35 .
[0024] In use, access opening closure device 10 is secured about an access opening in a door 35 , e.g., a prison cell door. In the closed position, access door 14 and top cover 16 are closed (FIG. 1). When it is desired to provide the confined person with some item, such as a lunch tray 60 , cover 16 is pivoted to open the top of housing 12 . To pivot cover 16 , lock 66 must be manually released. Lunch tray 60 is placed in receptacle 25 of housing 12 (FIG. 2). The access door 14 is closed. Next, sliding door 14 is slid open by manually rotating key 58 and pulling handle 40 (FIG. 4). It is noted that in order to slide access door 14 to the fully open position, projection 55 of lock 44 must be manually lifted over recess 50 . The confined person now has access to the interior of housing 12 but the interior of housing 12 is enclosed with respect to the passageway in front of cell door 35 . Thus, persons in the passageway are protected from any debris the confined person may attempt to throw through the access opening. With sliding door 14 in the open position and cover 16 in the closed position, the lunch tray or other item can be left in housing 12 for the confined person to retrieve at his or her convenience.
[0025] Access opening closure device 10 may also be used to handcuff a prisoner before releasing the prisoner from the cell. To handcuff a prisoner, access door 14 need only be opened to its halfway point with projection 55 of lock 44 positioned in recess 50 of door 14 . After the prisoner places his hands through the access opening into receptacle 25 , top cover 16 can be pivoted open to facilitate the placing of the handcuffs on the prisoner. It is noted that, with top cover 16 pivoted in front of a prison guard, top cover 16 acts as a shield for the guard.
[0026] Referring to FIG. 5, a slot 62 is formed in side bracket 32 adjacent the concavity formed in bottom bracket 34 . Slot 62 allows any debris positioned on the guide track in concavity 35 , when access door 14 is opened, to be pushed from the end of the guide track. Thus, access door 14 will not be prevented from closing by placing debris on the guide track.
[0027] [0027]FIG. 6 illustrates an alternate embodiment of the access opening closure device shown generally as 100 . Closure device 100 is substantially identical to closure device 10 except that.top cover 116 is slidable between open and closed positions along a track 113 formed about the top of housing 112 .
[0028] [0028]FIG. 7 illustrates a partial cutaway, cross-sectional view of an alternate embodiment of access door 14 and lock 44 . (Note the five photographs attached hereto.) In the alternate embodiment, access door 14 ′ has a top edge 37 ′ having a plurality of teeth 39 ′. Adjacent teeth define recesses 50 ′. Lock 44 ′ includes a housing 100 , a lever 102 pivotably secured to housing 100 by a pivot pin 104 , a reciprocal engagement member 106 , a tubular inner housing 108 and a biasing member 110 . Tubular inner housing 108 is threadably received within a threaded bore 112 formed in top bracket 30 ′. Engagement member 106 includes an annular flange 114 and a tooth engaging distal end 116 . Biasing member 110 is positioned between flange 114 and the upper end of inner housing 108 and functions to urge distal end 116 of engagement member 106 into engagement with teeth 39 ′ of access door 14 ′. Lever 102 is manually pivotable in the direction indicated by arrow “A” in FIG. 7 to lift engagement member 106 from engagement with access door 14 ′. Teeth 39 ′ and lock 44 ′ prevent access door 14 ′ from being repeatedly slammed between open and closed positions. Housing 100 of lock 44 ′ can be secured to top bracket 30 ′ using screws 120 . Alternately, other attachment devices may be used to secure housing 100 to bracket 30 ′, e.g., brazing, welding, etc.
[0029] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, access door 14 need not slide horizontally but rather may slide vertically. Further, the dimensions of the access opening closure device can be varied to accommodate any size access opening. Moreover, the access opening closure device is not limited for use on hospital room and prison cell doors but rather may be used in other areas such as bank teller stations. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. | An access opening closure device is provided for enabling passage of food or medication into a confined spaced without providing direct access from within the confined space to outside of the confined space. The device includes a housing defining a receptacle, an access door and a top cover. The top cover and the access door are independently movable between open and closed positions to provide access to within the receptacle. An engagement member is provided adjacent the access door to selectively look the door at a plurality of different positions. | 4 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/701,077, filed Jul. 21, 2005.
BACKGROUND
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention are related to telecommunications. More particularly, embodiments of the present invention are related to systems and methods for improving IP communications such as Instant Messaging and voice over internet protocols (VoIP). This may include the use of Internet Technology to support legacy networks such as the circuit switched and the cellular/GSM networks.
[0004] 2. Background of the Invention
[0005] Certificates are widely used today in Web servers and e-commerce servers. They are used for authentication, encryption and digital signatures. They have been shown to provide excellent security properties as shown by the wide use of secure web sites and e-commerce sites by both consumers and enterprises. However, widespread certificate usage in smaller Internet hosts such as PCs and laptops has not happened to date, despite the fact that these devices could use these same security services using certificates. The main reasons for this are:
1. Certificates are difficult to acquire, and the enrollment process is time-consuming 2. Certificates issued by commercial Certificate Authorities (CAs) are expensive, often costing hundreds of dollars per year 3. Certificates have been generally associated with hosts (devices) rather then users.
[0009] Attempts to simplify the enrollment and reduce the dependency on CAs have been made. For example, enterprises have acted as their own CA and issued certificates to users. However, these certificates have no validity outside the enterprise and as such have had little use. Schemes to do away with the CA entirely such as Pretty Good Privacy (PGP) where users sign each other's certificates has also been tried but has not achieved widespread adoption.
SUMMARY OF THE INVENTION
[0010] Embodiments of the present invention build on methods developed in the IETF SACRED (Securely Available Credentials) and SIP (Session Initiation Protocol) Working Groups, the efforts of which are well-known. Embodiments utilize self-signed certificates but provides a secure method of storage and retrieval. The system and methodology described in this document introduces a novel Voice Recognition Server which combines with passcodes (usernames and passwords) to provide the highest level of security while overcoming the drawbacks listed earlier. As such, this approach should enable millions of VoIP devices (clients, phones, adapters, gateways, cell phones, WiFi phones, presence and instant messaging clients) to utilize certificates to provide end-to-end secured communications services at low cost. While the system and method are most efficient with SIP [SIP] VoIP endpoints, the system and method can also be used with other signaling protocols by using HTTPS or SACRED for credential/certificate operations and a Gateway for the Voice Recognition Server. Also introduced is a novel Certificate Factory that generates random self-signed credentials and certificates for users of the System. Note that certificates are normally generated and signed by a Certificate Authority (CA), or generated and signed by a user.
[0011] For example, certificates stored and retrieved using this system can be used for:
1. Secure Multipurpose Internet Mail Exchange (S/MIME) integrity of signaling and message bodies 2. S/MIME encryption of signaling and message bodies 3. S/MIME signing for authentication of messages and bodies 4. Establishment of secure media sessions, such as Secure Real-time Transport Protocol (SRTP) for encrypted and authenticated voice, video, text, and gaming sessions. 5. Authentication with Transport Layer Security (TLS) connections
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 depicts components of an exemplary system in accordance with an embodiment of the present invention.
[0018] FIG. 2 depicts an enrollment process in accordance with an embodiment of the present invention.
[0019] FIG. 3 depicts a credential download process in accordance with an embodiment of the present invention.
[0020] FIG. 4 depicts a certificate download process in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0000] Components of the System:
[0021] The main components of a system 100 in accordance with an embodiment of the present invention as shown in FIG. 1 are as follows.
[0022] Certificate Database 102 —for storage of credentials and certificates. The credentials consist of the user's private key, while the certificate consists of the user's public key and identity, signed by a CA. The certificate can also be self signed. The credential can be encrypted by the user using a passcode known only to the user to provide the highest level of security.
[0023] Certificate Factory 104 —used to generate self-signed or CA signed certificates. Users can either generate their own certificates or utilize this function to have one randomly generated for them upon enrollment.
[0024] SIP Certificate Server 106 [SIPCerts]—a SIP presence server used for uploading and retrieving credentials and certificates using SIP Events [SIPEvents] including the PUBLISH, SUBSCRIBE, and NOTIFY methods.
[0025] HTTPS Certificate Server 108 —a secure web server used for uploading and retrieving credentials and certificates using GET/POST, or the SACRED protocol[SACRED]. The HTTPS Certificate Server 108 can be utilized by VoIP endpoints that either do not support SIP (such as H.323 or proprietary endpoints) or do not support SIP Events extensions (PUBLISH, SUBSCRIBE, NOTIFY).
[0026] SIP Identity Server 110 —used to provide enhanced SIP identity [SIPIdentity] for certificate notifications.
[0027] Voice Authentication Server 112 —used to perform voice print enrollment and authentication for credential download requests. The Voice Authentication Server 112 is capable of answering calls in SIP, and, through a Gateway, H.323 and PSTN calls. Even proprietary signaling protocols such as Skype could be used with an appropriate gateway as well as the PSTN and Cellular networks.
[0000] Operation of the System:
[0028] The system has three main modes of operation which will be described in the following sections. The first is Enrollment, when a new user establishes service, gets a credential and certificate. The second is Credential Download in which a user downloads a credential and certificate into one of his or her VoIP devices. The third is Certificate Download, in which any user downloads the public certificate of the user.
[0029] As shown in FIG. 2 , Enrollment in the service for an endpoint that supports SIP and SIP Events comprises several steps.
[0030] At step 201 , a VoIP endpoint wishing to obtain a certificate places a call (dials a phone number or SIP Uniform Resource Identifier (URI)). For highest security, a Secure SIP (sips) URI is used which allows the user to verify the certificate presented by the Voice Authentication Server 112 over the TLS connection.
[0031] At step 202 , the Voice Authentication Server 112 authenticates the user using HTTP Digest (shared secret). This shared secret may be used for registration and authentication, or it may be a unique one for this service.
[0032] At step 203 , the Voice Authentication Server 112 steps the user through the enrollment process including billing, etc. At step 203 , the server also records voice samples to be used for authentication of future authentication of the user.
[0033] The user has the option of generating his own self signed certificate and credential (step 204 A) or requesting the Service generate one for the user (step 204 B). If the user requests the Service generate one, the Certificate Factory 104 generates a unique certificate and stores it in the Certificate Database 102 . If the user wishes to upload his own, the user sends a SIP PUBLISH to the SIP Certificate Server 106 to upload the certificate, which stores the certificate in the Certificate Database 102 .
[0034] As shown in FIG. 3 , Credential Download for a VoIP device that supports SIP Events comprises several steps.
[0035] At step 301 , any VoIP endpoint under the control of the user sends a SUBSCRIBE to the SIP Certificate Server 106 and requests the credential. The SIP Certificate Server 106 authenticates the user using a shared secret (passcode), then places the subscription in a pending state.
[0036] At step 302 , the user is directed to call the Voice Authentication Server 112 to complete the authentication process. This can be done using a SIP REFER [REFER], an instant message with a SIP URI, or some method.
[0037] At step 303 , the user calls the Voice Authentication Server 112 and provides its shared secret key to authenticate. The Voice Authentication Server 112 then authenticates the user's voice against the stored voiceprints from the enrollment stage.
[0038] Once the user is fully authenticated, the subscription is authorized and, at step 304 , SIP Certificate Server 106 generates a SIP NOTIFY which is routed through the SIP Identity Server 110 , which signs the request and provides integrity protection over the certificate, then to the VoIP endpoint.
[0039] The VoIP endpoint installs the credential and certificate and is ready to establish secure sessions.
[0040] For a VoIP endpoint that supports SIP but not SIP Events, the enrollment is the same as before, but the only option is to have the Certificate Factory 104 generate the certificate. Downloading the certificate uses the following steps.
[0041] The VoIP endpoint, initiates a secure web session to the HTTPS Certificate Server 108 authenticates the user using a shared secret (passcode), then places the subscription in a pending state.
[0042] The user is directed to call the Voice Authentication Server 112 to complete the authentication process. This can be done by passing a SIP URI in a web page, sending a SIP REFER, an instant message with a SIP URI, or some method.
[0043] The user calls the Voice Authentication Server 112 and provides its shared secret to authenticate. The Voice Authentication Server then authenticates the user's voice against the stored voiceprints from the enrollment.
[0044] Once the user is fully authenticated, the HTTPS Certificate Server 108 pushes a web page which contains the credential and certificate. The VoIP endpoint installs the credential and certificate and is ready to establish secure sessions.
[0045] Certificate Download, as shown in FIG. 4 , comprises the following steps when another user (User B) wishes to establish a secure session with User A, uses the Service to fetch the public certificate of the user prior to establishing the session.
[0046] If the endpoint supports SIP Events, a SUBSCRIBE is sent to the SIP Certificate Server 401 . Since the public certificate is freely available to anyone who requests it, the SIP Certificate Server does not authenticate the requestor.
[0047] At step 402 , a NOTIFY is sent with the certificate which is routed through the SIP Identity Server, which signs the message and provides integrity protection over the certificate.
[0048] The caller now can utilize the certificate to establish a secure session with the user.
[0049] If the user does not support SIP Events, the steps are as follows:
[0050] The user (User B) initiates a secure web session to the HTTPS Certificate Server 108 to request the public certificate (step 404 ).
[0051] The user validates the signature provided by the HTTPS Certificate Server to ensure that the certificate returned is the correct one (step 405 ).
[0052] The HTTPS Certificate Server then provides the certificate to the user which can then utilize the certificate to establish secure sessions with the user (step 406 ).
[0053] Note that this Service can be provided within a domain, in which case all the requests (SIP, HTTPS, etc.) are sent to the user's well known URI. The service can also be provided outside a domain, in which case requests are sent to a URI constructed based on the user's URI and the Service URI.
[0054] For example, if the user's URI is sips:user@example.com and the Service is provided by the example.net domain, a method of constructing the URI could be to escape the user's URI into the user part of the URI, e.g. sips:user%40example.com@example.net. HTTPS URIs could be generated as follows: https://certs.example.net/user%40example.com Other SIPS and HTTPS URI mapping conventions could be used.
[0055] Another variant on the system would be to leave out the voice recognition part for a lower level of security. In this case, the Voice Authentication Server 112 would just become an IVR for an automated enrollment system.
[0056] Another variant would use H.323 as the call signaling protocol for the VoIP endpoint. In this scenario, the HTTPS Certificate Server 108 would be used, and H.323 would just be used for the voiceprint validation.
[0057] Note that the same credential can be installed on multiple devices at the same time. The credentials and certificates can be synchronized using the SIP Events mechanism.
[0058] Another variant on the System is to use voiceprint certificates instead of X.509 certificates. The Service could then generate self-signed voiceprint certificates of users after enrollment and distribute them to users who could use them to verify the voice of the user they have established a session with.
[0059] The following references may provide additional useful background:
[0060] [SIP] Rosenberg, J., Schulzrinne, H., Camarillo, G., Johnston, A., Peterson, J., Sparks, R., Handley, M., and E. Schooler, “SIP: Session Initiation Protocol”, RFC 3261, June 2002.
[0061] [SIPEvents] Roach, A., “Session Initiation Protocol (SIP)-Specific Event Notification”, RFC 3265, June 2002.
[0062] [SIPCert] Jennings, C. and J. Peterson, “Certificate Management Service for SIP”, draft-ietf-sipping-certs- 00 (work in progress), October 2004.
[0063] [SIPIdent] Peterson, J., “Enhancements for Authenticated Identity Management in the Session Initiation Protocol (SIP)”, draft-ietf-sip-identity-03 (work in progress), September 2004.
[0064] [SACRED] Gustafson, D., M. Just, M. Nystrom, “Securely Available Credentials (SACRED)—Credential Server Framework,” RFC3760, April 2004
[0065] [REFER] Sparks, R. “The SIP Refer Method,” RFC 3515.
[0066] The foregoing disclosure of the preferred embodiments of the present 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 forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
[0067] Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention. | A system and method for enabling secure Voice over IP (VoIP) communication includes receiving a request for the generation of a certificate to be used in conjunction with a VoIP communication, generating a certificate in response to the request, the certificate being generated based, at least in part, on a voice sample of a user that made the request, and thereafter making the certificate available for use to enable secure VoIP communication. The system and method preferably leverages the session initiation protocol (SIP). | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefits of U.S. Provisional Application No. 62/122,224, filed Oct. 16, 2014, and entitled “High Isolation and High Return Loss 2-Port Optical Retro-Reflector”, which is hereby incorporated by reference for all purposes.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The invention is generally related to the area of optical communications. In particular, the invention is related to high isolation and high return loss 2-Port optical retro-reflector.
[0004] The Background of Related Art
[0005] In optical network, it is important to have OTDR (optical time-domain reflectometer) to monitor the system operation to detect any possible breakdown or issue in the network. Previously, people have broadly discussed and deployed OTDR monitoring in optical network such as US patent 2012/0134663. At the same time, optical network nowadays has been rapidly developed into smart network with more functional layers and complicated multiple dimensional configurations, and thus monitoring and feedback function of the OTDR signal implementation are ever increasingly demanded.
[0006] With multiple layer of network configurations, high isolation and high return loss requirement is inevitably important since each layer is supposed to superimpose the signals one by another and thus any unwanted returned signal shall be degraded and deteriorate the single-to-noise ratio. Furthermore, Next Generation PON (NGPON) is pushing the last mile into individual homes and migrates into much higher speed for optical network such as FTTX (fiber to the x), the premium grade retro-reflector which can provide OTDR function for the multiple layer smart network plays an important role and is in urgent demand.
[0007] The present invention disclosure teaches unique devices with high isolation for the data signal that has transmitted through and high return loss in retro-reflected OTDR signal so as to meet the premium grade retro-reflector requirement in multiple layer smart network.
SUMMARY OF THE INVENTION
[0008] This section is for the purpose of summarizing some aspects of the present invention and to briefly introduce some preferred embodiments. Simplifications or omissions may be made to avoid obscuring the purpose of the section. Such simplifications or omissions are not intended to limit the scope of the present invention.
[0009] In general, the present invention is related to two-port optical retro-reflectors with high isolation and high return loss. According to one aspect of the present invention, the device is designed to increase the number of optical filtering using one or more filters uniquely disposed to increase the isolation and return loss.
[0010] The present invention may be implemented as an individual device, a method and part of system. According to one embodiment, the present invention is an two-port optical retro-reflector comprising: a first port for receiving an incoming signal including a first signal and a second signal; a second port; a first filter designed to transmit the first signal and reflect the second signal; a reflector; and a lens directing the incoming signal to the first filter that transmits the first signal and reflects the second signal, wherein the transmitted first signal impinges upon the reflector to cause a reflected first signal to go through the first filter again before the reflected first signal goes to the second port, and the reflected second signal is coupled to the first port. Depending on implementation, the reflector may be a mirror or a second filter. The first and second filters are identical in optical characteristics.
[0011] According to another embodiment, the present invention is a two-port optical retro-reflector comprising: a first port for receiving an incoming signal including a first signal and a second signal; a second port; a first filter designed to transmit the first signal and reflect the second signal; a lens directing the incoming signal to the first filter that transmits the first signal and reflects the second signal, wherein the transmitted first signal is coupled to the second port, and the reflected second signal is coupled to a device including: a single fiber pigtail; a lens; and a second filter, wherein the reflected second signal is impinged upon the second filter via the single fiber pigtail and the lens.
[0012] Other objects, features, and advantages of the present invention will become apparent upon examining the following detailed description of an embodiment thereof, taken in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0014] FIG. 1 shows a configuration in which a retro-reflector is coupled between two connectors;
[0015] FIG. 2 shows an exemplary embodiment according to one embodiment of the present invention;
[0016] FIG. 3A shows a design with an incoming optical signal of full band going through a com port fiber, a data signal is reflected from a filter, an OTDR signal goes through the filter and is then reflected by a mirror;
[0017] FIG. 3B shows an improvement over FIG. 2A with the change of the mirror to a thin film filter;
[0018] FIG. 3C shows an improvement over FIG. 3A that improves the data port isolation by using a quad fiber pigtail in the small tubular device;
[0019] FIG. 3D shows an improvement over FIG. 3C by replacing the mirror with the filter 312 . The light path of passing through is exactly same as the path in FIG. 3C ;
[0020] FIG. 4A shows a device made of two mini tubular devices, where the two mini tubular devices are spliced together to achieve the high isolation in data port and high return loss in retro reflected com port;
[0021] FIG. 4B shows an improvement over FIG. 4A by adding a second filter in series to another filter to make double filtering;
[0022] FIG. 4C shows an improvement over FIG. 4A by replacing a mirror with a thin film filter;
[0023] FIG. 4D shows an improvement over FIG. 4B by replacing the mirror with a thin film filter;
[0024] FIG. 5A - FIG. 5D show the use of a quad fiber pigtail respectively in each of the designs in FIG. 4A - FIG. 4D ; and
[0025] FIG. 6 shows a cassette design encapsulating all the parts shown in the previous figures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will become obvious to those skilled in the art that the present invention may be practiced without these specific details. The description and representation herein are the common means used by those experienced or skilled in the art to most effectively convey the substance of their work to others skilled in the art. In other instances, well-known methods, procedures, components, and circuitry have not been described in detail to avoid unnecessarily obscuring aspects of the present invention.
[0027] Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the order of blocks in process flowcharts or diagrams representing one or more embodiments of the invention do not inherently indicate any particular order nor imply any limitations in the invention.
[0028] Embodiments of the present invention are discussed herein with reference to FIGS. 2-10 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments.
[0029] To provide a solution for high isolation and high return loss, a 2-port optical retro-reflector is described herein. Referring now to the drawings, in which like numerals refer to like parts throughout the several views. FIG. 1 shows a configuration 100 in which a retro-reflector 102 is coupled between two connectors 104 and 106 , where the connector 104 couples an incoming light signal 108 to an input of the retro-reflector 102 and an output of the retro-reflector 102 is coupled to the connector 106 . In operation, when some or all of the incoming signal 108 is transmitted through in the retro-reflector 102 , the returned or reflected signal 112 is minimized by the unique designs of the retro-reflector 102 .
[0030] FIG. 2 shows an exemplary embodiment according to one embodiment 200 of the present invention. The device includes two ports 201 and 203 , wherein the port 201 is also referred to as a com port or com port fiber while the port 203 is referred to as a data port or data port fiber. In operation, an incoming signal (light) is coupled to the com port and impinged upon a lens 210 via a dual fiber pigtail 208 . The incoming light then hits an optical filter 202 (e.g., a thin film filter). The optical filter 202 is designed to pass signals at certain wavelengths while reflecting others. The transmitted or passed signal is reflected by a reflector 212 . Depending on implementation, the reflector 212 may be a mirror or another optical filter. The passed signal is caused to pass through the filter 202 again, thus increasing the isolation. The twice filtered signed by the filter 202 is led to the data port 203 . Meanwhile, the reflected signal by the filter 202 is led to a designated port. As a two-port device, the reflected signal is led to the corn port 201 . As described below, the passed signal corning out from the data port 203 is referred to as a data signal while the reflected signal is referred to as an OTDR signal.
[0031] It is general known in the industry, the thin film filter coating intrinsic reflection isolation can only provide 20 dB and thus the pass-through isolation is only 40 dB in FIG. 2 . To increase isolation and return loss, multiple reflections and multiple pass-through in a mini tubular structure are used to achieve the requirement. It should be noted in the description herein that an OTDR signal may also be referred to as a retro reflect signal and a data signal may also be referred to as a pass-through signal. Depending on implementation, an actual device may be very versatile with various wavelength combinations that may be realized by different thin film coatings. For example, the incoming signal carries both OTDR signal (1630-1670 nm) and data signal (1260-1618 nm), the data signal is supposed to pass through the device 200 while the OTDR is supposed to be reflected back to the incoming corn port thereof. Without implying any limitations, depending on the filter, the data signal can be a reflected signal while an OTDR signal may also be a passed signal.
[0032] Referring now to FIG. 3A , it shows a design with an incoming optical signal of full band (e.g., 1260-1670 nm) going through a corn port fiber and a data signal (e.g., 1260-1618 nm) is reflected from a filter 302 , an OTDR signal (e.g., 1630-1670 nm) goes through the filter 302 and is then reflected by a mirror. The reflected OTDR signal is then going through the filter 302 again back into the corn fiber as a retro signal. With this configuration, it is estimated that it can achieve a high return loss 80 dB for the data signal in retro-reflected OTDR 80 dB but the data port isolation is only 20 dB.
[0033] FIG. 3B shows an improvement over FIG. 2A with the change of the mirror to a thin film filter, the return loss of data signal retro reflected back to the com port can be improved to 100 dB since the data signal is passed through the filter 302 twice and reflected by the filter 312 once while the data port signal isolation remains 20 dB for this embodiment. Thus this embodiment has 20 dB data port isolation and 100 dB data signal return loss in the retro com port.
[0034] FIG. 3C shows an improvement over FIG. 3A that improves the data port isolation by using a quad fiber pigtail in the small tubular device. The light path to pass through is exactly same as FIG. 3B , but the reflected data signal from the filter 302 is caused to go back to another fiber of the quad fiber pigtail 308 and is reflected from the filter 302 as second reflection, thus the data port isolation is enhanced by this double reflection (each reflection has 20 dB isolation) and the final isolation for this design for data port is 40 dB. Thus the design in FIG. 3C has 40 dB data port isolation and 80 dB data signal return loss in retro com port.
[0035] FIG. 3D shows an improvement over FIG. 3C by replacing the mirror with the filter 312 . The light path of passing through is exactly same as the path in FIG. 3C . The light path of reflecting is exactly same as the path in FIG. 2B . Thus the design in FIG. 3D has 40 dB data port isolation and 100 dB data signal return loss in retro com port.
[0036] Referring now to FIG. 4A , it shows a device made of two mini tubular devices 401 and 403 . The two mini tubular devices 401 and 403 are spliced together to achieve the high isolation in data port and high return loss in retro reflected com port. As shown in FIG. 4A , the data signal goes through filter 302 and enters the data port with isolation of 40 dB, the OTDR signal reflected on filter 302 and comes out from the dual fiber on com port side and then enter the single fiber tubular device 303 . This OTDR signal is reflected by the mirror and goes back to filter 302 one more time and eventually retro reflected back to the com port. With such configuration, this embodiment has 40 dB data port isolation and 40 dB data signal return loss in retro com port.
[0037] FIG. 4B shows an improvement over FIG. 4A by adding a second filter 305 in series to the filter 302 to make double filtering, the data signal passes through the filter 302 twice to enhance the isolation while the OTDR signal path goes exactly same as FIG. 4A . Thus the design in FIG. 4B has 80 dB data port isolation and 40 dB data signal return loss in the retro reflected com port.
[0038] FIG. 4C shows an improvement over FIG. 4A by replacing the mirror with a thin film filter 302 then the OTDR signal will be enhance by 20 dB additional return loss for data signal while the data signal will pass through the filter 302 exactly same as in FIG. 4A . Thus the design in FIG. 4C has 40 dB data port isolation and 60 dB data signal return loss in the retro reflected com port.
[0039] FIG. 4D shows an improvement over FIG. 4B by replacing the mirror with a thin film filter 302 then the OTDR signal will be enhanced by 20 dB additional return loss for the data signal while the data signal passes through the filter 302 twice as exactly as in FIG. 4B . Thus this design has 80 dB data port isolation and 60 dB data signal return loss in retro reflected com port.
[0040] FIG. 5A - FIG. 5D show the use of a quad fiber pigtail respectively in each of the designs in FIG. 4A - FIG. 4D . As explained above, the introduction of such a quad fiber pigtail is to increase the isolation, resulting in 40 dB data port isolation and 80 dB data signal return loss in the retro reflected com port in FIG. 5A , 80 dB data port isolation and 80 dB data signal return loss in the retro reflected com port in FIG. 5B , 40 dB data port isolation and 100 dB data signal return loss in the retro reflected com port in FIG. 5 C, and 80 dB data port isolation and 100 dB data signal return loss in the retro reflected corn port in FIG. 5D .
[0041] For completeness, FIG. 6 shows a cassette design encapsulating all the parts shown in the previous figures. In one embodiment, all the parts are packaged in a small ruggedized cassette with a 2-mm jacket protected cable for various tough environment deployment.
[0042] The present invention has been described in sufficient details with a certain degree of particularity. It is understood to those skilled in the art that the present disclosure of embodiments has been made by way of examples only and that numerous changes in the arrangement and combination of parts may be resorted without departing from the spirit and scope of the invention as claimed. For example, the variable neutral density filter may be replaced by another device that can strengthen an optical signal. Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description of embodiments. | Two-port optical retro-reflectors with high isolation and high return loss are described. Such retro-reflectors are designed to increase the number of optical filtering using one or more filters uniquely disposed to increase the isolation and return loss. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a super-high pressure discharge lamp of the short arc type in which the mercury vapor pressure during operation is at least equal to 150 atm. The invention relates especially to a super-high discharge lamp of the short arc type which is used as the backlight of a liquid crystal display device and a projector device using a DMD (digital mirror device) and a DLP (digital light processor) or the like.
[0003] 2. Description of Related Art
[0004] In a projector device of the projection type there is a demand for illumination of the images uniformly onto a rectangular screen and with sufficient color reproduction. The light source is thus a metal halide lamp which is filled with mercury and a metal halide. Furthermore, recently smaller and smaller metal halide lamps and more and more often spot light sources have been produced and lamps with extremely small distances between the electrodes have been used in practice.
[0005] Against this background, recently, instead of metal halide lamps, lamps with an extremely high mercury vapor pressure, for example, of 150 atm, have been proposed. Here, the increased mercury vapor pressure suppresses broadening of the arc (the arc is compressed) and a major increase of the light intensity is desired. One such super-high pressure discharge lamp is disclosed in U.S. Pat. No. 5,109,181 (JP-OS HEI 2-148561) and U.S. Pat. No. 5,497,049 (JP-OS HEI 6-52830).
[0006] In one such super-high pressure discharge lamp, the pressure within the arc tube during operation is extremely high. In the side tube parts which extend from the two sides of the emission part, it is therefore necessary to arrange the quartz glass comprising these side tube parts, the electrodes and the metal foils for power supply in a sufficient amount, and moreover, almost directly tightly adjoining one another. When they are not adjoining one another tightly enough, the added gas leaks or cracks form. In the process of hermetic sealing of the side tube parts, therefore the quartz glass is heated, for example, at a high temperature of 2000° C., and in this state, the quartz glass with a great thickness is gradually subjected to shrinking (a so-called shrink seal) or a pinch seal. In this way, the adhesive property of the side tube parts is increased.
[0007] However, if the quartz glass is heated up to an excessively high temperature, the disadvantage occurs that, after completion of the discharge lamp, the side tube parts are easily damaged, even if the adhesive property of the quartz glass to the electrodes or metal foils is increased.
[0008] It can be imagined that the cause of this disadvantage is the following:
[0009] After heat treatment, in the stage in which the temperature of the side tube parts is gradually reduced, as a result of differences between the coefficient of expansion of the material (tungsten) comprising the electrodes, and the coefficient of expansion of the material (quartz glass) comprising the side tube parts, there is a relative difference in the amount of expansion. This causes the formation of cracks in an area in which the two come into contact with one another. These cracks are very small, but together with the super-high pressure state during lamp operation they lead to growth of the cracks; this causes damage to the discharge lamp.
[0010] In order to eliminate this disadvantage, the arrangement shown in FIG. 11 was proposed. Here, part of the discharge lamp is shown in an enlarged view. The emission part 10 adjoins a side tube part 11 in which an electrode 2 is connected to the metal foil 3 . A coil component 5 is wound around the electrode 2 which has been installed in the side tube part 11 . This arrangement of the coil component 5 which has been wound around the electrode 2 reduces the stress which is exerted on the quartz glass as a result of the thermal expansion of the electrode 2 . This arrangement is described, for example, in Japanese patent disclosure document HEI 11-176385.
[0011] However, in reality, there was the disadvantage that, in the vicinity of the electrode 2 and the coil component 5 , cracks K remain even if the thermal expansion of the electrode 2 is relieved by this arrangement. These cracks K are very small, but there are often cases in which they lead to damage of the side tube part 11 when the mercury vapor pressure of the emission part 10 is roughly 150 atm. Furthermore, in recent years, there has been a demand for a very high mercury vapor pressure of 200 atm, and moreover, up to 300 atm. At such a high mercury vapor pressure, the growth of cracks is accelerated during lamp operation. As a result there was the disadvantage that damage of the side tube part 11 clearly occurs. This means than the cracks gradually become larger during lamp operation with a high mercury vapor pressure, even if the cracks K were extremely small at the start. It can be stated that this is a new technical task which is never present in a mercury lamp with a vapor pressure during operation from roughly 50 atm to roughly 100 atm, or no more than roughly 50 atm to roughly 100 atm.
[0012] Two of the present applicants have already proposed the arrangement shown in FIG. 12 in commonly-owned U.S. patent application Ser. No. 09/874,231 (corresponding to Japanese Patent Application 2000-168798). In this arrangement. an emission part 10 has a side tube part 11 in which an electrode 2 is connected to a metal foil 3 . The electrode 2 with its side 2 a and its end face 2 b is located in an extremely small intermediate space B out of contact with the quartz glass. This intermediate space arrangement makes it possible to eliminate the above described defect of crack formation if the intermediate space can be formed completely precisely. However, it has been found that, in reality, completely precise formation of this intermediate space is difficult. Specifically, it is disclosed that the intermediate space is formed by applying a vibration to the electrode. However, in practice, the intermediate space cannot be adequately produced by vibration alone.
[0013] Furthermore, the arrangement shown in FIG. 12 yielded another, new disadvantage. FIGS. 13 ( a ), 13 ( b ), and 13 ( c ) are each an enlarged representation of the encircled area A of FIG. 12. FIG. 13( a ) shows the area A of FIG. 12 in an identical enlarged representation. FIG. 13( b ) is a cross section in which the cross section C-C′ as shown in FIG. 13( a ) is viewed from the top (in direction of arrow D), the position of foil 3 being shown in phantom outline. FIG. 13( c ) shows cross section D-D′ of FIG. 13( a ) viewed from the left side (in the direction of arrow C). As shown in FIGS. 13 ( a ) to 13 ( c ), the intermediate space B is present from the side 2 a of the electrode 2 as far as the end face 2 b . However, on the end face 2 b of the electrode 2 , there is an undesirable wedge-shaped intermediate space X.
[0014] [0014]FIG. 14 shows the intermediate space X in an enlarged representation. Since the intermediate space X is directly connected via the intermediate space B to the emission part 10 , the high internal pressure which forms within the emission part 10 (of at least 150 atm) is exerted in the same way. This high pressure is intensely exerted in the wedge-shaped intermediate space X in the directions P 3 and P 4 of the arrows shown in FIG. 14, and this phenomenon ultimately leads to detachment of the metal foil 3 from the quartz glass. This results in damage to the discharge lamp. It can furthermore be stated that this phenomenon is a characteristic technical task which arises in a discharge lamp which has an arrangement in which the emission part and the end face of the electrode are coupled to one another by an intermediate space, and which has an extremely high internal pressure that is greater than or equal to 100 atm, 150 atm, 200 atm, and moreover, at least 300 atm, as in the invention.
SUMMARY OF THE INVENTION
[0015] The invention was devised to eliminate the above described disadvantage in the prior art, a primary object of the invention being to devise an arrangement with relatively high pressure tightness in a super-high pressure mercury lamp which is operated with an extremely high mercury vapor pressure.
[0016] This object is achieved in accordance with the invention in a super-high pressure discharge lamp of the short arc type which comprises the following:
[0017] an emission part in which there are a pair of opposed electrodes and which is filled an amount of mercury at least equal to 0.15 mg/mm 3 mercury and
[0018] side tube parts of quartz glass which extend from opposite sides of the emission part and in which the electrodes are partially hermetically sealed,
[0019] wherein the electrodes are arranged in the side tube parts a respective extremely small intermediate space formed between the sides and the end faces of the electrodes and the quartz glass of the side tube parts, and that the electrodes are provided with concave-convex parts.
[0020] The object is furthermore achieved in accordance with the invention by the above described extremely small space being formed of a size that, as a result of the difference between the coefficient of expansion of the material comprising the electrodes and the coefficient of expansion of the material comprising the side tube parts, the electrodes are not constricted in the axial direction, but can freely expand.
[0021] The object is furthermore achieved according to the invention by the above described concave-convex parts having a depth of from 1.0 micron to 100 microns.
[0022] The object is furthermore achieved by the invention in a super-high pressure discharge lamp of the short arc type which comprises:
[0023] an emission part in which there are a pair of opposed electrodes and which is filled with at least 0.15 mg/mm 3 of mercury and
[0024] side tube parts of quartz glass which extend from both sides of the emission part and in which metal foils which are connected to the electrodes are hermetically sealed,
[0025] wherein the electrodes are arranged such that, in the above described side tube parts, an extremely small intermediate space is formed between the sides and the end faces of the electrodes and the quartz glass comprising the side tube parts, the end faces of the electrodes and the metal foils forming an acute-angled arrangement in which the quartz glass is located.
[0026] This object is moreover achieved in accordance with the invention by the above described acute-angled arrangement having an angle of less than or equal to 70°.
[0027] The above described arrangement makes it possible to avoid completely or essentially completely the extremely small cracks which form in the side tube parts in the super-high pressure discharge lamp of the short arc type of the invention.
[0028] The reason for this is that, for the electrodes located in the side tube parts (upholding parts of the electrodes), there is an intermediate space between the electrode surfaces (including the end faces) and the quartz glass so that the quartz glass and the electrodes do not directly tightly adjoin one another.
[0029] In this arrangement, the surfaces of the electrodes are not in contact with the quartz glass. Even if the electrodes move relative to the quartz glass, no cracks due to this motion form between them.
[0030] Furthermore, according to the invention, the electrode surfaces are provided with concave-convex parts in order to make these intermediate spaces simple and moreover more reliable.
[0031] The technical explanation that formation of the concave-convex shape leads to reliable formation of the intermediate space is not always apparent. As a result of thorough research, the applicant has arrived at the following conclusions:
[0032] As is also disclosed in the above described commonly-owned, co-pending U.S. application, in the production process for forming the intermediate space in the last segment of the process of hermetic sealing, an impact is applied to the electrodes. It is assumed that the quartz glass which is in the molten state and which is present in the concave parts is pressed more easily to the outside during the impact if concave-convex parts are present and that the intermediate space is reliably formed by this pressing-out.
[0033] Furthermore, the inventors have conducted thorough studies to eliminate the disadvantage of the wedge-shaped space and as a result they have developed a concept for the shape of the end faces of the electrodes.
[0034] The invention is explained in detail below using several embodiments shown in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] [0035]FIG. 1 a cross-sectional view of a super-high pressure discharge lamp of the short arc type;
[0036] [0036]FIG. 2 shows an enlarged partial view of a super-high pressure discharge lamp of the short arc type in accordance with the invention;
[0037] [0037]FIG. 3 is a cross section taken along line A′-A′ as shown in FIG. 2;
[0038] FIGS. 4 ( a ) & 4 ( b ) each schematically show an arrangement of the electrode in accordance with the invention;
[0039] FIGS. 5 ( a ) to 5 ( d ) each schematically show a step in a process for producing a super-high pressure discharge lamp of the short arc type according to the invention;
[0040] [0040]FIG. 6 shows a partial view of a super-high pressure discharge lamp of the short arc type in accordance with another embodiment of the invention;
[0041] FIGS. 7 ( a ) & 7 ( b ) each show a partial cross-sectional the FIG. 6 embodiment of the invention;
[0042] [0042]FIG. 8 shows a partial view of a super-high pressure discharge lamp of the short arc type in accordance with a third embodiment of the invention;
[0043] FIGS. 9 ( a ) through 9 ( c ) show schematics of other embodiments of a super-high pressure discharge lamp of the short arc type in accordance with the invention;
[0044] [0044]FIG. 10 is a graph showing the results of tests performed with the invention;
[0045] [0045]FIG. 11 shows a partial view of a conventional super-high pressure discharge lamp of the short arc type;
[0046] [0046]FIG. 12 shows a partial view of another conventional super-high pressure mercury lamp of the short arc type;
[0047] FIGS. 13 ( a ) to 13 ( c ) each show a partial view of the encircled region A of FIG. 12; and
[0048] [0048]FIG. 14 shows a partial view of another known super-high pressure discharge lamp of the short arc type.
DETAILED DESCRIPTION OF THE INVENTION
[0049] A super-high pressure discharge lamp of the short arc type in accordance with the invention is described below. First, the overall arrangement of the discharge lamp is described using FIG. 1. In essentially the middle of the discharge lamp 1 is an emission part 10 which is made of quartz glass and has side tube parts 11 on opposite ends that are hermetically sealed.
[0050] In the emission part 10 , there are a pair of opposed tungsten electrodes 2 , for example, that are separated by a distance of at most equal to 2.5 mm. A metal foil 3 is welded to one end of each electrode 2 . The metal foil 3 and part of the electrode 2 are installed in the side tube part 11 and are hermetically sealed. An outer lead 4 is connected to the other end of the metal foil 3 . The tip of the electrode 2 is wound with a coil. The reason for this to improve the operation starting property. Here, tungsten is wound around the tip four to five times.
[0051] The emission part 10 contains as the emission substance mercury, and furthermore, a rare gas, such as argon, xenon or the like, as the operation starting gas. The amount of mercury added is an amount in which the vapor pressure during stable operation is at least equal to 150 atm, preferably is greater than or equal to 200 atm, and more preferably, is at least 300 atm, computed and added one at a time. For example, in the case in which the mercury vapor pressure is greater than or equal to 150 atm, the amount of mercury added is greater than or equal to 0.15 mg/mm 3 .
[0052] The invention is described specifically below. FIG. 2 relates to a first embodiment of the invention and shows the boundary area of the emission part 10 and the side tube part 11 in an enlarged representation. FIG. 3 is a cross section corresponding to line A-A′ as shown in FIG. 2. The intermediate space B and the concave-convex part 20 in FIG. 2 and FIG. 3 are extremely small in practice, but are shown exaggerated in the drawings to facilitate the explanation. It is also noted that the terms “concave” and “convex” as used herein are not intended to be restricted to spherically or arcuately curved surfaces but rather as used in the term “concave-convex” is intended to describe a series of surfaces that are alternately displaced inward and outward with respect to each other including the inward and outward series of steps shown in FIG. 2 and the zig-zag configurations that are shown in FIGS. 4 ( a ) & 4 ( b ).
[0053] In the side tube part 11 , the electrode 2 is welded to the metal foil 3 . In the other area between the electrode 2 and the quartz glass comprising the side tube part 11 , there is an intermediate space B. Specifically, the side 2 a of the electrode and the end face 2 b on the hermetically sealed side are not in contact with the side tube part 11 (the quartz glass).
[0054] Here, the intermediate space B is fixed in the respect that, as a result of the difference between the coefficient of expansion of the material comprising the electrodes, and the coefficient of expansion of the material comprising the side tube parts, the electrodes are not constricted in the axial direction, but can freely expand. In the case in which the electrodes are made of tungsten and the side tube parts are made of quartz glass, the width b of the intermediate space B is chosen in the range from 6 microns to 16 microns. The length of the intermediate space B in the lengthwise direction of the electrode is 2 mm to 5 mm. The outside diameter of the side tube part of the electrode is for example 0.3 mm to 1.5 mm.
[0055] FIGS. 4 ( a ) & 4 ( b ) show two specific arrangements for the electrodes 2 . In FIG. 4( a ), the electrode has the same diameter from the end to the tip. In FIG. 4( b ), the area which projects into the emission space is thicker than the part in the hermetically sealed area. Furthermore, electrodes with different shapes can be used. The tip on the side of the emission space of the electrode can be flat, as shown in FIG. 4( a ), or curved, as shown in FIG. 4( b ). Furthermore, the tip can also have other shapes, such as a cone shape and the like. The portion of the electrode 2 which corresponds to the side tube part is provided with a concave-convex part 20 . The concave section between two elevations has a width W and a depth d. As shown in FIGS. 4 ( a ) & 4 ( b ), a zig-zag shape can be used or the square/rectangular shape shown in FIG. 2 can be used. Furthermore, other shapes, such as a curved (rounded) shape or a corrugated shape can be used. The depth d of the concave-convex area 20 is, for example, 1 micron to 100 microns. This concave-convex part 20 can be formed by turning, cylindrical grinding or the like.
[0056] A process for producing a super-high pressure discharge lamp of the short arc type according to the invention is described below. FIGS. 5 ( a ) to 5 ( d ) show a series of production processes. FIG. 5( a ) shows the process of hermetic sealing. FIG. 5( b ) shows the cooling process. FIG. 5( c ) shows the heat-up process. FIG. 5( d ) shows the vibration process. The electrode 2 is, as was described above, provided with a concave-convex part. But in FIGS. 5 ( a ) to ( d ) the convex-concave part is advantageously omitted for describing the production processes.
[0057] First, the process of hermetic sealing as shown in FIG. 5( a ) is described. In one of the side tube parts 11 , specifically the side tube part 11 a , of a glass bulb, of which an emission part 10 and the side tube parts 11 are formed, an electrode module is inserted in which an electrode 2 , a metal foil 3 and an outer lead pin 4 are made integral with one another. Here, the tip of the electrode 2 projects into the emission part 10 . The base part of the electrode 2 and the metal foil 3 are positioned in the side tube part 11 . The area C of the side tube part 11 a which surrounds the base part of the electrode 2 and metal foil 3 is heated up to a temperature which is at least equal to the softening point of this side tube part 11 a . Specifically, the softening point in the case in which the side tube part is made of quartz glass is 1680° C. It is heated at roughly 2000° C. with a gas burner.
[0058] In this process of hermetic sealing, the end of the side tube part 11 a is already closed. The inside of the glass bulb is exposed to a negative pressure via an open end of the other side tube part 11 b , for example, up to 100 torr. When the side tube part 11 a is heated up, therefore the diameter of this part is reduced. In this way, the electrode 2 and the metal foil 3 are hermetically sealed against one another. Besides the process (shrink seal) in which the inside of the glass bulb is exposed to a negative pressure, the side tube part 11 can also be hermetically sealed after heating with pincers.
[0059] Next, the cooling process as shown in FIG. 5( b ) is described. Following the above described process of hermetic sealing, the side tube part 11 a is cooled. This cooling takes place by forced cooling or natural cooling and the side tube part 11 a is cooled, for example, down to 1200° C.
[0060] This cooling process shifts the electrode 2 and the side tube part 11 a into a state which they are welded to one another in one section. However, this welding does not take place on the entire surface of the electrode 2 . The reason for this is that the material of which the electrode is made, for example, tungsten, and the material of which the side tube part is made, for example, quartz glass, have different coefficients of expansion and that part of the area in which the electrode 2 and the side tube part 11 are welded to one another (in which they are welded to one another in the process of hermetic sealing) detaches. When this detachment takes place, the above described extremely small cracks K form.
[0061] Next, the heat-up process as shown in FIG. 5( c ) is described. Following the above described cooling process, the area D in the drawings is heated again. This heating is carried out, for example, with a gas burner until the material of which the side tube part 11 is made, for example, quartz glass, passes into a plastic flow state and comes into contact with the electrode 2 . The electrode 2 and the material of the side tube part 11 can move relative to one another. In this re-heating process, only the area D of the side tube part 11 a is heated again, not the entire metal foil 3 . Therefore, there is no effect on the hermetic sealing of the metal foil 3 to the side tube part 11 . This re-heating can eliminate the extremely small cracks which were present in the vicinity of the electrode 2 .
[0062] Next, the vibration process as shown in FIG. 5( d ) is described. After completion of the above described heating process, in the state in which the temperature of the area D of the side tube part 11 a is less than or equal to the softening point of the material of the side tube part and is greater than or equal to the annealing temperature, vibration is applied to this side tube part 11 a . This vibration is caused in the directions of the arrows in FIG. 5( d ). The reason for this is that the area D of the side tube part 11 is in the plastic flow state and the electrode 2 and the quartz glass 11 move relative to one another. Vibration takes place, for example, one to ten times, resulting in movement of 0.1 mm to 1.0 mm. In the last vibration, the distance between the electrodes must be appropriate. This is done in addition by manual actuation or using an image processing device with an accuracy of ±0.05 mm.
[0063] During this vibration, a retaining component 13 , which clamps the side tube part 11 , is connected to a vibration means, such as a motor or the like. According to the drive of the motor, vibration is formed in the directions of the arrows. Due to this vibration, the electrode and the side tube part 11 necessarily, and moreover in relative terms, diverge from one another, and an intermediate space advantageously forms between the two. When this intermediate space forms, the action could furthermore be observed that the molten quartz glass which is located in the concave areas of the convex-concave part 20 (not shown in the drawings) is influenced by the vibration and is advantageously pressed out.
[0064] When the electrode is attached in the side tube part 11 b , after completion of the above described process, the emission part 10 is filled with mercury and the rare gas which are necessary for lamp operation and the same processes of hermetic sealing, cooling, heating and vibration are carried out for the other side tube part 11 b.
[0065] The frequency of vibration depends on the depth of the convex-concave part which has been formed in the electrode. The inventors confirmed as a result of several tests that, at a convex-concave depth of 35 microns to 100 microns, vibration one to ten times is necessary (the side tube part is subjected to one-time reciprocating motion during a single vibration in the arrow directions as shown in FIG. 5( d )), that, at a convex-concave depth of 12 microns to 25 microns, vibration three times to four times is necessary, and at a convex-concave depth of 1.0 microns to 6.5 microns, vibration five times to ten times is necessary. This result means that the smaller the frequency of vibration which suffices, the larger the convex-concave depth. This is also the reason for the influence of the convex-concave part when the intermediate space is formed.
[0066] The more frequently the vibration takes place, the more adverse effects can be exerted on the metal foil. The inventors have confirmed that a vibration frequency of at most 10 times, preferably no more than 5 times, is preferred with respect to the effect on the metal foil.
[0067] The convex-concave part which is to be formed in the electrode is not limited to the arrangement according to the above described embodiment, in which the concave areas and the convex areas are located bordering one another in the direction in which the electrode extends. This means that an arrangement is also possible in which the concave areas and the convex areas are located bordering one another in the circular peripheral direction of the electrode. In this case, the vibration is applied, not from the end of the side tube part, as was described above in the production process, but it is applied from the side of the side tube part. The convex-concave parts which have been formed in the circular peripheral direction of the electrode, instead of in the entire circular peripheral direction in conjunction with the direction in which the vibration is applied, can be formed in one part.
[0068] Another aspect of the invention is described below.
[0069] [0069]FIG. 6 shows the border area of the emission part 10 and of the side tube part 11 in an enlarged representation which corresponds to FIGS. 11 & 12. In the side tube part 11 , the electrode 2 is welded in the area in which it is welded to the metal foil 3 . In the remaining area between the electrode 2 and the quartz glass of which the side tube part 11 is formed, there is an intermediate space B. Specifically the electrode 2 on its side 2 a and the end face 2 b on the hermetically sealed side are not in contact with the quartz glass of which the side tube part 11 is formed. The metal foil 3 and the intermediate space B are in reality extremely small or thin. However, in the drawings they are shown exaggerated for the sake of description of the invention. FIGS. 7 ( a ), 7 ( b ), & 7 ( c ), likewise, show the end 2 b of the electrodes and correspond to FIGS. 13 ( a ), 13 ( b ) & 13 ( c ). FIG. 7( a ) is an enlarged representation of the end of the electrode. FIG. 7( b ) is a cross section in which the cross section C-C′ as shown in FIG. 7( a ) was viewed from the top (direction of arrow D). FIG. 7( c ) is a cross section in which the cross section D-D′ as shown in FIG. 7( a ) was viewed from the left side (direction of arrow C).
[0070] Here, the intermediate space B is fixed in the respect that, as a result of the difference between the coefficient of expansion of the material comprising the above described electrodes, and the coefficient of expansion of the material of which the side tube parts are made, the electrodes are not constricted in the axial direction, but can freely expand. In the case in which the electrodes are made of tungsten and the side tube parts are made of quartz glass, the width of the intermediate space B is chosen to be in the range of from 6 microns to 16 microns. The intermediate space B in the lengthwise direction of the electrode is 3 mm to 5 mm. The outside diameter of the side tube part of the electrode is, for example, 0.4 mm to 1.3 mm.
[0071] The formation of cracks can be advantageously prevented by the formation of such an intermediate space B even with relative motion of the electrodes and the quartz glass relative to one another.
[0072] Furthermore, in this invention, the end face of the electrode 2 does not have the flat end face shape shown in FIG. 12, but tapered so that the end face of the electrode and the metal foil are at an acute angle relative to each other. This arrangement makes it advantageously possible to achieve the above described technical task which arises due to the arrangement of the intermediate space B, i.e., prevention of the formation and growth of an unwanted, wedge-shaped intermediate space X.
[0073] [0073]FIG. 8 is an enlarged representation of the arrangement of the end of the electrode. As shown in FIG. 8, the end of the electrode does not have a flat end face (there is no plane perpendicular to the lengthwise direction of the electrode), but it is made spherical or curved. In this way, the intermediate space B which has been formed in the vicinity of the electrode is also formed essentially in the same shape.
[0074] The end of the electrode and the metal foil 3 are at an acute angle relative to one another. Quartz glass also enters into this acute-angled arrangement, as is shown in FIG. 8 at 11 a . Here, “acute-angled arrangement” means the angle θ in the drawings which is formed by the end face of the electrode in the intermediate space B and by the metal foil 3 . A high pressure P from the intermediate space B is exerted on the quartz glass 11 a in the directions of the arrows shown in the drawings. This pressure P is divided by the angle θ into a force component P 1 and a force component P 2 . The force component P 2 acts in such a way that the quartz glass 11 a and the metal foil 3 are arranged directly tightly adjoining one another. This action can advantageously eliminate the defect of detachment from this area.
[0075] In this invention, the above described unwanted wedge-shaped intermediate space does not form due to the concept of the end face arrangement of the electrode 2 . It is therefore possible to advantageously eliminate the defect of detachment of the metal foil which is caused by the wedge-shape intermediate space. Assuming that the wedge-shaped intermediate space X is formed in the production stage, formation of the defect can be suppressed, since the force P 2 with which the two are arranged directly tightly adjoining one another, acts more strongly than the force P with which the quartz glass and the metal foil are detached from one another.
[0076] The arrangement of the end of the electrode and the acute-angled arrangement which is formed by the end of the electrode and the metal foil is not limited to the arrangement shown in FIG. 8. FIGS. 9 ( a ), 9 ( b ) & 9 ( c ) show other acute-angled arrangements. In FIGS. 9 ( a ) & 9 ( b ), the end of the electrode is made conical. The acute angle θ at the point of contact 51 with the metal foil in FIG. 9( a ) is 45°. The acute angle θ at the point of contact 52 with the metal foil in FIG. 9( b ) is 30°. Furthermore, the shape which is shown in FIG. 9( c ) and which is formed by obliquely cutting off the cylindrical electrode can be used. In FIG. 9( c ) the acute angle θ at the point of contact 53 is 45°.
[0077] The acute-angled arrangement which is formed on the end of the electrode is not limited to these embodiments, but other arrangements can also be used. Different angles can also be used with respect to the angle which is formed in the acute-angled arrangement.
[0078] Next, in the arrangement shown in FIG. 8, i.e., in the acute-angled arrangement which is formed by the end face of the electrode and the metal foil, the relationship between the acute angle θ and the force component was checked. In this arrangement and in the other studies, discharge lamps with the following properties are used, without the invention being limited to these discharge lamps:
[0079] Outside diameter of the cathode: 0.8 mm
[0080] Outside diameter of the anode: 1.8 mm
[0081] Outside diameter of the side tube part: 6.0 mm
[0082] Total length of the lamp: 65.0 mm
[0083] Length of the side tube: 25.0 mm
[0084] Inside volume of the arc tube: 0.08 cm 3
[0085] Distance between the electrodes: 2.0 mm
[0086] Nominal luminous voltage: 200 W
[0087] Nominal luminous current: 2.5 A
[0088] Amount of mercury added: 0.15 mg/mm 3
[0089] Rare gas: 100 torr argon
[0090] In FIG. 10 the x-axis plots the angle θ, and data were collected in the range from 20° to 90°. The y-axis plots, in MPa units, the unwanted force component which forms in the wedge-shaped intermediate space, i.e., P 3 in FIG. 8 and FIG. 14. An angle θ of 90° means the conventional arrangement of the end face of the electrode shown in FIGS. 13 ( a ), 13 ( b ), & 13 ( c ). The relationship shown in FIG. 10 illustrates that, at an angle θ of less than 70°, the unwanted force component which forms in the wedge-shaped intermediate space is negative. This means that in the acute-angled arrangement defined by the angle θ, the stress P 2 becomes higher than the stress P 3 when the angle θ is less than 70°, with the stress P 3 the metal foil and the quartz glass being detached from one another and with the stress P 2 the two being arranged directly tightly adjoining one another. It is clearly shown that the stress P 3 becomes smaller, the smaller the angle θ.
[0091] Furthermore, it also becomes apparent that the action of the invention appears more clearly when the angle θ is less than 70°, and that the action becomes greater, the smaller the angle θ becomes, i.e., from 55°, 40° to 20°. In the case of the angle θ of greater than 70°, the difference between P 3 and P 2 can also be reduced even more than in the case of an angle θ of 90°, even if the stress P 3 cannot be made smaller than the stress P 2 .
[0092] The above described relationship differs, depending on the conditions, such as the size of the intermediate space B, the area of the end face of the electrode, the internal pressure of the discharge space and the like, if they are interpreted precisely. For the numerical value “70 20 ” of the above described angle θ, these conditions must be considered. However, the inventors have confirmed by various tests that essentially the same effect is obtained when the mercury vapor pressure is greater than or equal to 150 atm, the intermediate space B is 6 microns to 16 microns, and the angle θ is 70°. The acute-angled arrangement of the invention which is formed by the electrode and the metal foil can be advantageously used for either the anode or the cathode of the discharge lamp, and preferably, for both electrodes.
[0093] As was described above, the super-high pressure discharge lamp of the short arc type in accordance with the invention has an extremely small intermediate space on the sides and the end faces of the electrodes. Therefore, the formation of extremely small cracks in these areas can be completely or essentially completely suppressed. Furthermore, an extremely small intermediate space can be formed in the processes of producing the discharge lamp exactly and reliably by the arrangement of the concave-convex parts in the electrodes. Furthermore, an acute-angled arrangement can be formed between the end face of the electrode and the metal foil. Therefore, the formation and growth of the wedge-shaped intermediate space in this area can be advantageously suppressed. | An arrangement with relatively high pressure tightness in a super-high pressure mercury lamp which is operated with an extremely high mercury vapor pressure is achieved the following:
an emission part contains a pair of opposed electrodes, each of which has a side section and an end face, and which is filled with at least 0.15 mg/mm 3 mercury;
side tube parts made of quartz glass extend from opposite sides of the emission part and the side section and end face of a respective electrode is partially hermetically enclosed is each side part;
the electrodes are arranged in side tube parts with a small intermediate space formed between the side sections and the end faces of the electrodes and the quartz glass of which the side tube parts is made; and
the side parts of the electrodes have at least partially concave-convex areas in the side tube parts. Alternatively or in addition, each side section is joined to a metal foil which extends axially beyond the end face of the respective electrode and the end face of each metal foil adjoins the end face of the respective electrode at an acute angle. | 7 |
BACKGROUND
[0001] The present invention pertains to networking systems and pertains particularly to multiple protocol handshaking between systems.
[0002] When two host systems are communicating via a cable, each host system typically includes a transceiver that converts electrical signals received from the host system to signals that are suitable for the cable. Each transceiver also converts signals received from the cable to electrical signals usable by the host system. Generally, the transceiver can convert the signals one bit at a time or the transceiver can encode/decode the signals. In addition, the transceiver can be an electro-optic transceiver (which converts electrical signals to optical signals and vice versa) or an electrical transceiver (which converts electrical signals of one format to another format and vice versa). Typically, the “one bit at a time” transceiver allows handshaking to occur directly between two host systems and the “encoding/decoding” transceiver does not. Typically, the electro-optic transceiver allows the use of a receiver status signal to be sent when a cable connection is detected and the electrical transceiver does not.
[0003] For example, in 1000BASE-X systems transceivers typically perform the conversion one bit at a time. The transceiver can be electro-optical or electrical in nature. When the transceiver is electro-optical, the two communicating systems are connected with a fiber optic cable. The electrooptic transceiver converts each bit in the electrical signal received from the host system to a bit in an optical signal to be sent across the fiber optic cable. Each electro-optic transceiver also converts optical signals received from the fiber optic cable to electrical signals used by the host system. When an electro-optic transceiver first receives light from a source at the other end of the fiber optic cable, the electro-optic transceiver updates its receiver status signal. When both electro-optic transceivers forward to their respective host systems a receiver status signal that indicates the reception of optical power the two host systems perform their handshaking protocol to establish a link.
[0004] Whenever a fiber optic cable link between two electro-optic transceivers is broken, each electro-optic transceiver changes its receiver status signal to indicate optical power is no longer being received. When the fiber optic cable link between two electro-optic transceivers is restored, each electro-optic transceiver changes its receiver status signal to indicate the reception of optical power and the systems again perform handshaking.
[0005] When two host systems are communicating via electrical (e.g., copper-based) cables, each host system typically includes an electrical transceiver that converts electrical signals in a format used by the host system to electrical signals in a format appropriate to be sent across the electrical cables. Each electrical transceiver also converts electrical signals received from the electrical cables to electrical signals in a format used by the host system. A typical 1000BASE-X transceiver converts data one bit at a time. Typically, in systems based on electrical cable, there is nothing equivalent to a receiver status signal that indicates the reception of optical power. This results in an incompatibility between protocols used between host systems using two electrical transceivers to exchange information over electrical cables and protocols used between host systems using two electro-optic transceivers to exchange information over a fiber optic cable.
[0006] If 1000BASE-X host systems are communicating and non-1000BASE-X transceivers that encode/decode data are used, then direct handshaking between the host systems is not possible. For example, if 1000BASE-T electrical transceivers are used in two communicating 100OBASE-X systems, the data from a host system is encoded by the 1000BASE-T transceiver and the special handshaking codes sent by the system are not passed through the 1000BASE-T transceiver. In addition, as in the case when a 1000BASE-X electrical transceiver is used, the receiver status signal does not exist when the 1000BASE-T electrical transceiver is used in the system.
[0007] For further information, see, for example, the IEEE Std. 802.3, 2000 Edition, Part 3: Carrier sense multiple access with collision detection (CSMA/CD) access method and physical layer specifications, Clause 36 and Clause 37, in which pertinent parts of the 1000BASE-X protocol are discussed, and Clause 40 and Clause 28, in which pertinent parts of the 1000BASE-T protocol are discussed.
SUMMARY OF THE INVENTION
[0008] In accordance with the preferred embodiment of the present invention, handshaking is performed between a first host system and a second host system. First handshaking is performed between a host module within the first host system and a first transceiver within the first host system. The first handshaking includes passing from the first transceiver to the host module dummy information about the second host system. Second handshaking is performed between a second transceiver within the second host system and the first transceiver. The second handshaking includes obtaining, by the first transceiver from the second transceiver, first information about the second host system. Handshaking between the host module and the first transceiver is restarted. This includes passing from the first transceiver to the host module the first information about the second host system. The first information replaces the dummy information passed from the first transceiver to the host module during the first handshaking.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a simplified block diagram illustrating handshaking between two host systems adapted to electro-optic transmissions when each host system utilizes an electro-optic transceiver in accordance with the prior art.
[0010] [0010]FIG. 2 is a simplified block diagram illustrating failure of handshaking between two host systems adapted to electro-optic transmissions when each host system utilizes an electrical transceiver.
[0011] [0011]FIG. 3 is a flowchart illustrating operation of an electrical transceiver in order to allow handshaking between two host systems adapted to electro-optic transmissions in accordance with a preferred embodiment of the present invention.
[0012] [0012]FIG. 4 is a simplified block diagram illustrating handshaking between two host systems adapted to electro-optic transmissions when each host system utilizes an electrical transceiver in accordance with a preferred embodiment of the present invention.
[0013] [0013]FIG. 5 is a simplified block diagram illustrating handshaking between two host systems adapted to electro-optic transmissions when each host system utilizes an electrical transceiver and a first handshaking is not performed in accordance with a preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] [0014]FIG. 1 shows a host 11 that includes an electro-optic transceiver 15 and a host module 12 adapted to electro-optic transmissions. A data path 13 represents data transmissions between host module 12 and electro-optic transceiver 15 . A receiver status signal 14 represents transmission of receiver status from electro-optic transceiver 15 to host module 12 . For example, host module 12 and electro-optic transceiver 15 are adapted to use the 1000 BASE-X protocol.
[0015] A host 21 includes an electro-optic transceiver 25 and a host module 22 adapted to electro-optic transmissions. A data path 23 represents data transmissions between host module 22 and electro-optic transceiver 25 . A receiver status signal 24 represents transmission of receiver status from electro-optic transceiver 25 to host module 22 . For example, host module 22 and electro-optic transceiver 25 are adapted to use the 1000 BASE-X protocol.
[0016] Electro-optic transceiver 15 and electro-optic transceiver 25 are connected via a fiber optic cable link 10 . When electro-optic transceiver 15 first detects light from fiber optic cable link 10 , electro-optic transceiver 15 transmits the receiver status signal 14 to host module 12 indicating reception of optical power. Likewise, when electro-optic transceiver 25 first detects light from fiber optic cable link 10 , electro-optic transceiver 25 transmits the receiver status signal 24 to host module 22 indicating reception of optical power. When each host module receives a receiver status transmission, handshaking 20 is performed between host module 12 and host module 22 . Electro-optic transceiver 15 and electro-optic transceiver 25 serve as conduits of information during handshaking 20 .
[0017] [0017]FIG. 2 illustrates what occurs when fiber optic cable link 10 is replaced with an electrical cable link 33 , when within host 11 , electro-optic transceiver 15 is replaced by an electrical transceiver 31 , and when within host 21 , electro-optic transceiver 25 is replaced by an electrical transceiver 32 . In electrical cable base systems there is nothing equivalent to a receiver status signal that indicates the reception of optical power. Therefore, electrical transceiver 31 never transmits a receiver status transmission to host module 12 indicating reception of optical power. Likewise, electrical transceiver 32 never transmits a receiver status transmission to host module 22 indicating reception of optical power. Handshaking 34 , between host module 12 and host module 22 is never started and communication between host 11 and host 21 does not take place.
[0018] In the preferred embodiment of the present invention, the protocol under which a standard electrical transceiver operates is modified to allow for communication between host 11 and host 21 over an electrical cable link.
[0019] For example, FIG. 3 shows a flowchart illustrating operation of an electrical transceiver that allows for communication between host 11 and host 21 over an electrical cable link. In a preferred embodiment, the operation uses a three-step handshaking process that establishes a link between two BASE-X hosts with BASE-T transceivers while maintaining the receiver status signal functionality. Modifications are made only to the electrical transceivers to accommodate the new handshaking process. The host modules remain unchanged and thus are unaware that they are performing handshaking across an electrical link rather than a fiber optic link.
[0020] In a block 41 handshaking begins. In a block 42 , handshaking is started between the transceiver and the host. This is illustrated in FIG. 4. FIG. 4 shows an electrical transceiver 51 placed within host 11 , and an electrical transceiver 52 placed within host 21 . Electrical transceiver 51 and electrical transceiver 52 are connected via an electrical cable link 53 .
[0021] The starting of handshaking between the transceiver and the host is represented by handshaking 54 between host module 12 and an electrical transceiver 51 . Handshaking 54 is initialized by electrical transceiver 51 transmitting the receiver status signal 14 to host module 12 indicating reception of optical power. This is a dummy transmission since electrical transceiver 51 is not connected to an optical fiber cable and does not detect reception of optical power.
[0022] The use of a dummy transmission allows initial initiation of a link and allows restoration of a link when recovering from a signal loss in an established link (e.g., caused by a cable being unplugged). After a predetermined amount of time after loss of signal, each electrical transceiver transmits a dummy receiver status signal 14 to its host indicating reception of optical power. The transmission of the dummy receiver status signal 14 causes the host module to be ready to begin handshaking. This allows handshaking 54 to begin between host module 12 and the electrical transceiver 51 after a link is disrupted. Further handshaking, however, will not be able to proceed until the link is restored.
[0023] In the preferred embodiment of the present invention, the functionality of the receiver status signal is maintained by the use of a single pulse with pre-determined width (i.e., the pre-determined amount of time after loss of signal). In the prior art, when an electro-optic transceiver is used, the pulse width is not pre-determined; rather, the pulse width is determined by the length of time between when optical power is lost and when optical power is once again sent into the electro-optic transceiver. In the preferred embodiment of the present invention, when an electrical transceiver is used, the receiver status signal will change to alert the host system that the link has been broken. After a pre-determined amount of time, the status signal is returned to its “link-established” state and the host module is thereby informed that the handshaking process must resume. The pulse width is determined by the length of time required by a given host module to react to the change in receiver status. Individual host modules might have different requirements, so in the preferred embodiment, the pulse width is programmable within the electrical transceiver.
[0024] During handshaking 54 , electrical transceiver 51 obtains information from host module 12 that electrical transceiver 51 will need to perform handshaking with electrical transceiver 52 . For example, when host module 12 and host module 22 operate in accordance with the 1000 Base-X protocol, electrical transceiver 51 obtains from host module 12 the FD (full duplex), HD (half duplex), PS1 (PAUSE), PS2 (ASM_DIR), RF (remote fault) bits from host module 12 . These bits are passed in a word (or collection of bits) called a “configuration register base page” or “config_reg base page”. For example, electrical transceiver 51 passes to host module 12 dummy values for these bits pertaining to host module 22 in order to perform handshaking 54 .
[0025] After obtaining from host module 12 the information which electrical transceiver 51 will need to perform handshaking with electrical transceiver 52 , electrical transceiver suspends handshaking with host module 12 . For example, when host module 12 operates in accordance with the 1000 Base-X protocol, electrical transceiver 52 holds host module 12 in the idle_detect state while further handshaking (auto-negotiation) proceeds.
[0026] In a block 43 (shown in FIG. 3) handshaking between transceivers is performed. This is represented in FIG. 4 by handshaking 55 . During the handshaking between the electrical transceivers, the transceivers agree on settings for optimal communication. In addition, the electrical transceivers share the information that they obtained from their respective host modules during the handshaking performed in block 42 . For example, when the host modules operate in accordance with the 1000 Base-X protocol, the information obtained from the host modules is composed of the FD (full duplex), HD (half duplex), PS1 (PAUSE), PS2 (ASM_DIR), RF (remote fault) bits.
[0027] For example, when electrical transceiver 51 and electrical transceiver 52 operate in accordance with the 1000 Base-T protocol, the values of the FD, HD, PS1 and PS2 bits are used as the “local” values during Clause 28 autonegotiation (handshaking 55 ). PS1 and PS2 are sent in bits of the clause 28 auto-negotiation “page 1”. FD (Clause 28 1000FDX) and HD (Clause 28 1000HDX) are sent in bits of the clause 28 auto-negotiation “base pages/next pages”. Clause 37 logic does not implement next pages, which are only used in clause 28 logic for 1000Base-T. Conflicts in the pause encoding and/or the duplex status are resolved as in IEEE802.3:2000, annex 28 B, and the resulting values of these 4 bits are carried to the next auto-negotiation. The Clause 28 auto-negotiation also determines which module is the master and which is the slave.
[0028] Once handshaking 55 is completed, in a block 44 (shown in FIG. 3), the electrical transceivers restart the traditional electro-optical handshaking with the host modules. This is represented in FIG. 4 by handshaking 56 . Handshaking 54 is terminated. In handshaking 56 , electrical transceiver 51 passes the actual information regarding host module 22 that electrical transceiver 51 received during handshaking 55 . Electrical transceiver 51 allows the handshaking with host module 22 to complete, thereby establishing the link with common settings at each end of the electrical cable link 53 .
[0029] For example, when host module 12 and host module 22 operate in accordance with the 1000 Base-X protocol, during handshaking 56 , the config_reg base page electrical transceiver 51 receives from host module 12 is checked against the config_reg base page which electrical transceiver 51 received from host module 12 during handshaking 54 . If no difference is detected, then the bit values resulting from the resolution of handshaking 56 are placed into bits of a register in the host module and data is sent and received according to the protocol specified by these bits.
[0030] If the config_reg base page which electrical transceiver 51 received from host module 12 during handshaking 56 is different than the config_reg base page which electrical transceiver 51 received from host module 12 during handshaking 54 , electrical transceiver 51 will force the entire handshaking process to start again, beginning with handshaking 54 .
[0031] In an alternative embodiment of the present invention, handshaking 54 can be disabled provided the electrical transceivers can obtain necessary information to perform handshaking 55 and handshaking 56 without performing handshaking 54 . This is illustrated in FIG. 5, where handshaking 54 is eliminated from the initialization process.
[0032] For example, when host module 12 and host module 22 operate in accordance with the 1000 Base-X protocol, during handshaking 55 (e.g., a clause 28 auto-negotiation), each electrical transceiver obtains the local values for PS1, PS2, FD and HD from values previously stored in registers within the electrical transceiver.
[0033] When handshaking 54 is disabled, a preferred embodiment allows the option to set RX-LOS to be the opposite of link_status. In this case, the receiver status can reflect the actual status of the link.
[0034] The present invention provides for assurance of link establishment when electrical transceivers are used in a system that was originally designed for electro-optic transceivers an when encoding/decoding transceivers are used in a system that was originally designed for transceivers that pass data bit for bit. In addition, improved system performance and integrity is achieved by providing expected acknowledgment of signal loss and acquisition to the system when electrical transceivers are used in a system that was originally designed for electrooptic transceivers.
[0035] The foregoing discussion discloses and describes merely exemplary methods and embodiments of the present invention. As will be understood by those familiar with the art, the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims. | Handshaking is performed between a first host system and a second host system. First handshaking is performed between a host module within the first host system and a first transceiver within the first host system. The first handshaking includes passing from the first transceiver to the host module dummy information about the second host system. Second handshaking is performed between a second transceiver within the second host system and the first transceiver. The second handshaking includes obtaining, by the first transceiver from the second transceiver, first information about the second host system. Handshaking between the host module and the first transceiver is restarted. This includes passing from the first transceiver to the host module the first information about the second host system. The first information replaces the dummy information passed from the first transceiver to the host module during the first handshaking. | 7 |
BACKGROUND OF THE INVENTION
1. Technical Subject
The innovation disclosed hereunder consists in a device for controlling at least one thread in a textile machine, especially a warp thread in a weaving loom.
2. State of the Art
Numerous devices for the controlling of the transverse movement of a thread in a textile machine, especially a warp thread are well known to those learned in the art. The threads are threaded through and guided by the eyes of heddles which are moved, according to a determined programme and via connecting structures, by different driving devices such as jacquard machines, heddle looms, treadle looms and colour control units. These machines and devices involve large numbers of different components, which unavoidably exerts a negative influence on the speed of the thread control mechanism. The already disclosed systems are additionally characterised by the following significant disadvantages: high forces of gravity, significant wear and tear, great emission of noise, significant vibration, enormous space requirements, high production and operating costs, poor ergonomic characteristics, etc.
So far, many attempts were made to eliminate these disadvantages.
Under U.S. Pat. No. 3,867,966, for example, a device of the type mentioned above was disclosed which attempts to eliminate the disadvantages described by way of introduction. This device comprises a dragging element inserted between two springs, which serves to drag at least one thread. An arresting device controlled by means of a control unit serves to temporarily arrest the dragging element in at least one extreme position. The dragging element is designed in the form of a heddle, which comprises a ribbon section, which contains a conductor and is located between two isolators. This ribbon section runs over a roller, which can be electrically activated. As soon as electrical current is fed to the roller or to the ribbon section, respectively, friction between the roller and the ribbon section increases so that the ribbon section can be dragged by the roller and moved to an extreme position where magnetic arresting devices are located which arrest the heddle as long as the electrical arresting devices are activated. A considerable disadvantage of this type of device, however, consists in the fact that the heddle must be equipped with a ribbon section, which contains electrically conducting elements and that dragging is effected by friction only. This causes high wear between the roller and the ribbon section. Additionally, even friction between the ribbon section and the roller cannot be guaranteed, because friction is constantly changing due to both wear and the accumulation of dirt.
SUMMARY OF THE INVENTION
The purpose of the invention disclosed hereunder consists in further improving a device of the type mentioned above.
The invention's characterising features employ springs and a dragging element. As the springs and the dragging element are designed as a system that oscillates freely at its natural frequency, the system, once activated, continues to oscillate independently, the only further requirement consisting in supplying a sufficient amount of energy to make up for system-related losses of energy, e.g. due to friction, etc. This energy supply, however, can be effected by extremely simple means.
Thus an extremely simple and economically viable device for controlling the transverse movement of at least one thread of a textile machine can be designed. Additionally, the design stands out for good wear-resistance and requires only a small energy supply to keep it operating. The arresting device allows selective control immediately at the thread-dragging element. With only few components and good wear-resistance, the device allows significantly higher drive speeds.
Several different advantageous designs are available.
One design allows programmed controlling of the device by very simple means.
In one design which is particularly advantageous an additional individual control can be achieved, for example, by keeping one shed open. It is, in particular, possible to adapt the oscillating system to the rotational speed of the machine connected thereto, in particular a weaving loom. The arresting device can be designed in a variety of different ways. It is, for example, possible to allocate a mechanically, pneumatically or electrically operated arresting pin to the dragging element. A particularly simple and low-wear design employs an arresting device with a releasable magnet device. The magnetic device can, for example, consist of a permanently magnetic device, which interacts with a ferromagnetic component and can be released by mechanical or pneumatic means. However, a design employing a permanent magnet influenced by an electromagnet is more advantageous.
To keep the oscillating system moving, energy must be supplied. This can be effected in different ways. In one design which is particularly recommended, the arresting device at the same time serves to supply the required energy as the dragging element is always lifted to the same height. A more active way of supplying energy is allowed by a piston and cylinder. In this case, a hydraulic fluid supplied to the piston and cylinder design can serve as a means to supply energy. In a particularly simple solution, on the other hand, the energy supply can be designed in such a way that it exceeds the amount of energy required to keep the oscillating system moving, thus allowing additional control effects to be achieved.
The device should preferably be equipped with a resetting device which temporarily renders the springs of the oscillating system ineffective. Such a resetting device is especially recommended for applications where the thread dragging elements must be moved to a centre shed position for adjusting and/or repair work. From this position, the device cannot start itself as the spring forces offset each other. Thus, the thread dragging elements must be moved to the corresponding arresting devices in one of the extreme positions by means of the resetting device. From these extreme positions, the thread dragging elements can then, due to the corresponding spring tension, be released to oscillate. The resetting device can, for example, act directly on the thread-dragging element or relieve the springs on one side.
The thread can be connected to the dragging element in different ways. In the simplest design the thread-dragging element is located between the springs and designed in the form of an eye. However, the unit to which the thread is connected can be located outside the oscillating system by means of an extension of the dragging element. The oscillating system can be used to control a single thread or several threads at the same time. In the latter case the dragging element can be designed in the form of a heddle frame.
BRIEF DESCRIPTION OF THE DRAWINGS
Examples for the design of the invention are described below on the basis of the following drawings showing the structures indicated below:
FIG. 1 shows the oscillating system of a device according to the invention disclosed hereunder in the raised position.
FIG. 2 shows the oscillating system illustrated in FIG. 1 in the lowered position.
FIG. 3 shows the theoretical ideal sequence of oscillations of the oscillation system illustrated in FIG. 1 and FIG. 2.
FIG. 4 shows the actual sequence of oscillations of the oscillation system illustrated in FIG. 1 and FIG. 2.
FIG. 5 shows the oscillating system illustrated in FIG. 1 and FIG. 2 including arresting devices in the extreme positions.
FIG. 6 shows a controlled sequence of oscillations of the oscillation system illustrated in FIG. 5.
FIG. 7 shows the curve of the oscillating system depending on the rotational position of the machine connected thereto at different rotational speeds.
FIG. 8 shows a vertical section of a combination of an arresting device and an energy supplying mechanism.
FIG. 9 and FIG. 10 show a vertical section of another arresting device in the two extreme positions.
FIG. 11 shows a vertical section of yet another arresting device.
FIG. 12 shows a schematic illustration of a weaving loom equipped with the device disclosed hereunder.
FIG. 13 shows the load characteristic of the upper and the lower spring of the device illustrated in FIG. 12 during half an oscillation cycle.
FIG. 14 shows a schematic lateral view of a weaving loom with arresting devices according to FIG. 11.
FIG. 15 shows the weaving loom illustrated in FIG. 14 with an arresting device according to FIG. 9 and FIG. 10.
FIG. 16 shows a schematic lateral view of a weaving loom with another modified version of the device disclosed hereunder.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 and FIG. 2 as well as diagrams 3 and 4 illustrate the principle underlying the invention disclosed hereunder, i.e. an oscillating system consisting of a dragging element 2 for the transverse movement of a thread 4, the dragging element 2 being attached to a machine frame 10 by means of an upper spring 6 and a lower spring 8. In the ideal case, the oscillation system would, according to curve 13 in FIG. 3, continue to oscillate indefinitely at the natural frequency f (oscillations/second): ##EQU1## where: m=mass of the oscillating system, whereby also the mass of the spring and the mass of the threads to be moved must be taken into account.
c=spring constant of the oscillating system, taking into account not only the upper spring 6 and the lower spring 8, but also the restoring force caused by the transverse movement of the thread 4.
In the ideal case--which, however, doesn't exist--the oscillating system would oscillate according to curve 13 illustrated in FIG. 3, the amplitude A being a full oscillation during time T: ##EQU2##
This ideal case doesn't occur in real life. Instead, friction, work of deformation, etc. consume the oscillation energy, so that the oscillating system oscillates according to curve 13a illustrated in FIG. 4, the amplitude decreasing from one oscillation to the next by ΔA. To keep the system moving, it is therefore necessary to continuously supply a smaller or larger quantity of energy.
FIG. 5 and diagram 6 show the oscillating system of FIG. 1 and FIG. 2, the device, however, being supplemented by an upper arresting device 12 and a lower arresting device 14, which are designed as electromagnetic units and can be controlled by a control unit 16. The arresting devices 12 and 14 deflect the oscillating dragging element 2 during each oscillation into the extreme position determined by the amplitude A. Thereby, the arresting devices 12 and 14 serve both to supply energy, as they make up for the reduction of the oscillation by ΔA, and to control the oscillating system. Thus the dragging element can for an adjustable period ts, for example for a full oscillation, be kept in the upper or lower position as this is illustrated by curve sections 13b and 13c of curve 13 in FIG. 6. Thus, the transverse movement of the thread 4 can be individually controlled in the way required, for example, for the production of patterned fabrics on a weaving loom.
FIG. 7 shows the curve travelled by the device during one rotation of the main shaft of a weaving loom at different rotational speeds π (rotations/second). Curve 13 shows the borderline case where the rotational speed of the weaving loom equals the frequency of the oscillating system. When the weaving loom works more slowly, the oscillating system must be stopped at periodic intervals so as to synchronise the oscillating system with the rotational speed of the weaving loom. Curve 13d shows the situation that prevails in the case of fast operating weaving looms where the arresting time per half oscillation is 2×ts1. The arresting time increases when the rotational speed of the weaving loom is reduced and amounts, for example in curve 13e where the situation prevailing when the weaving loom works more slowly is illustrated, to 2×ts2. FIG. 7 also indicates the area 15 available for weft insertion.
FIG. 8 shows another design of the device for the transverse movement of a thread. In this case, the dragging element 2a is provided with a rod 18 on which a piston-shaped element 20 is mounted which consists of a permanent magnet. This piston-shaped element moves within a cylinder 22 which is provided with a ferromagnetic terminal section 24 and 26 at the upper and lower end against which element 20 is arrested in the upper or lower extreme position, respectively. Cylinder 22 contains a coil 28, which is connected with the control unit 16 via wires 30. Depending on the activation of the coil 28, this device performs different tasks. On the one hand, the coil can be used to release element 20 from the ferromagnetic terminal section 24 or 26 so as to trigger the oscillating movement. On the other hand, the coil 28 can be activated in such a way that it supports the movement of the element 20 and, thus, the movement of the dragging element 2a against the terminal section 24 or 26, respectively. In this case, coil 28 serves to supply the oscillating system with energy. The system can be designed in such a way that the cylinder 22 extends over the entire travelling distance of the dragging element 2a. It is, however, also possible to divide the cylinder 22 and to limit it, as shown in FIG. 11, to the extreme positions of the oscillating system. Instead of the coil, the cylinder can also be connected to a hydraulic fluid system, which can serve to provide a controlled energy supply.
FIG. 9 and FIG. 10 show another dragging element 2b which is provided with a rod 32 on which two piston-shaped elements 34 and 36 are mounted between arresting devices 12b and 14b which are mounted in block-type arrangement. In this case the arresting device 12b, which marks the upper extreme position and to which the piston-shaped element 34 adheres, is located at the bottom and the arresting device 14b, which marks the lower extreme position and to which element 36 adheres, at the top. The arresting devices 12b and 14b consist of permanently magnetic rings 38 arranged in such a way that their identical poles are facing each other. Within each ring 38, there are electromagnets 40, which can be operated by the above-mentioned control unit 16. As soon as the extreme position is reached, the piston-shaped elements 34 and 36 adhere to the respective arresting devices 12b and 14b and are released only upon activation of the electromagnets 40 to perform another oscillating movement.
FIG. 11 shows the device illustrated in FIG. 9 and FIG. 10, the arresting devices 12c and 14c, however, being arranged at a distance from each other which defines the travelling distance and the dragging element 2c being provided with only one piston-shaped element 42 which moves between the two arresting devices 12c and 14c.
FIG. 12 contains a schematic illustration of a weaving loom provided with the devices disclosed hereunder. The weaving loom contains a warp beam 44 around which warp threads 46 are wound and which are fed over a guide roller 48 to the weaving site 50. The devices 52 disclosed hereunder are used to control the warp threads 46 and to create the shed 54 into which weft threads 56 are inserted and arrested by means of a weaving reed 58. The resulting fabric 60 is removed via an outfeed unit 62. The control unit 52 contains a dragging element 2a and an arresting device 12a and 14a according to FIG. 8. The dragging element 2a is provided with a heddle 64, which contains an eye 66 for the dragging of a warp thread 46. The control unit 52 is, additionally, provided with a resetting device 68 which comprises an arm 72 which swivels around axle 70 and to which the lower end of the respective lower spring 8 is attached. An actuator 74 can move the swivelling arm upwards, thus relieving the springs 8. The resetting device 68 is used to take the control unit 52 back into the initial position required to put the system into operation in which the piston-shaped element 20 adheres to the respective arresting device 12a or 14a, should a reset be required for any reason, e.g. after adjustment or repair work. Such a situation exists, for example, when the eyes are located in the centre shed 76. Then the lower springs 8 are relieved upon operation of the actuator 74 whereupon the spring force of the upper springs 6 prevails so that the piston-shaped elements 20 can be moved towards and adhere to their respective upper arresting devices 12a.
FIG. 13 shows the spring force characteristics of the springs 6 and 8, Ko referring to the upper spring 6 and Ku to the lower spring 8, Kr being the force characteristics resulting for the dragging element 2a. This illustration shows that no force acts upon the dragging element when the dragging element 2a is located in the centre shed 76, which means that a resetting device 68 is needed to take the dragging element 2a back to one of the arresting devices.
FIG. 14 shows a schematic illustration of another weaving loom designed in analogy to the weaving loom shown in FIG. 12 but provided with arresting devices 12c and 14c according to FIG. 11. FIG. 15 contains a schematic illustration of the equipment of a weaving loom with the arresting devices 12b and 14b according to FIG. 9 and FIG. 10.
FIG. 16 shows the weaving loom schematically illustrated in FIG. 14, the eye 78 for the dragging of the warp thread 46, however, not being located within, i.e. between the upper and the lower spring 6 and 8 but outside. For this purpose, the dragging element 2d is designed in the form of a rod which is extended upward through the upper spring 6 and provided with the eye 78 in this extended section.
In the designs presented, the thread-dragging element is usually illustrated as an eye for the dragging of a single thread. The arrangement, however, can also be designed in such a way that the dragging element is, instead of an eye, connected to a known heddle frame design which can be used to control several threads at the same time.
Due to the elimination of the state of the art connecting elements and the known upstream shedding machines, the device disclosed hereunder can, for example, be used to achieve the following significant characteristics or advantages, respectively:
Significantly reduced space consumption. Thus the workplace can be optimally designed.
The top of the machine need not be provided with additional structures. This offers the advantage of an optimal view over the entire machine and better handling.
Small forces of inertia as fewer parts are moving. Therefore, higher rotational speeds are possible.
Small number of wearing points and practically no vibrations. This allows a high reduction of the noise emission level.
Dramatic reduction of the danger of accidents due to fewer critical moving parts.
Simple maintenance due to simple parts and few components.
The workplace can be optimally equipped from an ergonomic point of view.
The cost of the device disclosed hereunder is extremely low, as no expensive additional components are required. Economically viable textile production is possible both in high and in low wage countries.
No harness, no beams and utilisation of the oscillation energy. Thus enormous energy savings are possible. Energy is only supplied to make up for friction losses.
No force from spring restoring devices and no forces of inertia due to acceleration of the connecting elements.
______________________________________LIST OF REFERENCES______________________________________A amplitudeΔA lost share of the amplitudeT durationTs arresting timets1 arresting time at fast operationts2 arresting time at slow operation 2 dragging element 2a dragging element 2b dragging element 2c dragging element 2d dragging element 4 thread 6 spring, upper 7 spring, lower10 machine frame12 arresting device, upper12a arresting device, upper12b arresting device, upper12c arresting device, upper13 oscillation curve (ideal)13a oscillation curve (actual)13b curve section, upper13c curve section, lower13d oscillation curve, fast operation13e oscillation curve, slow operation14 arresting device, lower14a arresting device, lower14b arresting device, lower14c arresting device, lower15 weft insertion area16 control unit18 rod20 piston-shaped element22 cylinder24 ferromagnetic terminal section26 ferromagnetic terminal section28 coil30 wire32 rod34 piston-shaped element36 piston-shaped element38 ring40 electromagnets42 piston-shaped element44 warp beam46 warp thread48 deflection roller50 weaving site52 control unit54 shed56 weft thread58 weaving reed60 fabric62 outfeed unit64 heddle66 eye68 resetting device70 axle72 arm74 actuator76 centre shed78 eye______________________________________ | In a textile machine, a device for controlling the transverse movement of a thread, such as a warp thread in a weaving machine, comprises a dragging element (2) for dragging a thread (4) moving in a transverse direction, whereby said dragging element (2) is attached on both sides to a frame (10) by means of springs (6,8). The device forms a system that oscillates freely at its natural frequency. Arresting devices (12,14) can adjustably and temporarily hold the dragging element in the extreme positions. | 3 |
TECHNICAL FIELD
The present invention is directed to high purity carbon fiber reinforced carbon composite (C/C composite) with lowering impurities content by high purity treatment. More particularly, the present invention is directed to high purity C/C composite of using high purity carbon fibers which was high purified at carbon fiber stage and manufacturing method thereof.
BACKGROUND OF THE INVENTION
FIG. 2 shows a pulling single crystal apparatus used in the Czochralski process (CZ process) for manufacturing a single crystal ingot for use as a material of the semiconductor wafer and the like. As shown in FIG. 2, the CZ apparatus is so structured that a raw material in a quartz crucible 1 is heated to a high temperature by a heater 2 disposed around the quartz crucible 1 so that the raw material can be converted into the melt 3 which is pulled under vacuum pressure to form the single crystal ingot 4 .
The structural elements, such as a crucible 5 supporting the quartz crucible 1 and an upper ring 6 , an inner shield 7 and others which are subjected to radiant heat of the heater 2 , are exposed to high temperature when pulling a single crystal ingot 4 from the quartz crucible 1 within a molten silicon. Accordingly, the structural elements must be formed of a material that can maintain a prescribed mechanical strength under high temperature. Further, the structural elements must be formed of a material of high-purity, because impurities, such as metals, contained in the structural elements become a cause of crystal defects in orientation of the solidifying of the single crystal ingot 4 and also become a factor of reduction of purity, when leaked during manufacturing. In general, a high purity graphite having excellent mechanical properties at high temperature and having high-purity is used for the structural elements of the CZ apparatus (Japanese Patent Publication No. Hei 6(1994)-35325).
Recently, with increasing diameter of the single crystal, the single crystal pulling apparatus used in the CZ process is increased in size. This produces a handling problem caused by the increased weights for the existing graphite elements and a problem of reduction in effective processing size of the inside of the apparatus.
The C/C composite has properties of lightweight and strong mechanical strength, as compared with the graphite material. By virtue of this, even when reducing in thickness, the structural elements of the C/C composite can have a strength equal to those of the graphite material, to enable an effective use of a processing chamber of the apparatus. In addition, by virtue of being lightweight, a good handling can be achieved in, for example, placement in the apparatus. By virtue of these, the crucible components used in the CZ apparatus having a large diameter are now moving from those made of the graphite to those made of the C/C composite.
However, the C/C composite was difficult to high purity for the CZ apparatus in comparison with the graphite. Then, such a problem is not only for the CZ apparatus in the semiconductor industry. An atomic energy field, aviation and universe fields have also the same problem.
SUMMARY OF THE INVENTION
In the object of the present invention to provide a high purity C/C composite with lowering contents of metal impurities with high mechanical properties at high temperature and manufacturing method thereof.
To accomplish the above the object, the high purity C/C composite formed by graphitizing a molded member packed with carbon fibers and carbon material of a matrix. The carbon fibers are high purified under halogen gas atmosphere before graphitizing. The purified carbon fibers are molded into the desired shape on a tool or in die with infiltrating the carbon material of the matrix. The molded member packed with carbon fibers and carbon material of the matrix are either independently or simultaneously graphitized with the high-purification under halogen gas atmosphere.
The carbon material of the matrix infiltrated carbon fiber become into graphite fiber after graphitizing. The carbon material of the matrix around the graphite fibers are also became into graphite and coated the graphite fibers. The inventive high-purity C/C composite consists of two graphite, namely, the high-purity graphite fibers and the high-purity graphite matrix. According to the structural of the C/C composite, the metal impurities may be difficult to dissolve from the inside of the graphite fibers.
Therefore, for example, the C/C composite was high purified under halogen gas at one time after graphitizing the molded C/C composite whose are structured to coat the graphite matrix on the graphite fibers. Accordingly the structure, the C/C composite may be mainly purified around the outside surface of the graphite matrix, and the impurities of the inside of the graphite matrix and of the graphite fibers may be difficult to purify in the purification process of these. The graphite fibers of the present invention is high purified because of the fibers are purified under halogen gas atmosphere before molding and graphitizing, and then the graphitized and the molded C/C component are either independently or simultaneously graphitized with high-purification under halogen gas atmosphere. An ash content of the C/C composite is 5 to 100 ppm, more preferably 5 to 30 ppm.
The carbon fibers may be used polyacrylonitrile (PAN), rayon or pitch. The impurities content (ash content) of the carbon fiber may be not more than 100 ppm, and more preferably 80 ppm, and more preferably 60 ppm because of the impurities content of the C/C composite is not more than 20 ppm. The carbon fibers may be high purified before or after infiltrating with the matrix.
The matrix may be used carbon including resin and/or pyrolytic carbon (PyC). The resin may be selected from the group including phenol (resole, novolak), furan, polyimide, polyamide-imide, polyether imide, polycarbodiimide and bisallyldiimide or combination thereof may be used within the range within which its property is not impaired. Solvent may be used in combination, when necessary. The material gas of the PyC may be selected from the group including aliphatic hydrocarbon as methane and propane, aromatic hydrocarbon as benzene, toluene and xylene and chlorine including hydrocarbon as dichloroethylene, dichloromethane, trichloromethane and trichloroethylene or combination thereof may be used within the range within which its property is not impaired.
The high purity C/C composite can be used for the structure member of the CZ apparatus, which manufactures bulk crystal as shown in FIG. 2 . In FIG. 2, it can be used for crucible 5 , upper ring 6 , inner shield 7 , lower ring 8 , lower heater 9 , thermal insulator 10 and spiltray 11 . Furthermore, the high purity C/C composite can be used for the plasma confrontation the first wall of the nuclear fusion device for the atomic energy, the tile of divertor, the material for the universe aviation, and so on.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of the manufacturing the high purity C/C composite.
FIG. 2 is a schematic cross sectional views of the CZ apparatus.
DETAILED DESCRIPTION OF THE INVENTION
The manufacturing process of the high-purity C/C composite of the present invention is separating as a molding carbon fibers, a first high purification process of the carbon fibers, a densification, a baking and a carbonization, a graphitization and a second high purification process.
The first high purification process of the carbon fibers was treated at heating temperature of 1,800 to 2,200° C. for heating time of 5 to 30 hours under halogen gas atmosphere. The second high purification process was treated at heating temperature of 2,000 to 2,400° C. equal to or higher than the first high purification process temperature by 100 to 200° C. for heating time of 5 to 30 hours under halogen gas atmosphere. The first high purification process can be disposed every time before graphitization.
The carbon fibers were high purified in the first high purification process before the graphitization. Accordingly, the carbon fibers of the graphitized member can be very high purity. Therefore, the C/C composite which comprising the carbon fibers and the matrix can be very high purity by high-purified to the matrix in the second high purification process.
The densification process is desirable to densify with the matrix by repeating the infiltrating process, the graphitization and the second high purification process. The matrix of the each infiltrated thereof can be high purified every time after the densification. Accordingly, the matrix of the C/C composite can be high purified in comparison with conventional C/C composite.
The infiltrating process is desirable to impregnating with the PyC by Chemical Vapor Infiltration (CVI), because of CVI can be prevented impurities contaminating to the member. Therefore, it is because it can get the C/C composite under the condition which high purity turns to all the more because of the impurities, which exist in the depths of the matrix, are decreased before graphitization.
As following, the manufacturing process of the above is explained in detail based on the flow chart of FIG. 1 .
As shown in FIG. 1, the PAN or pitch carbon fibers are prepared first (S 1 ). Then, the carbon fibers are subjected to high purification at 1,800° C. to 2,200° C. under a halogen gas atmosphere (first high purification process) (S 2 ). The halogen gas used including halogen or gas of a compound thereof. The halogen gases which may be used include chlorine, chlorine compound, fluorine and fluorine compound, together with compounds including chlorine and fluorine in the same molecule (monochlorotriflu oromethane, trichloromonofluoromethane, dichlorofluoroethane, trichloromono-fluoroethane and the like).
Then, the carbon fibers are allowed to react with these halogen gases, where by the impurities included in carbon fibers, metallic impurities in particular, are evaporated and volatilized as halide and removed from the carbon fibers. Thereafter, after the carbon fibers are allowed to stand in the same processing furnace for a prescribed time under a halogen gas atmosphere, hydrogen gas is fed to a reaction vessel so that the impurities, such as sulfur, can be deposited as hydride and thereby be removed.
After the high purification process (first high purification process) removes the impurities in the carbon fibers, the carbon fibers are molded and baked for carbonization on depending carbon fibers (S 3 ). And then, the infiltrating method for the carbon fibers molded member is selected (S 4 ). When infiltrating method by impregnating with resin and/or pitch is selected, the resin and/or the pitch are prepared for the matrix and impregnating with the matrix to the carbon fibers molded member (S 5 ). It is noted that although no particular limitation is imposed on the resin used, as long as it is the one that converts into solid phase carbon, one resin selected from the group including phenol (resole, novolak), furan, polyimide, polyamide-imide, polyether imide, polycarbodiimide and bisallyldiimide or combination thereof may be used within the range within which its property is not impaired. Solvent may be used in combination, when necessary. After the impregnated with the matrix, the molded member are baked at temperature 800 to 1,000° C., and thereby the matrix is carbonized in N 2 atmosphere (S 7 ). After the carbonization (S 7 ), it is judged whether it disposes of the graphitizing (S 8 ). If it is judged that it does not dispose of the graphitizing (S 8 , NO), when go back to step 4 and repeating this process 2 to 4 times for densification. On the other hand, if it is judged that it disposes of the graphitizing (S 8 , YES), when go to step 9 and the graphitizing at temperature of 2,000 to 2,500° C. (S 9 ).
On the other hand, when infiltrating method by CVI is selected, the hydrocarbon as methane, propane, benzene, toluene, xylene, dichloroethylene, dichloromethane, trichloromethane or trichloroethylene are prepared for the matrix. And then the hydrocarbon is heated in 700 to 2,000° C. to form the PyC and infiltrating to the molded member for densification (S 6 ). After this, the member is putted in a furnace for the graphitizing at temperature of 2,000 to 2,500° C. (S 9 ).
After the graphitizing, the halogen gas is supplied to the furnace, which is same furnace of the graphitizing with maintaining pressure of the furnace. Then, the carbon fibers and the matrix are allowed to react with these halogen gases, where by the impurities included in the carbon fibers and the matrix, the impurities in particular, are evaporated and volatilized as halide and removed from the carbon fibers and the matrix by second high purification process (S 10 ). Thereafter, after the carbon fibers and the matrix are allowed to stand in the same furnace for a prescribed time under a halogen gas atmosphere, hydrogen gas may be fed to a reaction vessel so that the impurities, such as sulfur, can be deposited as hydride and thereby be removed.
And then, it is judged whether it disposes of the densification based on the product specification (S 11 ). If it is judged that it disposed of the densification (S 11 , NO), when go back to step 4 and repeating this process 2 to 4 times for densification and high purification. Then, when the density of the member is corresponding to the product specification, it is judged that the densification isn't done (S 11 , YES), when the process is finished.
Above the manufacturing process, the graphitization process (S 9 ) and the second high purification process (S 10 ) are included the densification process. The graphitization process (S 9 ) and the second high purification process (S 10 ) can be disposed after the densification to thereby produce the end product.
While the present invention is described below more specifically with reference to the following examples, embodiments of the present invention are by no means limited to the following examples.
Example 1
A plain weave cloth of PAN carbon fibers (T-300 6K, made by TORAY INDUSTRIES, INC.) was cut out in 200 mm×200 mm. The cut plain weave cloth were heated to 2,000° C. under a halogen gas atmosphere for 25 hours (the first high purification process). The ash content was 76 ppm. The first high purified plain weave cloth laid 50 sheets and hot pressed at 160° C. under pressure of 3 MPa. Further the hot pressed 50 layers plain weave cloth was subjected to a pitch impregnation process and then was increased in temperature up to 1,000° C. at the heating ratio of 10° C./hr in the electric oven with nitrogen flow for baking. The impregnating with pitch and the baking process was repeated 3 times. Further the molded member was heated up to 2,000° C. for 50 hours under normal pressure of Argon gas atmosphere for the graphitization. After the graphitization,the member was high-purified at 2,200° C. for 30 hour under normal pressure of Halogen gas atmosphere for second high purification. The ash content of the C/C composite was not more than 20 ppm and the impurities as V, Ti, Fe, B and Al are mesured by ICP-OES. The impurities of the C/C composite are below the detection limit for ICP-OES.
Example 2
Except the using carbon fibers which are super yarn plain weave cloth of PAN carbon fibers (W-0202, made by TOHO RAIYON INDUSTRIES, INC.) were heated up to 800° C. for carbonization, the same processes as the Example 1. The ash content is not more than 20 ppm. The impurities of the C/C composite are below the detection limit for ICP-OES.
The ash content was measured precisely and filled in the platinum crucible having a 50 cc capacity, was heated at 950° C. in the oxygen stream (2-31/min) until it reached the constant weight, as aforementioned. Then, the test example was spontaneously cooled in the desiccator and the remaining ash content was measured. Also, the metal impurities were analyzed by ICP-OES (SPS-4000, made by SEIKO ELECTRIC Co.). The specimen were prepared 4 types solution for ICP-OES. The first one is a dissolved hydrochloric acid after a dissolved sodium bicarbonate. The second one is a dissolved hydrochloric acid after dissolved pyrosulfuric potassium. The third one is a dissolved nitric acid after a dissolved hydrogen fluoride. The fourth one is a dissolved hydrochloric acid. The detection limits of the elements are calculated from 3 times standard deviation of background noise level of the individual metal elements.
The high purity C/C composite of the present invention are below the detection limit for ICP-OES for almost metals, and are not more than 5 ppm for the ash content. | The high purity C/C composite formed by graphitizing a molded member packed with carbon fibers and carbon material of a matrix. The carbon fibers are high purified under halogen gas atmosphere. The purified carbon fibers are molded into the desired shape on a tool or in die with infiltrating the matrix. The molded member packed with carbon fibers and carbon material of the matrix are either independently or simultaneously graphitized and then high-purification under halogen gas atmosphere. According to the present process, the metal impurities can be very low contents. | 8 |
CLAIM OF PRIORITY
[0001] This patent application is a continuation of U.S. patent application Ser. No. 12/543,391, filed Aug. 18, 2009, which claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 61/089,763, entitled CERVICAL DILATION METER, (Attorney Docket No. 2872.001PRV), filed on Aug. 18, 2008, which is hereby incorporated by reference herein in its entirety.
BACKGROUND
[0002] The cervix is the portion of the uterus connecting the uterus to the vagina. The cervix is cylindrical or conical in shape, approximately one inch in length, and having a cervical canal passing through it with an external os opening to the vaginal cavity and internal os opening to the uterine cavity. During labor and delivery, the cervical canal is the channel through which the baby passes from the uterine cavity into the vaginal cavity. During labor, the position (station) of the cervix rotates from posterior to anterior
[0003] During labor, in response to coordinated uterine contractions and pressure created by the descending fetal head, the length of the cervix shortens and the cervical walls thin in a process known as “effacement”, and the cervix opens further or dilates. Effacement can be quantified in percentage, from 0% (no change) to 100% (completely thinned). Cervical dilation can be quantified as the diameter of the cervical opening, e.g., in centimeters ranging from zero (0) to ten (10) centimeters. When the cervix dilates to ten (10) centimeters or greater, the cervical dilation can be deemed complete, and the patient can be encouraged to push the baby out. Before effacement and complete dilation, patients are encouraged not to push due to the risk of injury to both mother and baby. Effacement and dilation are critical indicators of the progress, or lack of progress, of labor. The degree and rate of effacement and dilation are monitored periodically during the first stage of labor. Slow or inadequate cervical dilation may indicate the need for administering a cervical ripening drug or applying a cervical dilating instruments or the need for surgical delivery.
[0004] A digital palpation is currently the standard procedure clinicians (physician, nurse, mid-wife, etc.) use to measure the cervical diameter. In digital examination, the clinician inserts a gloved hand into the vagina and uses the middle and index fingers to palpate or probe the cervix and external cervical os. The fingertips palpate and locate the external cervical os and are then spread until the fingertips contact opposing walls of the cervix. The distance between the spread fingertips corresponds to the cervical diameter. Using the digital palpation approach, the degree of dilation of the cervical os is estimated without any means to confirm visually the spacing between the index and middle fingers while situated within the cervical os.
[0005] During the course of labor in a patient, one or more clinicians perform, on average, ten digital examinations. However, digital examination provides only intermittent data for assessment of labor progression. Furthermore, the accuracy of digital examination is very subjective and may depend upon many factors, including the experience, judgment, and the size of the clinician's fingers, and error caused by the stretching of the cervix by the clinician's fingers. Although an individual clinician may achieve acceptable repeatability and accuracy using this method, it is normal to see a one (1) centimeter error or variation in measurement among serial measurements by the same clinician. If different clinicians examine the same patient during the course of labor, the inaccuracy of cervical dilation measurements increases due to inter-clinician variability.
[0006] Inaccurate or inconsistent measurements of cervical dilation may hinder the early detection of dysfunctional labor or delivery complications. Furthermore, despite the use of gloves, digital examination increases the risk of infection of the fetal membranes (chorioamnionitis), the lining and/or muscle of the uterus (endomyometritis), or of the infant (neonatal sepsis). This risk increases significantly after the fetal membranes have ruptured, and the risk of infection correlates to the number of digital exams. For this reason, it is preferable to minimize the number of digital exams, particularly after the fetal membranes have ruptured. Other disadvantages of digital examination measurements to determine cervical dilation include the inability to monitor dilation continuously, the procedure may dislodge fetal or uterine monitors, and the procedure is embarrassing and causes even more discomfort to the mother who is already experiencing significant pain due to labor.
[0007] Various mechanical and electrical systems have been devised to measure cervical dilation. See, e.g., Cervimetry: A Review of Methods for Measuring Cervical Dilation During Labor , Obstetrics & Gynecology Survey, Vol. 55(5): 312-320 (2000); see also, e.g., Sharf Y, Farine D. et al., Continuous Monitoring of Cervical Dilation and Fetal Head Station During Labor , Medical Engineering & Physics 29: 61-71 (2007). See also, e.g., the following U.S. Pat. Nos. and U.S. Patent Application Publication Nos. 2,924,220; 3,768,459; 4,141,345; 4,207,902; 4,245,656; 4,476,871; 4,611,603; 4,682,609; 4,719,925; 5,222,485; 5,450,857; 5,658,295; 5,713,371; 5,935,061; 6,039,701; 6,066,104; 6,200,279; 6,270,458; 6,383,137; 6,419,646; 6,423,000; 6,423,016; 6,524,259; 6,540,977; 6,669,653; 6,802,917; 6,966,881; 6,994,678; 7,150,108; 7,207,941; US 2005/0049509; US 2006/0020230; US 2007/0156067; US 2007/0156068; US 2007/0179410; US 2007/0179410; US 2007/0213640; US 2008/0021350; and also PCT Patent Application Publications WO 1987/03189; WO 2000/051494; WO 2004/098375; WO 2004/00373.
SUMMARY/OVERVIEW
[0008] The present inventors have recognized, among other things, that, unfortunately, none of the above-mentioned methods or devices have gained commercial acceptance for many reasons, including: patient discomfort and cervical tissue trauma due to attachment, penetration or active fixation engagement of the device to the cervical tissue (e.g., by needles, barbs, hooks, clamps, grips, or sutures); lack of accuracy due to cervical tissue distortion; inability to isolate measurement of cervical os dilation from measurement of changes in the station or movement of cervix during the progression of labor; blockage of the cervical canal (thus inhibiting descent of the fetal head and monitoring of fetal status and labor progression by known monitoring devices); complexity of the device or its installation; lack of disposability (thus high cost or a need to sterilize the device for later reuse in the patient); radiation, ultrasonic and electrical shock hazards; and unsuitability for patient ambulation or home use. Consequently, the present inventors have recognized and believe that there is currently no commercially available simple, objective mechanical monitoring device or system to measure cervical diameter, and digital examination continues to be the preferred method for measuring cervical diameter and dilation.
[0009] Thus, the present inventors have recognized, among other things, the usefulness of an objective monitoring device that can accurately measure cervical dilation, that can differentiate cervical dilation from change in cervical station, that need not be invasive (need not penetrate tissue by barbs, needles, clips, sutures, or other invasive means) and need not grip, clamp or compress the cervix or otherwise distort the cervix. The present inventors have also recognized the usefulness of a device to monitor cervical dilation that can be placed and retained in the patient throughout the first stage of labor, thereby allowing continuous or ongoing monitoring of cervical dilation. The present inventors have also recognized the usefulness of a device for measuring cervical dilation that can remain in place in the patient without obstructing descent of the fetal head (which can inhibit delivery) and that can easily be displaced or expelled from the patient, such as by the natural progression of labor, without requiring manual removal by the clinician. The present inventors have also recognized the usefulness of a device that has a measurement scale that can be located outside the body and that can be simple enough to interpret that the patient or her family can directly monitor the patient's cervical dilation, without the need for clinician oversight. The present inventors have also recognized the usefulness of a cervical dilation monitoring device that can permit the patient to remain ambulatory while the device is in place. In certain examples, the present devices and methods can provide one or more of such useful characteristics in monitoring cervical dilation. To better illustrate the subject matter described herein, a non-limiting list of examples follows.
[0010] Example 1 describes an apparatus comprising first and second arms, comprising respective proximal and distal portions, the proximal portions of the first and second arms coupled together, the distal portions of the first and second arms configured to be inserted between, and to exert enough of an outward force against, opposing lateral walls of a cervix or vagina to hold the apparatus in position, while measuring cervical dilation, without requiring active fixation to the cervix or vagina. In this example, a cervical dilation gauge assembly, communicatively coupled to the first and second arms to receive information about the cervical dilation, and comprising an external cervical dilation indicator to provide an indication of the cervical dilation to a user.
[0011] In Example 2, the apparatus of Example 1 is optionally configured such that an intermediate region of the first arm comprises an outwardly bowed first cephalic curve, and wherein an intermediate region of the second arm comprises an outwardly bowed second cephalic curve, and wherein concave portions of the first and second cephalic curves are opposing each other.
[0012] In Example 3, the apparatus of any one or any combination of Examples 1-2 is optionally configured such that the concave portions of the first and second cephalic curves are sized and shaped to receive and accommodate a fetal head therebetween.
[0013] In Example 4, the apparatus of any one or any combination of Examples 1-3 is optionally configured such that the concave portions of the first and second cephalic curves are sized and shaped to receive a descending fetal head therebetween during birthing while the first and second arms continue to exert enough of an outward force against opposing lateral walls of a cervix or vagina to hold the apparatus in position while measuring cervical dilation without requiring active fixation to the cervix or vagina.
[0014] In Example 5, the apparatus of any one or any combination of Examples 1-4 is optionally configured such that the first and second arms comprise respective first and second pelvic curves at or near a location between the intermediate and proximal portions of the respective first and second arms, such that the respective intermediate portions of the respective first and second arms angle or curve upward from the respective proximal portions of the respective first and second arms at an angle that is about 15 degrees to allow placement of the apparatus if the cervix is in a mid or anterior position.
[0015] In Example 6, the apparatus of any one or any combination of Examples 1-5 optionally comprises a spring, providing a force that is coupled to the first and second arms to bias the first and second arms away from each other.
[0016] In Example 7, the apparatus of any one or any combination of Examples 1-6 is optionally configured such that the spring is configured to exert enough of an outward force of the first and second arms against opposing lateral walls of the cervix or vagina to hold the apparatus in position while measuring cervical dilation without requiring active fixation to the cervix or vagina, and without exerting so much outward force so as to substantially affect the measuring of the cervical dilation.
[0017] In Example 8, the apparatus of any one or any combination of Examples 1-7 is optionally configured such that distal portions of the respective first and second arms respectively comprise first and second feet that are respectively coupled to respective intermediate portions of the respective first and second arms by respective first and second flexible members that are respectively more flexible than the respective first and second feet and the respective intermediate portions of the respective first and second arms, and wherein the respective first and second feet flex at respective angles, with respect to the respective first and second arms, in a plane formed by intermediate portions of the first and second arms.
[0018] In Example 9, the apparatus of any one or any combination of Examples 1-8 is optionally configured such that the first and second feet are respectively angled upward from a plane formed by the respective intermediate portions of the first and second arms by an angle that is about 30 degrees.
[0019] In Example 10, the apparatus of any one or any combination of Examples 1-9 is optionally configured such that the first and second feet respectively provide a surface area of at least about 2.0 cm 2 for contacting the cervix.
[0020] In Example 11, the apparatus of any one or any combination of Examples 1-10 optionally comprises a rotational pivot joint, coupling the proximal portions of the first and second arms together; and a spring, coupled to the first and second arms to exert an outward force to drive the first and second arms apart.
[0021] In Example 12, the apparatus of any one or any combination of Examples 1-11 optionally is configured such that the spring is located at a proximal end of a member extending from a location near or distal to the rotational pivot joint to a more proximal external location.
[0022] In Example 13, the apparatus of any one or any combination of Examples 1-12 is optionally configured such that the spring is located at the external location.
[0023] In Example 14, the apparatus of any one or any combination of Examples 1-13 is optionally configured such that the member comprises a cable.
[0024] In Example 15, the apparatus of any one or any combination of Examples 1-14 is optionally configured such that the member comprises a portion of a rack-and-pinion assembly.
[0025] In Example 16, the apparatus of any one or any combination of Examples 1-15 is optionally configured such that the spring is located at the rotational pivot joint.
[0026] In Example 17, the apparatus of any one or any combination of Examples 1-16 optionally comprises a stem including: a proximal portion coupled to the external indicator of cervical dilation; and a distal portion coupled to the proximal portion of at least one of the first and second arms.
[0027] In Example 18, the apparatus of any one or any combination of Examples 1-17 optionally comprises an introducer sheath, sized and shaped to constrain the first and second arms toward each other during insertion of the apparatus, and to permit removal of the sheath over the stem.
[0028] In Example 19, the apparatus of any one or any combination of Examples 1-18 optionally comprises a cable including a proximal portion coupled to the external indicator of cervical dilation, and a distal portion coupled to at least one of the first and second arms, and wherein the cable is constrained such that a position of a proximal end of the cable is correlative to the cervical dilation.
[0029] In Example 20, the apparatus of any one or any combination of Examples 1-19 optionally comprises a spring, coupled to a proximal end of the cable, the spring configured to tend to move the proximal end of the cable in a proximal direction to exert, via the cable, a force on at least one of the first and second arms to tend to move respective portions of the first and second arms apart.
[0030] Example 21 describes a method comprising: inserting first and second arms of a cervical dilation measuring apparatus into a vagina such that respective distal portions of the first and second arms exert enough of an outward force against, opposing lateral walls of a cervix or vagina to hold the apparatus in position, while measuring cervical dilation, without requiring active fixation to the cervix or vagina; communicating information about the cervical dilation to an external location; and providing an external indicator of the cervical dilation to a user, using the information.
[0031] In Example 22, the method of Example 21 optionally comprises inserting first and second arms comprising respective outwardly bowed cephalic curves, wherein concave portions of the respective cephalic curves oppose each other.
[0032] In Example 23, the method of any one or any combination of Examples 21-22 optionally comprises comprising receiving a fetal head between portions of the first and second arms.
[0033] In Example 24, the method of any one or any combination of Examples 21-23 optionally comprises receiving a fetal head between portions of the first and second arms during birthing while the first and second arms continue to exert enough of an outward force against opposing lateral walls of a cervix or vagina to hold the apparatus in position while measuring cervical dilation without requiring active fixation to the cervix or vagina.
[0034] In Example 25, the method of any one or any combination of Examples 21-24 optionally comprises placing the apparatus when the cervix is in a mid or anterior position such that respective intermediate portions of the respective first and second arms angle or curve upward from respective proximal portions of the respective first and second arms at an angle that is about 15 degrees.
[0035] In Example 26, the method of any one or any combination of Examples 21-25 optionally comprises exerting enough of an outward force of the first and second arms against opposing lateral walls of the cervix or vagina to hold the apparatus in position while measuring cervical dilation without requiring active fixation to the cervix or vagina, and without exerting so much outward force so as to substantially affect the measuring of the cervical dilation.
[0036] In Example 27, the method of any one or any combination of Examples 21-26 optionally comprises inserting into a cervical os first and second feet at respective distal portions of the first and second arms, such that the first and second feet flex at an angle, with respect to the respective first and second arms, in a plane formed by intermediate portions of the first and second arms.
[0037] In Example 28, the method of any one or any combination of Examples 21-27 optionally comprises inserting into the cervical os the substantially flat first and second feet at respective distal portions of the first and second arms, such that the first and second feet are angled upward with respect to the plane formed by the intermediate portions of the first and second arms.
[0038] In Example 29, the method of any one or any combination of Examples 21-28 optionally is performed such that communicating information about a cervical dilation to an external location comprises receiving the information using a longitudinal position translation correlative to a degree of pivoting of intercoupled proximal portions of the first and second arms.
[0039] In Example 30, the method of any one or any combination of Examples 21-29 optionally is performed such that using a longitudinal position translation correlative to a degree of pivoting of intercoupled proximal portions of the first and second arms comprises using at least one of: a position of a rack in a rack-and-pinion; or a position of a proximal end of a member, wherein the member is constrained such that the proximal end of the member represents the degree of pivoting.
[0040] This overview is intended to provide an overview of the subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The detailed description is included to provide further information about the present patent application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
[0042] FIG. 1 illustrates an isometric drawing of an example of portions of a cervical dilation meter apparatus.
[0043] FIG. 2 illustrates a top view of an example of portions of the cervical dilation meter, the arms of which can be drawn together into a closed position for insertion.
[0044] FIG. 3 illustrates a side view of an example of portions of the cervical dilation meter.
[0045] FIG. 4 illustrates an isometric view of an example of the arms, including an example of the pivot joint.
[0046] FIG. 5 illustrates a top view of the example of the arms, including an example of the pivot joint.
[0047] FIG. 6 illustrates a side view of the example of the arms, including an example of the pivot joint.
[0048] FIG. 7 illustrates a front view of the example of the arms, including an example of the pivot joint.
[0049] FIG. 8 illustrates a front view of the example of the arms, including an example of the pivot joint.
[0050] FIG. 9 illustrates an isometric view of an example of an arm and, at its proximal portion, a pivot joint.
[0051] FIG. 10 is a schematic illustration of an example of a dilation meter, in which the stem can be hollow or otherwise configured to guide a rod that extends longitudinally along a length of the stem.
[0052] FIG. 11 is an exploded view of an example of portions of the apparatus in which a flexible string or cable can be used (e.g., instead of the rod) to communicate the cervical dilation information from the arms to an external gauge.
[0053] FIG. 12 is an exploded view of an example of portions of the apparatus in which a rack-and-pinion configuration of the pivot can be used (e.g., instead of a rod or a flexible string or cable) to communicate the cervical dilation information from the arms to an external gauge assembly.
[0054] FIG. 13 is an exploded view of an example of portions of the apparatus in which a tension cable can be used to communicate a force, such as to bias the arms away from each other.
[0055] FIG. 14 is an example of portions of the apparatus in which a dial gauge can be provided and coupled via a cable within a flexible sheath to a receptacle of a pivot joint from which the arms extend.
[0056] FIG. 15 is a schematic diagram corresponding to an example of the apparatus such as shown in the example of FIG. 14 .
DETAILED DESCRIPTION
[0057] FIG. 1 illustrates an isometric drawing of an example of portions of a cervical dilation meter 100 apparatus. In this example, the cervical dilation meter 100 can include arms 102 A-B, which can be drawn together into a closed position, such as for insertion. In an example, the arms 102 A-B can include respective proximal portions 103 A-B, intermediate portions 104 A-B, and distal portions 105 A-B, which can be configured such as shown in the example of FIG. 1 .
[0058] In an example, the proximal portions 103 A-B can be intercoupled to each other, such as at a pivot or other moving or flexing joint 110 . The joint 110 can be configured to hold the proximal portions 103 A-B close to each other while permitting the distal portions 105 A-B to be movably spread apart from each other. This can allow measuring of an amount of cervical dilation, such as when the distal portions 105 A-B are positioned within or beyond the cervical opening, for example, such that the distance between at least one of the distal portions 105 A-B, the intermediate portions 104 A-B, or the proximal portions 103 A-B represents the amount of cervical dilation. In an example, the cervical dilation meter 100 can include a cervical dilation gauge assembly 112 , which can include a stem 114 . The stem 114 can have a length (e.g., such as about 33 centimeters) that extends from its distal portion, such as at the joint 110 , to its proximal portion, which can include or be coupled to an external gauge. The external gauge can be configured to provide a user with a visual or other external indication of the amount of cervical dilation. This external indication can be based upon cervical dilation information that is communicated along the stem 114 , such as explained below.
[0059] In an example, the spreading apart of the distal portions 105 A-B of the arms 102 A-B results from providing a bias force that is communicated to the distal portions 105 A-B of the arms 102 A-B In an example, the cervical dilation meter 100 can be configured such that the bias force against the cervical or vaginal walls is enough to hold the cervical dilation meter 100 apparatus in place, with the distal portions 105 A-B in or beyond the cervical opening, such as to allow measuring of the amount of cervical dilation, but not such much as to significantly distort the dilation measurement. In an example, the cervical dilation meter 100 apparatus is held in place using the bias force and without requiring active fixation of such distal portions 105 A-B to the cervix. This means that attachment to the cervix by clipping to tissue or by penetrating tissue is not required. By not requiring active fixation, the present techniques can increase convenience and can reduce discomfort, tissue trauma, or risk of infection. Instead of using active fixation, the present techniques can provide an outward lateral force can cause the arms 102 A-B to be continuously engaged with vaginal walls or cervical walls. The lateral outward force is sufficient to overcome the inward lateral force exerted by the vaginal and cervical walls against the arms 102 A-B. Engagement of proximal portions of the arms 102 A-B with the vaginal walls, e.g., because of their shape, allows the internal portions of the cervical dilation meter 100 to be secured and retained within the body cavity, while engagement of the distal ends of the arms 102 A-B with the cervical walls allows the relative movement of the arms 102 A-B to measure cervical dilation without requiring the active fixation of invasive physical penetration, or attachment or gripping of cervical tissue (e.g., by needles, barbs, clamps, clips, grips).
[0060] In an example, the bias force can be provided at least in part by a spring 118 , such as can be located about a pin of a rotational pivot joint 110 , or located elsewhere. In an illustrative example, the spring 118 can have about six coils, an inner diameter of about 0.454 inches, an outer diameter of about 0.556 inches, a body length of about 0.39 inches, a wire diameter of about 0.051 inches, and can be wound around a mandrel having a mandrel diameter of about 0.36 inches, such available from Century Spring Corp. of Los Angeles, Calif., U.S.A. or Lee Spring Co. Other spring dimensions or configurations can be used, for example, such as can have between 5.0 and 8.0 coils, an inner diameter between about 0.2 inches and about 0.4 inches, an outer diameter between about 0.25 and 0.55 inches, a body length of about 0.18 and 0.4 inches, or other suitable dimensions or configurations.
[0061] However, neither a rotational pivot joint, or a spring is required. In an example, the bias force can be provided at least in part by a shape-memory property of the plastic or other material used for the arms 102 A-B, such as in an example in which the proximal ends of the arms 102 A-B can instead be joined together by a flexing joint 110 , such as in a manner like that of a tweezers or forceps. In another example, the bias force can be provide at least in part by a spring 122 , such as can be located along the stem 114 , such as at or near its proximal portion, or at or near its distal portion. In an illustrative example, the bias force can be communicated from a spring 122 at or near the proximal end of portion stem 114 to the arms 102 A-B, such as via an elongate member extending along the stem 114 . In an example, such an elongate member can include a cable or a rack (e.g., of a rack-and-pinion) or a shaft, such as explained below.
[0062] FIG. 2 illustrates a top view of an example of portions of the cervical dilation meter 100 , the arms 120 A-B of which can be drawn together into a closed position for insertion. As illustrated in the example of FIG. 2 , the bias force can be provided at least in part by the spring 118 , such as can be located about the pin 200 , such as with spring ends inserted into and retained by the respective arms 102 A-B. As can be observed by viewing the example of FIG. 2 , the bias force holding the apparatus in place need not be confined to the distal portions 105 A-B of the arms 102 A-B pressing against the internal walls of the cervix. In the example of FIGS. 1-2 , the intermediate portions of the arms 102 A-B can include outwardly bowed intermediate portions 104 A-B. These outward bows can be referred to as cephalic curves. In an example, the outward-facing convex sides of the outwardly bowed intermediate portions 104 A-B are shaped so that they can engage the respective opposing vaginal walls or proximal outer regions of the cervix, when inserted. This can help deliver a portion of the bias force to the respective vaginal walls or proximal outer regions of the cervix, which can help hold the cervical dilation meter 100 in place, such as while measuring the change in cervical dilation from zero (0) centimeters to ten (10) centimeters during early labor. In an example, the bowed cephalic curves of the intermediate portions 104 A-B can be sized and shaped to accommodate a descending fetal head between their opposing concave portions during birthing. In an example, the fetal head can be accommodated within the cephalic curves without dislodging the cervical dilation meter 100 , such as until the descending fetal head begins to push against the concave portions of the cephalic curves, which can then automatically dislodge the cervical dilation meter 100 without requiring any clinician or other user intervention. In another example, entry of the fetal head between the opposing concave portions of the cephalic curves during birthing automatically dislodges the cervical dilation meter 100 , without requiring any clinician or other user intervention.
[0063] In an example, the cephalic curves can respectively include a chordal length 202 (directly across) of about 3.5 cm. In an example, the cephalic curves can respectively include a curved or circumferential length of about 4.75 cm. In an example, the cephalic curves are bowed out by an amount that is between about 0.5 cm and about 1.0 cm from the chordal dimension.
[0064] FIG. 3 illustrates a side view of an example of portions of the cervical dilation meter 100 . In an example, the intermediate portions 104 A-B of the respective arms 102 A-B can respectively extend upward from a plane formed by the proximal portions 103 A-B of the respective arms 102 A-B, such as by an angle of about 15 degrees. This upward angle or curvature (which can be referred to as a pelvic curve) can help allow placement of the cervical dilation meter 100 even if the cervix is in a mid or anterior position.
[0065] In an example, the respective distal portions 105 A-B of the respective arms 102 A-B can extend upward from a plane formed by the intermediate portions 104 A-B of the respective arms 102 A-B, such as by an angle that is about 30 degrees. This upward angle can help allow the cervical dilation meter 100 to be placed such that the respective distal portions 105 A-B of the respective arms 102 A-B can be easily positioned in the cervical canal, just above the internal cervical os, below the fetal head.
[0066] FIG. 4 illustrates an isometric view, FIG. 5 illustrates a top view, FIG. 6 illustrates a side view, FIG. 7 illustrates a front view, and FIG. 8 illustrates a back view of an example of the arms 102 A-B, including an example of the pivot joint 110 , in which facing opposing-shell pivot joint housings 400 A-B can be used to carry the spring 118 and the pin 200 . In this example, one of the housings 400 A-B can be coupled to a snap-in receptacle 402 , which can extend outward from the housing 400 B, such as at an angle of about 20 degrees. A distal portion of the stem 114 can be inserted into and retained by the receptacle 402 , such as by snap-fitting the stem 114 into the angled receptacle 402 . In an example, the angled receptacle 402 can permit the inserted stem 114 to bend slightly toward the same side of the apparatus 100 as the intermediate portions 104 A-B and the distal portions 105 A-B.
[0067] In an example, the respective distal portions 105 A-B can include substantially flat or other feet 404 A-B. In an example, each foot 404 A-B can provide an outward-facing surface area that can be between about 2.4 cm 2 and about 3.84 cm 2 . The feet 404 A-B can have rounded or otherwise atraumatic distal corners and edges, or can be made of (or coated by) a softer durometer material, such as to help avoid or reduce the possibility of tissue abrasion or other injury to the mother or fetus. In an example, the feet 404 A-B can be hingedly or flexibly attached to the intermediate portions 104 A-B, such as by respective flexing couplers 406 A-B. In an example, the flexing couplers 406 A-B can include portions that are thinner than the respective feet 404 A-B and thinner than the respective intermediate portions 104 A-B, such as to provide the flexing. The flexing between the feet 404 A-B and the respective intermediate portions 104 A-B can, in an example, help resist upward movement of the cervical dilation meter 100 into a lower uterine segment. Such flexing can also help accommodate downward pressing of the fetal head against the feet 128 A-B in an example. Such flexing can also help ease removal of the cervical dilation meter 100 without damaging cervical, vaginal, or other tissue during the removal. In an example, the inward facing portions of one or both of the feet 404 A-B can optionally include a pressure sensor, such as to monitor pressure of the fetal head pressing against such inward-facing portions of the feet 128 A-B. Moreover, the orientation of the flexing feet 404 A-B, in combination with the cephalic curves of the intermediate portions 104 A-B of the arms 102 A-B can help direct pressure, delivered outward by the feet 404 A-B, more laterally against the cervical walls, rather than directing such pressure upward toward the uterus.
[0068] FIG. 9 illustrates an isometric view of an example of an arm 102 B and, at its proximal portion, a pivot joint 110 including a pivot joint housing 400 B including an opening 902 into which the pin 200 (of the opposing pivot joint housing 400 A at a proximal portion of an arm 102 A) can be inserted. This allows rotational pivoting about the pin 200 , which can be driven by the spring 118 carried within the housings 400 A-B, with ends of the spring 118 received into respective slots 904 A-B in the respective arms 102 A-B. In this way, the spring 118 can press against the outward sidewalls of the slots 904 A-B to impart the outward bias force to the arms 102 A-B, such as to hold the apparatus 100 in place for measuring cervical dilation.
[0069] In examples such as those shown in FIGS. 1-9 , portions of the apparatus 100 , such as the arms 102 A-B, the pivot joint 110 , the stem 114 , or other portions, can include or consist of molded polypropylene. This can provide an inexpensive apparatus 100 , such as to provide a single-use disposable apparatus 100 . In another example, brass or aluminum components can be used, such as to provide a more durable re-usable apparatus 100 that can be heat or chemically sterilized between uses.
[0070] FIG. 10 is a schematic illustration of an example of a dilation meter 100 , in which the stem 114 can be hollow or otherwise configured to guide a rod 1000 or other member that extends longitudinally along a length of the stem 114 . This can permit communicating of cervical dilation information from the arms 102 A-B to an external gauge 1002 . The example of FIG. 10 illustrates that a rotational pivot joint 110 can be omitted. Instead, the arms 102 A-B can be joined (e.g., in a wishbone-like fashion) to the distal portion of the stem 114 . A shape memory property of the arms 102 A-B and their respective attachments to the stem 114 can allow the distal portions of the arms 102 A-B to be drawn together, such as for insertion into the cervix, and to be self-spread apart, such as during the cervical dilation, such as to provide information about the degree of the cervical dilation.
[0071] In the example of FIG. 10 , a distal portion of the rod 1000 can be pivotably connected (e.g., via a pin) to proximal portions of respective resilient linkages 1004 A-B. The distal portion of the linkage 1004 A can be pivotably connected to the arm 102 A, such as via a pin at a proximal portion 103 A (as shown) or to a more distal portion of the arm 102 A. The distal portion of the linkage 1004 B can be similarly pivotably connected to the arm 102 B, such as via a pin at a proximal portion 103 B (as shown) or to a more distal portion of the arm 102 B. In this way, as the arms 102 A-B spread apart from each other, a proximal portion of the rod 1000 is drawn into a proximal portion of the tubular or other stem 114 and, concurrently, a distal portion of the rod 1000 is extended out from a distal portion of the tubular or other stem 114 .
[0072] In an example, the external gauge 1002 can include cervical dilation markings 1006 on the rod 1000 , which can be read against the end of the tubular or other stem 114 to provide an external indication of the degree of cervical dilation to a viewing user. For example, the rod 1000 can be manufactured such that the markings 1006 provide a scale that corresponds to the number of centimeters of cervical dilation measured using the arms 102 A-B. The scale can be linear, but need not be linear. In an example, there can be a logarithmic correlation between the scale of the markings 1006 on the rod 1000 and the degree of separation of the arms 102 A-B, which provides the indication of cervical dilation.
[0073] FIG. 11 is an exploded view of an example of portions of the apparatus 100 in which a flexible string or cable 1100 can be used (e.g., instead of the rod 1000 ) to communicate the cervical dilation information from the arms 102 A-B to an external gauge 1102 . A distal end of the cable 1100 can be anchored or otherwise affixed at one of the arms 102 A-B, such as at a proximal portion 103 A-B or an intermediate portion 104 A-B of the one of the arms 102 A-B. Measurement of the indication of cervical dilation at a location that is near the proximal portions 103 A-B of the arms can help avoid entanglement or obstruction of the cable 1100 by the fetal head or other instrumentation that may be inserted into a vagina, cervix or uterus. In an example, the cable anchoring or affixing can involve tying off or otherwise widening a distal end of the cable 1100 and inserting the cable 1100 through a hole 1101 B in the one of the arms 102 A-B, such that the widened end of the cable 1100 cannot be pulled through the hole 1101 B in the one of the arms 102 A-B. The cable 1100 can then extend across to the other one of the arms 102 A-B, such as through an opposing hole 1101 A in the other one of the arms 102 A-B. The cable 1100 can then extend within or along a tubular lumen, sheath, or other cable guide along that other one of the arms 102 A-B, into or along the pivot joint housing 400 A-B, within or along the receptacle 402 , within or along the stem 114 , and to the external gauge assembly 1102 .
[0074] At the external gauge assembly 1102 , the cable 1100 can terminate at a gauge plunger 1106 , which can travel back-and-forth within a transparent cylindrical or other elongate gauge body 1108 , as the arms 102 A-B are drawn toward each other or spread apart from each other. Scale markings on the gauge body 1108 can be read against the gauge plunger 1106 to provide an external indication of cervical dilation. Tension in the cable 1100 can be maintained by a compression spring 1110 , which can be located around the cable 1100 , such as at or near the proximal end of the cable 1100 . The compression spring 1110 can be used in addition to the spring 118 , in an example, or instead of the spring 118 , in another example. The cable-tensioning compression spring 1110 can have its proximal end seated against the plunger 1106 and its distal end seated against a stop 1112 portion of the stem 114 . In an example, a distal portion of the gauge body 1108 can also be seated against the stop 1112 . In an example (not shown in FIG. 11 ), the compression spring 1110 can instead be located near the pivot 110 , for example, its force can be communicated to the external gauge assembly by a rod or tube within the stem 114 .
[0075] The exploded view example of FIG. 11 also demonstrates an example in which the pivot 110 can include a disk-like base portion 1114 , coupled to the receptacle 402 , and including the pin 200 . The pivot 110 can also include a proximal end of the arm 102 B, which can include a housing 400 B that includes disk 1118 having a center hole 1116 through which the pin 200 can be inserted. Next, the spring 118 can then be placed about the pin 200 , such as with one end of the spring 118 inserted into or otherwise constrained by the arm 102 B, and the other end of the spring 118 then inserted into or otherwise constrained by the arm 102 A. Next, the proximal end of the arm 102 A, which can include a cylindrical housing to carry the spring 118 and a center hole 1120 , can be placed with the center hole 1120 about the pin 200 , with the end of the spring 118 constrained by the arm 102 A, such as explained above. Then, a snap-on cap 1122 can be placed about and snapped onto the pin 200 , which can help hold the various components of the pivot 110 together.
[0076] FIG. 12 is an exploded view of an example of portions of the apparatus 100 in which a rack-and-pinion configuration of the pivot 110 can be used (e.g., instead of a rod 1000 or a flexible string or cable 1100 ) to communicate the cervical dilation information from the arms 102 A-B to an external gauge assembly 1202 . In this example, the pivot 110 can include a pinion pivot base 1204 . The stem receptacle 402 can extend outward from the pivot base 1204 , in a similar manner to that described above. The base 1204 can include separate pins 200 A-B that can extend upward into respective receptacles 1206 A-B of respective arms 102 A-B. This can allow the respective arms 102 A-B to pivot about their respective pins 200 A-B. This can allow the arms 102 A-B to be drawn toward each other or spread apart from each other. The pivoting proximal ends of the arms 102 A-B can include opposing facing pinion toothed gears 1208 A-B. A toothed geared distal portion of a rack 1210 can be inserted between the opposing facing pinion toothed gears 1208 A-B. Like the rod 1000 , the rack 1210 can extend proximally through the tubular stem 114 to an external gauge assembly 1202 . In an example, a distal portion of the rack 1210 can travel into a rack receptacle 1212 . A proximal end of the rack 1210 can include a plunger 1214 that travels within an at least partially transparent barrel 1216 . The barrel can include markings 1218 forming a cervical dilation scale for user readout. In this way, as the cervix dilates, and the distal portions of the arms 102 A-B spread apart, a distal end of the rack 1210 travels toward or into the receptacle 1212 , and a proximal end of the rack 1210 travels such that the rack plunger 1214 moves more distally within the barrel 1216 of the dilation gauge assembly 1202 . The barrel 1216 can include an end-cap 1220 at its proximal end. A spring 1222 can be located near the proximal or distal portion of the rack 1210 , such as at the barrel 1216 or at the receptacle 1212 . The spring 1222 can be used to bias the rack 1210 in a distal direction such that the arms 102 A-B tend to self-spread apart, such as to allow measurement of the cervical dilation. The spring 1222 can be designed to provide a pushing or pulling force, as appropriate, to provide such a bias force to tend to spread the arms 102 A-B apart. A cap 1224 can be snap-fitted onto the pins 200 A-B, such as to hold or house the components of the rack-and-pinion pivot 110 .
[0077] In an example, the apparatus 100 can be packaged together in a kit with an introducer that can hold the arms 102 A-B together during insertion. In an example, the introducer can include a peel-away sheath that keeps the arms 102 A-B together during insertion, but which can include two separate proximal tails that can be used to concurrently pull apart and retract the sheath, leaving the arms 102 A-B in place in the opening of the cervix, and thereby permitting such arms 102 A-B to self-expand apart from each other to measure the cervical dilation. In another example, the apparatus 100 can be provided with a proximal push-rod such as to communicate a force to hold the arms 102 A-B together during insertion.
[0078] FIG. 13 is an exploded view of an example of portions of the apparatus 100 in which a tension cable 1300 can be used to communicate a force, such as to bias the arms 102 A-B away from each other. In an example, the tension cable 1300 can include a bifurcated distal portion 1302 A-B. The distal portion 1302 A can terminate at a coupling feature such as a post 1304 A, which can extend perpendicular to the distal portion 1302 A. The distal portion 1302 B can terminate at a coupling feature such as a post 1304 B, which can extend perpendicular to the distal portion 1302 B.
[0079] In the example of FIG. 13 , proximal ends of the arms 102 A-B can be coupled together, such as at a pivot joint 110 , which can include respective disks 1306 A-B at the respective proximal ends of the arms 102 A-B. The disks 1306 A-B can include respective center holes 1120 , 1118 through which a pin 200 can be inserted. A distal end of the pin 200 can be snap fitted into or otherwise engaged to a cap 1308 , thereby holding together the cap 1308 , the disks 1306 A-B, the pin 200 and the disk 1114 , such as to provide the joint 110 .
[0080] In the example of FIG. 13 , the disks 1306 A-B can include arc-shaped, semicircular, or similar guide rails 1310 A-B. The cable distal portions 1302 A-B can respectively wrap around the outsides of the respective rails 1310 A-B. The posts 1304 A-B can be respectively inserted into and engage the respective recesses 1312 A-B. The cable 1300 can pass through a tubular receptacle 402 and a flexible tubular or other sheath 1314 back to a proximal gauge 1316 , which can be located external to the patient when the distal portions of the arms 102 A-B are located within the cervix, such as to measure its diameter.
[0081] In an example, the gauge 1316 can include a proximal end of the sheath 1314 , which can include an outward flange 1315 , which can serve as a distal stop for a spring 1316 . An outward flange 1318 near a proximal end of the cable 1300 can serve as a proximal stop for the spring 1316 . In such an example, the spring 1315 can be captured between the flanges 1315 and 1318 . In an example, the spring 1315 can provide the force that is communicated by the cable 1300 to the arms 102 A-B such as to bias the arms 102 A-B away from each other during the cervical dilation measurement. In an example, a gauge pointer 1320 is optionally coupled to the flange 1318 at the proximal end of the cable 1300 , such as for reading the cervical dilation against graduations or demarcations on a transparent or translucent gauge cylinder 1322 . In another example, the flange 1318 can itself optionally be used to provide a gauge pointer for reading against the graduations or demarcations on the gauge cylinder 1322 . In another example, the apparatus 100 can be provided with a proximal push-rod (e.g., extending further proximally from the gauge pointer 1320 ) such as to communicate a force to hold the arms 102 A-B together during insertion. A dial or other gauge readout can be substituted for the linear translational gauge cylinder in this example or in one or more of the other examples described herein.
[0082] FIG. 14 is an example of portions of the apparatus 100 in which a dial gauge 1400 can be provided and coupled via a cable within a flexible sheath to a receptacle 1404 of a pivot joint 110 from which the arms 102 A-B extend. The dial gauge 1400 can include a dial gauge housing 1406 having a window 1408 through which a dilation reading on a rotating dial can be read.
[0083] FIG. 15 is a schematic diagram corresponding to an example of the apparatus 100 such as shown in the example of FIG. 14 . In this example a short cable 1500 can include ends with respective couplers, such as balls 1502 A-B, that can be coupled to respective arms 102 A-B, such as by being inserted into respective sockets in the respective arms 102 A-B at a desired proximal, intermediate, or distal location along the length of such arms 102 A-B. A middle region of the cable 1500 can be coupled to a distal end of a longer cable 1504 , which can be passed through a flexible tubular or other sheath 1506 . In an example, the sheath 1506 can extend from the receptacle 1404 on the pivot joint 110 to a spring housing 1508 . In an example, the spring housing 1508 can extend outward from the dial gauge housing 1406 . A proximal end of the cable 1504 can be coupled to a distal portion of a rack gear 1510 , which can form a rack-and-pinion arrangement with a pinion gear 1512 . The pinion gear 1512 can engage a dial gear 1514 , which drives a rotational movement of a dial 1516 . The dial 1516 can provide numerical or other indicia indicative of cervical dilation, such as can be viewable through the window 1408 on the housing 1406 of the dial gauge 1400 . In an example, the pinion gear 1512 can include a multiple stage pinion gear, such as a two-stage pinion gear, such as to translate linear movement of the rack gear 1510 into a desired degree of rotation of the dial 1516 . For example, the two-stage pinion gear 1512 can include a smaller gear 1512 A, which engages the rack gear 1510 , and which rotates together with a larger gear 1512 B, which engages the dial gear 1514 . In this example, the spring housing 1508 can include a coil spring 1518 , which can be located about the cable 1504 and confined within the spring housing 1508 between the spring housing 1508 and the distal portion of the rack gear 1510 . The spring 1518 can provide a force against the rack gear 1510 . The rack gear 1510 can communicate this force via the cables 1504 and 1502 to the arms 102 A-B such as to bias the arms 102 A-B away from each other, such as for performing the cervical dilation measurement.
ADDITIONAL NOTES
[0084] The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown and described. However, the present inventors also contemplate examples in which only those elements shown and described are provided. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also examples using any combination or permutation of those elements shown or described, either with respect to a particular example, or with respect to other examples shown or described herein.
[0085] All publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference(s) should be considered supplementary to that of this document; for irreconcilable inconsistencies, the usage in this document controls.
[0086] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.
[0087] Method examples described herein can be machine or computer-implemented at least in part. Some examples can include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform methods as described in the above examples. An implementation of such methods can include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code can include computer readable instructions for performing various methods. The code may form portions of computer program products. Further, the code may be tangibly stored on one or more volatile or non-volatile computer-readable media during execution or at other times. These computer-readable media may include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memories (RAMs), read only memories (ROMs), and the like.
[0088] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. | An instrument for measuring cervical dilation can have a pair of arms connected at their proximal ends to an arm pivot or articulating member, the arms being in movable communication with a gauge assembly for measuring the relative distance between the arms at a fixed location near the proximal ends of the arms. The arms can be disposed to apply an outward lateral pressure against the walls of the cervix, thereby engaging the cervix without the need for physical penetration, gripping, or other attachment of the device to the cervical tissue. Continuous outward lateral pressure of the arms against the cervical walls can allow the arms to expand in response to and in concert with expansion and dilation of the cervix. The relative distance between the arms correlates to the diameter of the cervix, such that the correlated measurement indicated on a scale of the gauge means is the measurement of cervical dilation. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to and is a continuation of PCT Application No. PCT/JP2011/070274, filed Sep. 6, 2011, the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to a method of producing a quantum crystal of metal complex including metal nanoclusters or nanoclusters as metal quantum dots by using an aqueous solution of the metal complex and its use based on the effect of localized surface plasmon enhancement.
BACKGROUND OF THE INVENTION
Field of the Invention
As a typical material of the next generation in the nano technology, surface modified nano particles, which are made from metal atoms by controlling a shape and a size in nano level so as to form a nanocluster or nanoclusters, have been drawing attention, because nanoclusters can be designed to have a new electronic property or materiality due to so-called quantum size effect which would happen in nanometer area. Hereinafter, the word “nanocluster” means agglomeration of several to several hundred atoms and molecules having several nm (nano meters) to several 10 nm in size. It is known that these clusters are bigger than a single molecule, and smaller than a nano crystal. The nanocluster is a material which shows a unique function or property different from that in a state of atoms, molecules and bulk crystals. Therefore, by controlling the size and the number of material composition atom, a new knowledge and a finding concerning a phase transition, a crystal growth, a chemical reaction, catalytic action, and the like are expected. One of them is a so-called Surface Plasmon Resonance (SPR) on the metal surface. In general, electrons in the metal do not tend to interact with light, but the light can interact with electrons existing in metal nano particles under a special condition, resulting in occurrence of so called Localized Surface Plasmon Resonance. Especially, according to the theoretical consideration of so-called “dimmer of nano Ag particles” in case in which the silver nano particles are positioned in a predetermined distance, it is thought that the degree of electric field enhancement made by the wavelength around 400 nm-would be particularly very high, and in case of less than 400 nm, there would exist a peak at the wavelength around 300 nm. And, in relation to the particles diameter, it is thought that as a particle diameter is widened, the position of the peak becomes high, and further, the peak would shift to the long wave side and the peak width would become bigger, so that the field enhancement effect can be expected in a wide range of wavelength.
Therefore, it has been proposed that on a substrate for measuring SERS (Surface Enhance Raman Scattering), in order to accumulate nano particles of Noble metal such as Ag, Au and the like having a diameter of about several 10 nm, there have been used a Chemical Vapor Deposition (CVD) method or a method for synthesizing colloidal particles of Ag or Au in an aqueous solution and fixing it on a glass substrate which is decollated by lysine or cyan (referring to the following Non-patent literatures 1 to 3 and Patent Document 1). Therefore, at the present, the above CVD method has now to be used for mass-production of the SERS substrate.
RELATED ART DOCUMENT
Patent Document
Patent Document 1: Japanese Patent Application Laid-Open Publication No. 11(1999)-61209
Non-Patent Literatures
Non-patent Literature 1: S. Nie and S. R. Emory, Science. 275, 1102 (1997)
Non-patent Literature 2: K. C. Grabar, P. C. Smith, M. D. Musick, J. A. Davis, D. G. Walter, M. A. Jackson, A. P. Guthrie and M. J. Natan, J. Am. Chem, Soc., 118, 1148 (1996)
Non-patent Literature 3: R. M. Bright, M. D. Musick and M. H. Natan, Langmuir, 14, 5695 (1998)
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
However, the substrate formed by the CVD method does not have a function for absorbing a sample to be detected, so that the substrate for SERS detecting has to be prepared by so-called drop & dry method including coating and drying steps of the sample to be detected. It is difficult for the prompt detection and therefore, it has a disadvantage due to the deterioration of the sample. Furthermore, there is the biggest disadvantage in the matter of a poor repeatability of the measurement, resulting in a great problem of barrier for variety applications of the SERS method.
Therefore, the inventors came back to the fundamental points of the SERS function and/or phenomenon and deeply thought it to overcome the above problems. It is known that the degree of enhancement in the surface plasmon phenomenon is depended on a variety of physical and chemical parameters including various atom bonding position and orientation existing in absorbed molecules on the electro-magnetic field of the metal surface. Accordingly, in order to provide a best substrate for keeping a good repeatability in relation of the SERS measuring, it is necessary to develop the substrate from the following two points relating to the mechanism of the occurrence of the SERS; (i) achievement of the best physical condition for surface plasmon resonance in the metal to enhance a local strength of the incident light and (ii) achievement of the best chemical condition for formation of so-called charge-transfer complex between metal surfaces and Raman active molecules to be absorbed and transition thereafter. The inventors have found that in order to achieve the best physical condition, it is possible to apply the CVD method as long as the physical condition is concerned, although it is difficult to control the particle size and orientation. However, at the same time, it is impossible for the CVD method to achieve the best chemical condition for the formation of the charge-transfer complex.
By the way, in recent years, it has been reported that Prof. Kimura, Ph.D. of Hyogo prefectural university succeeded in the preparation of a two or three dimensional artificial particle crystal by using nano particles as component or element for the crystal, and further succeeded in the IV group cluster crystal from the aqueous solution by using the Si cluster. It is the first successful case in the world. The crystal of these particles can be said as the quantum dot crystal which has the periodic structure of nanometer, and it has come to be expected as the key material of the nano-technology in the 21st century. Taking about the above findings and knowledge into consideration, in order to provide a new method for making a crystal of metal quantum dots on the substrate in place of the prior CVD method, the inventors have made a lot of research by using a various kinds of metal complex in the aqueous solution and have found that in case in which a plasmon metal can coordinate with a ligand and form a metal complex in the aqueous solution, the metal complex tends to crystalize into quantum crystals on a metal substrate and metal nanoclusters included in the quantum crystals are formed as quantum dots, resulting in observation of strong plasmon enhancement effect which has never been seen before. It would be caused by a function due to the formation of charge-transfer complex.
Means for Solved by the Invention
The present invention relates to a method of producing quantum crystals of metal complex and has been made on the basis of the above new knowledge, which includes a step of providing a plasmon metal complex aqueous solution including a ligand and a plasmon metal selected from the group consisting of Au, Ag, Cu, Ni, Zn, Al and Pt, a step of contacting the aqueous solution of the plasmon metal complex with a carrier made of a metal or a metal alloy showing an electrode potential lower (ionization tendency higher) than an electrode potential of the plasmon metal or a carrier made of metal being adjusted at an electrode potential lower than the electrode potential of plasmon metal in the aqueous solution, and a step of depositing the plasmon metal complex from the aqueous solution on the carrier to form and arrange the quantum crystals having plasmon enhancement effect on the carrier.
It is remarkable that the deposition and agglomeration of plasmon metal complex from the aqueous solution on the metal carrier is effective on production of the conditions relating to mechanism of SERS phenomenon, one of which is the achievement of (i) the best physical condition for surface plasmon resonance enhancing the local strength of incident light and (ii) the best chemical condition for formation of the charge-transfer complex between the metal surface and Raman active molecules.
As a carrier which forms the quantum crystal, one of the group consisting of a metal particle, a metal needle, and a metal film inside the capillary may be chosen corresponding to the use of metal quantum crystal. For example, in case of silver plasmon metal, the metal carrier is chosen in order to have an electrode potential lower (ionization tendency higher) than that of Ag plasmon metal or complex to be deposited on the metal carrier. For example, the carrier made of metal may be selected from the group consisting of copper, brass and phosphor bronze, and the form of the carrier is adopted so as to receive a drop of the metal complex solution as shown in FIG. 7 , on which the aqueous solution of sample to be measured is put a drop on the prepared carrier and then SERS detection may be done. In case of the metal particles provided with quantum crystals of the plasmon metal complex, it can be used for a light transmission electrode material used in the light-incident side of the solar battery. In case of a metal needle provided with quantum crystals of the plasmon metal complex, it can be used for the thermal therapy, wherein the metal needle is inserted into the affected part directly, and the quantum crystal part becomes hot due to surface enhancement resonance by the laser irradiation. In case of a capillary including quantum crystals of the plasmon metal complex, the small sample is absorbed therein without being contaminated. Therefore, the quantum crystals of the present invention can be formed on the metal film or a piece of metal made by chemical deposition or metal parts inserted in the capillary.
The metal complex is formed in the manner in which the quantum crystal of the present invention includes nanocluster of plasmon metal particles on the metal carrier (refer to FIGS. 2 , 3 ( a ) and 3 ( b )). From the effect of strong plasmon enhancement on the surface of plasmon metal, it presumes that the plasmon metal particles are agglomerated in a state of nanoclusters having average size of several nano meters to ten and several nano meters so that quantum dots having nano size are formed with an arrangement at certain regular intervals. As a result, the best physical condition for the aspect of (i) the surface plasmon resonance enhancing local strength of the incident light can be provided.
Further, as the metal complex is crystallized on the metal carrier, it can presume that at least a part of plasmon metal particles to form nanocluster is deposited in a state of metal and also a remainder of plasmon metal particles is deposited in a state of a metal complex ion bonding with the ligand, so that plasmon metal complexes can keep or make an ionized state which can absorb a sample to be detected by drop of the solution so that (ii) plasmon metal particles and Raman active molecules make a charge-transfer complex. As a result, SERS detection can be instantly applied in a state of solution of the sample without drying before detection.
The plasmon metal in the present invention can coordinate with a various kinds of ligands so as to deposit metal complexes from the aqueous solution on the metal substrate. The ligand to be chosen for the metal complexes should be determined by considering important parameters relating to the formation of the quantum crystal of metal complexes such as a constant of the metal complex stability in the aqueous solution, a complex structure coordinated with ligands and the like. It is important that at least the selection of ligands should be done by considering that the metal complex to be formed between the plasmon metal and the ligand becomes a complex for forming a charge-transfer complex with the sample. At the present, a ligand selected from the group consisting of an amino acid ion, an ammonia ion, a thiosulfate ion and a nitrate ion, can form the plasmon metal complexes and coordinate with the plasmon metal quantum dots as a ligand, which surface plasmon resonance can be detected by the SERS method. As a result, it presumes that (i) the best physical condition for surface plasmon resonance enhancing local strength of incident light and (ii) the best chemical condition for formation of the charge-transfer complex between the metal surface and Raman active molecules and transition thereafter can be achieved by formation of the quantum crystal of the plasmon metal complexes, so that it comes to know that the in order to detect the sample by SERS method, it is preferable to ion-bond with plasmon metal particles by electro-charge.
When the above plasmon metal complex is formed according to the present invention, it is preferable that one selected from the group consisting of Au (gold), Ag (silver) and Cu (copper) is chosen as the plasmon metal.
The metal concentration in the aqueous solution of the plasmon metal complex is 500 to 5,000 ppm, and the concentration of 500 to 2,000 ppm is particularly preferable. In case in which Ag plasmon metal is used, a determined amount of silver chloride is added into the aqueous solution including a ligand compound such as ammonia and a sodium thiosulfate to make silver complex with the ligand. The aqueous solution in the present invention is used for making the metal complex to be precipitated and agglomerated on the metal carrier in order to produce nano metal dots arranged in a suitable intervals on the metal carrier. In case of less than 500 ppm, it is impossible to form nano metal dots in the suitable intervals or it needs a long time to make nano metal dots in the suitable intervals. On the other hand, in case of more than 2,000 ppm, it is difficult to control the dots in suitable intervals due to the prompt deposition and agglomerate of the metal complex. The preservation of the metal complex solution can be improved when a dispersant is added in order to prevent the metal complex or its ion from progress of agglomeration in the aqueous solution as long as a measurement is not obstructed.
In case of Ag nanocluster (cluster of 10-20 nm includes from twenty to forty Ag atoms), the dispersant may be added at 1/50 to 1/150 molar rate based on a weight of Ag atom. It can get a good localized plasmon enhancing effect with a silver thiosulfate complex, a silver amine complex, a silver nitrate complex and a silver amino acid complex in a range of Ag equivalent of 500 to 2000 ppm.
In the present invention, an antibody can be absorbed on the plasmon metal dots through an electro-charge therebetween as a ligand or a substitute of ligand, so that the antigen-antibody reaction can be detected by using the method of the present invention (referring to FIGS. 6 ( a ) and ( b )).
Effects of the Invention
1) If the metal complex in the aqueous solution can be made of a various kinds of ligands and the plasmon metal to be coordinated with the ligand, the metal complex in the aqueous solution can be reductively deposited on the metal carrier by potential difference between the metal complex and the metal carrier to make the metal complex crystallized so as to form metal nanoclusters, which are included in quantum crystals, with the metal complex having a suitable quantum size and formed in a controlled arrangement which is the best physical condition resulting in achievement of a desirable quantum size effect. Among them, the nanoclusters of Au, Ag and Cu tend to form quantum dots which are useful materials for surface plasmon resonance excitation element.
2) Moreover, the metal complex leads to a good result of the repeatability in the SERS detection method, because it may be in the condition (ii) that a metal element of the metal complex is easy to be ionized and absorb the Raman activated molecule on the ionized surface of the metal or metal complex to form a charge-transfer complex which is the best chemical condition.
3) The metal complex is easy to control a charge property into a plus or minus which is easy to absorb a protein such as virus and the like. For example, if quantum dots of the metal complex are bonded with a protein Avidin or a living body material Biotin and deposited on the metal substrate, a SERS substrate suitable for the protein detection can be provided.
4) The metal complex is also possible to be bonded with an antibody in the aqueous solution by adding the antibody thereinto and dispersing it in the aqueous solution. Therefore, if the metal complex together with the antibody is deposited on the metal substrate, the choice of the antibody can provide a suitable substrate for absorbing a predetermined antigen and detecting the antigen in the antigen-antibody reaction.
5) If the metal complex is formed in the point of a metal needle, which can be inserted into the affected part directly, the plasmon enhancement effect is obtained by irradiation of the laser light, so that the needle point becomes hot and a hyperthermia therapy can be enforced in the affected part.
It is observed that the plasmon metal complex made of a silver coordinated with thiosulfate ion produces plate-like crystals of 100 to 200 nm on the metal substrate, which shows the excellent effects of surface plasmon resonance excitation and electro-field reinforcement, which may be probably resulted from the formation of quantum dots made by Ag nanocluster in the hexagonal plate-like crystals (as shown in FIGS. 3 ( a ) and ( b )).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing a Raman scattering spectrum of 4,4′-bipyridine of 100 nM on a SERS substrate prepared according to the method of the present invention, from which an excellent plasmon resonance excitation effect is observed.
FIG. 2 is a photograph (20,000 times) of scanning type electron microscope, which shows a state of formation that the silver complex crystal forms a hexagonal plate-like crystal on the brass substrate.
FIG. 3( a ) is a photograph (50,000 times) of scanning type electron microscope, which shows a state of formation that the silver complex crystal forms quantum dots on the phosphor bronze substrate.
FIG. 3( b ) is a photograph (200,000 times) of scanning type electron microscope-which shows the state that the silver complex crystal forms quantum dots crystal on the phosphor bronze substrate.
FIG. 4( a ) is a graph showing a Raman scattering spectrum of pure water of 100 nM on a phosphor bronze substrate where Ag complex is formed in Ag nitrate aqueous solution according to the method of the present invention.
FIG. 4( b ) is a graph showing a Raman scattering spectrum of 4,4′-bipyridine of 100 nM on a phosphor bronze substrate where Ag complex is formed in Ag nitrate aqueous solution according to the method of the present invention.
FIG. 5 is a graph showing a Raman scattering spectrum of rhodamine 6G of 1 μM on a phosphor bronze substrate where Ag complex is formed in Ag thiosulfate aqueous solution according to the method of the present invention.
FIG. 6( a ) is a graph showing a Raman scattering spectrum of antibody formed on phosphor bronze substrate prepared by antibody added aqueous solution of Ag thiosulfate according to the method of the present invention.
FIG. 6( b ) is a graph showing a Raman scattering spectrum of antigen-antibody on phosphor bronze substrate prepared by a drop of antigen on the substrate of FIG. 6( a ).
FIG. 7 is a drawing showing a process for preparing a SERS substrate.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of this invention is explained with reference to the following drawings in detail. As shown in FIGS. 7( a ) to ( c ), a circle dish shaped metal plate 2 having a thickness of about 0.1 mm made by means of punching is adhered on a plate 1 made of glass or plastics. The substrate is provided with the circle dish shaped metal plate 2 so as to receive drops of the aqueous solution and there is a rise of the droplet 3 on the metal plate as shown in FIG. 7 ( b ). Thereafter, the droplet is blown out by a blow of Nitrogen gas and as a result, there is left an agglomeration area 4 formed on the surface of metal plate, where nanoclusters are formed as the quantum dots as shown in FIG. 7( c ). In place of the thin metal plate 2 , a metal film may be formed by a chemical plating or a chemical vapor deposition.
Example 1
The aqueous solution of plasmon metal complex was prepared in the manner in which a predetermined amount of silver chloride was dissolved in an aqueous solution of sodium thiosulfate according to a known standard method. The aqueous solution was diluted with pure water up to a concentration of 500 to 2000 ppm (based on a weight of Ag atom), and amino acid (L-alanine) of 10 to 20 ppm was added to have a colorless solution containing Ag nanoclusters (Ag complex). One droplet (10 μL) of the metal complex aqueous solution was put on the brass substrate (Cu 60; Sn 40) and 3 minute later the droplet on the metal substrate was blown off and dried out to have a Surface Plasmon Resonance Excitation (SERS) substrate. FIG. 2 is a photograph of the scanning type electron microscope (20,000 times) of the surface profile of the SERS substrate. From the profile as shown in FIG. 2 , it was confirmed that a hexagonal plate-like crystal of 100 to 150 nm was formed on the substrate. In case of Ag complex crystals formed on the phosphor bronze substrate, the photographs (50,000 and 200,000 times) of the scanning type electron microscope show formation of a lot of nano metal dots encapsulated in the quantum crystals as shown in FIGS. 3( a ) and 3 ( b ). On the resultant brass substrate prepared by 3 minute agglomeration of the metal complex, 4,4′-bipyridine droplets (10 μL) of 10 mM, 1 μM and 100 nM were put down and the effect of surface plasmon enhancement were measured by using Raman Station 400 made in Parkin Elmer Japan Co. Ltd with a laser having a wavelength of 785 nm (resolution: 4.0 cm-1, laser output 300 mmW, spot size 100μΦ). Raman spectrum up to 100 nM can be confirmed as shown FIG. 1 . Compared with SERS substrate prepared through CVD by Vladimir Poponin, Ph.D. wherein a Raman scattering spectrum of 100 μM can be detected, the present substrate can get a sensitivity of 1,000 times magnification. It can be thought that the sensitivity of 1000 times magnification was achieved because the quantum dots made of Ag nanocluster in the hexagonal plate-like crystal was formed on the brass substrate.
Example 2
The Ag complex aqueous solution of 1,000 ppm (based on a weight of Ag atom) was prepared and one droplet of the aqueous solution was put on the phosphor bronze substrate and after 3 minutes, the droplet was blown off by Nitrogen gas to stop agglomeration of the metal complex. On each of the substrates, pure water or 4,4′-bipyridine of 100 nM were put and the effect of surface plasmon enhancement was measured by Raman spectroscopy made in Ramuda Vision Co. Ltd. with laser having a wavelength of 785 nm (Output: 80 mmW, Spot size: 50μΦ). The Raman spectrum can be confirmed up to 100 nM, as shown in FIGS. 4( a ) and 4 ( b ).
Example 3
In place of 4,4′-bipyridine, Rhodamine 6G (R6G) was used as a target sample to be detected. The aqueous solution of Ag thiosulfate complex was prepared and the phosphor bronze substrate was used. The R6G aqueous solution was put a drop on the metal complex substrate and the Raman spectrum of 1 μM can be confirmed by Raman spectroscopy (laser having a wavelength of 514 nm) made by Kaiser Co. Ltd as shown in FIG. 5 . Compared with SERS substrate prepared through CVD by Vladimir Poponin Ph.D. wherein a Raman scattering spectrum of 100 μM can be detected, the present substrate can get a sensitivity of 1,000 times magnification.
Example 4
Humanized IgE monoclonal antibody (antibody concentration 1.23 mg/ml) (Mlkuri Immuno Laboratory Co. Ltd. Lot. No. 214-01-002: Solution PBS: including 0.09% sodium azide) was diluted ten times with pure water and was mixed with Ag thiosulfate aqueous solution of 1,000 ppm (based on a weight of Ag atom) without amino acid at a mixture ratio of 1 to 1. The resultant solution was put as a drop on the phosphor bronze substrate in a same manner as Example 1 to prepare a measuring substrate for SERS.
After the confirmation that the Raman spectrum of the measuring substrate prepared by blending of the metal complex and the antibody was obtained by irradiation of the laser of the excitation wavelength 514 nm as shown FIG. 6 ( a ), an antigen was put a drop on the measuring substrate and was subjected to a Raman measuring to obtain the Raman spectrum, which was confirmed as shown FIG. 6 ( b ).
Compared with those Raman spectrum, it was confirmed that a peak was appeared near 1350 cm −1 due to an antigen-antibody reaction, and as a result, the antigen-antibody reaction was detected when both were compared.
Comparative Example
In place of Ag complex solution used in Example 1, Ag nano colloid solution of 5,000 ppm (based on a weight of Ag atom) containing 2-pyrrolidone of 100 to 150 ppm as dispersant was used and other than that, a substrate was prepared in a same manner as Example 1. As Ag nanoclusters was much agglomerated as some solid-like points, there cannot be observed a surface plasmon resonance excitation effect.
INDUSTRIAL APPLICABILITY
By using the method of the present invention, the metal nanoclusters are precipitated at the same time as the metal complex crystals being precipitated from the aqueous solution, and therefore, the metal complex crystals, which encapsulate quantum dots in nano size or are precipitated on the surface, can be formed. The metal complex crystals, which prepared from the aqueous solution by using the method of the present invention, are probably the first case of nano sized complex crystals in the world. In case of Au, Ag, Cu or Pt, compared with nano dots produced by physical methods such as Vapor Deposition and the like, the quantum crystals of the present invention attain a thousand times magnification of surface plasmon resonance excitation effect, so that the quantum crystals are useful for surface plasmon resonance elements such as a SERS detecting substrate, a photoelectric transducer of solar-cells, a scanning near field optical microscopy element, and a metal needle for a medical thermo-therapy.
In the above examples, although phosphor bronze and brass were used as a substrate metal, any other metal substrates are used corresponding to a kind of the metal of nanocluster. It is preferable that the substrate metal should be selected from a metal having a lower electrode potential than that of nanocluster. In case of silver nanocluster, copper and phosphor bronze substrate can be used in place of bronze. Though the metal carrier is usually in a form of a board-shaped, a particle-shaped, a needle-shaped and a capillary-shaped ones, any other forms can be used depending on the kind of use, wherein the metal complex crystals is deposited on this surface, and it is desirable to make it form the quantum crystal which encapsulates metal nano cluster. | The present quantum crystals are produced by a method characterized in that an aqueous solution of plasmon metal complex made from a ligand and a plasmon metal selected from the group consisting of gold, silver, copper, nickel, zinc, aluminum, and platinum is prepared and brought into contact with a carrier made of a metal or a metal alloy having an electrode potential lower than an electrode potential of the plasmon metal in the aqueous solution. When the plasmon metal complex is precipitated as quantum crystals arranged on the carrier, the metal complex crystals are formed as metal quantum dots. | 2 |
FIELD
The invention relates generally to the field of hand tools. More specifically, the invention relates to hand tools used for installing wiring in existing structures.
BACKGROUND
Many modern electronic devices such as television sets, computers, telephones, alarm systems and other devices used in buildings and other structures require extensive wiring. The use of many of these modern electronic devices is often not anticipated at the time the building or other structure is erected. Introduction of these devices into the building or structure often requires modifying the building or structure slightly to accommodate the wiring. To accommodate the wiring, holes may be drilled in the walls of the existing structure. Wires can then be fed through the drill holes providing additional wiring access to selected portions of the building or structure.
For example, a television set may be added to a bedroom in which there is no television cable outlet. A television cable outlet may, however, exist in an adjacent living room. To accommodate the television set in the bedroom, a technician can drill a hole through the inner wall separating the living room and the bedroom room and feed a television cable through the wall. The drill hole in the inner wall might go through the wall board of the living room forming an entrance drill hole and through the wall board of the bedroom forming an exit drill hole. The technician can then feed the television cable through the entrance drill hole in the living room wall board and then try to manipulate the cable to feed the television cable through the living room wall board. Further complicating this feeding task is the fact that there is usually open space between the first wall board and the second wall board. Not surprisingly, feeding the television cable or any other type of wire through both the entrance and exit drill hole can be a time consuming and frustrating task.
Technicians approach this task in different ways. Some technicians will try to feed the wire through the second hole by peering through the first hole and then wiggling the wire to try to feed it through the second hole. This is problematic not only because it requires some dexterity and skill but also because electrical wiring can also be present in the wall board to wall board presenting a shock hazard. Other technicians may use fish tape to help feed the wire through the hole. Technicians often insert the fish tape through the first and second drill holes, then attach the fish tape to the wire and then pull the wire through the drill holes. It can be appreciated that this is also a time practice since it requires feeding the fish tape through the drill hole, then going to the other side of the wall attaching the fish tape to the cable and then returning to the feed through side again to pull the fish tape and the cable back through the wall.
Thus, it is apparent that there is a need for more efficient and safe tools for installing wire in an existing building or structure. The invention addresses this need as well as other needs.
SUMMARY
In an exemplary embodiment the wire installation tool has a handle with a first opening for receiving a wire is attached to a tube having a second opening for evacuating the wire. The handle at some point may have a lip with external radius larger than that of the tube allowing the tube to be inserted in the drill hole of a structure allowing the handle to engage with the structure.
The wire installation tool can, for example, be inserted in the drill hole of an inside wall with the lip of the handle engaging the wallboard and the tube extending through the inside wall. Cabling can then easily be fed into the first opening at the end of the handle with the wire evacuating through the second opening at the end of the tube. In this way, wiring can quickly and easily be fed through the wall.
BRIEF DESCRIPTION OF THE FIGURES
Claimed subject matter is particularly pointed out and distinctly claimed in the concluding portion of the specification. However, such subject matter may be understood by reference to the following detailed description when read with the accompanying drawings in which:
FIG. 1 shows an illustration of a side view of an exemplary embodiment of the present invention;
FIG. 2 shows an illustration of a rear view of the exemplary embodiment shown in FIG. 1 ;
FIG. 3 shows an illustration of a front view of an exemplary embodiment shown in FIG. 1 ;
FIG. 4 shows a cutaway cross sectional view of the tube in the exemplary embodiment shown in FIG. 1 ;
FIG. 5 shows a cross sectional view of the handle portion in the exemplary embodiment shown in FIG. 1 ;
FIG. 6 shows an exemplary use of the exemplary embodiment of FIG. 1 ;
FIG. 7 shows an alternate embodiment of the tube of the present invention; and
FIG. 8 shows an alternate embodiment of the handle of the present invention.
DETAILED DESCRIPTION
Methods and apparatuses that implement the embodiments of the various features of the disclosure will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate embodiments of the invention and not to limit the scope of the invention. Reference in the specification to “one embodiment” or “an embodiment” is intended to indicate that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearance of the phrase “in one embodiment’ or “an embodiment” in various places in the specification are not necessarily all referring to the same embodiment. Throughout the drawings, reference numbers are re-used to indicate correspondence between the referenced elements. In addition, the first digit of each reference number indicates the figure in which the element first appears.
FIG. 1 shows a side view 100 of an exemplary embodiment of the wire installation tool. The wire installation tool 100 includes a handle 102 connected with a tube 104 . The handle 102 has a lip 106 at a distal end. The tube 104 has a chamfer 108 at its distal end. The handle 102 has a handle opening 116 at its proximal end and a curved surface 100 near the lip 106 . The tube 102 has a tube opening 114 at its distal end.
The handle 102 is adapted to be held comfortably in a hand with a closed grip forming a gripping means. The handle 102 has a curved surface 110 accommodating the forefinger and thumb of the closed grip. The lip 106 portion of the handle 110 is substantively flat forming an engaging means for engaging a wallboard or other structural surface. The handle opening 116 for receiving a wire is located at the proximal end of the handle 102 . The handle 116 may be formed from a variety of materials including plastics, woods, rubbers, metals, composites and/or any other rigid or semi rigid material.
The handle 102 is connected with the tube 104 . The tube 104 is substantially cylindrically shaped with a hollow substantially cylindrically shaped interior. The tube 104 has a chamfer 108 of approximately 35 degrees at the distal end that aids a technician in inserting the wire installation tool in a snug fitting drill hole. The tube 104 is preferably rigidly connected with the handle 102 . The tube 102 may be formed from a variety of materials including plastics, woods, rubbers, metals, composites and/or any other rigid or semi rigid materials. The tube 104 may extend longitudinally almost through the entire handle 102 to the handle opening 116 .
Other embodiments feature varying lip shapes that accommodate varying structural engagement surfaces such as corners, curved and cantilevered surfaces. Other embodiments also feature curved handle interiors and handle openings at more distal locations on the handle. The chamfer configuration varies in different embodiments with some embodiments featuring chamfers with large chamfer angles, other embodiments featuring chamfers with small chamfer angles and still other embodiments featuring no chamfer at all. In various embodiments, the handle is composed primarily of an electrical insulating material to prevent electric shock. In other embodiments the handle includes an electrically insulating covering for preventing electric shock.
FIG. 2 shows a rear view 200 of the exemplary embodiment of the wire installation tool. The wire installation tool has a rear surface 202 having a double flair 204 forming a recess in the rear surface 202 with the double flair 204 further defining handle opening 116 . The double flair 204 aids in feeding wire (not shown) into the handle opening 116 . The double flair 204 is particularly useful when the wire diameter is close to the diameter of the handle opening 116 .
FIG. 3 shows a front view 300 of the exemplary embodiment of the wire installation tool. The wire installation tool includes the tube 104 that defines the tube opening 114 . In this embodiment, the tube opening 114 is substantially the same diameter as the handle opening 116 .
FIG. 4 shows a cutaway cross section 400 of the exemplary embodiment of the tube 104 portion of the wire installation tool. On the distal side of the tube is the tube opening 114 and chamfer 108 . The tube opening 114 defines an opening into tube passageway 402 . The tube 104 is connected with the handle 102 at the handle's distal end. In this embodiment, tube 104 extends longitudinally almost until the handle opening 116 . The tube passageway 402 is substantially cylindrical allowing a wire to be fed through the tube passageway 402 and out the tube opening 114 .
FIG. 5 shows a cross section 500 of the exemplary embodiment of the handle 102 with a cutaway of the tube 104 of the wire installation tool. The handle 102 has a handle opening 116 that defines an opening into handle passageway 502 . The handle passageway 502 defined by the handle configuration, transitions to the tube passageway 402 defined by the tube configuration inside the handle 102 . In this embodiment, the handle passageway 502 and tube passageway 504 are substantially cylindrical, longitudinally aligned, with equal radii forming a uniform handle-tube passageway 502 , 504 . This configuration allows a wire to be fed in the handle opening 116 through the handle-tube passageway 502 504 and out the tube opening 114 forming a wire guiding means. A countersunk portion 506 of the handle 102 is adapted to engage a double flair in the tube 104 .
In this embodiment, tube 104 extends almost all of the way to the handle opening 116 . The handle 102 may be precision drilled for the tube to be press fit into the handle 102 . In a preferred embodiment, the rear of the handle 102 may also be countersunk to accept a double flair in the tube 104 thus making the tube 102 flush fit with the end of the handle 102 . The press fit producing tensile and compressive forces that frictionally secure the tube 102 to the handle 104 .
In other embodiments, the tube extends varying lengths into the handle. In some embodiments the tube extends through the handle with the tube forming the handle opening. In yet other embodiments, the tube does not extend into the handle at all.
Those skilled in the art will recognize that there are many embodiments and methods of manufacture of the wire installation tool having handle and tube in accordance with the invention. For example, in one embodiment, the handle and tube are composed of the same material, such as a plastic and is formed as a single structure using a dye cast. In another embodiment the handle is formed from cellulose acetate with the tube being constructed of steel and inserted into the handle. In yet another embodiment the handle and the tube have mating threads for rigidly connecting the handle with the tube. In some embodiments, the handle and/or the tube are constructed of electrical insulating materials to prevent electrical shock. In still other embodiments the handle and/or tube are coated or sheathed in electrical insulating material to prevent shock.
Those skilled in the art will also recognize that the dimensions of the wireless tool may vary. For example, in one embodiment the tube extends approximately 18″ from the handle allowing the tube to extend through both wallboards of an inside wall. The tube is constructed of steel tubing has an outside diameter of ¼″, 5/16″ and inside diameters of 3/16″ and ⅜″respectively in two exemplary embodiments. A ¼ inch 35 degree chamfer is provided at the distal end in some embodiments. The handle may be for example approximately 4″ in length allowing an average size hand to comfortably grip the handle.
FIG. 6 shows an exemplary use 600 of the wire installation tool of FIG. 1 . The handle 602 of the wire installation tool is placed flush against a first wall board 606 with lip 106 engaging the first wall board 606 . The tube 104 extends through a first drill hole (not shown) in the first wall board 606 and through a second drill hole in a second wall board 608 . A wire 612 extends through the wireless tool from the handle opening 116 to the tube opening 114 .
In an exemplary use 600 of the wireless tool a technician drills a hole through the first and second wall boards 606 , 608 of an inside wall. After the drill is removed the technician grips the handle 102 of the wire installation tool and inserts the tube 104 through the first and second drill holes of the first and second wall boards 606 , 608 until the lip 106 engages the first wall board 606 . The technician then feeds a wire 612 into the handle opening 116 until the wire 612 evacuates the tube opening 114 . The technician can then remove the tool from the tool from the inside wall pulling the tool proximally with the tool riding along wire 612 until the wire is pulled completely through the tool.
FIG. 7 shows an alternate embodiment of the tube 700 of the wireless installation tool. The inner portion 702 is cylindrical in shape and defines an inner passageway 704 , a distal opening 706 and proximal opening 708 . An outer portion 710 surrounds the inner portion 702 and covers most of the inner portion 702 of the tube 700 . An uncovered portion 712 extends into a handle (not shown).
The inner portion 702 of the tube is formed of a rigid material such as steel. The outer portion 710 is composed of an electrical insulator for preventing shock. The electrical insulator may be composed of any insulator, for example, rubber-shrink tubing. The outer portion 710 is particularly useful when live wires may present when a technician uses the wire installation tool.
FIG. 8 shows an alternate embodiment of the handle 800 of the wireless installation tool. The handle includes a lip 802 with a planar surface 812 connected with tube 804 . The tube 804 extends distally until tube opening 806 . The tube 804 has a handle opening 808 at the proximal end. The tube 804 also has a grip 810 attached the tube 804 .
In this embodiment a single homogenous tube, preferably of steel, provides both the handle opening 808 and the tube opening 806 forming a single homogeneous guiding means for guiding a wire. A gripping means 810 attached to the tube provides a gripping means for gripping the handle 800 . The lip 812 provides a planar surface for engaging another planar surface providing an engaging means.
The previous description of the disclosed embodiments is provided to enable a person skilled in the art to make or practice the invention. Various modifications to these embodiments will readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit and scope of the disclosure. Thus, the present disclosure is intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and rang of equivalency of the claims are to be embraced within their scope. | A wire installation tool having a handle with a first opening for receiving a wire attached to a tube having a second opening for evacuating the wire. In one embodiment, the handle has a lip with external radius larger than that of the tube allowing the tube to be inserted in the drill hole of a structure with the handle engaging the structure. This configuration allows a technician to easily feed cabling through the drill hole in the inner wall of an existing structure. The tool is particularly useful for safely feeding wiring through a drill created through the first and second wallboards of an inside wall. | 7 |
RELATED APPLICATION
This application is related to provisional application 60/338,152, filed Dec. 6, 2001, the contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
The herein disclosed invention finds applicability in producing optimum fly ash resistivity in flue gas.
BACKGROUND OF THE INVENTION
Many utilities now burn a variety of coals at their fossil fuel plants. This practice is growing for several reasons, including (1) the need to lower SO 2 emissions by burning low-sulfur coals and (2) the need to reduce fuel costs to enhance their competitive position. Frequently, these coal changes have adverse affects on ESPs (ESP=electrostatic precipitator). Low-sulfur coals produce high resistivity ash that is difficult to collect in an electrostatic precipitator (the technology most commonly used to control particulate emissions from coal-fired power plants). Inexpensive coals are frequently variable in their properties and sometimes high in ash or low in sulfur. Conditioning the ash with SO 3 before the ash enters a precipitator, can lower ash resistivity and improve ESP performance. In fact, this well established technology is used at several hundred plants both here and abroad to control fly ash resistivity in low-sulfur or variable-sulfur coals. While commercial conditioning systems are relatively reliable, the controls for these are not sophisticated, and this lack of sophistication can result in non-optimum ESP performance, and sometimes excess SO 3 addition rates (and emissions).
The inventors have developed a correlation between certain ESP electrical operation parameters and fly ash resistivity. In particular, the inventors have found it to be possible to monitor the current density in an ESP electrical section, and using this number, estimate the resistivity of the fly ash in that electrical section. Using these correlations makes it possible to determine if the resistivity in this section is at an optimum level or not. Further, the inventors have also participated in the development of correlations between fly ash resistivity and the flue gas SO 3 concentration needed to produce optimum fly ash resistivity. These correlations can be combined (as described below) to produce a superior SO 3 conditioning system control algorithm.
Current SO 3 conditioning systems use a preset rate of SO 3 addition that is only adjusted for unit load. The invention, described herein, uses a unique combination of calculations to provide a rate of addition that is based on actual ESP operating data. These data, which can easily be obtained from modem ESP controls, are both real time and continuous. Hence, the new control algorithm is capable of producing an optimum rate of SO 3 addition when coal and ash properties are changing.
The primary application will be at utility plants that use SO 3 conditioning to improve ESP performance. These plants are located both here and abroad. In addition, SO 3 is used in some industrial applications, and the new SO 3 control algorithm could be used at those plants as well.
SUMMARY OF INVENTION
The herein disclosed invention is directed to a process for treating fly ash found in flue gas to produce effective fly ash electrical resistivity comprising employing an algorithm to determine the optimum amount of sulfur trioxide (SO 3 ) to be added to the flue gas. The sulfur trioxide can result from the burning of coal, or the sulfur trioxide can result from the burning of coal plus the extrinsic addition of sulfur trioxide. The process of this invention involves an algorithm which takes into account 1) flue gas SO 3 concentration, 2) initial fly ash resistivity, 3) electrostatic precipitator (ESP) current densities, 4) flue gas temperature and moisture and 5) fly ash composition.
Also, embraced by this invention is a process for treating fly ash found in flue gas to produce effective fly ash resistivity comprising the following steps:
Step 1. Obtain the proximate ultimate analyses of coal being burned in boiler and ash mineral analysis for this coal;
Step 2. Determine the average temperature of flue gas entering the electrostatic precipitator (ESP);
Step 3. Estimate SO 3 background level in the flue gas using correlation relating flue gas SO 3 to coal type and coal sulfur content.
Step 4. Calculate the base ash resistivity using empirical equations relating ash resistivity to ash composition, flue gas moisture and flue gas temperature.
Step 5. Use a correlation relating the base fly ash resistivity and flue gas SO 3 concentration to determine the flue gas SO 3 concentration needed to produce the optimum fly ash resistivity.
Step 6. Subtract the background SO 3 concentration from the needed SO 3 concentration from the needed SO 3 that must be added to the flue gas to produce the optimum fly ash resistivity and
Step 7. Send rate of addition signal to the controls that operate the SO 3 conditioning system.
Another method encompassed by the invention involves determining a most effective injection rate for SO 3 into flue gas comprising the following steps:
Step 1. Obtain the proximate and ultimate analysis of the coal being burned in the boiler and the ash mineral analysis for the coal,
Step 2. Determine the average temperature of the flue gas entering the ESP from plant instrumentation,
Step 3. Estimate SO 3 background level in the flue gas using correlation relating flue gas SO 3 to coal type and coal sulfur content,
Step 4. The secondary current applied to the electrostatic precipitator is obtained from the controls for each transformer-rectifier set that is powering the precipitators,
Step 5. Determine effective fly ash resistivity level in the ESP using a correlation that relates fly ash resistivity to ESP current density for each electrical field, average the results to produce an effective resistivity for the ESP.
Step 6. a. If indicated ash resistivity is equal to or less than optimum resistivity, decrease rate of injection by x percent where x is between 5 and 25, or
b. if indicated ash resistivity is greater than optimum resistivity, increase rate of injection by x percent where x is between 5 and 25.
Step 7. Repeat Step 6 until indicated fly ash resistivity passes through optimum resistivity point and then set rate of injection at a point in the range bounded by the levels calculated in the last two interactions, and then
Step 8. Every y minutes, where y is number between 5 and 30, restart the process beginning at Step 2.
A still further method involves a method for determining a most effective injection rate for SO 3 into flue gas comprising the following steps,
Step 1. Obtain the proximate and ultimate analysis of the coal being burned in the boiler and the ash mineral analysis for the coal,
Step 2. Determine the average temperature of the flue gas entering the ESP from plant instrumentation,
Step 3. Estimate SO 3 background level in the flue gas using correlation relating flue gas SO 3 to coal type and coal sulfur content,
Step 4. The secondary current applied to the electrostatic precipitator is obtained from the controls for each transformer-rectifier set that is powering the precipitators,
Step 5. Determine effective fly ash resistivity level in the ESP using a correlation that relates fly ash resistivity to ESP current density for each electrical field. Average the results to produce an effective resistivity for the ESP. If this resistivity is not close to, or lower than, the optimum range, proceed with Step 6; otherwise, go to Step 10.
Step 6. Use a correlation relating fly ash composition and flue gas temperature and SO 3 concentration to fly ash resistivity to determine the flue gas SO 3 concentration to needed to produce the optimum fly ash resistivity,
Step 7. Subtract the background SO 3 from the needed SO 3 concentration from Step 6 to determine the amount of SO 3 that must be added to the flue gas to produce the optimum fly ash resistivity.
Step 8. Send rate of additional signal to the controls that operate the SO 3 conditioning system.
Step 9. Repeat Steps 4 and 5.
Step 10. a. If indicated ash resistivity is equal to or less than optimum resistivity, decrease rate of injection by x percent where x is between 5 and 25, or
b. if indicated ash resistivity is greater than optimum resistivity, increase rate of injection by x percent where x is between 5 and 25.
Step 11. Repeat Step 10 until indicated fly ash resistivity passes through optimum resistivity point and then set rate of injection at a point in the range bounded by the levels calculated in the last two interactions, and then
Step 12. Every y minutes, where y is number between 5 and 30, restart the process beginning at Step 2.
DETAILED DESCRIPTION OF THE INVENTION
The herein disclosed invention involves completing a sequence of unique calculations that result in the estimation of the amount of SO 3 that must be added to flue gas to produce optimum fly ash electrical resistivity. This sequence of steps is as follows:
“Typical” Starting Conditions:
a. Low flue gas SO 3 concentration measured at the ESP inlet—0 to 4 ppm. SO 3 —example number=3.5.
b. Moderate to high fly ash resistivity—8×10 10 ohm-cm to 5×10 12 ohm-cm.
c. Low ESP power level characterized by low average current densities.
For example, in a three-field electrostatic precipitator the average current densities in the inlet field might be 9.13 na/cm, in the middle field it might be 12.41 na/cm 2 and in the outlet field, it might be 15.19 na/cm 2 . These current densities correspond to a fly ash resistivity of 1.0×10 11 ohm-cm and this level of resistivity is too high to allow optimum ESP performance (see Table 1).
Desired “End” Conditions:
a. Increased flue gas SO 3 measured at ESP inlet—from 2 to 12 ppm, depending on flue gas temperature, flue gas moisture, and fly ash composition.
b. Optimum fly ash resistivity—8×10 9 ohm-cm to 4×10 10 ohm-cm, depending on ESP collection and reentrainment characteristics—example number 1×10 10 ohm-cm.
c. High ESP power levels as indicated by current density levels.
For example, when the correct level of SO 2 has been added to the flue gas, the average current densities in the ESP would increase to 27.67 na/cm 2 in the inlet field, 33.50 na/cm 2 in the middle field and 39.50 na/cm 2 in the outlet field. The current densities correspond to a fly ash resistivity of 1×10 10 ohm-cm and this level of resistivity should produce optimum ESP performance (see Table 1).
TABLE 1
Typical Per-Field Current Densities for a Range of Resistivies
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIELD 1
FIELD 2
FIELD 3
FIELD 4
FIELD 5
PARAMETER 1
6.255
5.839
5.697
5.018
4.718
PARAMETER 2
0.4813
0.4314
0.4105
0.3405
0.3036
RESISTIVITY
CURRENT
CURRENT
CURRENT
CURRENT
CURRENT
(ohm * cm)
na/cm 2
na/cm 2
na/cm 2
na/cm 2
na/cm 2
1.00E+10
27.67
33.50
39.08
41.02
48.08
2.00E+10
19.82
24.84
29.41
32.40
38.96
4.00E+10
14.20
18.42
22.12
25.59
31.57
6.00E+10
11.68
15.46
18.73
22.29
27.91
8.00E+10
10.17
13.66
16.64
20.21
25.58
1.00E+11
9.13
12.41
15.19
18.73
23.90
2.00E+11
6.54
9.20
11.43
14.79
19.36
4.00E+11
4.69
6.82
8.60
11.68
15.69
6.00E+11
3.86
5.73
7.28
10.18
13.87
8.00E+11
3.36
5.06
6.47
9.23
12.71
1.00E+12
3.02
4.59
5.90
8.55
11.88
2.30E+12
2.02
3.21
4.19
6.44
9.23
4.00E+12
1.55
2.53
3.34
5.33
7.80
6.00E+12
1.27
2.12
2.83
4.65
6.90
8.00E+12
1.11
1.87
2.51
4.21
6.32
1.00E+13
1.00
1.70
2.29
3.90
5.90
Note:
Resistivities and current densities above the line are in the range that will produce optimum ESP performance. Resistivities and current densities below the line are in the range that will produce suboptimum ESP performance
This invention has several methods to determine the rate of SO 3 addition that will produce the optimum level of fly ash resistivity and hence optimum ESP performance. The first method does not require data feed back from the ESP, while the second method does.
Method 1 is as follows:
Step 1. Obtain the proximate and ultimate analyses of the coal being burned in the boiler and the ash mineral analysis for this coal. Table 2 contains examples of typical analyses.
TABLE 2
Example Coal Composition
As Received
Example Fly Ash Composition
Ultimate Analysis
As Constituents
(%)
(%)
Carbon
68.00
LiO2
0.01
Hydrogen
3.86
Na 2 O
0.96
Oxygen
6.00
K 2 O
2.43
Nitogen
1.00
MgO
0.78
Sulfur
2.20
CaO
2.62
Moisture
3.60
Fe 2 O 3
7.76
Ash
16.34
Al 2 O 3
17.85
SUM
100.00
SiO 2
61.00
TiO 2
0.62
P 2 O 5
0.55
SO 3
2.43
SUM
97.01
Step 2. Determine the average temperature of the flue gas entering the ESP from plant instrumentation. For example, the instrumentation indicates the temperature of the flue gas entering the RSP is 291° F.
Step 3. Estimate SO 3 background level in the flue gas using correlation relating flue gas SO 3 to coal type and coal sulfur content. The SO 3 concentration is calculated as a percentage of SO 2 in the flue gas which can be determined from a combustion calculation using the coal analysis and flue gas O 2 or CO 2 or if the flue gas SO 2 is available from plant instruments, this number can be used in the SO 3 calculation. Using standard, well known chemical formulas and procedures, that calculation is as follows if the assumption for no excess air is used.
A. Calculation of Combustion Products, Air, and O 2 for 100% Combustion.
Required for
combustion
Ultimate
Moles/100 lb fuel
Coal
analysis
Molecular
Moles per
at 100% total air
Constiuent
lb/100 lb fuel
weight
100 lb fuel
Multipliers 1
O 2
Dry Air
C
68.00
÷
12.01
=
5.662
×
1.0 and 4.76
5.662
26.951
H 2
3.86
÷
2.02
=
1.911
×
0.50 and 2.38
0.956
4.548
O 2
6.00
÷
32.00
=
0.188
×
−1.00 and −4.76
−0.188
−0.895
N 2
1.00
÷
28.01
=
0.036
S
1.20
÷
32.06
=
0.037
×
1.00 and 4.76
0.037
0.176
H 2 O
3.60
÷
18.02
=
0.200
Ash
16.34
—
—
Sum
100.00
8.034
6.467
30.780
A correction for excess air, which is always added to the furnace to ensure complete combustion is next made as follows.
B. Calculation of Air and O 2 for 30% Excess Air (Typical Excess Air Level).
Required for
Combustion
moles/100 lb fuel
at 30% excess air
O 2
Dry air
O 2 and air × 130/100 total
8.407
40.014
Excess air = 40.014 − 30.780
—
9.234
Excess O 2 = 8.407 − 6.467
1.940
—
Using the values from these two calculations, the final composition of the flue gas is calculated, again using established and well known formulas and procedures.
C. Calculation of Flue Gas Composition.
Products of Combustion
Total
Flue gas
moles/100
% by volume
% by volume
Constituent
Combustion/Fuel/Air
lb fuel
wet basis
dry basis
CO 2
5.662
=
5.662
13.406
14.412
H 2 O
1.911 + 0.200 + 0.838 a
=
2.949
6.983
—
SO 2
0.037
=
0.037
0.088
0.094
N 2
0.036 + 31.611 b
=
31.647
74.931
80.555
O 2
1.940
=
1.940
4.593
4.938
Sum wet
42.235
Sum dry =
42.235 − 2.949
39.286
a Moles H 2 O in air = (40.014 × 29 × 0.013) ÷ 18 = 0.838
b Moles N 2 in air = (40.014 × 0.79) = 31.611
The critical numbers from these calculations are the SO 2 concentrations:
0.088%, wet basis, and 094%, dry basis.
The moisture concentration, 6.98% is also critical Once these numbers are known, the native SO 3 concentration in the flue gas can be calculated as follows:
The SO 2 concentration dry (the resistivity concentration in this example uses the equivalent SO 3 concentration of “dry” flue gas) is equal to 0.094%. the appropriate SO 2 to SO 3 conversion factor for this coal is 0.4% so the approximate SO 3 concentration is:
0.00094×0.004=3.76 PPM (dry basis)
As an alternative, the flue gas SO 2 concentration can be obtained from the plant's Continuous Emissions Monitoring (CEM) system, corrected for flue gas moisture concentration using factors from the combustion calculation and multiplied by the factor 0.004 to estimate to inherent or background SO 3 concentration. For other coals, for example, western coals, the appropriate conversion factor is 0.001 and for Powder River Basin Coals, the conversion factor is 0.005 (as opposed to 0.004).
Step 4. Calculate the base ash resistivity using empirical equations relating ash resistivity to ash composition, flue gas moisture and flue gas temperature. The Bickelhaupt equations are an example of relationships that can be used for this calculation. This particular calculation is made using the ash mineral analysis from Table 2 and the moisture and SO 3 calculations from step 2 using the following sequence of substeps:
Substep 1: Normalize the weight percentages to sum 100% by dividing each specified percentage by the sum of the specified percentages. Substep 2: Divide each oxide percentage by the respective molecular weight to obtain the mole fractions. Substep 3: Divide each mole fraction by the sum of the mole fractions and multiply by 100 to obtain the molecular percentages as oxides. Substep 4: Multiply each molecular percentage by the decimal fraction of cations in the given oxide to obtain the atomic concentrations.
These substeps are illustrated for the example ash in the following table.
Atomic
Specified
Normalized
Molecular
Mole
Molecular
Cationic
Concentration
Oxide
Weight %
Weight %
Weight
Fraction
Percentage
Fraction
Of Cation
Li 2 O
0.01
0.01
29.88
0.00034
0.024
0.67
0.016
Na 2 O
0.96
0.99
61.98
0.01600
1.116
0.67
0.744
K 2 O
2.43
2.50
94.20
0.02654
1.854
0.67
1.236
MgO
0.78
0.80
40.31
0.01985
1.387
0.50
0.694
CaO
2.62
2.70
56.08
0.04815
3.364
0.50
1.682
Fe 2 O 3
7.76
8.00
159.70
0.05009
3.500
0.40
1.400
Al 2 O 3
17.85
18.40
101.96
0.18046
12.608
0.40
5.043
SiO 2
61.00
62.89
60.09
1.04660
73.123
0.33
24.368
TiO 2
0.62
0.64
79.90
0.00801
0.560
0.33
0.186
P 2 O 5
0.55
0.57
141.94
0.00402
0.281
0.29
0.080
SO 3
2.43
2.50
80.06
0.03123
2.183
0.25
0.546
Sum
97.01
100.00
1.43129
100.000
Now that the atomic concentrations of the critical ash mineral constituents are known, the rest of the calculation proceeds by calculating three separate resistivities, the volume resistivity, ρ v , the surface resistivity, ρ s , and the acid resistivity, ρ a . These three resistivities are then combined to give the net resistivity of the ash using the parallel resistance formula. For the example coal, the calculation proceeds as follows using the following formulas and definitives.
Bickelhaupt Equations
ρ v =exp[−1.8916 ln X −0.9696 ln Y +1.234 ln Z +3.62876−(0.069078) E +9980.58 /T] ρ s =exp[27.59774−2.233348 ln X−( 0.00176) W− (0.069078) E− (0.00073895)( W )exp(2303.3 /T )] ρ a =exp[85.1405−(0.708046)CSO 3 −23267.2 /T− (0.069078) E] , for z <3.5% or K >1.0% ρ a =exp[59.0677−(0.854721)CSO 3 −13049.47 /T− (0.069078) E] , for z <3.5% or K >1.0% 1/ρ vs =1/ρ v +1/ρ s 1/ρ vsa =1/ρ vs +1/ρ a
ρ v =volume resistivity (ohm-cm)
ρ s =surface resistivity (ohm-cm)
ρ a =adsorbed acid resistivity (ohm-cm)
ρ vs =volume and surface resistivity (ohm-cm)
ρ vsa =total resistivity (ohm-cm)
X=Li+Na percent atomic concentration
Y=Fe percent atomic concentration
Z=Mg+Ca percent atomic concentration
K=K percent atomic concentration
T=absolute temperature (K)
W=moisture in flue gas (volume %)
CSO 3 =concentration of SO 3 (ppm, dry)
E=applied electric field (kV/cm)
Using the above definitions, equations and calculated values, the calculation proceeds for the example case as follows:
X=0.016+0.744=0.76
Y=1.40
Z=0.694+1.682=2.376
K=1.236
T=417 (Example gas temperature 291° F.)
W=6.983
CSO 3 =(from Calculation 2)3.76 ppm, dry
E=10(typical electric field value)
ρ v =exp[−1.8916 ln(0.76)−0.9696 ln(1.40)+1.237 ln(2.376)+3.62876−(0.069078)(10)+9980.58/417]
=1.636×10 12 ohm-cm
ρ s =exp[27.59774−2.23348 ln(0.76)−(0.00176)(6.983)−(0.069078)(10)−(0.00073895)(6.983)exp(2303.0/417)]
=2.392×10 11 ohm-cm
ρ a =exp[85.1405−(0.708046)(3.76)−23267.2/417−(0.069078)(10)]
=1.939×10 11 ohm-cm
1/ρ vs =1/1.636×10 12 +1/2.392×10 11 =4.792×10 −12
ρ vs =2.1×10 11 ohm-cm
1/ρ vsa =1/4.792×10 −12 +1/1.939×10 11 =9.949×10 −12
ρ vsa =1.0 ×10 11 ohm-cm
In this example, the calculated resistivity is found to be 1.0×10 11 ohm-cm, which is too high for optimum ESP performance, so additional SO 3 must be added to the flue gas.
Step 5. Use a correlation relating the base fly ash resistivity and flue gas SO 3 concentration to determine the flue gas SO 3 concentration needed to produce the optimum fly ash resistivity.
From the preceding step, the relationships between the acid resistivity, surface resistivity, volume resistivity and net ash resistivity are known. Further, it is known that the desirable level of resistivity is 1.0×10 10 ohm-cm. Hence, the calculation proceeds as follows:
1/ρ vsa =1/ρ vs +1/ρ a
where ρ vsa =1×10 10 ohm-cm(the desirable ρ)
ρ vs =2.1×10 11 ohm-cm(from preceding calculation)
1 / ρ a = 1 / ρ vsa - 1 / ρ vs = 1.0 × 10 10 - 2.761905 × 10 12 = 9.5238 × 10 11 ρ va =1.05×10 10 ohm-cm
also from the preceding calculation,
ρ a =exp[85.1405−(0.708046)CSO 3 −23267.2 /T− (0.069078) E]
where T=417 (from preceding calculation)
E=10 (from preceding calculation)
hence
1.05×10 10 =exp[85.1405−(0.708046)CSO 3 −23267.2/417−(0.069078)(10)]
ln(1.05×10 10 )=85.1405−(0.708046)CSO 3 −55.79664−0.69078
23.07464109=28.652−(0.708046)CSO 3
(0.708046)CSO 3 =5.578
CSO 3 =7.878
Correcting for wet conditions
SO 3 needed=7.878×(39.286/42.235)=7.33 ppm
Step 6. Subtract the background SO 3 concentration from the needed SO 3 concentration from the needed SO 3 that must be added to the flue gas to produce the optimum fly ash resistivity.
The combustion calculation results and the background SO 3 calculation in step 2, the SO 3 concentration is estimated to be 0.00088×0.004=3.52 ppm (wet basis). From the desired level calculation above, the desirable SO 3 level=7.33 ppm, hence the difference=7.33−3.52=3.81 ppm. Hence, 3.81 ppm, SO 3 must be added to the flue gas to produce the desired level of fly ash resistivity.
Step 7. Send rate of addition signal to the controls that operate the SO 3 conditioning system. In this case, the signal should be sent that will cause the SO 3 conditioning system to add 3.8 ppm SO 3 to the flue gas.
Notice that this procedure uses the equations developed by Dr. Bickelhaupt to relate flue gas composition and ash mineral analysis in the calculations, but any set equations relating flue gas SO 3 concentrations and ash mineral analysis to fly ash resistivity could be used. For example, the equations developed by Joe McCain and published in EPRI technical report 1004075 can be used.
This concludes Method 1.
Method 2 is as follows:
The example calculation for this method resumes the same starting conditions that were assumed for method 1. They are as follows:
a. Low flue gas SO 3 concentration measured at the ESP inlet—0 to 4 ppm: SO 3 —example number=3.5.
b. Moderate to high fly ash resistivity—8×10 10 ohm-cm to 5×10 12 ohm-cm.
c. Low ESP power level characterized by low average current densities.
For example, in a three-field electrostatic precipitator the average current densities in the inlet field might be 9.13 na/cm 2 , in the middle field it might be 12.41 na/cm 2 and the outlet field might be 15.19 na/cm 2 . These current densities correspond to a fly ash resistivity of 1.0×10 11 ohm-cm and this level of resistivity is too high to allow optimum ESP performance (see Table 1).
Typical Per-Field Current Densities for a Range of Resistivies
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIELD 1
FIELD 2
FIELD 3
FIELD 4
FIELD 5
PARAMETER 1
6.255
5.839
5.697
5.018
4.718
PARAMETER 2
0.4813
0.4314
0.4105
0.3405
0.3036
RESISTIVITY
CURRENT
CURRENT
CURRENT
CURRENT
CURRENT
(ohm * cm)
na/cm 2
na/cm 2
na/cm 2
na/cm 2
na/cm 2
1.00E+10
27.67
33.50
39.08
41.02
48.08
2.00E+10
19.82
24.84
29.41
32.40
38.96
4.00E+10
14.20
18.42
22.12
25.59
31.57
6.00E+10
11.68
15.46
18.73
22.29
27.91
8.00E+10
10.17
13.66
16.64
20.21
25.58
1.00E+11
9.13
12.41
15.19
18.73
23.90
2.00E+11
6.54
9.20
11.43
14.79
19.36
4.00E+11
4.69
6.82
8.60
11.68
15.69
6.00E+11
3.86
5.73
7.28
10.18
13.87
8.00E+11
3.36
5.06
6.47
9.23
12.71
1.00E+12
3.02
4.59
5.90
8.55
11.88
2.30E+12
2.02
3.21
4.19
6.44
9.23
4.00E+12
1.55
2.53
3.34
5.33
7.80
6.00E+12
1.27
2.12
2.83
4.65
6.90
8.00E+12
1.11
1.87
2.51
4.21
6.32
1.00E+13
1.00
1.70
2.29
3.90
5.90
Note:
Resistivities and current densities above the line are in the range that will produce optimum ESP performance. Resistivities and current densities below the line are in the range that will produce suboptimum ESP performance
As in the Method 1 example calculation, the desired end point is the same. It is described in the following paragraph:
Desired “End” Conditions:
a. Increased flue gas SO 3 measured at ESP inlet—from 2 to 12 ppm, depending on flue gas temperature, flue gas moisture, and fly ash composition.
b. Optimum fly ash resistivity—8×10 9 ohm-cm to 4×10 10 ohm-cm, depending on ESP collection and reentrainment characteristics—example number 1×10 10 ohm-cm.
c. High ESP power levels as indicated by current density levels.
For example, when the correct level of SO 3 has been added to the flue gas, the average current densities in the ESP would increase to 27.67 nA/cm 2 in the inlet field, 33.50 na/cm 2 in the middle field, and 39.08 na/cm 2 in the outlet field. The current densities correspond to a fly ash resistivity of 1×10 10 ohm-cm and this level of resistivity should produce optimum ESP performance (see Table 1).
Method 2 uses the following alternative sequence of steps to determine the optimum injection rate for SO 3 :
Step 1. Obtain the proximate and ultimate analysis of the coal being burned in the boiler and the ash mineral analysis for this coal. Table 2 contains examples of typical analysis.
TABLE 2
Example Coal Composition
As Received
Example Fly Ash Composition
Ultimate Analysis
As Constituents
(%)
(%)
Carbon
68.00
LiO2
0.01
Hydrogen
3.86
Na 2 O
0.96
Oxygen
6.00
K 2 O
2.43
Nitogen
1.00
MgO
0.78
Sulfur
2.20
CaO
2.62
Moisture
3.60
Fe 2 O 3
7.76
Ash
16.34
Al 2 O 3
17.85
SUM
100.00
SiO 2
61.00
TiO 2
0.62
P 2 O 5
0.55
SO 3
2.43
SUM
97.01
Step 2. Determine the average temperature of the flue gas entering the ESP from plant instrumentation. For example, the instrumentation indicates the temperature of the flue gas entering the ESP is 291° F.
Step 3. Estimate SO 3 background level in the flue gas using correlation relating flue gas SO 3 to coal type and coal sulfur content. The SO 3 concentration is calculated as a percentage of SO 2 in flue gas which can be determined from a combustion calculation using the coal analysis and flue gas O 2 or CO 2 or if the flue gas SO 2 is available from plant instruments, this number can be used in the SO 3 calculation. Using standard, well known chemical formulas and procedures, that calculation is as follows if the assumption for no excess air is used.
A. Calculation of Combustion Products, Air, and O 2 for 100% Combustion.
Required for
combustion
Ultimate
Moles/100 lb fuel
Coal
analysis
Molecular
Moles per
at 100% total air
Constiuent
lb/100 lb fuel
weight
100 lb fuel
Multipliers 1
O 2
Dry Air
C
68.00
÷
12.01
=
5.662
×
1.0 and 4.76
5.662
26.951
H 2
3.86
÷
2.02
=
1.911
×
0.50 and 2.38
0.956
4.548
O 2
6.00
÷
32.00
=
0.188
×
−1.00 and −4.76
−0.188
−0.895
N 2
1.00
÷
28.01
=
0.036
S
1.20
÷
32.06
=
0.037
×
1.00 and 4.76
0.037
0.176
H 2 O
3.60
÷
18.02
=
0.200
Ash
16.34
—
—
Sum
100.00
8.034
6.467
30.780
A correction for excess air, which is always added to the furnace to ensure complete combustion is next made as follows:
B. Calculation of Air and O 2 for 30% Excess Air (Typical Excess Air Level).
Required for
Combustion
moles/100 lb fuel
at 30% excess air
O 2
Dry air
O 2 and air × 130/100 total
8.407
40.014
Excess air = 40.014 − 30.780
—
9.234
Excess O 2 = 8.407 − 6.467
1.940
—
Using the values from these two calculations, the final composition of the flue gas is calculated, again using established and well known formulas and procedures.
C. Calculation of Flue Gas Composition.
Products of Combustion
Total
Flue gas
moles/100
% by volume
% by volume
Constituent
Combustion/Fuel/Air
lb fuel
wet basis
dry basis
CO 2
5.662
=
5.662
13.406
14.412
H 2 O
1.911 + 0.200 + 0.838 a
=
2.949
6.983
—
SO 2
0.037
=
0.037
0.088
0.094
N 2
0.036 + 31.611 b
=
31.647
74.931
80.555
O 2
1.940
=
1.940
4.593
4.938
Sum wet
42.235
Sum dry =
42.235 − 2.949
39.286
a Moles H 2 O in air = (40.014 × 29 × 0.013) ÷ 18 = 0.838
b Moles N 2 in air = (40.014 × 0.79) = 31.611
The critical numbers from these calculations are the SO 2 concentrations:
0.0870, wet basis, and 0.0970 dry basis.
The moisture concentration 6.970 is also critical.
Once these numbers are known, the native SO 3 concentration in the flue gas can be calculated as follows:
The SO 2 concentration dry (the resistivity concentration in this example uses the equivalent SO 3 concentration “dry” flue gas) is equal to 0.094%. The appropriate SO 2 to SO 3 conversion factor for this coal is 0.4% so the approximate SO 3 concentration is:
0.00094×0.004=3.76 PPM (dry basis).
As an alternative, the flue gas SO 2 concentration can be obtained from the plant's Continuous Emissions Monitoring (CEM) system, corrected for flue gas moisture concentration using factors from the combustion calculation and multiplied by the factor 0.004 to estimate inherent or background SO 3 concentration. For other coals, for example, western coals, the approximate conversion factor is 0.001 and for Powder River Basin Coals, the conversion factor is 0.005 (as apposed to 0.004).
To this point, the calculations for Method 1 and Method 2 are the same, however, they are different from this point on.
Step 4. The secondary current applied to the electrostatic precipitator is obtained from the controls for each transformer-rectifier set that is powering the precipitator. These current numbers are translated into current densities by dividing the plate area powered by the transformer-rectifier set. In this example-case, the precipitator has four electrical fields in the direction of gas flow with four transformer-rectifier sets per field.
Readings from the transformer/rectifier sets are as follows:
TR1 TR2 TR3 TR4 Field 1 165 ma 165 ma 165 ma 165 ma Field 2 224 ma 224 ma 224 ma 224 ma Field 3 274 ma 274 ma 274 ma 274 ma Field 4 338 ma 338 ma 338 ma 338 ma
In this example-case, each transformer/rectifier set energized 19,440 ft 2 of plate area.
For a typical field, these currents translate into current densities as follows:
165 ma×(1.0×10 −3 ma/a)/(19,440 ft 2 )=8.488×10 −6 a/ft 2 =8.488 μa/ft 2 8.488×10 −6 ×1.076=9.133 na/cm 2
Note: 1.0 μa/ft 2 =1.076 na/cm 2
Similar calculations can be used to produce the following table
TR1 TR2 TR3 TR4 Field 1 9.13 9.13 9.13 9.13 Field 2 12.41 12.41 12.41 12.41 Field 3 15.19 15.19 15.19 15.19 Field 4 18.73 18.73 18.73 18.73
Where the units are nA/cm 2
Notice that in this example, all of the TR sets in the same field have been assumed to have the same operating point, i.e., the same voltage and current levels. If these numbers were different, an averaging process, in Step 5, would be used to deal with this more common situation.
Step 5. Determine effective fly ash resistivity level in the ESP using a correlation that relates fly ash resistivity to ESP current density for each electrical field. Average the results to produce an effective resistivity for the ESP. If this resistivity is close to, or lower than, the optimum range, go to Step 10, otherwise proceed to Step 6.
In this example-case, the correlations published in EPRI report CS-5040, table 3–4 are used.
These correlations, after amplification are as follows:
Field 1 log 10 (J, nA/cm 2 ) = (6.455 ± 0.370) − 0.5013 log 10 (ρ, ohm-cm) Field 2 log 10 (J, nA/cm 2 ) = (6.839 ± 0.360) − 0.5214 log 10 (ρ, ohm-cm) Field 3 log 10 (J, nA/cm 2 ) = (5.497 ± 0.304) − 0.3905 log 10 (ρ, ohm-cm) Field 4 log 10 (J, nA/cm 2 ) = (5.718 ± 0.327) − 0.4005 log 10 (ρ, ohm-cm) Field 5 log 10 (J, nA/cm 2 ) = (3.328 ± 0.306) − 0.1736 log 10 (ρ, ohm-cm)
Where J is in nA/cm 2 and ρ is in ohm-cm.
Since, log(e)=1/ln(10) substitution gives:
log( J )=log( e )ln( J )=ln( J )/ln(10)=ln( J )/2.302585 similarly, log(ρ)=ln(ρ)/ln(10)=ln(ρ)/2.302585 and further substitution gives:
Field 1 ln(J)/ln(10) = 6.455 − 0.5013 ln(ρ)/ln(10) or ln(J) = 2.302585 × 6.455 − 0.5013 ln(ρ) Field 1 ln(J) = 14.8632 − 0.5013 ln(ρ) similarly Field 2 ln(J) = 15.74738 − 0.5214 ln(ρ) Field 3 ln(J) = 12.65731 − 0.3905 ln(ρ) Field 4 ln(J) = 13.16618 − 0.4005 ln(ρ) Field 5 ln(J) = 7.66300 − 0.1736 ln(ρ)
These equations are inverted to give the following:
Field 1 ln(ρ) = 29.64931 − 1.994813 ln(J) Field 2 ln(ρ) = 30.20211 − 1.917913 ln(J) Field 3 ln(ρ) = 32.41309 − 2.560819 ln(J) Field 4 ln(ρ) = 32.87435 − 2.496879 ln(J) Field 5 ln(ρ) = 44.14171 − 5.76037 ln(J)
From Calculation 3, we have the following:
J Field 1 9.13 na/cm 2 Field 2 12.41 na/cm 2 Field 3 15.19 na/cm 2 Field 4 18.73 na/cm 2
Using the ρ vs. J equation gives:
ρ Field 1 9.1 × 10 10 ohm-cm Field 2 10.4 × 10 10 ohm-cm Field 3 11.3 × 10 10 ohm-cm Field 4 16.2 × 10 10 ohm-cm Average 11.8 × 10 10 ohm-cm
Note that the resistivity is much higher than the optimum value of 10 10 ohm-cm.
Step 6. Use a correlation relating fly ash composition and flue gas temperature and SO 3 concentration to fly ash resistivity to determine the flue gas SO 3 concentration to needed to produce the optimum fly ash resistivity.
That calculation proceeds in a sequence of substeps as follows using the equations developed by Dr. Bickelhaupt and published in EPRI report C9-4145, Appendix A. Starting with the example ash composition in Table 2, complete substep as follows:
Substep 1: Normalize the weight percentages to sum 100% by dividing each specified percentage by the sum of the specified percentages. Substep 2: Divide each oxide percentage by the respective molecular weight to obtain the mole fractions. Substep 3: Divide each mole fraction by the sum of the mole fractions and multiply by 100 to obtain the molecular percentages as oxides. Substep 4: Multiply each molecular percentage by the decimal fraction of cations in the given oxide to obtain the atomic concentrations.
All of these sub-steps are illustrated in the following table for the data in Table 2.
Atomic Specified Normalized Molecular Mole Molecular Cationic Concentration Oxide Weight % Weight % Weight Fraction Percentage Fraction Of Cation Li 2 O 0.01 0.01 29.88 0.00034 0.024 0.67 0.016 Na 2 O 0.96 0.99 61.98 0.01600 1.116 0.67 0.744 K 2 O 2.43 2.50 94.20 0.02654 1.854 0.67 1.236 MgO 0.78 0.80 40.31 0.01985 1.387 0.50 0.694 CaO 2.62 2.70 56.08 0.04815 3.364 0.50 1.682 Fe 2 O 3 7.76 8.00 159.70 0.05009 3.500 0.40 1.400 Al 2 O 3 17.85 18.40 101.96 0.18046 12.608 0.40 5.043 SiO 2 61.00 62.89 60.09 1.04660 73.123 0.33 24.368 TiO 2 0.62 0.64 79.90 0.00801 0.560 0.33 0.186 P 2 O 5 0.55 0.57 141.94 0.00402 0.281 0.29 0.080 SO 3 2.43 2.50 80.06 0.03123 2.183 0.25 0.546 Sum 97.01 100.00 1.43129 100.000
Using the % atomic concentrations from the above calculations, use the following equations for calculation of fly ash resistivity (Bickelhaupt equations).
ρ v =exp[−1.8916 ln X− 0.9696 ln Y+ 1.234 ln Z+ 3.62876−(0.069078) E+ 9980.58 /T] ρ s exp[27.59774−2.233348 ln X−( 0.00176) W− (0.069078) E− (0.00073895)( W )exp(2303.3 /T )] ρ a exp[85.1405−(0.708046)CSO 3 −23267.2 /T− (0.069078) E] , for z< 3.5% or K> 1.0% ρ a =exp[59.0677−(0.854721)CSO 3 −13049.47 /T− (0.069078) E] , for z> 3.5% and K< 1.0% 1/ρ vs =1/ρ v +1/ρ s 1/ρ vsa =1/ρ vs +1/ρ a
ρ v =volume resistivity (ohm-cm)
ρ s =surface resistivity (ohm-cm)
ρ a =adsorbed acid resistivity (ohm-cm)
ρ vs =volume and surface resistivity (ohm-cm)
ρ vsa =total resistivity (ohm-cm)
X=Li+Na percent atomic concentration
Y=Fe percent atomic concentration
Z=Mg+Ca percent atomic concentration
K=K percent atomic concentration
T=absolute temperature (K)
W=moisture in flue gas (volume %)
CSO 3 =concentration of SO 3 (ppm, dry)
E=applied electric field (kV/cm)
For the example case,
X=0.016+0.744=0.76
Y=1.40
Z=0.694+1.682=2.376
K=1.236
T=417 (Example gas temperature 291° F.)
W=6.983
CSO 3 =(from Calculation 2)3.76 ppm, dry
E=10(typical electric field value)
ρ v =exp[−1.8916 ln(0.76)−0.9696 ln(1.40)+1.237 ln(2.376)+3.62876−(0.069078)(10)+9980.58/417]
=1.636×10 12 ohm-cm
ρ s =exp[27.59774−2.23348 ln(0.76)−(0.00176)(6.983)−(0.069078)(10)−(0.00073895)(6.983)exp(2303.0/417)]
=2.392×10 11 ohm-cm
ρ a = exp [ 85.1405 - ( 0.708046 ) ( 3.76 ) - 23267.2 / 417 - ( 0.069078 ) ( 10 ) ] = 1.939 × 10 11 ohm - cm 1/ρ vs =1/1.636×10 12 +1/2.392×10 11 =4.792×10 −12 ρ vs =2.1 ×10 11 ohm-cm 1/ρ vsa =1/4.792×10 −12 +1/1.939×10 11 =9.949×10 −12 ρ vsa =1.0 ×10 11 ohm-cm
This resistivity is consistent with the resistivity calculated from the precipitator current densities, but this consistency is not required for Method 2 since this calculation is being used to obtain an approximate SO 3 injection rate which will be refined in the following steps. The approximate level of SO 3 injection is calculated as follows:
From the preceding calculation,
1/ρ vsa =1/ρ vs +1/ρ a
where ρ vsa =1×10 10 ohm-cm(the desirable ρ)
ρ vs =2.1×10 11 ohm-cm(from preceding calculation)
1 / ρ a = 1 / ρ vsa - 1 / ρ vs = 1.0 × 10 10 - 2.761905 × 10 12 = 9.5238 × 10 11 ρ va =1.05×10 10 ohm-cm
also from Calculation 6,
ρ a =exp[85.1405−(0.708046)CSO 3 −23267.2 /T− (0.069078) E]
where T=417 (from preceding calculation)
E=10 (from preceding calculation)
hence
1.06×10 10 =exp[85.1405−(0.708046)CSO 3 −23267.2/417−(0.069078)(10)]
ln(1.05×10 10 )=85.1405−(0.708046)CSO 3 −55.79664−0.69078
23.07464109=28.652−(0.708046)CSO 3
(0.708046)CSO 3 =5.578
CSO 3 =7.878
Correcting for wet conditions
Hence, the approximate total
SO 3 needed=7.878×(39.286/42.235)
=7.33 ppm
Step 7. Subtract the background SO 3 from the needed SO 3 concentration from Step 6 to determine the amount of SO 3 that must be added to the flue gas to produce the optimum fly ash resistivity. That calculation, for the example-case, proceeds as follows:
The SO 3 from combustion calculation and background calculation,
=0.00088×0.004=3.52 ppm (wet basis)
From the calculation above, the approximate desirable SO 3 level=7.33 ppm.
Difference=7.33−3.52=3.81 ppm.
This calculation shows that approximately 3.8 ppm of SO 3 should be added to the flue gas to produce an optimum level of fly ash resistivity.
Consequently, output to SO 3 control system a signal that will raise the SO 3 level in the flue gas by 3.8 ppm.
Step 8. Send rate of additional signal to the controls that operate the SO 3 conditioning system.
Step 9. Repeat Steps 4 and 5.
Step 10.
a. If indicated ash resistivity is equal to or less than optimum resistivity, decrease rate of injection by x percent where x is between 5 and 25.
Or
b. If indicated ash resistivity is greater than optimum resistivity, increase rate of injection by x percent where x is between 5 and 25.
Step 11. Repeat Step 10 until indicated fly ash resistivity passes through optimum resistivity point and then set rate of injection at a point in the range bounded by the levels calculated in the last two interactions; for example, at a point that is halfway between the two levels.
Step 12. Every y minutes, where y is number between 5 and 30, restart the process beginning at Step 2.
Obviously, many modifications may be made without departing from the basic spirit of the present invention. | Optimizing fly ash resistivity by controlling concentration of sulfur trioxide (SO 3 ) in flue gas by the use of an algorithm. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a card connector, and more particularly to a so-called push-push type card connector in which positioning of a card to a card set position, and ejection of the card from the card set position are alternately conducted by repeating an operation of pushing the card.
2. Description of the Prior Art
Conventionally, card connectors configured in the following manner are known. When an initial pushing operation is conducted on a card inserted into a card insertion space of a case, a slider is pushed from a standby position to a pushed position, and the slider which reaches the pushed position is locked to the position so that the card is positioned to a card set position. By contrast, when a second pushing operation is conducted on the card, the locked state of the slider is canceled, and the card is retracted together with the slider to be ejected. In some of such card connectors, the functions of locking the slider and canceling the locked state are realized by a cam mechanism. The cam mechanism is configured as shown in FIGS. 12 and 13 .
FIG. 12 is a schematic perspective view showing a cam body 20 of a cam mechanism 10 which is employed in a conventional card connector, and FIG. 13 is a longitudinal side section view showing main portions of the cam mechanism 10 .
The cam mechanism 10 comprises the cam body 20 , and an engagement pin 40 which is formed by bending an elastic wire member. A loop groove 21 is formed in the cam body 20 . The loop groove 21 comprises: a forward path 22 ; a return path 23 ; a protruding engagement portion 24 which is formed between the paths; a lead-in path 25 which elongates from a forward-path end portion 22 a to the engagement portion 24 ; and an escape path 26 which elongates from the engagement portion 24 to a return-path start portion 23 a. The loop groove 21 is formed into a slender heart shape as a whole, and the lead-in path 25 and the escape path 26 form a heart-shape recess.
In the cam mechanism 10 , the cam body 20 is resiliently urged in the direction of the arrow A of FIG. 12 by an urging force indicated by the arrow A. By contrast, a basal portion (not shown) of the engagement pin 40 is swingably supported at a constant position, and an engagement end 41 at the tip end of the pin is always fitted into the loop groove 21 . At the initial position, the engagement end 41 is positioned in a junction 27 of the start portion of the forward path 22 and the end portion of the return path 23 (this state is not shown in the figures). The engagement pin 40 is always elastically pressed against a bottom face of the loop groove 21 by the elasticity of the pin itself or by a spring piece which is not shown.
When, in a state where the engagement end 41 of the engagement pin 40 is positioned in the junction 27 of the loop groove 21 , the cam body 20 is pushed against the urging force A, the engagement end 41 moves along the forward path 22 of the loop groove 21 to reach the forward-path end portion 22 a. When the pushing force is canceled at this timing, the cam body 20 is pushed back by the urging force A, so that the engagement end 41 moves along the lead-in path 25 and is then engaged with the engagement portion 24 as shown in FIG. 12 . When the cam body 20 is then pushed against the urging force A, the engagement end 41 moves along the escape path 26 to reach the return-path start portion 23 a. When the pushing force is canceled at this timing, the cam body 20 is pushed back by the urging force A, so that the engagement end 41 moves along the return path 23 and then returns to the junction 27 .
In the conventional card connector, the cam body 20 is disposed integrally with a slider (not shown) which is longitudinally movably attached to a case (not shown) forming a card insertion space, and the urging force A is applied to the slider. The slider is configured so that it is pushed by a card which is inserted into the card insertion space, to be moved from a standby position to a pushed position corresponding to the card set position. Then, the engagement end 41 is engaged with the engagement portion 24 as shown in FIG. 13 , whereby the slider is locked to the pushed position. Therefore, the card is positioned to the card set position by the first card pushing operation, and terminals of the card are in contact with contacts disposed in the case so as to make electrical connections therebetween. By contrast, when, in the state where the slider is locked, the slider is pushed by the card, the engagement end 41 moves along the escape path 26 to be disengaged from the engagement portion 24 as described above, so that the locked state of the slider is canceled. Then, the engagement end 41 returns via the return path 23 to the junction 27 , whereby the card is ejected. Therefore, the locked state of the slider is canceled by the second card pushing operation, and the card which has been positioned to the card set position is ejected.
As seen from FIGS. 12 and 13 , the cam mechanism 10 which is employed in the conventional card connector comprises a stepped surface 31 in the boundary between the escape path 26 of the loop groove 21 of the cam body 20 and the return path 23 . After the engagement end 41 moves along the escape path 26 and reaches the return-path start portion 23 a, during retraction of the cam body 20 , the stepped surface 31 slides in contact with the engagement end 41 , whereby the engagement end 41 is retained in the return path 23 , so that the engagement end 41 is prevented from reversely moving to a position a where the engagement end is to be engaged with the engagement portion 24 . A bottom face 26 a of the escape path 26 is formed as a horizontal surface. In the second card pushing operation, therefore, the engagement end 41 which is elastically pressed against the horizontal bottom face 26 a of the escape path 26 by the function of the spring piece slides on the bottom face 26 a and passes over the stepped surface 31 to reach the return-path start portion 23 a.
A prior art example discloses a structure in which a cam mechanism which is similar to the cam mechanism 10 is employed so that a slider is locked or the locked state is canceled (for example, see Japanese Patent No. 3,083,778).
Another prior art example discloses a structure in which a cam mechanism which is similar to the cam mechanism 10 is employed so that a slider is locked or the locked state is canceled. The other prior art example discloses also a structure in which means for directly engaging an elastic lock piece of the slider with a notch of a card is employed as means for positioning the card to a card set position, and an engagement end of an engagement pin of the cam mechanism is elastically pressed against a bottom face of a loop groove on the side of a cam body by a spring piece formed by stamping and raising a metal cover constituting a case (for example, see Japanese Patent Application Laying-Open No. 2002-134224).
SUMMARY OF THE INVENTION
In the cam mechanism 10 shown in FIGS. 12 and 13 , in the state where the slider is locked to the pushed position, i.e., the state where the engagement end 41 of the engagement pin 40 is engaged with the engagement portion 24 of the cam body 20 , the engagement portion 24 is pushed against and engaged with the engagement end 41 by the urging force A, and hence there does not occur a situation where the slider is retracted and the card is ejected. When any force such as a reaction due to a drop impact which is larger than the urging force A is applied to the slider in the direction opposite to the urging force A, however, a situation where the engagement end 41 moves along the escape path 26 to escape into the return-path start portion 23 a in the same manner as the case of the second card pushing operation may possibly occur. As a result, there occurs a situation where the locked state of the slider is canceled and the card is accidentally ejected. Particularly, the cam mechanism has the structure in which the bottom face 26 a of the escape path 26 is a horizontal surface, and the level relationships are set with setting the stepped surface 31 as a boarder so that the bottom face 26 a of the escape path 26 is higher and the bottom face of the return path 23 is lower. As a result, circumstances in which such a situation is allowed to easily occur are produced. When a situation where the locked state of the slider is canceled and the card is accidentally ejected occurs, electrical connections between the terminals of the card and the contacts of the case are interrupted, thereby producing the possibility that electronic components of the card and an apparatus are adversely affected.
The above-mentioned prior art examples similarly have this problem. Particularly, the technique disclosed in the other prior art example of Japanese Patent Application Laying-Open No. 2002-134224 cannot solve the problem because of the following reason. The card is prevented from being accidentally ejected by engaging the elastic lock piece with the card in the card set position, the elastic lock piece is disposed on the slider. When the locked state of the slider at the pushed position is once canceled, therefore, the card also is ejected together with the slider.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a card connector in which, even when only a simple countermeasure such as a slight modification of a cam mechanism is taken, accidental ejection of a card due to a drop impact or the like hardly occurs.
The card connector of the invention comprises: a slider which is longitudinally movably attached to a case forming a card insertion space, the slider being to be pushed by a card which is inserted into the card insertion space, to be moved from a standby position to a pushed position corresponding to a card set position, the slider being resiliently urged at the pushed position in a direction of ejecting the card; and a cam mechanism having functions of locking the slider to the pushed position, and canceling the locked state where the slider is locked to the pushed position. The cam mechanism has: an engagement pin attached to one of the case and the slider; and a cam body disposed on another one of the case and the slider, and comprising a loop groove into which an engagement end of the engagement pin is relatively displaceably fitted. The loop groove of the cam body comprises: a protruding engagement portion which is to be engaged with the engagement end that has passed through a forward path of the loop groove, thereby locking the slider to the pushed position corresponding to the card set position; an escape path which, when the slider at the pushed position is further pushed, allows the engagement end to escape from a position of engagement with the engagement portion to a start portion of a return path of the loop groove; and a stepped surface which, when the slider is to be retracted, is engaged with the engagement end that escapes to the start portion of the return path, to block the engagement end from reversely moving, thereby retaining the engagement end in the return path. The engagement end is elastically pressed against a bottom face of the escape path. The above configuration is identical with that of the conventional example shown in FIGS. 12 and 13 .
In the invention, the above configuration is further provided with a configuration in which the bottom face of the escape path has an inclined surface of a rising gradient which is directed toward an upper edge of the stepped surface.
As described above, the configuration in which the bottom face of the escape path has a rising inclined surface which is directed toward an upper edge of the stepped surface is added. When the engagement end of the engagement pin moves from the position of engagement with the engagement portion to the return-path start portion along the escape path, therefore, the rising inclined surface provides the engagement end which slidingly moves while being elastically pressed against the inclined surface, with a resistance (movement resistance), so that the engagement end hardly escapes from the engagement position to the return-path start portion by a reaction due to a drop impact or the like. As a result, a situation where the engagement end is disengaged from the engagement portion because of a drop or the like to cancel the locked state of the slider hardly occurs, and also a situation where the card which has been positioned to the card set position is accidentally ejected hardly occurs.
In the invention, at the position of engagement of the engagement end with the engagement portion, the loop groove may be formed at a depth which is equal to a depth of the return-path start portion, or at a depth which is larger than a depth of the return-path start portion. In the configuration in which the depth of the loop groove at the engagement position is equal to that of the return-path start portion, as compared with that shown in FIG. 12 in which the depth of the loop groove at the engagement position a is smaller than that of the return-path start portion 23 a, the engagement width of the engagement end 41 with respect to the engagement portion 24 is larger, and hence a situation where the engagement end 41 passes over the engagement portion 24 hardly occurs, with the result that the stability of the locked state of the slider at the pushed position is improved. When the depth of the loop groove at the engagement position a is equal to that at the return-path start portion 23 a, the engagement position a becomes equal to the return-path start portion 23 a which is the deepest portion in the conventional example shown in FIGS. 12 and 13 , and hence the other portions of the loop groove 21 can be made shallower. According to the configuration, in the case where the cam body 20 is molded integrally with the slider 70 , when the loop groove 21 is made shallower, the slider 70 can be easily thinned. By contrast, in the configuration where the depth of the loop groove at the engagement position is larger than that of the return-path start portion, the rising gradient of the inclined surface is larger than that in the case where the depths are equal to each other. Therefore, the movement resistance on the inclined surface when the engagement end moves along the escape path to enter the return-path start portion is large. As a result, the engagement end hardly escapes from the engagement position to the return-path start portion by a reaction due to a drop impact or the like, and a situation where the engagement end is disengaged from the engagement portion because of a drop or the like to cancel the locked state of the slider hardly occurs. Moreover, also a situation where the card which has been positioned to the card set position is accidentally ejected hardly occurs.
In the invention, preferably, the upper edge of the stepped surface is divided into one edge which elongates along a bottom face of the return-path start portion, and another edge of a falling gradient which elongates from an end of the one edge toward a root of the engagement portion, and the inclined surface is divided into one inclined surface of a rising gradient which extends toward the one edge, and another inclined surface of a rising gradient which extends toward the other edge. Preferably, a base of the other inclined surface crosses the escape path, and a base of the one inclined surface is positioned on a step-like wall face which is opposed to the engagement portion to form the escape path. According to the invention, in the case where a single flat rising inclined surface is formed in the escape path, the rising gradient of the other inclined surface is larger than that of the single rising inclined surface. Therefore, the movement resistance on the other inclined surface when the engagement end moves along the escape path to enter the return-path start portion is large. As a result, the engagement end hardly escapes from the engagement position to the return-path start portion by a reaction due to a drop impact or the like, and a situation where the engagement end is disengaged from the engagement portion because of a drop or the like to cancel the locked state of the slider hardly occurs. Moreover, also a situation where the card which has been positioned to the card set position is accidentally ejected hardly occurs. The functions of the invention will be described in more detail with reference to the following embodiment.
In the invention, preferably, the case has a body, and a sheet metal cover which is attached to the body, and a spring piece which is formed by inwardly stamping and raising the cover is in elastic contact with the engagement pin, whereby the engagement end is elastically pressed against the bottom face of the escape path. According to the configuration, an additional component(s) for elastically pressing the engagement end against the bottom face of the escape path is not required.
According to the invention, although only a simple countermeasure that the configuration of the cam mechanism, or specifically the shape of the bottom face of the escape path in the cam body is slightly changed is taken, an effect that accidental ejection of a card due to a drop impact or the like hardly occurs can be attained without impairing the card insertion operability.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of a card connector of an embodiment of the invention;
FIG. 2 is a partially cutaway plan view showing a state where a card is half locked to a slider at a standby position;
FIG. 3 is a partially cutaway plan view showing a state where the slider is pushed to a pushed position;
FIG. 4 is a partially cutaway plan view showing a state where a first pushing operation is conducted;
FIG. 5 is a plan view of the slider;
FIG. 6 is a perspective view of main portions of a cam body;
FIG. 7 is a plan view of main portions of a cam mechanism;
FIG. 8 is a section view taken along the line VIII—VIII of FIG. 7 ;
FIG. 9 is a view illustrating a portion where an engagement pin is coupled to a body;
FIG. 10 is a perspective view showing the shape of an inclined surface;
FIG. 11 is a perspective view showing the shape of the inclined surface in a modification;
FIG. 12 is a schematic perspective view showing a cam body of a cam mechanism employed in a conventional card connector; and
FIG. 13 is a longitudinal side section view showing main portions of a cam mechanism 10 comprising the cam body of FIG. 12 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic perspective view of a card connector of an embodiment of the invention, FIG. 2 is a partially cutaway plan view showing a state where a card 100 is half locked to a slider 70 at a standby position, with omitting a cover 55 of a case 50 , FIG. 3 is a partially cutaway plan view showing a state where the slider 70 is pushed to a pushed position by the card 100 , with omitting the cover 55 of the case 50 , FIG. 4 is a partially cutaway plan view showing a state where a first pushing operation is conducted on the card 100 , with omitting the cover 55 of the case 50 , FIG. 5 is a plan view of the slider 70 , FIG. 6 is a perspective view of main portions of a cam body 20 , FIG. 7 is a plan view of main portions of a cam mechanism 10 , FIG. 8 is a section view taken along the line VIII—VIII of FIG. 7 , FIG. 9 is a view illustrating a portion where an engagement pin 40 is coupled to a body 51 , FIG. 10 is a perspective view showing the shape of an inclined surface 32 , and FIG. 11 is a perspective view showing the shape of the inclined surface 32 in a modification.
As shown in FIG. 1 , the card connector has a case 50 comprising: a body 51 formed by a molded product of a synthetic resin; and a sheet metal cover 55 which is attached to the body 51 . A card insertion space which is surrounded by the body 51 and the cover 55 , and which comprises a card insertion port (slot) is formed inside the case 50 . As shown in FIG. 2 , a large number of contacts 57 are laterally arranged in a front end portion of the body 51 . The contacts 57 are in elastic contact with terminals of the card 100 which is inserted into the card insertion space to reach a card set position, thereby making electrical connections therebetween. The body 51 further comprises a rib-like projection 50 a for preventing a card from being erroneously inserted. As shown in FIGS. 3 and 4 , when the card 100 in an adequate posture is inserted into the card insertion space, the projection 50 a is accommodated in a groove 130 formed in the card 100 . By contrast, when the card 100 in an inverted posture is inserted into the card insertion space, the projection 50 a bumps against the tip end of the card 100 , thereby preventing the card 100 from being erroneously inserted.
As shown in FIGS. 2 to 4 , the slider 70 is placed inside the case 50 , and always rearward urged by a spring member 52 configured by a coil spring. When the rear end of the slider 70 butts against a projection 53 of the rear end of the body 51 , the slider 70 is positioned to the standby position. As shown in FIG. 5 , the slider 70 comprises an inward protrusion 71 in a front end portion. The protrusion 71 receives a front end corner 110 of the card 100 which is inserted into the card insertion space of the case 1 as shown in FIG. 2. A cantilevered elastic piece 76 which has a mountain-like engaging portion 75 at the tip end is molded integrally with the slider 70 .
As seen from FIGS. 5 to 8 , the cam mechanism 10 comprises an engagement pin 40 which is formed by bending an elastic wire member into a low-profile portal shape. In contrast to the cam body 20 which is molded integrally with the slider 70 as shown in FIG. 5 , a rear end leg 42 of the engagement pin 40 is rotatably fittingly supported by a support hole 54 (see FIGS. 2 or 3 ) which is formed in the projection 53 of the body 51 as shown in FIG. 9. A front end portion of the engagement pin 40 is formed as an engagement end 41 .
A loop groove 21 of the cam body 20 is formed into a generally similar shape as the loop groove which has been described with reference to FIG. 11 . Specifically, as shown in FIGS. 6 and 7 , the loop groove 21 comprises: a forward path 22 ; a return path 23 ; a protruding engagement portion 24 which is formed between the paths; a lead-in path 25 which elongates from a forward-path end portion 22 a to the engagement portion 24 ; and an escape path 26 which elongates from the engagement portion 24 to a return-path start portion 23 a. The loop groove 21 is formed into a slender heart shape as a whole, and the lead-in path 25 and the escape path 26 form a heart-shape recess. When the engagement end 41 of the engagement pin 40 is fitted into the loop groove 21 and the slider 70 is positioned at the standby position, the engagement end 41 is positioned at an initial position which coincides with a junction 27 of the start portion of the forward path 22 and the end portion of the return path 23 as shown in FIG. 2. A spring piece 56 which is formed by inwardly stamping and raising the cover 55 is placed on the engagement pin 40 . The engagement end 41 of the engagement pin 40 is always elastically pressed against the bottom face of the loop groove 21 by the elasticity of the spring piece 56 .
In this configuration, when the front end corner 110 of the card 100 which is inserted in an adequate posture into the card insertion space as shown in FIG. 2 rides over the mountain-like engaging portion 75 of the slider 70 that is retracted to the standby position by the spring member 52 , the mountain-like engaging portion 75 is fitted into a recess 120 formed in the card 100 . This state is a half-locked state of the card 100 . In the half-locked state, the card 100 is prevented from being freely extracted, by the engagement of the recess 120 with the mountain-like engaging portion 75 , and, when a pulling force of a certain degree is applied to the card 100 , the card 100 is caused to ride over the mountain-like engaging portion 75 and then pulled out.
When a first pushing operation is applied on the card 100 in the state of FIG. 1 , the cam body 20 is pushed together with the slider 70 by the card 100 against the urging force A of the spring member 52 , and the engagement end 41 of the engagement pin 40 moves along the forward path 22 with starting from the junction 27 of the loop groove 21 to reach the forward-path end portion 22 a (the position of the slider 70 at this timing is shown in FIG. 4 ). When the pushing force is canceled at this timing, the cam body 20 is pushed back together with the slider 70 by the urging force A, so that the engagement end 41 moves along the lead-in path 25 and is then engaged with the engagement portion 24 as shown in FIGS. 7 and 8 (the position of the slider 70 at this timing is shown in FIG. 3 ). When a second pushing operation is then applied on the card 100 , the cam body 20 is pushed together with the slider 70 against the urging force A, and the engagement end 41 moves along the escape path 26 to reach the return-path start portion 23 a. When the pushing force is canceled at this timing, the cam body 20 is pushed back by the urging force A, so that the engagement end 41 moves along the return path 23 and then returns to the junction 27 .
As a result of the push-push operation, the insertion of the card 100 to the card set position, and the ejection from the card set position are conducted. In the first card pushing operation, the slider 70 is pushed from the standby position to the pushed position corresponding to the card set position, and the engagement end 41 is engaged with the engagement portion 24 to lock the slider 70 to the pushed position, whereby the card 100 which is half locked to the slider 70 is positioned to the card set position, and terminals of the card are in contact with contacts disposed on the body 51 so as to make electrical connections therebetween. By contrast, in the second card pushing operation, the engagement end 41 moves along the escape path 26 and is then disengaged from the engagement portion 24 , and hence the locked state of the slider 70 is canceled. Thereafter, the engagement end 41 returns through the return path 23 to the junction 27 , whereby the card is ejected.
In the embodiment, as shown in FIGS. 6 to 8 and 10 , the bottom face of the escape path 26 of the loop groove 21 of the cam body 20 comprises the inclined surface 32 of a rising gradient which is directed toward an upper edge of a stepped surface 31 that is located in the boundary between the escape path 26 and the return-path start portion 23 a. In the embodiment, as shown in FIG. 10 , the upper edge of the stepped surface 31 is divided into one edge 33 which is parallel to the bottom face of the horizontal return-path start portion 23 a, and another edge 34 of a falling gradient which elongates from an end of the one edge 33 toward the root of the engagement portion 24 , and the inclined surface 32 is divided into one inclined surface 32 a of a rising gradient which extends toward the one edge 33 , and another inclined surface 32 b of a rising gradient which extends toward the other edge 34 . A base 32 b ′ of the other inclined surface 32 b crosses the escape path 26 , and a base 32 a ′ of the one inclined surface 32 a is positioned on a step-like wall face 35 which is opposed to the engagement portion 24 to form the escape path 26 .
In the configuration where the bottom face of the escape path 26 comprises the rising inclined surface 32 which is directed toward the upper edge of the stepped surface 31 , when the engagement end 41 which is engaged with the engagement portion 24 as shown in FIG. 8 moves from the engagement position a along the escape path 26 (see FIGS. 6 or 10 ) to the return-path start portion 23 a, the rising inclined surface 32 provides the engagement end 41 which slidingly moves while being elastically pressed against the inclined surface 32 by the urging of the spring piece 56 , with a movement resistance. In addition, the urging force A generated by the spring member 52 acts on the slider 70 . Therefore, the engagement end 41 hardly escapes from the engagement position a to the return-path start portion 23 a by a reaction due to a drop impact or the like. As a result, a situation where the engagement end 41 is disengaged from the engagement portion 24 because of a drop or the like to cancel the locked state of the slider 70 hardly occurs, and also a situation where the card 100 which has been positioned to the card set position is accidentally ejected hardly occurs.
In the embodiment, at the position a of engagement of the engagement end 41 with the engagement portion 24 , the loop groove 21 is formed at a depth which is larger than that of the return-path start portion 23 a. At the position a of the engagement of the engagement end 41 with the engagement portion 24 , the depth of the loop groove 21 may be formed so as to be equal to that of the return-path start portion 23 a. When the depth of the loop groove 21 at the engagement position a is made larger than that of the return-path start portion 23 a, however, the rising gradients of the one inclined surface 32 a and the other inclined surface 32 b are larger than those in the case where the depths are equal to each other, and hence the movement resistances on the inclined surfaces 32 a, 32 b which are exerted when the engagement end 41 moves along the escape path 26 to the return-path start portion 23 a are large. Therefore, the engagement end 41 hardly escapes from the engagement position a to the return-path start portion 23 a by a reaction due to a drop impact or the like. As a result, a situation where the engagement end 41 is disengaged from the engagement portion 24 because of a drop or the like to cancel the locked state of the slider 70 very hardly occurs, and also a situation where the card 100 which has been positioned to the card set position is accidentally ejected very hardly occurs. In the configuration in which the depth of the loop groove 21 at the engagement position a is larger than that of the return-path start portion 23 a, the engagement width of the engagement end 41 with respect to the engagement portion 24 is large, and hence a situation where the engagement end 41 slides over the engagement portion 24 hardly occurs, with the result that the stability of the locked state of the slider at the pushed position is improved. By contrast, in the configuration in which the depth of the loop groove 21 at the engagement position a is equal to that at the return-path start portion 23 a, the engagement position a is equal to the return-path start portion 23 a which is the deepest portion in the conventional example shown in FIGS. 12 and 13 , and hence the depths of other portions of the loop groove 21 can be made small. When the loop groove 21 is made shallow, therefore, the slider 70 with which the cam body 20 is integrally molded can be easily thinned.
In the embodiment, the upper edge of the stepped surface 31 is divided into the one edge 33 which is parallel to the bottom face of the horizontal return-path start portion 23 a, and the other edge 34 of a falling gradient which elongates from the end of the one edge 33 toward the root of the engagement portion 24 , and the inclined surface 32 is divided into the one inclined surface 32 a of a rising gradient which extends toward the one edge 33 , and the other inclined surface 32 b of a rising gradient which extends toward the other edge 34 . By contrast, as in a modification shown in FIG. 11 , the rising inclined surface 32 which is directed toward the upper edge of the stepped surface 31 may be formed by a single flat surface. In the configuration of FIG. 10 in which the inclined surface 32 is divided into the one inclined surface 32 a and the other inclined surface 32 b, as compared with that of FIG. 11 in which the inclined surface 32 is formed by the single flat surface, the rising gradient of the other inclined surface 32 b is larger than that of the inclined surface 32 of FIG. 11 , and hence the movement resistance on the other inclined surface 32 b which is exerted when the engagement end 41 moves along the escape path 26 to the return-path start portion 23 a is large. Therefore, the locked state of the slider 70 is hardly cancelled by a reaction due to a drop impact or the like.
As in the configuration of FIG. 10 in which the other edge 34 of the upper edge of the stepped surface 31 is inclined toward the root of the engagement portion 24 , or that of FIG. 11 in which the upper edge of the stepped surface 31 is inclined toward the root of the engagement portion 24 , the operation of the engagement end 41 in which the end moves from the escape path 26 to the return-path start portion 23 a while sliding over the stepped surface 31 can be smoothly conducted although the configuration can generate the above-mentioned movement resistance. Abnormal noises are hardly produced when the end slides over the stepped surface.
In the above, the embodiment in which the cam body 20 of the cam mechanism 10 is placed on the slider 70 , and the engagement pin 40 is placed on the case 50 has been described. Alternatively, the cam body may be placed on the case, and the engagement pin may be placed on the slider. In the above, the mountain-like engaging portion 75 which is used for half locking the card 100 inserted into the card insertion space is disposed on the cantilevered elastic piece 76 which is molded integrally with the slider 70 . Alternatively, a tip end portion of a spring piece which is an additional component attached to the slider may be bent into a mountain-like shape so as to function as the mountain-like engaging portion.
In FIGS. 1 to 13 , identical or corresponding components are denoted by the same reference numerals. | In a card connector, with a simple countermeasure, wherein the shape of a bottom face of an escape path in a cam body is slightly changed, accidental ejection of a card due to a drop impact or the like hardly occurs, without impairing the card insertion operability. A slider is longitudinally movably attached to a case. The card connector has a cam mechanism having functions of locking the slider to a pushed position, and canceling the locked state at the pushed position. The cam mechanism has an engagement pin and a cam body. A loop groove of the cam body has an engagement portion, an escape path, and a stepped surface. An engagement end of the engagement pin is elastically pressed against a bottom face of the escape path. The bottom face of the escape path has an inclined surface of a rising gradient which is directed toward an upper edge of the stepped surface. | 4 |
FIELD OF THE INVENTION
[0001] The present invention concerns a sash locking system for securing a sash window in a locked state.
BACKGROUND TO THE INVENTION
[0002] Whereas over recent years there has been substantial advancement in the design of locking mechanisms for the more modern type of hinged windows there has been relatively little advancement in the design of locking mechanisms for the more conventional windows, sash windows, i.e. windows comprising sashes, or sliding frames, that run in substantially vertical grooves. Indeed, the most common system for locking a sash window closed involves use of a screw member passing from the top rail of the bottom sash into the bottom rail of the top sash to provide additional locking security over and above the normal swivel latch and keep between the two rails.
[0003] The conventional sash locking mechanisms are inconvenient and clumsy to operate. It is accordingly an objective of the present invention to provide a more user-friendly locking assembly for a sash window that may be readily used by the elderly or disabled or more generally by anyone with greater ease than conventional locking assemblies.
SUMMARY OF THE INVENTION
[0004] According to a first aspect of the present invention there is provided a locking system for a sash window which comprises a first part that is installed in use to the sill of the sash window frame and which faces a second part that is mounted in use to the underside of the bottom rail of the lower sash wherein the first and second parts each have a respective complementary engagement means whereof one of the complementary engagement means of the first and second parts is moveable relative to the other to lockingly engage with the other and which, preferably, is biased towards locking engagement but may be drawn away from locking engagement by use of a magnetic key.
[0005] Preferably the magnetic key is a permanent magnet and which is handheld and whereby when the magnetic key is brought into proximity with an internal face of the sash window it will attract or repel a component of the first or second parts whereby they are disengaged from the locking state.
[0006] Preferably one of the first and second parts comprises a catch having the form of a protrusion having one of said complementary engagement means and the other of the first and second parts comprises a keep to receive the catch and having the other of the complementary engagement means therein. Suitably the said other complementary engagement means comprises a shoot bolt. Preferably the complementary engagement means on the catch comprises an aperture on the protrusion of the catch.
[0007] Suitably the shoot bolt is assembled on the keep substantially transverse to an axis of the keep along which the catch enters and withdraws from the keep. Suitably the shoot bolt is substantially perpendicular to said axis of the keep.
[0008] In one preferred embodiment of the invention the first part that is installed to the sill comprises the catch.
[0009] Preferably the shoot bolt is resiliently biased into locking engagement with the catch.
[0010] As a particularly preferred improvement, the locking system suitably further has a barrier component, e.g. a ferrous plate, that is installed in use to the sill or bottom rail of the lower sash to shield the moveable complementary engagement means against operation by a magnetic key advanced toward the moveable component from a wrong direction, i.e. direction other than that legitimately used by the operator and which for most purposes is the exterior face of the sash window. It will be appreciated that with certain configurations of the locking system such as where the moving shoot bolt is mounted to the lower sash rail, a very powerful magnet of reverse polarity approached towards the external face of the lower sash rail might be used to interfere with the shoot bolt. Accordingly, in a preferred embodiment the barrier plate to shield against “invalid” magnetic fields is mounted within the lower sash rail, shielding the shoot bolt from the external face of the lower sash rail.
[0011] A further preferred feature of the locking system is a releasable latching means for holding the moveable complementary engagement means/shoot bolt in a retracted state until the catch enters the keep but which is moved by the catch to free the moveable complementary engagement means to move. This latch means suitably comprises a resiliently deflectable component whose rest position blocks extending movement of the moveable complementary engagement means.
[0012] To facilitate installation of the locking system the system suitably further comprises a jig or template having a groove to seat over a ridge of the sill of the sash window and having a body with an aperture to define the area of the sill where the first part is to be inserted.
[0013] An alternative or additional feature to facilitate installation of the system comprises one or more demountable marker pins that demountably mount in use to one of the first and second parts projecting directly towards the other of the parts and whereby when the lower sash rail is advanced towards the sill the marker pins will mark the location where the other part is to be installed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Two preferred embodiments of the present invention will now be more particularly described, by way of example, with reference to the accompanying drawings wherein:
[0015] FIG. 1 is a longitudinal sectional view through the lower end of a sash window, including through the sill and the bottom rail of the lower sash showing the locking system in place;
[0016] FIG. 2 is a view similar to FIG. 1 but showing the arrangement with the parts of the locking system also in section;
[0017] FIG. 3 is a view similar to FIG. 2 but showing the magnetic key positioned against the locking system to draw the shoot bolt of the sill mounted first locking part from locking engagement with the catch of the second part of the locking system on the underside of the bottom sash rail, and with the bottom sash thereby released and shown partly raised away from the sill in consequence;
[0018] FIG. 4 is a perspective view of the first and second parts of the locking system demounted from the sash window and alongside the magnetic key;
[0019] FIG. 5 is a perspective view from above of a jig/template device for assisting the installer in fitting the sill mounted first part of the system to the sill.
[0020] FIG. 6 is a longitudinal sectional view similar to that of FIG. 1 but through a second preferred embodiment of the invention wherein the catch is on the first part of the locking system fitted to the sill;
[0021] FIG. 7 is a perspective view corresponding to FIG. 6 ;
[0022] FIG. 8 is an exploded assembly view through the locking system of the second preferred embodiment as the catch begins to enter the keep;
[0023] FIG. 9 is a view similar to FIG. 8 but with the shoot bolt and catch inter- engaged;
[0024] FIG. 10 is a perspective view similar to FIG. 7 but with a pair of marker pins mounted to the sash mounted part of the locking system to easily mark the correctly aligned location for the sill mounted part during installation; and
[0025] FIG. 11 is a transverse sectional view similar to FIG. 6 but showing the marker pins.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] As can be seen in FIG. 1 , the locking system of the present invention has a first part 1 that is mounted in use within the sill 2 of the sash window and which is illustrated as having a substantially circular cylindrical body portion 3 .
[0027] The cylindrical body/casing 3 of the sill mounted part 1 has a void 4 at its centre defining a first keep and further houses a shoot bolt 5 adjacent and transverse to the axis of the keep 4 and mounted within the cylindrical body/casing 3 to be moveable between an extended position where it extends into the bore of the keep 4 and a retracted position where it does not.
[0028] The shoot bolt 5 is resiliently biased to an extended state by a resilient biasing means/compression spring 6 within the casing 3 but the force of that resilient biasing means 6 is selected to be of a level where it may be overcome by use of a magnetic key 7 housing a permanent magnet 8 when the magnetic key 7 is brought into proximity with the sill 2 and the shoot bolt 5 there within.
[0029] The shoot bolt 5 itself may be magnetic/ferrous/magnetisable or it may, as illustrated, have a magnetic or magnetisable actuator component 9 linked to it and which is adapted to be attracted by placement of the key 7 there adjacent (see FIG. 3 ). Of course, the invention further encompasses a reverse configuration in which the magnetic key 7 repels the magnetic/magnetisable component 9 of the sill- mounted part 1 of the locking system by provision of a linkage or other mechanism that will cause the shoot bolt 5 to retract from its extended position in the keep 4 .
[0030] On the underside of the bottom rail 10 of the lower sash is mounted the second part 11 of the locking system and which comprises a catch in the form of an apertured protrusion 11 a that projects downwardly from the underside of the bottom rail 10 and is adapted to pass into the keep 4 of the sill mounted part 1 . The aperture 12 in the catch protrusion 11 a receives and co-operatively engages with the shoot bolt 5 whereby when the protrusion 11 a is brought down to be housed in the keep 4 on closing of the window (with the shoot bolt 5 initially retracted by holding the magnetic key 7 in proximity) the protrusion 11 a may be locked in the keep 4 simply by removing the magnetic key to allow the shoot bolt to be driven forward by its resilient biasing means/compression spring 6 into the aperture 12 of the catch protrusion 11 a.
[0031] To unlock the sash window all the user need do is bring the magnetic key 7 back into proximity with the magnetic/magnetisable component 9 of the sill mounted part 1 to thereby cause the shoot bolt 5 to be retracted from engagement with the aperture 12 of the protrusion 11 a and allowing the lower sash to be raised.
[0032] The magnetic key 7 suitably is provided with a visual indicator of when it is operative, having an LED 30 or similar that is energised to light up when the magnet 8 within the magnetic key 7 is brought into proximity with the magnetic/magnetisable component 9 of the sill mounted part 1 . This may occur through, for example, the magnet 8 shifting within the magnetic key 7 and thereby to make an electrical circuit to energise the LED.
[0033] Though in the first illustrated embodiment the catch comprising protrusion 11 a is shown as mounted to the bottom rail of the sash the respective positions of the protrusion 11 a and the keep 4 for the protrusion 11 a may be reversed, whereby the keep 4 is provided in the part that is mounted to the sash and the catch protrusion 11 a is provided in the part that is mounted to the sill, for which see the second embodiment described below with respect to FIG. 6 to 11 .
[0034] To guide the user where to place the magnetic key 7 to actuate the retraction of the shoot bolt 5 , there is suitably provided a guide marker/plate 13 that is mounted on the internal face of the sill 2 directly overlying the actuator extension of the shoot bolt 5 .
[0035] In order to facilitate the installation of the sill mounted part 1 of the system, a jig or template device 20 is suitably provided having a form such as illustrated in FIG. 5 . This device 20 is suitably a metal block or moulding that has a main body portion 20 a having a bore extending downwardly there through to guide a router or drill for carving out from the sill 2 the necessary void into which the cylindrical casing/body 3 of the sill mounted part 1 will sit. The jig/template device 20 has a bridging extension 22 that hooks over a lip 23 (see FIG. 3 ) of the sill 2 to hold the device 20 in place and which has a recess 24 to indicate where the marker/plate 13 . be positioned on the inner face of the sill 2 . When installed in the void the sill mounting part 1 is bolted or screwed in place.
[0036] Turning now to the second preferred embodiment of the present invention as illustrated in FIGS. 6 to 11 , here the locations of the catch 11 a ′ and keep 3 ′ of the locking. system are switched over. The keep 3 ′ is here mounted to the bottom sash member 10 whereas the catch 11 a ′ is mounted to the sill 2 . In this second embodiment, the shoot bolt 5 ′ is again resiliently biased to an extended state by resilient biasing means/compression spring 6 ′ within the casing 3 ′ and where the force of the resilient biasing means 6 ′ is selected to be of a level where it may be overcome by use of magnetic key 7 . As in the first embodiment, the second embodiment suitably uses the key 7 to magnetically attract shoot bolt 5 ′ pulling it back against the spring 6 ′ and back away from co-operative engagement with the aperture 12 ′ of the catch protrusion 11 a′.
[0037] Since here the shoot bolt is mounted to the lower sash rail 10 , a very powerful magnet of reverse polarity placed against the external face of the lower sash rail might conceivably be used to interfere with the shoot bolt 5 ′. Accordingly a ferrous barrier plate 25 to shield against magnetic fields from the front/external face of the lower sash rail is mounted within the lower sash rail 10 at the front.
[0038] Furthermore, for the user's convenience in order to avoid the need to use the key 7 to retract the shoot bolt 5 ′ when closing the sash the member 10 on to the sill 2 , a latching element 28 is provided that will hold the shoot bolt 5 ′ in retracted state until the leading end of the catch protrusion 11 a ′ is inserted into chamber 4 ′ of the keep 3 ′. Here the latching means 28 is shown as a pair of leaf springs 28 on the keep 3 ′ that are generally angled downwardly into the chamber 4 ′ of the keep but which may be deflected upwardly as the leading edge of the protruding part 7 a 40 enters chamber 4 ′ and thereby pushed up away from locking the shoot bolt 5 ′ so that it may be shot forward by the spring 6 ′ and into engagement with the aperture 12 ′ of the protrusion 11 a ′. Though not illustrated above with respect of the first embodiment of the invention, such an automatic latching arrangement may be employed in directly analogous fashion on that first embodiment.
[0039] To facilitate installation of the locking system of the second preferred embodiment, a pair of marker pins/spike-ended rods 29 are suitably demountably mounted to the sash mounted keep 3 ′, whereby when the sash 10 is lowered the marker pins 29 will puncture the upper surface of the sill 2 at precisely the locations where screws 27 may be tapped into the sill 2 to secure the sill mounting part 1 ′ with the protrusion 11 ′ in accurate alignment with the keep 4 ′ of the sash mounted part 3 ′.
[0040] The marker pins 29 may be fitted in recesses in the keep casing 3 ′ and as the sash is lowered the pins 29 will define where the countersunk sockets 26 of the sill- mounted part 1 ′ should be located to subsequently receive screws 27 to secure the sill mounted part 1 ′ in place. The marker pins 29 may then be demounted when they are no longer required, e.g. by pulling out with pliers. By this arrangement the user may very easily align the respective first and second parts of the locking system for efficient and effective operation. The configuration of the system as illustrated is extremely versatile and allows for substantial variation in the shapes and respective positions of the sash and sill, including e.g. for different angles of sill, and is simple to install and to operate. | The present invention provides a locking system for a sash window which comprises a first part that is installed in use within the sill of the sash window frame and which faces a second part that is mounted in use to the underside of the bottom rail of the lower sash wherein the first and second parts each have a respective complementary engaging parts whereof one of the complementary engaging parts of the first and the second parts is moveable relative to the other to lockingly engage with the other and which may be drawn away from locking engagement by use of a magnetic key. | 4 |
FIELD OF THE INVENTION
The present invention relates to a device for protecting an electronic system, for example, a banking card reader, especially a chip card reader, against intrusions.
DISCUSSION OF PRIOR ART
A banking card reader generally comprises a package containing a printed circuit on which electronic components are connected. The reader comprises a keyboard corresponding to a flexible membrane partially covering the printed circuit and at the level of which the keys of a keyboard are formed. Each key generally comprises, on the printed circuit side, a conductive land. The separate ends of two conductive tracks are arranged on the printed circuit under each key. These ends for example correspond to interdigitated combs.
In the absence of an external action on the keyboard, each key is in an idle position where it is distant from the printed circuit. When a user presses a key, said key moves until the associated conductive land creates an electric contact between the ends of the two underlying metal tracks. The key and the underlying printed circuit tracks thus behave as a generally off switch which is turned on when a user presses the key.
The card reader generally comprises a device of protection against intrusions formed of one or several dummy keys provided at the level of the keyboard membrane and which are not visible from the outside of the package. Each dummy key is maintained in permanent contact with the printed circuit by the reader package so that it creates a permanent electric connection between two tracks of the printed circuit.
When someone tries to open the package, the dummy key is no longer actuated by the package and moves away from the printed circuit. The dummy key and the underlying tracks of the printed circuit thus behave as a switch which is on when the reader package is properly closed and which is off when the package is open. The turning-off of this switch is detected by a specific electronic circuit provided at the printed circuit level.
The use of dummy keys may not provide a sufficient protection, especially in the case where a spacer is interposed between the keyboard membrane and the underlying printed circuit, for example, to behave as a light diffuser to light the keyboard membrane from the inside of the package (backlighting of the keys). The spacer comprises openings enabling the passing of the normal and dummy keys of the keyboard membrane. A disadvantage of such a reader structure is that it may be relatively easy to fill the spacer openings associated with the dummy keys with glue so that the dummy keys remain permanently glued to the printed circuit. The reader package can then be opened without interrupting the contact between the dummy keys and the printed circuit.
Document US-A-2007/152042 describes a keyboard for a chip card reader equipped with a light guide and with a membrane of protection against the introduction of the needle of a hypodermic syringe enabling to short-circuit safety keys (dummy keys).
Document DE-A-4312905 describes a device for protecting the keyboard of a chip card reader comprising a conductive track supplied by a peripheral connector. The device is intended to be folded up around the electronic circuit of the keyboard. The use of a conductive track protects the electronic circuit against possible intrusions. However, the presence of a peripheral connector to power the conductive track creates a weak point in the system security.
FIELD OF THE INVENTION
The present invention aims at a device for protecting an electronic system comprising a package containing a keyboard membrane separated from a printed circuit by a spacer against intrusion attempts.
Thus, an embodiment of the present invention provides an electronic system, comprising:
an electronic circuit having a surface on which at least two first conductive tracks are arranged;
an actuation device comprising at least one first bearing element;
a spacer interposed between the electronic circuit and the actuation device and comprising at least one opening at least partially receiving the bearing element; and
a protection device interposed between the electronic circuit and the spacer and comprising at least one second conductive track having ends respectively connected to first conductive portions of first deformable regions of the protection device, each first portion being capable of contacting one of the first conductive tracks of the electronic circuit to electrically supply the second track under the effect of a deformation of said first regions.
According to an embodiment of the present invention, said first deformable regions are arranged outside of the periphery of the protection device.
According to an embodiment of the present invention, said first conductive portions are distant from the first conductive tracks in the absence of an external action exerted on the first deformable region, the first bearing elements being capable of deforming the first deformable regions to put the first conductive portions in contact with the first conductive tracks, whereby the respective ends of the second track are connected to the first conductive tracks.
According to an embodiment of the present invention, the protection device comprises a deformed area, the electronic circuit comprising electronic components covered by said area, the second conductive track extending at the level of said area.
According to an embodiment of the present invention, the protection device further comprises at least one second conductive portion supported by a second deformable region and separated from the second conductive track by an insulating region, the second conductive portion being, in the absence of an external action exerted on the second deformable region, distant from the third and fourth conductive tracks supported by the electronic circuit, at least one second bearing element being capable of deforming the second deformable region to put the second conductive portion in contact with the third and fourth conductive tracks, whereby the third and fourth conductive tracks are electrically connected.
According to an embodiment of the present invention, the protection device comprises a stack of first, second, and third insulating films, the second conductive track being arranged between the first and second insulating films, the third film being in contact with the electronic circuit and comprising openings at least in front of the first conductive tracks, exposing the conductive portions.
According to an embodiment of the present invention the spacer is formed of a material capable of diffusing light and comprises a first surface on the side of the actuation device and a second surface on the side of the electronic circuit, the electronic circuit comprising at least one light source, and the spacer comprising a non-through recess on the side of the second surface, containing said light source.
According to an embodiment of the present invention, the spacer comprises a first planar surface on the side of the actuation device and a second planar surface on the side of the electronic circuit, the first surface being tilted with respect to the second surface by an angle ranging between 1° and 20°.
According to an embodiment of the present invention, the actuation device comprises a membrane covering the spacer, the membrane comprising at least one key which is mobile with respect to the electronic circuit, capable of being displaced by a user and extending in one of the second bearing elements.
According to an embodiment of the present invention, the actuation device comprises a package containing the electronic circuit, the spacer, and the protection device, the package comprising an internal surface and a portion projecting from the internal surface and being capable of holding the first bearing elements against the first deformable regions of the protection device when the package is closed.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features, and advantages of the present invention will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings:
FIG. 1 is a simplified perspective view of an example of a card reader;
FIG. 2 is a perspective view of an embodiment of some internal elements of the reader of FIG. 1 ;
FIGS. 3 and 4 are respective exploded perspective three-quarter top and bottom views of the elements of FIG. 2 ;
FIGS. 5 and 6 are perspective views of the two surfaces of the protection device shown in FIG. 2 ;
FIGS. 7 and 8 are simplified cross-section views of the reader of FIG. 1 at the level of a keyboard key at two stages of the reader operation;
FIGS. 9 and 10 are simplified cross-section views of the reader of FIG. 1 at the level of a dummy key respectively when the reader package is open and closed;
FIGS. 11 and 12 are cross-section views similar to FIGS. 9 and 10 at the level of a power supply contact area of the protection device;
FIG. 13 is a bottom view of an example of distribution of internal conductive tracks of a variation of the protection device shown in FIG. 6 ; and
FIG. 14 is a perspective view showing a cross-section of the elements shown in FIG. 2 .
DETAILED DESCRIPTION
For clarity, the same elements have been designated with the same reference numerals in the different drawings. Further, only those elements which are necessary to the understanding of the present invention will be described.
The present invention provides, in an electronic circuit comprising a package containing a printed circuit separated from a keyboard membrane by a spacer, to interpose a protection device between the spacer and the printed circuit. The protection device corresponds to a flex circuit formed of a layer stack. The flex circuit comprises conductive elements on the printed circuit side, which form switches with conductive tracks of the printed circuit. Further, one or several conductive tracks are arranged in a lattice in the layer stack and are connected to an electronic safety circuit provided at the printed circuit level. The safety circuit is capable of detecting a modification of the electric voltage of the conductive tracks of the protection device.
FIG. 1 schematically shows an embodiment of an electronic circuit 10 , for example, a banking card reader. Reader 10 comprises a package 12 formed of an upper package portion 14 connected to a lower package portion 16 . Openings 17 are provided at the level of upper package portion 14 for a display 18 and keys 20 belonging, for example, to a keyboard. Further, an opening, not shown, is provided in package 12 to enable to introduce cards.
FIGS. 2 , 3 , and 4 respectively are a general perspective view, an exploded three-quarter top view and an exploded three quarter bottom view of an embodiment of some internal elements of reader 10 of FIG. 1 . Reader 10 contains a printed circuit 22 on which electronic components are connected, only a few electronic components being shown in FIG. 3 . Printed circuit 22 comprises a surface 23 partially covered with a protection device 24 which will be described in further detail hereafter. In the present embodiment, protection device 24 is covered with a spacer 26 behaving as a light diffuser. Spacer 26 is covered with a flexible membrane 28 forming a keyboard, at the level of which keys 20 are formed. Keyboard membrane 28 comprises nineteen keys 20 .
Printed circuit 22 comprises conductive tracks, not shown, for example, made of copper, on the side of surface 23 . Only some locations of conductive tracks of printed circuit 22 forming switches of power supply contact areas have been shown in the form of ellipses 31 . A switch corresponds, for example, to the different ends of two conductive tracks which correspond, for example, to interdigitated combs. A power supply contact area corresponds, for example, to a comb.
Spacer 26 comprises an upper surface 33 covered with keyboard membrane 28 and a lower surface 34 resting on protection device 24 . According to the present embodiment, surfaces 33 and 34 are not parallel and form an angle of a few degrees, for example ranging between 1° and 20°, preferably between 2° and 6°.
Keyboard membrane 28 , for example made of silicone or polyurethane, comprises a base 35 having a surface 36 resting on spacer 26 and a surface 37 oriented towards upper package portion 14 . Each key 20 has a substantially parallelepipedal shape and is connected to base 35 by a thinned-down upper lip 38 . Further, each key 20 in continued on the side of surface 36 by a pin 40 which projects substantially perpendicularly to the plane of base 35 . Keyboard membrane 28 further comprises pins 41 which project from surface 36 substantially perpendicularly thereto and which are connected to base 35 by a thinned-down peripheral lip 42 . Keyboard membrane 28 also comprises lugs 43 distributed on surface 36 of base 35 . The length of pins 40 , 41 is not uniform. More specifically, the length of pins 40 , 41 increases along with the thickness of the portion of spacer 26 located close to the considered pins. In the present embodiment, keyboard membrane 28 comprises nineteen pins 40 , eight pins 41 , and ten lugs 43 .
Spacer 26 is crossed by nineteen cylindrical openings 44 intended to receive pins 40 of keyboard membrane 28 and eight cylindrical openings 45 , of same diameter or of smaller diameter than openings 44 and intended to receive pins 41 . Further, spacer 26 is crossed by ten cylindrical openings 46 of smaller diameter intended to receive lugs 43 . In the present embodiment, openings 44 , 45 , 46 have axes perpendicular to surface 33 of spacer 26 . Spacer 26 comprises through openings 49 intended for the passing of elements of reader 10 , for example, means for fastening package 12 . Spacer 26 comprises non-through recesses 50 , 51 on the side of surface 34 .
FIGS. 5 and 6 show more detailed perspective views of protection device 24 . Reference numeral 53 is used to designate the surface of protection device 24 in contact with spacer 26 and reference numeral 54 is used to designate the surface of protection device 24 covering printed circuit 22 . Surface 53 cannot extend under the entire surface 33 of spacer 26 . In particular, the peripheral shape of protection device 24 may enable the passing of electronic components connected to surface 23 of printed circuit 22 .
Protection device 24 has a resilient structure. It is capable of being locally deformed and takes, in the absence of external action, a generally planar shape except for indentations 56 which project on the side of surface 53 . Each indentation 56 is arranged at the level of one of recesses 50 of spacer 26 and may have a shape substantially complementary to the associated recess 50 . Each indentation 56 may be obtained by plastic deformation of protection device 24 . Electronic components 57 may be provided on printed circuit 22 at the level of at least some of indentations 56 of protection device 24 .
Through openings 58 , 60 may be provided in protection device 24 . More specifically, each opening 58 is provided substantially as an extension of one of openings 49 of spacer 26 and is intended to enable the passing of elements of the reader, for example means for fastening upper and lower package portions 14 , 16 . Openings 60 are provided substantially as an extension of recesses 51 of spacer 26 and are intended to enable the passing of light-emitting diodes 61 connected to surface 23 of printed circuit 22 .
Protection device 24 comprises, on the side of surface 54 , planar conductive lands 66 , for example, made of carbon, for each of keys 20 . Protection device 24 further comprises, on the side of surface 54 , domed conductive elements 68 A and 68 B, called domes. Each dome 68 A, 68 B is associated with a pin 41 . Domes 68 A and 68 B have slightly different structures, as will be described in further detail hereafter.
FIGS. 7 to 12 show partial simplified cross-section views of the stack formed by printed circuit 22 , protection device 24 , spacer 26 , and keyboard membrane 28 at the level of a carbon land 66 , of a dome 68 A, and of a dome 68 B. In the drawings, the ratios between dimensions are not kept with respect to the preceding drawings. According to the present embodiment, protection device 24 is a flex circuit formed of a substrate 78 made of a resilient material, for example, a thermoplastic resin such as polyethylene therephtalate (PET) having a thickness, for example, on the order of 0.1 mm. One or several conductive tracks 80 are formed on substrate 78 on the side of printed circuit 22 . Tracks 80 are, for example, made of silver ink and are obtained by serigraphy. Tracks 80 and substrate 78 are covered with a varnish layer 92 , for example, formed of a dielectric material. A stack 93 of three layers 94 , 96 , and 98 , forming a separator, covers varnish layer 92 . Separator 93 has, for example, a thickness on the order of 0.2 mm. It is possible for separator 93 not to be present at the level of each indentation 56 . Spacer 26 may be held on protection device 24 via a gluing material 99 . Separator 93 comprises an opening 100 at the level of each switch or power supply contact area 31 . For FIGS. 7 to 10 , a switch 31 has been shown in the form of two separate conductive tracks 101 , 102 formed on printed circuit 22 substantially at the level of opening 100 of separator 93 and, for FIGS. 11 and 12 , a power supply contact area 31 has been shown in the form of a conductive track 103 .
FIGS. 7 and 8 are cross-section views at the level of a conductive land 66 respectively in the absence of any action on key 20 and when key 20 is pressed. Carbon land 66 covers varnish layer 92 and opening 100 of separator 93 at least partially exposes carbon land 66 . As appears in FIG. 8 , when key 20 is pressed, lip 38 deforms to enable the key to move down along an axis D substantially perpendicular to surface 33 . Pin 40 causes a local deformation of protection device 24 along axis D′ perpendicularly to surface 34 at the level of opening 100 of separator 93 so that carbon land 66 comes into contact with tracks 101 and 102 and provides an electric connection between the tracks. When no further pressure is exerted on key 20 , protection device 24 resiliently returns to its neutral position in which it takes a planar configuration at the level of pin 40 , land 66 being then separated from conductive tracks 101 , 102 .
FIGS. 9 and 10 are cross-section views at the level of a conductive dome 68 A respectively in the absence and in the presence of upper package portion 14 . Dome 68 A is a metal part having, for example, a 0.05-mm thickness corresponding, for example, to a portion of a sphere or of an ellipsoid. Dome 68 A is formed, for example, by deformation of a spring steel plate. The peripheral edge of dome 68 A may be located in a housing 110 provided in separator 93 . When upper package portion 14 is arranged, a finger 112 provided at the level of the internal surface of upper package portion 14 bears against pin 41 , which is displaced and bears against dome 68 A. Dome 68 A deforms to come into contact with conductive tracks 101 , 102 , creating an electric contact between them. The deformed state of dome 68 A corresponds to an unstable position thereof so that, as soon as the action of finger 112 on pin 41 stops, dome 68 A takes back its domed shape and breaks the electric contact with tracks 101 , 102 .
FIG. 11 is a view similar to FIG. 9 at the level of a dome 68 B. As compared with what has been previously described in relation with FIG. 9 , varnish layer 92 comprises an opening 113 which exposes one or several sections of track 80 substantially at the level of dome 68 B. Thereby, when flex circuit 24 and dome 68 B are deformed under the action of pin 41 , dome 68 B comes into contact, on the one hand, with track 80 and, on the other hand, with track 103 of printed circuit 22 . Such a contact is used to supply track 80 . The deformed state of dome 68 B corresponds to an unstable position thereof so that, as soon as the action of finger 112 on pin 41 stops, dome 68 B takes back its domed shape and breaks the electric contact between track 103 and track 80 .
FIG. 13 is a bottom view of protection device 24 showing an example of distribution of conductive tracks 80 on substrate 78 . Domes 68 A and 68 B have been shown in the form of circles. In the present example, a single track 80 extends on substrate 78 . Track 80 comprises a first end pad 104 at the level of one of domes 68 B and a second end pad 105 at the level of the other dome 68 B. Track 80 substantially zigzags across the entire surface of protection device 24 . In particular, track 80 extends at the level of domes 68 A and of conductive lands 66 , not shown. Conductive track 80 also extends at the level of indentations 56 .
Preferably, the section of track 80 brought by deformable dome 68 B into contact with a conductive track 103 of circuit 22 corresponds to an end of track 80 . Thus, both ends of track 80 are connected to conductive portions of deformable regions (domes 68 B) of the protection device.
Although this is not clearly shown in FIGS. 11 and 12 , deformable conductive region 68 B is only in contact with the end point of track 80 by an opening through insulating layer 92 . Indeed, it is not desirable for the contact to short-circuit several sections since this risks to “blind” some areas of the protection device and then to adversely affect the reliability of the detection.
To avoid a pirate supply of track 80 , domes 68 B for supplying track 80 (and thus end pads 104 and 105 ) are placed outside of the periphery of the protection device. Thus, conductive track 80 protects not only against an intrusion attempt by means of a probe or the like, but also against a displacement of the system. The corresponding detections are performed by one or several adapted electronic circuits, supported by the printed circuit.
The width of conductive track 80 may be variable but preferably remains much lower (preferably, by a factor greater than 5) than the diameter of a dome. The narrower track 80 and the lower the intervals between sections, the better the sensitivity of the detection device. Further, the pattern followed by track 80 may take different shapes (coils, combs, curved sections, etc.). In the case where several tracks 80 are provided, they may be supplied by same deformable regions of the protection device and corresponding tracks of the printed circuit, or be associated with different deformable regions.
FIG. 14 is a view similar to FIG. 2 in which a cross-section has been made. Lugs 43 of keyboard membrane 28 are held in the corresponding openings 46 of spacer 26 and hold keyboard membrane 28 in position with respect to spacer 26 .
The present embodiment enables to prevent the access to metal tracks 101 , 102 of printed circuit 22 while preserving the switch function of pins 40 , 41 .
The present embodiment enables to protect some electronic components 57 present on printed circuit 22 against an intrusion by encapsulating these components 57 with protection device 24 .
In the present embodiment, the two surfaces 33 , 34 of spacer 26 may be tilted with respect to each other and not parallel. Spacer 26 enables to tilt the displacement axes of keys 20 of the keyboard with respect to the displacement axes of the deformable portions of protection device 24 . Keys 20 can thus be oriented to obtain the simplest and most natural possible motions for a user.
In the present embodiment, for each key 20 , protection device 24 is planar in the absence of an external action and is deformed to provide the electric connection between conductive land 66 and conductive tracks 101 , 102 . The travel of protection device 24 is on the order of 1 mm. The switching speed is thus privileged. For pins 41 , protection device 24 has, in the absence of an external action, a domed shape due to resilient conductive element 68 A and is deformed to provide the electric connection between conductive element 68 A and conductive tracks 101 , 102 .
Specific embodiments of the present invention have been described. Various alterations and modifications will occur to those skilled in the art. In particular, it may be provided to associate with keys 20 of keyboard membrane 28 the structure of protection device 24 shown in FIGS. 9 and 10 where protection device 24 comprise a resilient conductive element 68 A having a domed shape in the absence of an external action. In this case, when key 20 is pressed, pin 40 continuing key 20 deforms conductive element 68 A to provide the electric connection between conductive tracks 101 , 102 of printed circuit 22 . Further, a protection device in which membrane 28 would be used as a substrate for track 80 and where conductive lands 66 and domes 68 A and 68 B would be directly placed on membrane 28 , may be envisaged. Further, the resilient function of domes 68 A and 68 B may be achieved by thermoforming of protection device 24 above areas 31 . | An electronic system including an electronic circuit, an actuation device, a spacer and a protection device. The electronic circuit has a surface on which at least two first conductive tracks are arranged. The actuation device includes at least one first bearing element. The spacer is interposed between the electronic circuit and the actuation device and includes at least one opening at least partially receiving the bearing element. The protection device is interposed between the electronic circuit and the spacer and includes at least one second conductive track having ends respectively connected to first conductive portions of first deformable regions of the protection device. Each first portion is capable of contacting one of the first conductive tracks of the electronic circuit to electrically supply the second track under the effect of a deformation of first regions. | 8 |
[0001] This application claims priority of U.S. provisional application Ser. No. 61/789,923 filed on Mar. 15, 2013.
FIELD OF THE INVENTION
[0002] The present invention relates to a delivery of a topical anesthetic formulation to a subject in need thereof by employing a multi-chamber delivery system. The present invention also describes a method of improving the stability of such anesthetic formulations that are traditionally known to be susceptible to degradation.
BACKGROUND OF THE INVENTION
[0003] Topical anesthetics formulations have long been used for providing analgesia prior to any invasive medical procedure. Their use is essential for performing diagnostic, therapeutic, and cosmetic dermatology procedures. Topical anesthetics can be formulated in variety of dosage forms and mixtures such as solutions, creams, ointments, gels, and even patches and peels. They can be applied to certain areas of the body including skin, nose, mouth to cause loss of feeling or numbness to allow medical practioners to perform their procedure. Another area of use of anesthetic formulations is in pain control. Pain relief is especially important among both pediatrics and geriatrics patients, where even minimal pain may result in an anxious and uncooperative patient.
[0004] Among topical anesthetics, cocaine has been the golden standard. Cocaine is a weakly alkaline compound and can be combined with acidic compounds to form various salts. The hydrochloride (HCl) salt of cocaine is by far the most commonly used in the art. Different salts dissolve to a greater or lesser extent in various solvents. The hydrochloride salt is polar and quite soluble in water. For medicinal use, cocaine is typically available in powder and solutions of various concentrations. The powder can be applied via moistened cotton swabs generally for nasal or oral numbness. The premade topical solutions are available in strengths ranging from 2-10%, with the 4% solution being the most common. Epinephrine may be added to a cocaine solution to limit systemic absorption while promoting vasoconstriction and enhanced local availability of the drug. To use cocaine in the nasal cavity, cotton applicators may be soaked in the cocaine solution and then applied to the area of interest and then removed via suitable forceps. The cocaine aqueous solution is recommended to be stored at room temperature between 68-77° F. (20-25° C.) away from light and moisture. Such solutions should not be frozen as it may impact the stability and efficacy of the product. Once the vial of an anesthetic solution is opened, many events can lead to product's waste. Such events include bacterial contamination; solvent evaporation, change in drug concentration and eventual drug degradation.
[0005] Aside from cardiovascular side effects, cocaine is associated with psychological dependence, which may lead to cocaine abuse and increased chance of serious side effects. Due to the cost, the side effect profile, the potential abuse and the limited shelf life stability, cocaine's use as a topical anesthetic has been falling out of favor among practioners. Accordingly, other combinations of anesthetic have been receiving some attention. Tetracaine, epinephrine, and cocaine (TAC) solution is a dermal anesthetic that is used for wounds, such as lacerations and abrasions, to provide anesthetic effect prior to wound repair. The original formulation of TAC solution consisted of tetracaine 0.5%, 0.05% epinephrine 1:2000, and 11.8% cocaine in normal solution. At this concentration, each mL of TAC solution contains 5 mg tetracaine, 0.5 mg epinephrine, and 118 mg cocaine.
[0006] Another common use of topical anesthetics is in dental applications. These products are frequently applied to the gum prior to the injection of any anesthetic. Transdermal anesthetics are also useful for numbing an area prior to venipuncture, such as blood drawing. Lidocaine and prilocaine are another type of anesthetic. They are both amide-type local anesthetic agents. Amides, are favorable as anesthetic agents, compared to esters, which are more sensitizing and can produce redness, swelling, irritation, itching, and other reactions.
[0007] Regardless of the type of the anesthetic compound, a frequent issue facing their manufacturers and medical practioners is how they can improve their shelf-life, because their availability is impacted by their relatively short shelf-life. Therefore, advance orders for manufacturing of anesthetic solutions coupled with subsequent storage of such products frequently leads to large amount of product waste. Accordingly, there is a need to facilitate a product that reduces abuse, while preserving stability of the product.
SUMMARY OF THE INVENTION
[0008] The present invention addresses the need in the art. Broadly, at least one aspect of the present invention is directed to a multi-chamber delivery system for delivery of topical anesthetic formulations. In the preferred embodiments, the present invention is a two-chamber delivery system for improving the shelf life beyond the shelf-life of counterpart topical anesthetic formulations available in the art.
[0009] In at least one aspect of the invention, the topical anesthetic properties can be provided by a single anesthetic compound. In certain embodiments, the anesthetic properties are provided by a combination of anesthetic compounds present in the formulations. In at least one embodiment, the topical anesthetic formulation contains a secondary ingredient such as a vasoconstrictor, an anti-bacterial compound, a corticosteroid, or a non-steroidal anti inflammatory. In a preferred embodiment the anesthetic compound can be any one of tetracaine, lidocaine, benzocaine, dyclonine, pramoxine, dibucaine, butacaine, cocaine, mepivicaine, bupivicaine, levobupivicaine, ropivicaine, etidocaine, prolicaine, articaine, procaine, chloroprocaine, salts or other suitable pharmaceutically acceptable forms thereof including free acid or base, alone or in combination with each other.
[0010] In at least another aspect of the present invention, the first chamber of the described delivery system and the second chamber are connected through a narrow constricted neck. In yet another aspect of the invention, the neck is sealed by a septum plug. In one embodiment, one of the chambers contains an actuating stopper that seals the inside environment from the outside, effectively eliminating the access to the internal environment of the system. In yet another embodiment, the stopper may be of material that can act as an applicator. In yet another embodiment, the stopper can be actuated by downwards force being exerted thereon. In yet another embodiment, the septum plug can be displaced by actuating the stopper and applying pressure downwards on the stopper. In at least one embodiment, one of said chambers is of glass material. In another embodiment, the chambers may include a tamper resistant means for example, a protective member to be removed or at least transferred into a release configuration, thereby giving way to the actuating stopper.
[0011] In one embodiment, the removal or displacement of the protective member is only possible after a breakable seal is split open or destroyed. Thus, by coupling the protective member and the housing by means of a breakable seal, any tampering of the system can be detected.
[0012] In at least another aspect of the invention, the first chamber contains a plunger that is in directly contact with the septum plug located in the connecting neck. In one embodiment of the present invention pressing down on the plunger will displace the septum plug allowing free flow of the solvent through the connecting neck. In another embodiment, the top portion of the plunger is encircled by the stopper and the stopper can also act as an applicator. In yet another embodiment, the plunger is placed inside a cylindrical barrel that extends from the top of the first chamber to the septum plug.
[0013] In at least another aspect of the present invention, the first chamber and the second chamber can be separated. In such embodiment, the first chamber may be the upper chamber and carries the diluent, while the second chamber is the lower chamber containing the anesthetic ingredient. The chambers are sealed separately, yet can be connected to each other after removal of their respective seals, via a lock-and-seal mechanism. In this aspect of the invention, the lock and seal mechanism is designed to fit in the form of a narrowing neck between the chambers. In this aspect of the invention, the second chamber is connected through a turn and twist mechanism through a narrowing or a constricted neck forming the connection between the chambers. In yet another aspect of the invention, the neck is sealed by a septum that is placed at the bottom of the upper chamber. In another embodiment, an applicator can separately be placed on the lower chamber after the reconstitution of the formulation.
[0014] In at least one aspect of the invention, the lock-and-seal mechanism is the same as the turn and twist mechanism and is in the form of internal threaded system providing a mating engagement with threaded portions of the upper and lower chambers. Accordingly, the threaded system facilitates the coupling of the upper and the lower chambers. In a preferred embodiment, the upper chamber is rotated in a clockwise direction and the rotation bringing the chambers together and causes the sealing of the chambers from outside environment through their respective threads. In this aspect of the invention, the lower anesthetic containing chamber contains an applicator to be used for dabbing to the region of interest.
[0015] In accordance to another aspect of the invention, the lower chamber further contains a cap assembly to separately seal and cover the threaded region. The threaded region may further be adopted to carry an applicator located within a locking assembly. Such applicator will be sealed in a manner to stay sterile by a protective member or a tamper resistant means. The lower chamber can then be used as a reservoir to store the final solution and application of the anesthetic formulation. The applicator may further be capped to avoid contamination after use.
[0016] In another embodiment the anesthetic topical anesthetic formulation prepared by the two-chamber system is a cocaine solution. In such aspect of the invention, the two chamber system provides for a topical cocaine delivery system that contains a suitable solvent in one chamber and cocaine powder in another. In at least one embodiment of the present invention, the chamber is made of darker glass material to protect the anesthetic powder and/or the final solution from exposure to the sun light and potential degradation. At least one advantage of such glass material is that the cocaine powder can not be extracted from the chambers or is an abuse resistant formulation and therefore, the present delivery system offers less opportunity for improper appropriation of the cocaine powder.
[0017] The abuse resistant feature of this invention may be provided by incorporating surfactants, additives or stabilizers into the anesthetic mixture. In at least one embodiment, a suitable surfactant for example may be mixed with the anesthetic by the way of milling, blending, spray drying, coemulsifying, or melting of an additive, a surfactant, or a stabilizer with the anesthetic compound. In a more preferred embodiment, the additive, the surfactant, or the stabilizer may be adsorbed on the surface of the anesthetic particles, so that separating the anesthetic compound from such ingredients would not be readily achievable.
[0018] In another embodiment, the anesthetic compound is made more lipophilic by elimination reduction of the overall charge of the anesthetic compound. For example, a water soluble salt may be converted to a free base or free acid. In another embodiment, fatty acids or alcohols may be used to convert the water-soluble compound to a lipophilic construct. In yet another embodiment, the anesthetic compound may be coated with a water insoluble polymer which when exposed to the solvent can be removed by a separation mechanism such as a filter.
[0019] According to one aspect of the present invention, the delivery system is a two-chamber vial. In at least this aspect of the invention, an anesthetic liquid formulation is prepared in at least one of the chambers just prior to use. In another aspect of the invention, at least one of the chambers contains a plurality of anesthetic compounds in powder, crystal, particulate or nanocrystal forms and the other chambers contains a suitable solvent for dissolving such anesthetic compounds.
[0020] According to another aspect of the present invention, the delivery system is designed to stabilize the one or more anesthetic compound(s) prior to the topical application for at least 1, 2, 3, 4, 5, 6, 7, or 8 years, wherein less than 10% of the anesthetic compound is degraded during such period of time at temperature up to 40° C. In another embodiment the delivery system contains at least one anesthetic compound such as tetracaine, lidocaine, benzocaine, dyclonine, pramoxine, dibucaine, butacaine, cocaine, mepivicaine, bupivicaine, levobupivicaine, ropivicaine, etidocaine, prolicaine, articaine, procaine, chloroprocaine, salts or other suitable pharmaceutically acceptable forms thereof including free acid or base, alone or in combination with each other. That stays stable for at least 5, 4, 3, 2, or 1 year(s), wherein less than 10% of such compounds are degraded during such period of time at temperatures up to 40° C. According to another aspect of the present invention, the system is designed to keep the anesthetic formulation stable for at least 2, 3, 4, or 5 years at room temperature under atmospheric pressure. In another embodiment the shelf life stability of the delivery system is 3 years.
[0021] In another aspect of the present invention, the two-vial chamber delivery system contains no trace of bicarbonate. According to this aspect of the invention, the first chamber contains a pharmaceutically acceptable biocarbonate free incompressible liquid solvent; and the second chamber comprising a sterile solid particulate form of an anesthetic compound or a pharmaceutically acceptable salt thereof; a sealed septum separating the first and second chamber comprising material that is impermeable to said solvent, and an actuating stopper sealing the first or second chamber from the outside environment, wherein upon pressing said stopper, said incompressible liquid solvent is pressurized and drives said sealed septum downward, releasing the liquid solvent into the other chamber to form a mixture of liquid solvent and the anesthetic compound.
[0022] According to yet another aspect of the present invention, the system for releasing/delivering one or more active requires application of external force to the actuating stopper seal.
[0023] In yet another embodiment of the present invention, at least one of the anesthetic compounds in powder form is cocaine. In another embodiment, cocaine is the sole anesthetic compound present in the delivery system, the composition is free of any traces of bicarbonate. In another embodiment, the composition may contain bicarbonate.
[0024] In another aspect of the invention, the stopper material is of dehydrated water absorbable polymers or copolymers that would be converted to a ready to use applicator once hydrated with the solvent or mixture thereof. In one embodiment, the stopper material can also act as an applicator. In another embodiment, the applicator contains a solvent absorbable polymers and can be any one or combinations of sodium alginate, sodium carboxymethyl cellulose, sodium pectinate, sodium carboxymethyl chitosan, sodium polyacrylate, naturally occurring gums and synthetic polymers containing carboxylic acid, acrylic acid-methacrylic acid copolymers and/or dehydrated hydrogel, cross-linked macro-molecular network, fibers, nylons, rubber, cotton, and rayon, and mixtures thereof.
[0025] In another aspect of the invention, the stopper is an actuating stopper with a protruding means from at least one of the chambers, wherein said actuating means is a means for applying external pressure that is transferred via the liquid solvent in the first chamber to the sealed septum plug, and wherein said pressure disengages the plug from the constriction, thereby pushing the plug into the lower chamber to bring the solvent into contact with the solid particulates in the second chamber.
[0026] In another aspect of the invention, the product produced in the two-chamber delivery system is used for treating a skin, hair, ear, mucosal membrane, rectal, nasal or dental condition in a subject in need thereof the method comprising topically applying onto a skin, hair, ear, mucosal membrane, rectum, nose or tooth. Therefore another aspect of the present invention is directed to the use of the composition made by the two-chambered delivery system and topically delivering the composition. In yet another embodiment the delivery system contains an applicator.
[0027] According to still further features in the described preferred embodiments the final form of the composition is selected front the group consisting of an aqueous solution emulsion, an oil, a gel, a lotion, a suspension, a powder, an aerosol, a spray, and a foam. In on certain embodiment the present invention there is provided a method of delivering a topical anesthetic in the form of a solution, oil, lotion, suspension, aerosol, spray or foam made by the process for using the two-chamber delivery system. Another embodiment of the invention is directed to method of stabilizing an aqueous anesthetic composition using the presently described two-chambered delivery system.
[0028] In a preferred embodiment, the present invention is directed to a topical, transdermal anesthetic preparation comprising at least one of about 1-15% cocaine, 1-15% lidocaine; about 1-5%, prilocaine; about 0.1-1.0% dibucaine; with or without about 0.1-2.0% as effective for local vasoconstriction, of a sympathomimetic amine, preferably phenylephrine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is an enlarged side view of a two-chamber mixing delivery system that is an illustrative embodiment of the invention.
[0030] FIG. 2 is a side view of an alternative two-chamber delivery system.
[0031] FIG. 3 is a side view of another embodiment of the two-chamber delivery system.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Two-chamber mixing vials have been described in the art. At least one such vial is disclosed in U.S. Pat. No. 4,258,845 to Potts, incorporated herein by reference. The vials presented herein however are new for anesthetic formulations and are designed to increase shelf-life of such products beyond their commercially available counterparts.
[0033] At least one aspect of the present invention is directed to multi-chamber container containing separate chamber with thy anesthetic powder and at least another chamber containing a solvent. According to this aspect of the invention, additional chambers may be present to store a third ingredient or maintain additional space for mixing or withdrawal of the final mixture. According to this assembly, the desired material and measured quantities are placed in separate chambers.
[0034] Another aspect of the present invention is directed to a two-chamber delivery system for delivery of topical anesthetic formulations. One such embodiment of the present invention is illustrative as two-chamber system 100 , depicted here in FIG. 1 . In a more preferred embodiment, the system is a vial of any suitable material such as glass, plastic, nylon, aluminum, but preferably glass and contains two interior chambers; a lower chamber 110 and an upper chamber 120 which are separated by a constriction 130 . The constriction 130 is substantially airtight and watertight by a sealed septum plug 140 . The septum can be made of any suitable material, but is preferably of rubber to maintain an airtight seal. The upper chamber 120 corresponds to the “first chamber” and the lower chamber 110 to the “second chamber.”
[0035] In at least one embodiment, the upper chamber 120 contains solvent 121 . In another embodiment 200 , the upper chamber 220 contains anesthetic compounds 221 in powder, crystal powder, microparticle, or nanoparticle forms and the rest of the headspace is filled with an inert gas that does not interact with the to avoid degradation of the anesthetic compounds, see FIG. 2 . In one embodiment, the anesthetic properties are provided by a combination of anesthetic compounds present in the resulting formulations. In at least another embodiment, the topical anesthetic formulation contains a secondary ingredient such as a vasoconstrictor, an anti-bacterial compound, a corticosteroid, and a non-steroidal anti inflammatory, which can be in powder, microparticle, or nanoparticles residing in the first chamber.
[0036] In a preferred embodiment the anesthetic compound can be any one of tetracaine, lidocaine, benzocaine, dyclonine, pramoxine, dibucaine, butacaine, cocaine, mepivicaine, bupivicaine, levobupivicaine, ropivicaine, etidocaine, prolicaine, articaine, procaine, chloroprocaine, salts or other suitable pharmaceutically acceptable forms thereof including free acid or base, alone or in combination with each other. In more preferred embodiment the anesthetic is tetracaine, benzocaine, cocaine, bupivacaine, ropivicaine salts or other suitable pharmaceutically acceptable forms thereof. In another aspect of the present invention, anesthetic formulations are described that are produced by the instant process.
[0037] The septum plug 140 in FIGS. 1 and 240 in FIG. 2 corresponds to the sealing component placed within respectively the constrictions 130 and 230 separating the two chambers. The septum plug eliminates the availability of the content of the chambers to each other. In one embodiment, the septum plug prevents access to the anesthetic powder of the lower chamber until such septum is forcefully displaced or removed from the constriction 130 . The septum plug forms an interchamber seal preventing moisture from traveling into the lower chamber inadvertently causing clumping of the anesthetic powder. In at least another embodiment, the upper chamber contains an actuating means 124 or 224 . The actuating means is the component that would allow application of hydraulic pressure to the system and eventual displacement of the septum plug.
[0038] In at least one embodiment in FIG. 1 , the actuating means contains the securing portion 125 and the stopper 126 and the protective member structure 127 located on top of the stopper. In at least another embodiment the actuating means is located on top of the upper chamber 120 . In at least one embodiment, the user is able to press the actuating means and exert such pressure that is transmittable by the inert gas and the solvent within the upper chamber towards the neck of the vial and directly transferring the pressure to the septum plug 140 to dislodge the plug from the neck constriction 130 of the vial, pushing the plug into the lower chamber 110 , thereby bringing the solvent of the upper chamber 121 into contact with the anesthetic powder 111 of the lower chamber.
[0039] In at least another embodiment the stopper is of solvent resistant rubber material. In yet another embodiment the stopper is of solvent permeable material which can be hydrated with the formulated mixture of solvent and the anesthetic compound(s) and then act as a topical applicator upon removal of the protective member 127 . The applicator may then be separately capped or sealed to limit exposure to external contaminants.
[0040] In at least one embodiment, the actuating means contain the securing portion 125 on top of the upper chamber sealing the top chamber from the outside environment. In this embodiment, the securing portion is in the form of an assembly that covers the ledge, rim and the immediate region to facilitate proper sealing and further allow the stopper to move internally upon downward force. In a more preferred embodiment, the securing portion assembly is of a somewhat rigid material, typically a rigid plastic such as polyethylene, polypropylene, polyvinyl or acrylic material.
[0041] In yet another embodiment illustrated in FIG. 2 , the actuating means contains the securing portion 225 and the stopper 226 and the closure protective member structure 227 located on top of the stopper. In at least this embodiment the actuating means is located on top of the upper chamber 220 which can be pressed down to actuate and exert pressure that is transmittable by the inert gas within the upper chamber towards the neck of the vial and directly transferring the pressure to the septum plug 240 to dislodge the plug from the neck constriction 230 of the vial, pushing the plug into the lower chamber 210 , thereby bringing the solvent of the lower chamber 221 from into contact with the anesthetic powder 211 of the upper chamber.
[0042] In at least one embodiment, the upper chamber of the present delivery systems have a neck 123 , 223 , 323 which is the immediate region below the rim of the end of the upper chamber, and an access or the opening to the outside environment 122 , 222 , 322 . The neck 123 , 223 , 323 in the illustrated embodiment is of substantially the same interior diameter as the upper chamber 120 , 220 , 320 but optionally the neck 123 , 223 , 323 can be of reduced diameter or be merged with the stopper assembly. The neck 123 , 223 , 323 may further have an outward projecting and or can be in touch with a plunger like assembly that can move freely within the neck region. In another embodiment, the neck may contain a lock-and-seal, or a twist-and-turn mechanism to facilitate separation of chambers from each other.
[0043] In at least another embodiment the upper chamber 120 is substantially filled with a liquid solvent for dissolving the anesthetic powder. In a more preferred embodiment, the solvent is bicarbonate free. In another embodiment, the upper chamber contains the anesthetic powder 221 and the liquid solvent is in the lower chamber 211 .
[0044] In at least one embodiment, the neck 123 or 223 is provided with a securing portion in any structure or suitable design. In the illustrated embodiments the plug septum 140 , 240 , 340 is fabricated from flexible material such as elastomer that is impervious to aqueous solvents, such as water and/or gaseous substances such as air, nitrogen, or other inert gases such as helium, argon, xenon, radon, or radon or any combinations thereof. At least one example of such material is butyl rubber. The septum plug 140 , 240 , 340 has a sealing portion 141 , 241 , 341 seated within the constriction 130 or 230 between the two chambers. To improve the seal formed between the sealing portions 141 , 241 of the septum plug and the constriction neck 140 or 240 , there may be one to a plurality of spaced annular ridges, bulges or protrusions that can be fit within the structural design of the constriction.
[0045] In at least one embodiment, when the external force is applied downwards and internally to the actuating means and via the stopper 126 the generated pressure is transferred to the liquid solvent in the upper chamber 120 and subsequently transferred to the septum plug to be dislodged. In another embodiment, the external force is applied to the actuating means which subsequently increases the internal pressure of the upper chamber, thereby dislodging the septum plug. In another embodiment, the actuating means is connected to piercing column that can pierce through the septum plunge and create a hole, which upon retraction of the actuating means can allow free flow of the solvent through each of the chambers. In yet another embodiment, the actuating means is in the form of the plunger 330 that is in direct contact with the septum plug 350 and capable of dislodging the septum plug when direct forced is applied. In this embodiment, the plunger is placed inside a cylindrical barrel that extends from the top of the first chamber to the septum plug.
[0046] In a preferred embodiment, the upper opening of the upper chamber is sealed by protective means. Such structure contains the cap assembly 127 , 227 , the actuating stopper 126 , 226 and the securing portion 125 , 225 . The securing portion 125 , 225 surrounds the rim 129 , 229 and the upper chamber neck or immediate proximate region of the same. The upper the ledge or the rim may contain an internal or external component that covers the upper chamber opening which has a diameter smaller than the upper open end, such that the pressing the actuating stopper inward would result in retaining of the stopper at the rim or in the upper chamber's neck.
[0047] The cap assembly 127 , 227 may have an internal lock structure that acts with the stopper to prevent the stopper from being displaced downward relative to the middle of the upper chamber 120 , 220 . In at least one embodiment, the stopper is made of such material that can be rigid enough to withstand the external pressure and transfer the pressure inside. In another embodiment the stopper is capable of being hydrated with the solvent or the resulting anesthetic liquid mixture so that the stopper itself can act as a topical applicator.
[0048] A typical lock structure may contain a lock ring projecting inward from the lower end of the upper chamber to hold the stopper at the upper end of the upper chamber, a securing portion that extends outwardly to rim and the immediate upper region of the upper chamber, and a cap on top of the stopper to withstand external inward pressure, while prevent the stopper from moving to the middle of the upper chamber.
[0049] In at least another aspect of the present invention, the first chamber and the second chamber can be separated. In such embodiment, the first chamber 120 may be the upper chamber that carries the solvent or the diluent, while the second chamber 110 is the lower chamber containing the anesthetic ingredient. The chambers are sealed separately, yet can be connected to each other after removal of their respective seals, via a lock-and-seal mechanism. In this aspect of the invention, the lock and seal mechanism is designed to fit in the narrowing neck between the chambers. In this aspect of the invention, the first and second chambers are connected through a screw on mechanism through the narrow or the constricted neck between the chambers wherein the entire system will be locked and sealed from the outside environment. In yet another aspect of the invention, the neck is sealed by a septum that s placed at the bottom of the upper chamber. In an alternate embodiment, the applicator can separately be placed on the lower chamber after the reconstitution of the formulation. In another embodiment, the applicator may be sealed or covered by a cap to limit exposure to external contaminants.
[0050] In at least one aspect of the invention, the lock-and-seal mechanism is in the form of a twist and turn assembly. In yet another embodiment, the lock-and-seal mechanism is an internal threaded system providing a mating engagement with threads portions of the upper and lower chambers. Accordingly, the threaded system facilitates the coupling of the upper and the lower chambers. In one embodiment, the upper chamber is rotated in a clockwise direction and the rotation bringing the chambers together and causes the mating of the chambers through respective threads thereby facilitating the locking between the upper and the lower chambers. Accordingly, upon mixing the anesthetic compound and the solvent, the chambers are unscrewed and separated and the lower chamber containing the mixture is sealed with an applicator component that can be threaded into the lower chamber's threading system. Subsequently, the mixture may be applied to the region of interest via the applicator by dabbing the applicator to the region of interest. The applicator may further be sealed or capped to limit its exposure to external contaminants.
[0051] In accordance to another aspect of the invention, the lower chamber further contains a cap assembly to separately seal and cover the threaded system, wherein a lock latches and enable the lower chamber with an applicator located within the locking assembly would stay sterile. The lower chamber can then be used for direct dissolution and application of the anesthetic formulation. In this aspect of the invention, the lower chamber contains the anesthetic compound and the upper chamber contains the solvent and the actuating assembly. Accordingly, once the two-chamber system is assembled the actuating means of the upper chamber may be pressed down to dislodge the stopper positioned within the narrowing of the lower chamber. In one embodiment, the headspace in each chamber is filled with gaseous substances such as air, nitrogen, or other inert gases such as helium, argon, xenon, radon, or radon or any combinations thereof to keep the internal pressure constant for proper transfer of pressure.
[0052] In an alternative embodiment, the bottom threaded region of the upper chamber may be sealed by a cover and the upper threaded region of the lower chamber may be sealed by a removable cover. Accordingly prior to use, the sealed of each respective chambers are removed and the chambers are connected through their respective threaded assembly. The movement of the ingredients from one chamber to another can then be facilitated by pressing down the actuating means or via a piercing mechanism that allows connection of the upper to lower chamber. The piercing mechanism can be a protruding element or an inside hollow port within the one of the chambers threaded region that upon mating with the treaded region of the other chamber pierces through a seal or stopper, facilitating movement of solvent from upper chamber to the lower chamber.
[0053] In at least another embodiment, the two-system chamber assembly contains a first glass or plastic reservoir having a protective member covering at both ends, wherein at least one end contains an actuating means and the other end contains a cap sealed threaded region. In such embodiment, the at least second chamber has a threaded region that can mate with the threaded region of the first chamber facilitating a connection between the first and second chambers and transfer of material between the chambers.
[0054] In at least another embodiment the threaded sides of the chambers are protected by a tear-off type portion which can be removed from the respective chamber by pulling on a tear tab prior to the connecting of the first and the second chambers. In this embodiment, at least one of the upper or lower chambers contains external threads which are provided on glass or plastic reservoir and are exposed. The other chamber contains threaded ridges that can mate with the external threaded region of the upper or lower chamber sealing and locking the system yet allowing free transport of diluent from one chamber to the other.
[0055] The mixing of the solvent with the active anesthetic particles is facilitated by the locking of the two sets of internal threads from the respective chambers. The threads of each respective chamber are adapted to mate with external threads of the other chamber enabling interconnection of the chambers and the making the two-chamber delivery system. In at least one embodiment, the threaded system is located in the narrow neck of the delivery system.
[0056] In yet another embodiment, once the anesthetic mixture is prepared the chambers can be separated from each other. In such embodiment, a sterile applicator component prepared from suitable material and encased into a threaded assembly can be screwed on the top of the chamber carrying the anesthetic mixture. The anesthetic solution can then be administered h dabbing or wiping against the region of interest.
[0057] In at least one embodiment, to actuate the vial, the protective cap 127 , 227 sitting on top of the stopper is pressed downward, for example with a thumb, thereby breaking the sealed but fracturable connection that can exist between the stopper and the upper chamber opening, moving the lower end face of the stopper 126 , 226 inwards towards the center of the upper chamber until the stopper locking structure is engages, preventing the stopper to go any lower.
[0058] In at least one embodiment, once the stopper is pressed down words, an internal hydraulic pressure is created within in the upper chamber 120 which is respectively transferred to the septum plug. When the stopper is fully depressed, the created hydraulic pressure is respectively transferred to the septum plug dislodging the plug from its original position, into the middle of the bottom chamber allowing the solvent to reach the anesthetic powder crystals. Furthermore, the exchanged headspace from both of the chambers would provide sufficient space for shaking of the resulting mixture for creating a homogenous mixture.
[0059] In yet another embodiment, the lower chamber contains the anesthetic powder and the actuating means is a plunger 330 , FIG. 3 . In such embodiment the lower chamber may have a third polymeric seal at the external end of the lower chamber that is capable of being saturated with the resulting mixture and act as a topical applicator for the proper region of the body. This polymeric seal can be a detachable component that can be separately assembled at the top of the lower chamber.
[0060] In yet another embodiment, the actuating plunger 330 will be pressed against the seal 350 to facilitate the movement of the solvent from the upper chamber to the lower chamber.
[0061] In another embodiment, to actuate the delivery system, the plunger 330 is pressed downward to directly dislodge the plug septum downward and facilitate flow of the solvent into the chambers. In this embodiment, the headspace in each chamber is filled with sufficient amount of gaseous substances such as air, nitrogen, or other inert gases such as helium, argon, xenon, radon, or radon or any combinations thereof to allow proper transfer of pressure from one chamber to another. In yet another embodiment, the stopper is connected to piercing columns that pierces through the septum plug when the stopper is pressed downwards. In such embodiment, the stopper may have a pull back mechanism to allow free flow of solvent into all chambers.
[0062] According to the present embodiment, the mixing of the solvent and the anesthetic compound may differ from that known in the art at least by having an anesthetic compound in either of the upper or lower chambers and an aqueous solution in a separate chamber. Should the either of the chambers as presently contemplated functions as a reservoir for air or other gaseous medium such nitrogen, or other inert gases such as helium, argon, xenon, radon, or radon or any combinations thereof, it provides a headspace for effective agitation following actuation of the vial. As such, by virtue of its lack of contact with the upper chamber prior to actuation, the system minimizes or prevents exposure of ingredients of the formulation to an environment that would have otherwise promoted instability and degradation.
[0063] In another embodiment, the small and inert headspace protects the formulation in the vial from oxidative degradation. The small treatment is indicative of conditions in an article of the present invention, wherein the formulation substantially fills the chamber in which it is packaged, with very little headspace, optionally containing inert gases such as helium, argon, xenon, radon, or radon or any combinations thereof, and therefore the system as a whole is capable of transferring any applied external force through to the septum plug.
[0064] In another aspect of the present invention a method of preparing anesthetic solution comprising providing a two-chamber vial delivery system comprising (a) an upper chamber comprising pharmaceutically acceptable incompressible liquid solvent, (b) a lower chamber comprising a sterile dry anesthetic compound or a pharmaceutically acceptable salt thereof (c) a seal separating the upper and lower chamber, and (d) a stopper sealing the upper chamber from the outside environment, pressing the stopper sealing the upper chamber, releasing the liquid solvent into the lower chamber to form a mixture, shaking the mixture to provide an anesthetic solution. In at least one embodiment, the solvent is bicarbonate free. In yet another aspect of the invention, anesthetic formulations are described wherein such formulations are made by a process described herein above.
[0065] Accordingly, in a particular embodiment, an article of manufacture of the present invention comprises any one of the anesthetic compound, an inert gas and a suitable solvent to dissolve the anesthetic compound substantially by agitating and mixing the vial content up and down. In a preferred embodiment the anesthetic is selected from any one of the following compounds tetracaine, lidocaine, benzocaine, dyclonine, pramoxine, dibucaine, butacaine, cocaine, mepivicaine, bupivicaine, levobupivicaine, ropivicaine, etidocaine, prolicaine, articaine, procaine, chloroprocaine, salts or other suitable pharmaceutically acceptable forms thereof including free acid or base, alone or in combination with each other. In a more preferred embodiment the anesthetic is tetracaine, benzocaine, cocaine, bupivacaine, ropivicaine salts or other suitable pharmaceutically acceptable forms thereof.
[0066] In another embodiment, solvent is any one of water, saline, 5% dextrose solution, any C 1 -C 5 alcohol or any mixtures thereof. In yet another embodiment, the solvent is bacteriostatic and/or sterile. In another embodiment, the stopper system of the closure assembly in the upper chamber can act as a topical applicator once it is appropriately hydrated with the resulting mixture. In another embodiment, the applicator may be located in the lower chamber and capped with a secondary cap structure. In another embodiment, the secondary cap structure can contain a spaying means to deliver premeasured closes of the anesthetic.
[0067] In another embodiment, the formulation of the final product contains one or more additives such as a wetting and/or suspending agents in an amount effective to provide controlled flocculation of the drug, at least one of the wetting and/or suspending agents being susceptible to oxidative degradation; and, in a lower chamber thereof, only a gaseous medium, for example air or nitrogen, helium, argon, xenon, radon, or radon or any combinations thereof.
[0068] In a preferred embodiment of the present invention, at least the anesthetic compound of the present invention is cocaine as one of the anesthetic compounds. In another embodiment, cocaine is the sole anesthetic compound present in the delivery system.
[0069] In another aspect of the invention, the product produced in the two-vial chamber is used for treating skin, hair, ear, eyes, mucosal membrane, rectal, nasal or dental tissues in a subject in need thereof the method comprising topically applying onto a skin, hair, ear, mucosal membrane, rectum, nose or tooth. Therefore another aspect of the present invention is directed to the methods of use of the composition made by for example, a two-chambered delivery system directly to the site of interest in patients in need thereof.
[0070] In one embodiment, the stopper material is of dehydrated water absorbable polymers or copolymers that would be converted to a ready to use applicator once hydrated with the solvent or mixture thereof. In another embodiment, the stopper material can also act as an applicator. In another embodiment, the applicator contains a solvent absorbable polymers can be any one or combinations of sodium alginate, sodium carboxymethyl cellulose, sodium pectinate, sodium carboxymethyl chitosan, sodium polyacrylate, naturally occurring gums and synthetic polymers containing carboxylic acid, acrylic acid-methacrylic acid copolymers and/or dehydrated hydrogel, cross-linked macro-molecular network, fibers, nylons, rubber, cotton, and rayon and mixtures thereof. In another embodiment, the stopper material absorbs the mixture, containing the anesthetics in sufficient amounts to provide effective numbness in the area of interest.
[0071] In another embodiment of the present invention, the shelf life stability of the delivery system is at least 1 year, 2 years, 3 years, 4 years, 5 years but preferably up to at least 3 years and more preferably up to 5 years. In such assessment, the shelf-life stability is the degree of degradation of the original topical anesthetic compounds. In another embodiment, the stability is defined as any value that is higher than 15% percent degradation of the anesthetic compound during the storage period at temperature ranging from 15-28° C., but preferably at room temperature and atmospheric pressure. In a preferred embodiment, the corresponding anesthetic content does not degrade by more than 5% by weight of the initial amount after storage at room temperature for at least 5, 4, 3, 2, or 1 year(s), in the most preferred embodiment, the degree of degradation of the anesthetic is less than 1%
[0072] In one embodiment, the present invention, the system is designed to keep the anesthetic formulation stable for at least 2, 3, 4, or 5 years at room temperature under atmospheric pressure. In a most preferred embodiment, the content of the anesthetic compound does not degrade by more than 1% for at least 3 years.
[0073] According to an additional aspect of the present invention there is provided a method of delivering a topical anesthetic made by the process for using the two-chamber delivery system as well as methods of stabilizing an aqueous anesthetic composition using the presently described two-chambered delivery system.
[0074] According to still further features in the described preferred embodiments the final form of the composition is selected from the group consisting of an aqueous solution, emulsion, an oil, a gel, a lotion, a suspension, a powder, an aerosol, a spray, and a foam.
[0075] In a preferred embodiment, the present invention is directed to a topical, transdermal anesthetic preparation comprising (with all percentages being by weight) at least one of: about 1-15% cocaine, 1-15% lidocaine; about 1-5%, prilocaine; about 0.1-1.0% dibucaine; with or without about 0.1-2.0% as effective for local vasoconstriction, of a sympathomimetic amine, such as phenylephrine.
[0076] It will be apparent to those of skill in the art that many modifications can be made to the delivery system described immediately above without taking the final product outside the scope of the present invention. For example, the actuating means can comprise, in place of a means for applying hydraulic pressure to the contents of the upper chamber, a substantially rigid member that, when a downward force is applied to the cap assembly or a portion thereof, transmits the force directly to the septum or plug separating the upper and lower chambers. Applicator can be positioned in a manner to maximize integrity of the system without causing leakage or exposure of the product to the outside environment. Other two-chamber devices that can be substituted include those described, for example, in the patents individually listed below, each incorporated herein by reference. Other than the anesthetic compound can be in a piggyback structure of flexible polymeric structure.
[0077] To enhance the shelf-life stability, the drug particles are preferably very small, for example having a mean particle size smaller than about 0.01 microns to about 500 microns. It is sometimes desirable that the drug be micronized, i.e., reduced to an average particle size of about 1 to about 50 microns. Optionally all or a portion of the drug can be in nanoparticulate form, i.e., having an average particle size smaller than 1 microns.
[0078] In another embodiment, the product can contain at least one additive ingredient to act as wetting agent, suspending agents, emulsifier, surfactants, pH stabilizer, buffer, or other excipients in an amount effective to provide a product having a shelf life of at least 1 year, preferably at least 2, 3, 4, 5, 6, 7 or 8 years.
[0079] Example of such agents include without limitations polyethylene glycols (PEGs) with average molecular weight from about 100 to about 20,000, more typically about 200 to about 10,000. Suitable PEGs include PEG 2000, having an average molecular weight of 1800 to 2200, PEG 3000, having an average molecular weight of 2700 to 3300, PEG 3350, having an average molecular weight of 3000 to 3700, PEG 4000, having an average molecular weight of 3000 to 4800, and PEG 4600, having an average molecular weight of 4400 to 4800. Other agents further include poloxamers (polyoxyethylene-polyoxypropylene copolymers), illustratively of grades listed in the United States Pharmacopeia such as poloxamers 124, 188, 237, 338 and 407.
[0080] Emulsifiers or surfactants can include surfactants having a hydrophobic alkyl or acyl group, typically of about 8 to about 18 carbon atoms, and a hydrophilic polyoxyethylene chain. Preferred such surfactants are nonionic surfactants, illustratively including polyoxyethylene alkyl ethers such as laureth-9, laureth-23, ceteth-10, ceteth-20, oleth-10, oleth-20, steareth-10, steareth-20 and steareth-100; polyoxyethylene castor oil, polyoxyethylene hydrogenated castor oil, polysorbates such as polysorbate 20, polysorbate 40, polysorbate 60, polysorbate 65, polysorbate 80, polysorbate 85 and polysorbate 120; and polyoxyethylene alkyl esters, for example polyoxyethylene stearates. Polysorbates, for example polysorbate 80, are particularly preferred in such concentration as low as about 0.5 to about 10 mg/ml, typically about 1 to about 5 mg/mL.
[0081] The formulation can further contain antioxidants such as tocopherols (vitamin E), ascorbic acid (vitamin C) and salts and esters thereof, butylated hydroxytoluene (BHT), thiol derivatives including acetylcysteine, cysteine cystine, dithioerythritol, dithiothreitol, glutathione, methionine and thioglycerol, especially L-methionine, fimaric acid and salts thereof, hypophosphorous acid, malic acid, and L-methionine, typically in a total concentration of about 0.1 to about 50 mg/mL, preferably about 0.2 to about 20 mg/mL, and more preferably about 0.5 to about 10 mg/mL. Illustratively, L-methionine can usefully be present at a concentration of about 1 to about 5 mg/mL.
[0082] The formulation optionally further comprises a chelating agent. Optionally, the formulation can comprise, in addition to components described hereinabove, excipients such as those mentioned below. One or more additional wetting and/or suspending agents, can optionally be present. Such agents include polyvinylpyrrolidone (PVP), for example PVP having a molecular weight of about 2,000 to about 54,000, such as PVP K12, K17, K25 and K30, and surfactants such as phospholipids (e.g., lecithin), cationic surfactants (e.g., myristyl .gamma.-picolinium chloride), anionic surfactants (e.g., sodium lauryl sulfate), etc. One or more thickening or viscosity adjusting agents can optionally be present, for example cellulosic polymers (e.g., methylcellulose, carboxymethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose), gelatin and gums (e.g., acacia).
[0083] One or more preservatives can optionally be present, for example phenol, chlorobutanol, benzyl alcohol, methyl paraben, propyl paraben, sodium benzoate, benzalkonium chloride and cetylpyridinium chloride. One or more tonicity adjusting agents can be present, for example sodium chloride, sodium sulfate, dextrose, mannitol and glycerol. One or more buffering agents can optionally be present, for example buffers derived from acetic, aconitic, citric, glutaric, lactic, malic, succinic, phosphoric and carbonic acids. Typically such a buffer is an alkali or alkaline earth metal salt of such an acid. Phosphate and citrate buffers such as sodium phosphate and sodium citrate are preferred. In another embodiment, the buffering system may comprise sodium or potassium bicarbonate, chloride, acetate salts to alleviate pain at the site of injection.
[0084] Preferably the final composition of the invention has a pH of about 3 to about 7.5. An advantage of the invention is that pH of the composition can often be controlled within a narrower range. For example, in a cocaine composition as described herein, pH can typically be controlled within a range of about 3 pH to about 7.5 more preferably within a range of about 4 to about 7. In one embodiment, the composition comprise a blend of cocaine, a buffer system, and a bicarbonate salt.
[0085] In a preferred embodiment the final formulation contains an anesthetic compound in concentrations ranging from about 0.1% to about 25% weight. In another embodiment, such a concentration ranges from about 0.5% to about 15%. In a more preferred embodiment, such concentration is from 0.75% to 10%. For example, at least one such formulation is a 4% cocaine solution prepared immediately prior to use and had at least a 3 year shelf life before being reconstituted into the final solution. Solubility in water for many pharmaceutically useful compounds can be readily determined from standard pharmaceutical reference available in the art. The most preferred embodiment of the present invention is to providing stable formulations for compounds that are very soluble in the intended solvent system employed in the art. Cocaine HCl is the prime candidate of such compounds. Typically the cocaine salt powder used in the delivery system is highly solubility in water, for example having a solubility of at least 10 mg/mL or more.
[0086] In one embodiment, the anesthetic is cocaine to be administered topically. In this case, the cocaine is cocaine hydrochloride USP in crystalline, granular or powder form having a saline, slightly bitter taste that numbs tongue and lip. In a more preferred embodiment cocaine is present in concentrations of about 0.1% to about 25% in the final mixture. In a more preferred embodiment the concentration of the anesthetic is up to about 15% in the final mixture. In a more preferred embodiment, the solution may contain citric acid and sodium benzoate. In a more preferred embodiment, the external surface of unopened delivery system may be sterilized by ethylene oxide, but not steam autoclave.
[0087] In another embodiment, cocaine is present in a concentration of about 0.001 to about 50 mg/mL, preferably about 0.01 to about 10 mg/mL. In the case of tetracaine, the concentration of the active ingredient is between 0.1 to about 10 mg/mL, preferably about 0.5 to about 10 mg/mL. When both cocaine and tetracaine are present, the concentrations of the individual drugs are typically as given above. In the case that epinephrine is added to the powder, it can be in concentration of about 0.001 to about 2 mg/mL, preferably about 0.1 to about 0.2 mg/mL.
[0088] In another embodiment, the present system is formed in a chamber having a volume ranging from 0.5 mL to 50 mL. In one embodiment, the system offers a volume of about 10 mL dispensable as a solution delivered by in the form of a spray.
[0089] In yet another embodiment, the present system generates air anesthetic formulation free of any preservative consist essentially of a sterile anesthetic compound such as the cocaine, a stabilizer, and a solvent. In yet another embodiment, the system provides for a formulation that only consists of the anesthetic compound such as cocaine, an additive, a stabilizer, and the suitable solvent.
[0090] The present delivery system offers less opportunity for improper appropriation of the cocaine powder. In at least one embodiment of the present invention, the chamber is made of darker glass material to protect the anesthetic powder and/or the final solution from exposure to the sun light and potential degradation.
[0091] The abuse resistant feature of this invention may be provided by incorporating surfactants, additives or stabilizers into the anesthetic mixture. In at least one embodiment, a suitable surfactant for example may be mixed with the anesthetic by the way of milling, blending, spray drying, coemulsifying, or melting a surfactant, an additive or a stabilizer with the anesthetic compound. In a more preferred embodiment, the surfactant, additive or stabilizers can be adsorbing on the surface of the anesthetic particles, so that separating the anesthetic compound from such ingredients would not be readily achievable.
[0092] In another embodiment, the anesthetic compound is made more lipophilic by elimination reduction of the overall charge of the anesthetic compound. For example, a water soluble salt may be converted to a free base or free acid. In another embodiment, fatty acids or alcohols may be used to convert the water-soluble compound to a lipophilic construct. In yet another embodiment, the anesthetic compound may be coated with a water insoluble polymer.
[0093] According to one aspect of the present invention, the delivery system is a two-chamber vial. In at least this aspect of the invention, an anesthetic liquid formulation is prepared in at least one of the chambers just prior to use. In another aspect of the invention, at least one of the chambers contains a plurality of anesthetic compounds in powder, crystal, particulate or nanocrystal forms and the other chambers contains a suitable solvent for dissolving such anesthetic compounds.
[0094] In another embodiment, the chambers may include a tamper resistant means for example, a protective member to be removed or at least transferred into a release configuration, thereby giving way to the actuation means. In one embodiment, the removal or displacement of the protective member is only possible after the breakable seal is split open or destroyed. Thus, by coupling protective member and housing by means of a breakable seal, a tamper-evident closure means can be provided for a two-chamber system indicating, whether the system has been tampered or not.
[0095] In yet another aspect of the present invention, the anesthetic composition of the present invention contains an anesthetic selected from any one of the following compounds tetracaine, lidocaine, benzocaine, pramoxine, dibucaine, butacaine, cocaine, mepivicaine, bupivicaine, levobupivicaine, ropivicaine, etidocaine, prolicaine, articaine, procaine, chloroprocaine, salts or other suitable pharmaceutically acceptable forms thereof including free acid or base, alone or in combination with each other. In a more preferred embodiment the anesthetic is tetracaine, benzocaine, cocaine, bupivacaine, ropivicaine salts or other suitable pharmaceutically acceptable forms thereof and at least any one of the following secondary agents such as epinephrine, a stabilizer such as bicarbonates, a pH adjuster including suitable acids or bases as described above and oxymetazoline, or xymetazoline or both oxymetzoline and xymetazoline.
EXAMPLE
[0096] The following examples illustrate aspects of the present invention but are not to be construed as limitations.
Example 1
[0097] Samples of commercial cocaine topical formulation were prepared according to the process below. The cocaine delivery system of the present invention contained an upper chamber containing saline, and a lower chamber containing a dry mixture of cocaine HCl salt, sodium benzoate and citric acid formulation respectively in amounts, cocaine 4%, sodium benzoate 0.01 and citric acid 5%.
[0098] In this embodiment, the lower chamber and upper chamber of delivery system are separated at the center with a septum plug that is inserted into the neck constriction that exist between the two chamber and the solvent is placed in the upper chamber 120 , 220 , 320 , all in a well-known manner. During the manufacturing process, the stopper is inserted into the neck of the upper chamber so that the enlarged stopper portion seals and engages the inner wall of the opening in the upper chamber. The cap and the securing system is positioned on the assembly so as to secure the stopper and the chambers themselves
[0099] At least one embodiment of the present invention is shown in FIG. 1 . In this embodiment, the protective means is positioned so that the stopper portion 126 is received within the upper chamber. During the initial mounting of the protective means on the delivery system, the lower edge of the securing portion 125 is deformed so as to pass over the rim 129 and the cap snaps inwardly beneath the rim to be secured to the upper chamber. The stopper is thus positioned as illustrated in Figure, wherein the upper end of the stopper portion 126 is spaced downwardly from the upper end of the actuating means.
[0100] When it becomes desirable to use the cocaine product, the two-chamber vial is gripped within the hand so that the thumb can press against the upper end of the upper chamber. By urging the stopper toward the vial with the thumb, the connection between the tip of the stopper and the upper chamber is initially fractured and the stopper moves downwardly toward the center of the upper chamber. During this initial movement of the stopper, a locking mechanism at the upper neck may be activated along the stopper's ending until a locking ring engages in the manner to halt the stopper from going down any further. Continued downward depression of the sleeve portion may result in the stopper being pressed downwardly into the vial would not likely create any more hydraulic pressure than what has already been created within the upper chamber respectively forcing the septum plug 140 , 240 out of the neck constriction 130 or 230 so that the solvent can move into the lower chamber and mix with the anesthetic dry powder.
[0101] When the stopper 126 , 226 is depressed, it dislodges interchamber seal allowing the cocaine powder to mix with the aqueous solution. One advantage associated with this method of forming a cocaine solution is that the aqueous phase can be instilled first and sterilized separately for example via autoclaving or other means. This will prevent potential microbial growth in the aqueous phase prior to sterilization. In the case of using a plunger instead of a stopper, the depression of the sleeve plunger 331 passes through the opening in the upper chamber and causing the dislodging of the interchamber septum. Once the plunger is hilly depressed as indicated above, the solvent and the anesthetic powder can be freely mixed to provide a ready to use solution.
[0102] Various embodiments of the present invention provide surprising advantages. A spray dried starch formulations provide prolonged in-vial stability, particularly when the molecular weight of the starch is over about 500,000. The use of two-chamber vials with water providing an additional seal for the formulation and provide increased shelf life, and greater use convenience.
[0103] In another embodiment the contents of one commercial product vial were transferred into an applicator to provide a large surface area of application. In another embodiment, the contents of the commercial product vials were prepared into a single kit or box for delivery that can sit on the shelf for at least 3 years without losing any more than 10% of the active ingredient and/or any bacterial contamination.
[0104] Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | The present invention is directed to a multi-chamber delivery system of a topical anesthetic formulation for improving the stability of such anesthetic compositions. Topical anesthetics formulations have long been used for providing analgesia prior to any invasive medical procedure. Their use is essential for performing diagnostic, therapeutic, and cosmetic dermatology procedures. Topical anesthetics can be formulated in variety of dosage forms and mixtures such as solutions, creams, ointments, gels, and even patches and peels. | 0 |
[0001] This application is based on and claim priority under 35 U.S. C. § 119 with respect to Japanese Application NO. 2001-160471 filed on May 29, 2001, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention generally relates to a torque transmission device. More particularly, the present invention pertains to a torque transmission device which is applied as an operational force transmission mechanism of a window regulator and a height adjustment device of a vehicle seat, in which an output shaft can be rotated for transmitting the rotation from the operation side to the device and the output shaft cannot be rotated from the device side.
BACKGROUND OF THE INVENTION
[0003] A known torque transmission device for achieving foregoing characteristics is disclosed in U.S. Pat. No. 5,460,253. The known torque transmission device according to the U.S. Pat. No. 5,460,253 includes an inside ring connected to a fixed member, an outside ring positioned keeping a clearance from the inside ring, two pairs of rollers positioned in the clearances between the outside ring and the inside ring, a spring positioned between the pair of rollers for increasing the distance between the rollers, a pawl portion inserted from a hole provided on a side wall of the outside ring for sandwiching the pair of rollers from the different side from the spring, an operation lever rotatably supported on a circumference of the inside ring, and a shaft fixed to the outside ring and positioned to be penetrated into a bore of the inside ring. The clearance between the inside ring and the outside ring includes a gradually narrowed portion. The spring provided between the pair of rollers pushes each roller towards the narrowed clearance. According to the torque transmission device with this construction, the large load is generated between the rollers and the inside ring and the outside ring by the wedge effect to obtain the large frictional force accompanied with the load. Thus, the relative rotation between the inside ring and the outside ring is checked strongly. When the torque transmission device with the foregoing construction is assembled to an application device for providing the rotational torque, a stress on the shaft of the torque transmission device is caused by a gear of the application device. The rotational torque is transmitted from the shaft to the outside ring, notwithstanding, the shaft is not rotated because the relative rotation between the outside ring, the roller, and the inside ring is strongly checked and the inside ring is connected to the fixed member.
[0004] On the other hand, when the operational lever is operated, the pawl portion displaces the roller to be released from the condition sandwiched in the clearance between the inside ring and the outside ring against the biasing force of the spring. The operational lever also has a construction for rotating the shaft with lighter operational force by rotating the outside ring by the contact between the pawl portion and the hole on the outside ring side wall.
[0005] According to the foregoing known torque transmission device with the construction for locking the outside ring and the inside ring by sandwiching the roller in the clearance between the outside ring and the inside ring, the respective rings and the roller are in line contact each other when the torque is transmitted from the outside ring to the inside ring via the roller. The large stress is generated because the load is concentrated on the contacted line portion. In addition, because the inside ring, the outside ring and the roller under operation contact each other at approximately the same position on every checking operations, the wear-out of the inside ring and the outside ring is increased.
[0006] A need thus exists for a torque transmission device which does not cause the concentration of the load applied to the inside ring and the outside ring and achieves high durability.
SUMMARY OF THE INVENTION
[0007] According to one aspect, A torque transmission device comprises an inside support member having a first contact surface portion positioned on an outer periphery of the inside support member, an outside support member having a second contact surface portion positioned on an inner periphery of the outside support member, a first holding portion in which a clearance between the first contact surface portion and the second contact surface portion is gradually decreased in one peripheral direction, a second holding portion in which a clearance between the first contact surface portion and the second contact surface portion is gradually decreased in the other peripheral direction, a pair of interposition members which is supported on the first holding portion and the second holding portion respectively, an elastic member positioned between the pair of interposition members for biasing each interposition member in a direction in which the each clearance of the first and the second holding portion is decreased, an operation member for moving one of the pair of interposition members in a direction for increasing the clearance of the first or the second holding portion against a biasing force of the elastic member.
[0008] Each interposition member comprises a third contact surface portion being in surface contact with the first contact surface portion and a fourth contact surface portion being in surface contact with the second contact surface portion.
[0009] According to another aspect, a torque transmission device comprises an inside support member having a first contact surface portion positioned on an outer periphery of the inside support member, an outside support member having a second contact surface portion positioned on an inner periphery of the outside support member, a first holding portion in which a clearance between the first contact surface portion and the second contact surface portion is gradually decreased in one peripheral direction, a second holding portion in which a clearance between the first contact surface portion and the second contact surface portion is gradually decreased in the other peripheral direction, a pair of interposition members which is supported on the first holding portion and the second holding portion respectively, an elastic member positioned between the pair of interposition members for biasing each interposition member to a direction in which the each clearances of the first holding portion and the second holding portion is,decreased, an operation member for moving, one of the pair of interposition members to a direction in which the clearance of the first or the second holding portion is increased against a biasing force of the elastic member, a gear formed on the inside support member for transmitting an operational force to an external device, a shaft inserted through the inside support member, the operation member, the outside support member, and an operation handle, for transmitting the operational force from the operational handle to the external device.
[0010] Each interposition member comprises a third contact surface portion being in surface contact with the first contact surface portion and a fourth contact surface portion being in surface contact with the second contact surface portion.
[0011] According to further aspect, a torque transmission device comprises an inside support member having a first contact surface portion positioned on an outer periphery of the inside support member, an outside support member having a second contact surface portion positioned on an inner periphery of the outside support member, a first inclined surface provided on the inside support member, the first inclined surface gradually increasing a height in one peripheral direction, a second inclined surface provided on the inside support member, the second inclined surface gradually increasing a height in the other peripheral direction, a pair of interposition members which are disposed on the first inclined surface and the second inclined surface, an elastic member positioned between the pair of interposition members for biasing each interposition member to a direction in which each clearances between the inside support member and the outside support member at the first and the second inclined surface is decreased, an operation member for moving one of the paired interposition members to a direction in which the clearance between the inside support member and the outside support member at the first and the second inclined surface is increased selectively against a biasing force of the elastic member, a gear formed on the inside support member for transmitting an operational force to an external device, a shaft inserted through the inside support member, the operation member, the outside support member, and an operation handle, for transmitting the operational force from the operational handle to the external device.
[0012] Each interposition member comprises a third contact surface portion being in surface contact with the first contact surface portion and a fourth contact surface portion being in surface contact with the second contact surface portion.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0013] The foregoing and additional features and characteristics of the present invention will become more apparent from the following detailed description considered reference to the accompanying drawing figures in which like reference numerals designate like elements.
[0014] [0014]FIG. 1 is an exploded perspective view of a torque transmission device according to an embodiment of the present invention.
[0015] [0015]FIG. 2 is a plane view of the torque transmission device according to the embodiment of the present invention.
[0016] [0016]FIG. 3 is a cross-sectional view of a central portion of the torque transmission device according to the embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] An embodiment of a torque transmission device according to the present invention will be explained referring to FIGS. 1 - 3 as follows.
[0018] A torque transmission device 1 includes a housing 20 . The housing 20 is formed with a space portion 2 by a cylinder portion 25 , one end thereof is blocked up with a longitudinal wall surface portion 26 , and the other end thereof is open. A bearing hole 22 is formed on the central portion of the longitudinal wall surface portion 26 . A flange portion 24 outwardly extended in radial direction is formed on the open end side of the cylinder portion 25 . The flange portion 24 includes plural fitting holes 23 which are used for installing the torque transmission device 1 to an application device 80 (FIG. 3).
[0019] An operation plate 30 is positioned at a bottom portion closest to the longitudinal wall portion 26 in the back of the space portion 2 of the hosing 20 . The operation plate 30 is formed with a plane plate in a circular shape whose diameter is slightly smaller than an internal diameter of the cylinder portion 25 . Four recess portions 32 with a predetermined width are provided on the periphery of the operation plate 30 . A hole 33 is formed on the central portion of the operation plate 30 . The hole 33 includes a pair of plane surfaces 33 a which are opposed and in parallel each other.
[0020] A shaft 10 which is provided with a stepped portion 12 having portions 12 a with plane surfaces in parallel each other so that the stepped portion 12 may be engaged with the hole 33 to fix the shaft 10 in the hole 33 . The shaft 10 is inserted into the hole 33 and penetrating the bearing hole 22 of the housing 20 . The shaft 10 is formed with a large diameter shaft portion 11 for rotatably supporting one side of the shaft 10 to the housing 20 . The shaft 10 includes a projecting portion on one end portion formed with a serration 15 with plural slits extended in axial direction. The serration 15 projects to the outside of the housing 20 when the shaft 10 is assembled in the housing 20 . An operation handle 90 (shown in FIG. 3) for operating the shaft 10 is fixed on the serration 15 by engaging another serration formed on an internal surface of the operation handle 90 . A boss portion 13 contacting the stepped portion 12 is formed on the shaft 10 . A small diameter shaft portion 14 is formed on the other end portion of the shaft 10 opposite to the serration 15 .
[0021] A disc shaped inside support member 50 is positioned on the portion closest to the open end side of the space portion 2 of the housing 20 . The external diameter of the inside support member 50 corresponds to the size which is fitted into the internal diameter surface 21 of the cylinder portion 25 , of the housing 20 and is rotatably supported. A gear 53 is integratedly formed on one side surface of the inside support member 50 in axial direction to be projected to the outside of the space portion 2 . The gear 53 is, for example, provided to be geared with an operational gear 70 of a seat height adjustment device 80 (shown in FIG. 3) for operating the seat height adjustment device 80 . A ring portion 58 is formed on the other side surface of the inside support member 50 to be projected in axial direction in the space portion 2 . The internal diameter of the ring portion 58 includes a shape for accommodating the boss portion 13 of the shaft 10 . As shown in FIG. 2, the outer profile of the ring portion 58 includes four inclined surfaces 51 symmetric with respect to the center of the ring portion 58 . The four inclined surfaces 51 are provided on the-top-right, top-left, bottom-right, and bottom-left of the ring portion 58 of FIG. 2. Two inclined surfaces 51 , 51 on the right side of FIG. 2 make a pair of the inclined surfaces 51 , 51 and the other two inclined surfaces 51 , 51 on the left side of FIG. 2 make an another pair of inclined surfaces 51 , 51 . The inclined surfaces 51 , 51 of the pair are connected via a connecting portion 51 a therebetween. The inclined surfaces 51 , 51 have the largest clearance relative to the internal diameter surface 21 of the cylinder portion 25 of the housing 20 at the position of connecting portions 51 a. Each inclined surface 51 shown on the top right and on the bottom left of FIG. 2 has a shape whose clearance relative to the internal diameter surface 21 is gradually reduced in the counterclockwise direction. The clearance of each inclined surface 51 shown on the top left and on the bottom right of FIG. 2 relative to the internal diameter surface 21 is gradually reduced in the clockwise direction. In other words, the height of each inclined surface 51 in radial direction is gradually increased in the counterclockwise direction regarding the inclined surfaces 51 , 51 on the top right and the bottom Left of FIG. 2. And the height of each inclined surface 51 in radial direction is gradually increased in the clockwise direction regarding the inclined surfaces 51 , 51 on the top left and bottom right of FIG. 2. Peripheral length of each inclined surface 51 corresponds to a sector of 50 degrees. As shown in FIG. 2, a stepped diameter portion 56 with arc shaped surface is formed on a position closer to the center of the ring portion 58 compared to the inclined surface 51 between each pair of inclined surfaces 51 , 51 positioned on the right and left of FIG. 2. A shoulder portion 55 is formed on the boarder between the inclined surface 51 and the stepped diameter portion 56 .
[0022] As shown in FIG. 2, four interposition members 40 are placed in a holding portion 51 b formed between the internal diameter surface 21 of the cylinder portion 25 of the housing 20 and each inclined surface 51 . The interposition members 40 contact the inclined surfaces 51 for covering each pair of the inclined surfaces 51 . Each interposition member 40 includes an inside contact surface 44 contacting the corresponding inclined surface 51 within the range up to approximately 40 degrees. A projecting portion 42 is formed on one end portion of the interposition member 40 which is engageable with the shoulder portion 55 . Normally, the projecting portion 42 is positioned keeping a small clearance “d” from the shoulder portion 55 . The interposition member 40 contacts on the inclined surface 51 and contacts on the internal diameter surface 21 by an outside contact surface 45 . The interposition member 40 is tightly contacted on both of the inclined surface 51 and the internal diameter surface 21 simultaneously, because the interposition member 40 has a wedge shape whose width is gradually narrowed.
[0023] As shown in FIG. 2, springs 60 for affecting of increasing the distance between the paired interposition members 40 are positioned between the paired interposition members 40 between the outer surface of the ring portion 58 and the internal diameter surface 21 of the cylinder portion 25 . The spring 60 is a W-shaped leaf spring, and is always pushing the interposition members 40 by contact portions 61 on the both sides of the spring 60 to the direction in which the clearance between the inclined surface 51 and the internal diameter surface 21 is decreased. The pushing force of the spring 60 generates the large pressing load on both of the ring potion 58 and the cylinder portion 25 by the wedge effect. Thus, the housing 20 and the ring portion 58 are strongly fixed via the interposition members 40 by the frictional force accompanied by the large pressing load.
[0024] Projections 41 projecting to be respectively inserted into four recess portions 32 formed on the periphery of the operation plate 30 is formed in the approximately center of the interposition members 40 . The width of the projection 41 is narrower than the width of the recess portion 32 . The projection 41 is positioned to be opposing to an end surface of the recess portion 32 keeping a small clearance “e” on one side and leaving the large clearance on the other side. Each clearance “e” is positioned for the operation plate 30 to contact one side of the projection 41 for pushing the interposition member 40 to the direction in which the clearance between the inclined surface 51 and the internal diameter surface 21 is increased. When the operation plate 30 is rotated to either the clockwise direction or the counterclockwise direction of FIG. 2 more than the angle corresponding to the clearance “e”, the interposition member 40 is moved along the inclined surface 51 by the rotation of the operation plate 30 . Then the tight contact between the inclined surface 51 and the internal diameter surface 21 is released because the interposition member 40 is pushed to the direction in which the clearance between the inclined surface 51 and the internal diameter surface 21 is increased.
[0025] As explained above, the operation handle 90 is connected to the operation plate 30 via the shaft 10 . When the operation handle 90 is rotated, the operation plate 30 and one of the interposition members 40 of the paired interposition members 40 , 40 are contacted to be rotated. Thus, the tight contact of one of the interposition members 40 of the paired interposition members 40 , 40 relative to the inclined surface 51 and the internal diameter surface 21 is released. When one of the paired interposition members 40 , 40 is moved by the clearance “d”, the corresponding projection 42 provided on the interposition member 40 engages with the corresponding shoulder portion 55 of the ring portion 58 for rotating the ring potion 58 in the rotational direction of the operation handle 90 . By the rotation of the ring portion 58 relative to the housing 20 , the clearance between the inclined surface 51 and the internal diameter surface 21 which are sandwiching the other interposition member 40 of the paired interposition members 40 , 40 which does not contact on the operation plate 30 increases. Thus, the tight contact of the other interposition member 40 of the paired interposition members 40 , 40 relative to the inclined surface 51 and the internal diameter surface 21 is also released. Accordingly, the tight contact at all four positions is released. The gear 53 integratedly formed on the ring portion 58 can be rotated by the light rotational operation force by the operation handle 90 .
[0026] The operation of the torque transmission device 1 with the forgoing construction applied to, for example, the seat height adjustment device 80 . The seat height adjustment device 80 includes the gear 70 for operating the mechanisms (not shown) which is geared with the gear 53 of the torque transmission device 1 . The occupant of the seat operates the operation handle 90 in order to achieve the appropriate seat height for rotating the gear 70 and for operating the mechanism of the seat height adjustment device 80 . Load generated in the mechanism due to such as vibration during the vehicle running is transmitted to the gear 53 , the appropriate height is maintained by the strong biding force between the interposition members 40 and the housing 20 and the ring portion 58 which construct the torque transmission device 1 .
[0027] Although the seat height adjustment device 80 is applied in this embodiment, a window regulator device or other devices may be applied as the application device 80 .
[0028] According to the torque transmission device of the embodiment of the present invention, because of the strong biding force of the inside support portion and the outside support portion relative to the interposition member which are contacted via surfaces, the generation of the large stress on the inside support portion, the outside support portion and the interposition member are prevented by avoiding the concentration of the load on the contact portions. Thus, the torque transmission device which excels in high durability with less wear-out is achieved. In addition, because the interposition member includes the integratedly formed engagement portion which is enagegable with the inside support portion, the number of the parts is reduced, thus the strong torque transmission device is achieved with less manufacturing cost.
[0029] The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. However, the invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. Variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations, changes and equivalents which fall within the spirit and scope of the present invention as defined in the claims, be embraced thereby. | A torque transmission device which can rotate an output shaft for transmitting the rotation from the operation side to he device and cannot rotate the output shaft form the device side. The torque transmission device excels in the durability with less wear-out by preventing the generation of the load concentration by the line contact of each component. | 5 |
This application is a continuation of application Ser. No. 08/408,280, filed Mar. 22, 1995, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image forming apparatus having a separating means for separating a recording sheet from a movable member, and more particularly, it relates to an image forming apparatus for forming an image on a recording sheet by transferring a toner image formed on an image bearing member onto a recording sheet supported by a movable member.
2. Related Background Art
There have been proposed color image forming apparatuses wherein a color image can be obtained by successively transferring different color toner images formed on a photosensitive drum onto a recording sheet supported by a transfer drum in a superimposed fashion. In such image forming apparatuses, a separation pawl interposed between the transfer drum and the recording sheet to separate the recording sheet from the transfer drum is made of metal, for example, iron.
However, when the separation pawl earthed is made of metal, since ions generated by peeling discharge between the recording sheet and the transfer drum are concentrated into an area where the metal pawl is positioned, there is a danger of distorting the non-fixed toner images transferred to the recording sheet. On the other hand, if the separation pawl is made of insulation resin, there arises risk that the non-fixed toner images transferred to the recording sheet are distorted due to friction charge between the separation pawl and the recording sheet.
Further, if the separation pawl is constituted by a metal pawl which is earthed, and a coating layer (coated on the metal pawl) made of insulation resin of fluoro-group, initially, the recording sheets can be separated from the transfer drum. However, in this case, a thickness of the coating layer of the insulation resin of fluoro-group must be reduced to prevent the friction charge between the recording sheet and the resin of fluoro-group (500 μm or less). Therefore, as the number of copies is increased, the coating layer is worn, thereby causing the same problem as the metal pawl.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an image forming apparatus having a separation means for separating a recording sheet from a movable member without distorting non-fixed toner image(s) transferred to a recording sheet.
Another object of the present invention is to provide an image forming apparatus including a separation means for effectively separating a recording sheet from a movable member high volume resistance.
The other objects and features of the present invention will be apparent from the following detailed description of the present invention explained with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a transfer drum (5a) and therearound for explaining an embodiment of the present invention;
FIG. 2 is an enlarged view showing a charged condition in a recording sheet peeled area, generated when a separation pawl is made of metal;
FIG. 3 is an enlarged view showing a charged condition in a recording sheet peeled area, generated when a separation pawl is made of insulation resin;
FIG. 4 is a table showing image quality, separability and strength regarding various pawl materials;
FIG. 5 is an explanatory view for explaining the recording sheet;
FIGS. 6A and 6B are views showing a recording sheet separation means; and
FIG. 7 is a schematic view showing a means for measuring a resistance value of the separation pawl.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An image forming apparatus according to an embodiment of the present invention will now be explained with reference to the accompanying drawings.
After a photosensitive drum (image bearing member) 1 is uniformly charged by a charger, light corresponding to image information is illuminated onto the photosensitive drum, thereby forming an electrostatic latent image on the drum. Then, the latent image is developed by toner from a developing means as a toner image. The toner image formed on the photosensitive drum 1 is transferred onto a recording sheet (for example, paper sheet) P supported by a transfer drum 5a. The above-mentioned image forming process is repeated with respect to magenta toner, cyan toner, yellow toner and black toner, respectively, so that the four different color toner images are successively transferred onto the recording sheet P in a superimposed fashion. Thereafter, the recording sheet P is separated from the transfer drum 5a, and the separated recording sheet is sent to a fixing device, where the four different color toner images are fused and mixed to obtain a full color image.
Next, a transfer device having the transfer drum will be fully explained.
In FIG. 1, a transfer sheet (recording sheet bearing member) 5f for electrostatically absorbing the recording sheet and for conveying the recording sheet in a direction shown by the arrow C is wound around a peripheral surface of the transfer drum 5a in such a manner that tip and rear ends of the transfer sheet 5f are adhered to a connecting member 5j of the transfer drum 5a. In the illustrated embodiment, the transfer sheet 5f is formed from a flexible PC (polycarbonate) film having a thickness of 150 μm and a volume resistance of 10 15 Ωcm or more, because an absorbing force for absorbing the recording sheet to the transfer sheet 5f is improved by using the dielectric film having high volume resistance as the transfer sheet. Accordingly, it is possible to use a thick sheet as the recording sheet and to increase a process speed by increasing a rotational speed of the transfer drum 5a.
The recording sheet P is supplied by a sheet supply means (not shown) from a direction shown by the arrow B. An absorb roller 5g is contacted with the transfer sheet 5f by a drive source (not shown) and absorb current (charge) is applied by an absorb charge brush 5c. Since the absorb roller 5g is electrically earthed, current (charge) having polarity opposite to that of the current (charge) applied by the absorb charge brush 5c is induced on the absorb roller, thereby electrostatically absorbing the recording sheet P to the transfer sheet 5f.
Then, current (charge) is applied from a positive high voltage source to a transfer brush 5b so that the toner image charge negatively is transferred from the photosensitive drum 1 onto the recording sheet as mentioned above. In the multi-transferring, the above transferring operation is repeated by desired times.
After the transferring operations are finished, the recording sheet is moved in a direction shown by the arrow A. When the recording sheet approaches an urging roller 8b, the urging roller 8b is driven by a drive means, thereby pushing up the transfer sheet 5f toward a separation pawl (separation member) 8a as shown in FIG. 5. In synchronous with this operation, the separation pawl 8a is operated by a drive means to be lowered toward the transfer sheet 5f as shown in FIG. 5. In this case, a separation pawl roller 8c is contacted with the transfer sheet 5f to prevent the transfer sheet from being damaged by a tip end of the separation pawl 8a. That is, as shown in FIG. 5, the transfer sheet 5f is deformed by the urging roller 8b so that a tip end of the recording sheet is peeled from the transfer sheet 5f. Then, when the recording sheet is shifted toward the separation pawl 8a, the recording sheet is separated from the transfer sheet by the separation pawl.
On the other hand, a separation electricity removal charger 5h shown in FIGS. 1 and 5 performs discharging operation during the recording sheet separating operation to assist the separation of the recording sheet and to neutralize ions generated due to peel discharge between the recording sheet P and the transfer sheet 5f, thereby preventing occurrence of uneven discharge.
After the separating operation is finished, a transfer sheet cleaner 16 is rotated by a drive motor (not shown) and is urged against the transfer sheet 5f by a drive means, so that the cleaner cooperates with a back-up brush 17 opposed to the cleaner 16 with the interposition of the transfer sheet 5f to remove the residual toner from the transfer sheet 5f. Further, an inner and outer electricity removal chargers 5d, 5e are operated before and after the series of absorbing, transferring and separation operations to electrically initialize the transfer sheet 5f.
Next, concrete values of various elements are shown.
A diameter of the transfer drum 5a is 180 mm and a moving speed of the transfer drum is 130 mm/sec. Further,
(i) Current of absorb brush I Q =15 μA
(ii) Current of transfer brush I T =10 μA
(iii) Output of separation electricity removal charger
AC V=12 kvpp
DC I s =300 μA
(if necessary)
(iv) Output of inner electricity removal charger
AC V=12 kVpp . . . (a)
DC I i =-200 μA
(v) Output of outer electricity removal charger
AC V=12 kVpp . . . (b)
DC I o =200 μA
Incidentally, the above (a) and (b) are sine waves having opposite phases.
The separation pawl 8a is made of polyester including dispersed carbon and having resistance of about 10 7 Ω. The resistance value of the separation pawl 8a was measured by applying voltage of 1 KV to the pawl having a thickness (d) of 6 mm, as shown in FIG. 7.
Further, as shown in FIGS. 6A and 6B, the separation pawl 8a is supported by a separation assist wing 8d for supporting the separation pawl 8a and for directing the recording sheet separated by the separation pawl toward the fixing device. The separation assist wing 8d is formed from iron coated for UV protection, if possible, grounded and is electrically. Incidentally, the separation pawl 8a may be made of polyamide having resistance of 10 3 to 10 11 Ω.
(Test 1)
The function of the separation pawl is to stably separate the recording sheet from the transfer drum 5a. Strictly speaking, the following three factors must be ensured; that is, (i) predetermined recording sheets should be stably separated (separability), (ii) the toner images on the recording sheet should not be distorted during the separating operation (image quality), and (iii) the separation pawl should not be damaged if the sheet jam occurs during the separating operation (strength).
In this test 1, in addition to the earthed separation pawl 8a made of resin having resistance of 10 7 Ω, as comparison examples, earthed metal Iron, earthed resin and earthed metal with fluoride coat were also used as separation pawls, respectively, to determine good (O) or bad (x) regarding the above three factors. The results are shown in FIG. 4.
Regarding the separability (i), recording sheets P having weights of 64, 80, 105, 128 and 157 gr/m 2 were used, respectively (in this case, if the poor separation occurred regarding even one sheet, the result was judged as bad (x)). In FIG. 4, regarding the recording sheet having weight of 64 gr/m 2 , the poor separation occurred. It was found that this phenomenon occurs because (although the tip end of the recording sheet could be separated) the separation pawl was penetrated into the recording sheet during the movement of the separated sheet (particularly, recording sheet having a large size, for example, A3 size).
Regarding the image quality (ii), toner scattering was checked at a position where the separation pawl 8a is disposed. When the separation pawl is formed from the earthed metal, a white stripe was generated at that position. The reason is that, as shown in FIG. 2, the ions generated due to the peel discharge between the recording sheet P and the transfer sheet 5f are concentrated onto the separation pawl 8a and the toner image on the sheet P is distorted by the ions. Further, since the charges generated due to the corona discharge from the separation electricity removal charger 5h are concentrated into the position where the separation pawl 8a is disposed, the image at that position is distorted. On the other hand, when the separation pawl is formed from the insulation resin, the arrangement of toner at a position where the pawl is disposed was delicately changed to generate a stripe pattern. The reason is that, as shown in FIG. 3, the non-fixed toner image on the recording sheet P is distorted by the friction charge between the pawl 8a and the recording sheet P. When the separation pawl is formed from metal with insulation fluoride coat, although the good result was obtained in the initial period, after about 500 sheets were copied, the fluoride coat was worn by the recording sheets P, the same problem as the metal separation pawl occurred.
The thickness of the fluoride coat must be reduced (less than 500 μm) to prevent the distortion of the non-fixed image due to the friction charge between the separation pawl 8a and the recording sheet P. When the transfer sheet 5f having high volume resistance (more than 10 15 Ωcm) is used as is in the illustrated embodiment, since the absorbing force between the transfer sheet 5f and the recording sheet P is great, the wear of the coating due to the contact between the coating and the recording sheet is also great.
However, according to the illustrated embodiment, since the thickness P (in FIG. 6) of the separation pawl 8a made of resin having resistance of 10 7 Ωis 3 mm or more and the entire separation pawl is formed from the resin having the resistance of 10 7 Ω, even when a large number of recording sheets are treated, the non-fixed toner image on the recording sheet P is not distorted.
Regarding the strength (ii), the poor separation of the thick sheet (having a weight of 157 gr/m 2 ) was forcibly occurred at the separation pawl 8a and damage of the pawl 8a was checked. When a width of the tip end of the separation pawl 8a in a direction (axial direction of the transfer drum 5a) perpendicular to the moving direction of the recording sheet P was 1 mm and the separation pawl was made of insulation resin, the separation pawl 8a was damaged by the resiliency of the recording sheet P. Similarly, when a separation pawl having a width of 1 mm and made of resin having resistance of 10 7 Ω was used, this pawl was also damaged by the resiliency of the recording sheet P.
On the other hand, when the separation pawl was made of metal, the transfer sheet 5f was damaged when the transfer sheet is contacted with the separation pawl 8a.
(Test 2)
The image quality was checked by changing the resistance value of the earthed separation pawl by varying an amount of carbon dispersed in the polyester resin. To this end, five kinds of separation pawls having resistance values of 10 3 , 10 6 , 10 9 , 10 11 and 10 13 Ωwere prepared.
Each separation pawl had a configuration as shown in FIGS. 6A and 6B and the resistance values were measured at a position where the thickness P is 6 mm in the manner as shown in FIG. 7.
As a result, although the separation pawls having resistance values of 10 3 , 10 6 , 10 9 , and 10 11 Ωachieved good result as is in the separation pawl having resistance of 10 7 Ω(test 1), the separation pawl having resistance of 10 13 Ω created a stripe pattern as is in the insulation resin pawl (test 1).
(Conclusion)
From the test result, the separation pawl 8a formed from earthed resin having resistance value of 10 3 to 10 11 Ω is optimum for the image quality. However, in order to obtain this resistance value, since conductive filler such as carbon is normally dispersed in the plastic, it is preferable that a width of the separation pawl 8a in a direction perpendicular to the moving direction of the recording sheet is 2 mm or more to ensure the strength and separability of the separation pawl. | An image forming apparatus includes a movable member carrying a recording sheet bearing a non-fixed image and a separation device for separating the recording sheet from the movable member. The separation device includes a peel member made from resin and having a resistance between 10 3 and 10 11 Ω) and an electricity removing charger. The peel member is supported by a support member and is positioned such that a part of the resin peel member is within the discharge area of the electricity removing charger and the support member is disposed outside the discharge area and is electrically grounded. | 8 |
FIELD OF THE INVENTION
This invention relates to an electronic information retrieval system and, more particularly, to an information retrieval system used in the musical field for searching details of musical compositions through an identifying key such as, for example, a composer.
DESCRIPTION OF THE RELATED ART
In general, a musical data file consists of a large number of books respectively assigned to, for example, musical compositions, and each of the musical compositions is accompanied with indexing key words indicative of some attributes such as a composer's name and a phrase featuring the musical composition. When an information retrieval system is fabricated for providing an access way to the musical data file, a user supplies an identifying key word representative of an attribute of one of the musical compositions, and the information retrieval system searches the data file for the musical composition accessed. The information retrieval system then provides pieces of musical information indicative of the musical composition through an appropriate interface, and, for this reason, the user is able to quickly obtain the necessary musical information.
However, no relative difference analyzer is provided in the prior art information retrieval system, and, therefore, a problem is encountered in that an average access time is relatively long whenever the user has merely a vague identifying key. For example, assuming now that the user needs to access pieces of stored musical information related to a Japanese composer "Oomachi", however, if the name is vague for the user and, accordingly, the user supplies an incorrect identifying key word indicative of "Ohmachi" or "Oomati", the user hardly accesses the necessary pieces of information, and, for this reason, needs to repeatedly try the access until the identifying key word is hit or match with the indexing key.
If a wildcard is available in the information retrieval system, the user can access the necessary pieces of information with an indexing key word such as "O*achi" or "O?machi" (where "*"or "?" is the wildcard indicative of the undefined character); however, the user thus accessing needs to be familiar with the wildcard, and should know the undefined character "o" in the correct character string "Oomachi". However, most of the users are not familiar with the wildcard, nor are they able to specify the undefined character. In this situation, the information retrieval system responsive to such an identifying key word with a wildcard never provides a solution, and most of the users respectively repeat the procedure or abandon the same through the information retrieval system.
SUMMARY OF THE INVENTION
It is therefore an important object of the present invention to provide an information retrieval system through which a user accesses necessary pieces of information even though an identifying key is not know precisely.
It is also an important object of the present invention to provide an information retrieval system which is easy for a user in the musical field.
To accomplish these objects, the present invention proposes to provide a relative difference analyzer in an information retrieval system.
In accordance with the present invention, there is provided an information retrieval system including a relative difference analyzer which comprises a) input means for providing a key word representative of a piece of identifying information, b) a data base including a data file having a plurality of books respectively having index records for storing respective pieces of attributive catalog information and detail data records for storing respective pieces of detailed data information, the pieces of attributive catalog information being associated with the pieces of detailed data information, respectively, c) analyzing means for searching the index records for relative differences of the piece of identifying information represented by the key word, each of the relative differences being partially identical with the piece of identifying information but partially different from the piece of identifying information, and d) indicating means for indicating the relative differences, if any.
In accordance with another aspect of the present invention, there is provided an information retrieval system for providing pieces of musical information including a relative difference analyzer, the relative difference analyzer comprising: a) input means for providing a key word representative of a piece of identifying information, the piece of identifying information being indicative of a musical attribute; b) a data base including a data file having a plurality of books respectively having index records for storing respective pieces of musical attributive catalog information and detail data records for storing respective pieces of detailed musical data information, the pieces of musical attributive catalog information being associated with the pieces of detailed musical data information, respectively, c) analyzing means for searching the index records for relative differences of the piece of identifying information represented by the key word, each of the relative differences being partially identical with the piece of identifying information but partially different from the piece of identifying information, and d) indicating means for indicating the relative differences, if any
If a user causes the input means 1 to supply a key word representative of a piece of identifying information, the input means 1 transfer the key word to the analyzing means 2 as shown in FIG. 1. With the key word, the analyzing means 2 access to the data file 3, and the pieces of the indexing information are sequentially read out to the analyzing means. The analyzing means 2 analyzes the pieces of indexing information to determine the relative differences between the indexing information and the key word. After the pieces of indexing information are thus examined, the relative differences, if any, are supplied to the indicating means for indication. Then, the user notices that the key word is incorrect, and can select the correct key word from the relative differences. This assistance is conducive to enhancing the access speed or decreasing the access time even though the user is not familiar with the electronic information processing technology.
The information retrieval system thus arranged may be used for searching for pieces of musical data information such as, for example, musical compositions, and each of the musical compositions may be provided with labels or indexes each indicative of an attribute of the musical composition such as the composer's name or a typical phrase featuring the composition.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of an electronic information retrieval system according to the present invention will be more clearly understood from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram showing the interrelation between the elements of the present invention;
FIG. 2 is a block diagram showing the arrangement of an information retrieval system embodying the present invention;
FIG. 3 is a view showing the layout of a musical data file to which a user can access through the information retrieval system shown in FIG. 2;
FIG. 4 is a view showing the layout of index tables used in the searching operation carried out by the information retrieval system shown in FIG. 3;
FIG. 5 is a view showing the relationship between bit positions and the letters in the alphabet used for producing a reference bit string;
FIG. 6 is a view showing the relationship between bit positions and the notes of a musical scale used for producing a reference bit string;
FIG. 7 is a flowchart showing a program sequence executed by a data processing section of the information retrieval system shown in FIG. 3;
FIG. 8 is a flowchart showing a program sequence of a preliminary analytic sub-routine program executed by the data processing section of the information retrieval system shown in FIG. 3; and
FIG. 9 is a front view showing a display unit where relative differences are indicated together with messages.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Arrangement of Hardware
Referring first to FIG. 2 of the drawings, an information retrieval system embodying the present invention largely comprises a key word input section 11, a data storage section 12, a data processing section 13 and a display section 14 which are analogous to the input means 1, the data file 3, data analyzing means 2 (together with a program sequence described hereinbelow) and the indicating means 4, respectively, and the four sections 11 to 14 are communicable with one another through a multi-bit bus system 15.
The key word input section 11 has a character keyboard unit 16 associated with a keyboard scan controlling unit 17 for detection of a keying-in on the character keyboard unit 16. The character keyboard unit 16 has a plurality of keys assigned to the alphabet and/or another set of characters, and the keys are periodically scanned by the keyboard scan controlling unit 17. While the controlling unit 17 scans the character keyboard unit 16, the keys depressed by a user are detected and identified by the controlling unit 17 through an execution of a certain software. However, such a scanning technology is well known in the art, so that no further description is incorporated hereinbelow. After the identification of the keys successively depressed, the keyboard scan controlling unit 17 codes the character string into a key word representative of a piece of identifying information, the piece of identifying information being, by way of example, indicative of a composer's name. Since the keyboard scan controlling unit 17 is coupled to the multi-bit bus system 15, the key word is relayed to the data processing section 13 therethrough.
A musical keyboard unit 18 is further incorporated in the data input section 11, and is also associated with a keyboard scan controlling unit 19. When a series of keys of the musical keyboard unit 18 are sequentially depressed by the user, the keyboard scan controlling unit 19 identifies the keys depressed, and produces another key word on the basis of the keys thus identified. The key word supplied from the musical keyboard unit 18 is representative of another piece of identifying information which in turn is indicative of a typical phrase featuring a musical composition. However, the key word may be indicative of the first phrase of a musical composition in another implementation. The keyboard scan controlling unit 19 is also coupled to the multi-bit bus system 15, and, accordingly, is transferred to the data processing section 13 similar to the key word supplied from the character keyboard unit 16.
The data storage section 12 is implemented by a hard disk or a magnetic disk 20a associated with a disk controlling unit 20b, and a musical data base is established in the hard disk 20a. The structure of musical data base is described hereinbelow in detail.
The data processing section 13 comprises a central processing unit 21 (which is abbreviated as "CPU" in the drawings), a data memory unit 22 implemented by random access semiconductor memory devices (which are abbreviated as "RAM") and a program memory unit 23 implemented by read only semiconductor memory devices (which are abbreviated as "ROM"), and these component units are communicable with one another through the multi-bit bus system 15. The program memory unit 23 stores a program sequence necessary for implementation of various functions such as arithmetic and logical functions, a data transfer function and so on which are used for implementing a relative difference analyzer. The central processing unit 21 executes the program sequence to achieve the relative differences as well as other jobs assigned thereto, and the data registers incorporated therein are assumed to be n bit in size in this instance. The data memory 22 provides a temporary data storage used on the way to achievement of the various jobs.
The display section 14 comprises a display unit 24 associated with a display controlling unit 25, and the display controlling unit is supplied from the central processing unit 21 with image signals indicative of character strings, and the character strings are indicative of messages and relative differences of a piece of identifying information supplied from either character or musical keyboard 16 or 18.
Structure of Data Base
The musical data base established in the hard disk unit 20a has a musical data file MDF and two index tables TBL1 and TBL2, and the layout of the musical data file MDF is shown in FIG. 3. Referring to FIG. 3, the musical data file MDF consists of a plurality of musical data books MDB1, MDB2, . . . . and MDBn, and all of the musical data books MDB1 to MDBn are identical in the structure with one another, so that description is made on the musical data book MDB1 only for the sake of simplicity.
The musical data book MDB1 has four records R1, R2, R3 and R4, i.e., a locative record R1, attribute records R2 and R3 and score record R4, and the attribute records R2 and R3 are assigned to pieces of musical attributive catalog information. In this instance, the attribute record R2 memorizes one of the pieces of musical attributive catalog information indicative of a composer's name, and the attribute record R3 is used for storing another piece of musical attributive catalog information indicative of a typical phrase of a musical composition. The full score of the musical composition is memorized in the score record R4, and a piece of locative information LCT1 is provided in the locative record R1. The typical phrase is selected from the musical composition in such a manner as to be the first phrase or a typical phrase featuring the musical composition.
The locative record R1 has a plurality of fields used for memorizing a piece of locative information, and one of the fields is assigned to a book name, but another keeps an address location where the piece of musical data information is memorized.
The attribute record R2 is also provided with a plurality of fields, and a coded composer's name and a reference bit string thereof are maintained in two of the fields. The composer's name is coded into the corresponding reference bit string for the sake of alignment with the data registers incorporated in the central processing unit 21, and, for this reason, each of the reference bit strings is equal in size to the data registers incorporated in the central processing unit 21. As described hereinbefore, each of the data registers is assumed to be n bit in size, and, for this reason, the reference bit string is also n bit in size. Thus, each of the composer's names is coded into the reference bit string equal in size to the data registers, so that the central processing unit 21 easily searches the index table TBL1 or TBL2 at a high speed as described hereinbelow with reference to FIG. 7. One of the musical data books contains
"Oomachi Ox-00005185 /usr /songs /eseq / 00000001.esp", Oomachi being a Japanese composer's name which is coded into the corresponding reference bit string "Ox-00005185" where Ox indicates that the bit string is in hexadecimal coding. A piece of information indicated by "usr" to "00000001.esp" is representative of a memory space where the coded name is memorized. The rule of coding are hereinafter described in detail.
The index tables TBL1 and TBL2 are provided in association with the musical data file MDF for making the searching operation easy, and are also memorized in the hard disk unit 20a. The layout of the first index table TBL1 is illustrated in FIG. 4, and the first index table TBL1 has a plurality of columns respectively assigned to the composer's names, the reference bit strings thereof and pieces of locative information LCT1, LCT2, . . . and LCTn used for linking the index table TBL with the music data file MDF. Each of the composer's names is linked with the corresponding reference bit string as well as with the piece of locative information, so that the central processing unit 21 can access the piece of musical data information by searching the index table TBL1 for the reference bit string corresponding to the composer's name as represented by the key word. Since the reference bit string is equal in size to the data registers, the searching operation consumes a relatively short time period.
The second index table TBL2 is similar in the layout to the first index table TBL1, and also has a plurality of columns respectively assigned to the phrases of the musical compositions, the reference bit strings thereof and the pieces of locative information LCT1 to LCTn. The piece of locative information is used for linking the index table TBL2 with the musical data file MDF. Each of the phrases corresponds to the reference bit string thereof and the piece of locative information. The central processing unit 21 also searches the second index table TBL2 within a relatively short time period, because the phrases are associated with the respective reference bit strings equal in the size to the data registers of the central processing unit 21.
Description is now made on the rule through which the composer's name and the phrase are coded into the respective reference bit strings. Assuming now that bit positions of 32-bit word are assigned to all of the letters in the alphabet, letter a is assigned the first bit position or the least significant bit, letter b is assigned the second bit position, and letter a is assigned the twenty-sixth bit position, so that the letters are related to the bit positions as indicated by Table 1.
TABLE 1______________________________________Bit Position Letter______________________________________First (The least significant bit) aSecond bThird c . . . . . .Eighth hNinth i . . . . . .Thirteenth m . . . . . .Fifteenth o . . . . . .Twenty sixth z______________________________________
According to the rule, component letters of a composer's name make the corresponding bit positions be "1", but any corresponding bit position of nonuse letter is allowed to be "0". Let us construct the reference bit string of the Japanese composer "Oomachi" in accordance with the rule. The component letters are "o" (twice), "m", "a", "c", "h" and "i", so that the first third, eighth, Ninth, thirteenth and fifteenth bit positions should be "1", but the other bit positions remain in "0" as shown in FIG. 5. The four bits from the right side are "0101" which is "5" in hexadecimal notation, and the fifth to eighth bits are "1000" which is "8" in hexadecimal notation, the ninth to twelve bits "0001" being represented as "1" in hexadecimal notation, the thirteenth to sixteenth bits "0101" as "5", but the other four bit groups are tantamount to "0" in hexadecimal notation. As a result, the Japanese composer "Oomachi" is coded into the reference bit string "00005185".
This rule is also applicable to another set of characters such as the Japanese cursive kana characters. The Japanese cursive kana character set consists of more than 32 characters, so that a part of the bit positions are assigned twice as shown in Table 2.
TABLE 2______________________________________Bit Position Character______________________________________First (The least significant bit) a and muSecond i and meThird u and mo . . . . . . . . .Thirty second mi______________________________________
In Table 2, the Japanese cursive kana characters are represented by using a method of writing Japanese in Roman characters. If the rule is applied to another Japanese composer "Rentaro", we obtain the corresponding reference bit string "00009804" in the hexadecimal notation.
The rule is further applied to a phrase consisting of a plurality of notes. In this application, the bit positions are assigned the notes of a musical scale, and Table 3 shows the correspondence between the bit positions and the notes.
TABLE 3______________________________________ Bit Position Note______________________________________ First C Second C♯ or D♭ . . . . . . Twelfth B______________________________________
Using Table 3, a phrase "C,D,E,C,E,C,D" is coded int a reference bit string "00000015" in hexadecimal notation, with only the first, third and fifth bit positions being "1" as shown in FIG. 6.
Software
In this instance, the related difference analyzer is implemented by a program sequence executed by the data processing section 13. Referring to FIG. 7 of the drawings, the program sequence starts with the acceptance of the key word supplied from either character or musical keyboard unit 16 or 18 as by step S1 or S2. As described hereinbefore, the key word indicative of a composer's name is provided through keying-in operation on the character keyboard 16, and is coded by the keyboard scan controlling unit 17. On the other hand, the key word indicative of a phrase is supplied through keying-in operation on the musical keyboard 18, and is also ooded by the keyboard scan controlling unit 19.
When the acceptance is completed, the central processing unit 21 proceeds to an index table transferring subroutine program SR1. In the index table transferring subroutine program SR1, the central processing unit 21 checks the key word to see whether the accepted key word represents a composer's name or a phrase. If the key word represents a composer's name, the central processing unit 21 requests the disk controlling unit 20b to transfer the index table TBL1 to the data memory unit 22. However, if the accepted key word represents a phrase, the index table TBL2 is transferred from the hard disk 20a to the data memory unit 22. Thus, when the index table transferring sub-routine program is completed, the central processing unit 21 proceeds to a key word coding sub-routine program SR2.
In the key word coding sub-routine program SR2, the central processing unit 21 produces a reference bit string of the accepted key word under the rule described hereinbefore. The reference bit string thus produced is transferred to the data memory unit 20a and memorized therein. Since the index table TBL1 or TBL2 has been already been memorized in the data memory 22, the data memory unit 22 maintains the pieces of musical attributive catalog information in the form of both the reference bit strings and the coded character or note strings, and further keeps the piece of identifying information also in the form of both of the reference bit string and the character or note string. When both of the reference bit strings are memorized in the data memory 22, the central processing unit 21 begins to execute an instruction sequence of a preliminary analytic sub-routine program SR3.
The sequence of the preliminary analytic sub-routine program is illustrated in FIG. 8 in detail. The reference bit string of the piece of identifying information and each of the reference bit strings of the pieces of musical attributive catalog information are hereinbelow referred to as "key bit string" and "lock bit string", respectively, for the sake of simplicity. The sequence starts with reading the key bit string into one of the data registers 81 of the central processing unit 21, and the central processing unit 21 sequentially accesses the index table TBL1 or TBL2 to put the lock bit string into another data register 82. On the key and lock bit strings, the central processing unit 21 carries out a series of logical operations. Namely, the key bit string is ex-ORed with the lock bit string at step S81, and the resultant bit string is further ANDed with the key bit string at step S82. Both of the key bit string and the lock bit string are n bit in size, and, for this reason, those logical operations are relatively simple.
Let us give you an example on the assumption that the key bit string and the lock bit string respectively represented by "ABC" and "CBD" are "111" and "111", respectively. When the key bit string "ABC" is ex-ORed with the lock bit string "CBD", the resultant bit string "ABCD" is "1001". The AND operation between the resultant bit string "1001" and the key bit string "111" yields a bit string "ABCD" of "100" which teaches that only the "A" characterizes the key bit string.
The resultant bit string of the AND operation is counted to decide the number of the bits of "1" incorporated therein at step S83, and the key bit string is also counted at step S84. Then, the central processing unit 21 proceeds to step S85 and calculates the ratio Rb of different bits to the total bits of the key bit string. The ratio Rb is given by Equation 1:
Rb=(b1-b2)/b1 (Equation 1)
where b1 is the number of the bits incorporated in the key bit string and b2 is the number of the bits of "1" contained in the resultant bit string of the AND operation. The ratio Rb is then compared with a predetermined boundary value k to see whether or not the ratio Rb is equal to or greater than the predetermined boundary value k as by step S86. If the answer to the step S85 is given in the positive, the central processing unit 21 decides that the lock bit string is roughly resemblant to the key bit string as by step S87, and stores the lock bit string in the data memory unit 22 as being a candidate of the relative difference of the key bit string. On the other hand, if the answer to the step S86 is given in the negative, the central processing unit discards the lock bit string at step S88 as not being a candidate of the relative difference. Thus, the lock bit string is memorized as a candidate of the relative difference or is discarded depending upon the ratio Rb, and the central processing unit repeats the access to the data memory unit for retrieving another reference bit string in the index table TBL1 or TBL2 until all of the reference bit strings are analyzed. In this way, the central processing unit 21 continues the preliminary analysis. When the preliminary analysis is completed, the central processing unit 21 leaves the preliminary analytic sub-routine program, and proceeds to a final analytic subroutine program SR4 as shown in FIG. 7.
In the final analytic sub-routine program SR4, the central processing unit 21 produces a two-dimensional matrix for calculating a similarity S. Namely, the central processing unit 21 retrieves the key word (not the reference bit string) and stores it in the data register. Subsequently, the central processing unit 21 accesses one of the composer's name or the phrases in the index table TBL1 or TBL2 with reference to the reference bit strings determine to be candidates in the preliminary analytic sub-routine program SR3. The central processing unit adds one character or symbol to the character string or the note string of the key word, and the same character or symbol is added to the composer's name or the phrase read out from the index table TBL1 or TBL2. The key word thus added with the character or symbol is hereinafter referred to as a "modified key word", and the composer's name or the phrase from the index table is referred to as a "modified composer's name or the modified phrase". Then, every character or every note of the modified key word is successively compared with all of the characters or the notes of the modified composer's name or the modified phrase to see whether or not two characters or notes are identical with each other. If ith character or note of the modified key word is matched with jth character or note of the modified composer's name or the modified phrase, the central processing unit 21 calculates a score mi,j as follows
m.sub.i,j =m(j-1), (j-1)+a (Equation 2)
where a is a predetermined positive point. However, if the ith character or note is mis-matched with the jth character or note, the score is given as
m.sub.i,j =Maximum [m.sub.i,j-1 -b, m.sub.i-1,j -c] (Equation 3)
where b and c are predetermined negative points, respectively and "Maximum" instructs to pick up either of m i ,j-1 -b, m i-1 ,j -c whichever is larger than the other. Thus, the central processing unit 21 repeats the comparison followed by either calculation for every character or note of the modified key word. In the series of the calculations, if the predetermined positive point is increased in absolute value or the predetermined negative points are decreased in absolute value, the central processing unit 21 tends to decide the composer's name or the phrase resemblance. The initial values of the score are given as Equations 4 and 5.
m.sub.0,j =-j*b (Equation 4)
m.sub.i,0 =-i*c (Equation 5)
When the scores are calculated for all of the characters or notes, a matrix is completed in the data memory 22, and the central processing unit 21 further calculates a similarity S as follows
S=(The maximum score in the matrix)/(the length of the key word)(Equation 6)
If the similarity exceeds a predetermined value x, the composer's name or the phrase is decided to be resemblant to the key word. Thus, similarities for each of the candidates can be used to determine the relative differences between the candidates and the key word.
Assuming now that the key word is representative of "Oumati" and that the index table TBL1 contains the correct Japanese composer's name "Oomachi", the matrix is formed as Table 4 where the symbol ? has the initial values, the positive point a is "1", and the negative points b and c are "0".
TABLE 4______________________________________ ? o o m a c h i______________________________________? 0 0 0 0 0 0 0 0o 0 1 1 1 1 1 1 1u 0 1 1 1 1 1 1 1m 0 1 1 2 2 2 2 2a 0 1 1 2 3 3 3 3t 0 1 1 2 3 3 3 3i 0 1 1 2 3 3 3 4______________________________________
Table 5 shows another matrix on the assumption that the composer's name "Machida" is read out from the index table TBL1. In this example, the positive point a is assumed to be and the negative points b and c are "0".
TABLE 5______________________________________ ? m a c t i d a______________________________________? 0 0 0 0 0 0 0 0o 0 0 0 0 0 0 0 0u 0 0 0 0 0 0 0 0m 0 1 1 1 1 1 1 1a 0 1 2 2 2 2 2 3t 0 1 2 2 2 2 2 3i 0 1 2 2 2 3 3 3______________________________________
Let us calculate the similarities of "Oomachi" and "Machida" . Since the key word length is "6" and the maximum value in the matrix for "Oomachi" is "4", the similarity So of "Oomachi" is given as follows
So=(4/6)×100=66.7%
However, the similarity Sm of "Machida" is given as:
Sm=(3/6)×100=50%
If the predetermined value x or the criterion is 50%, both of the composer's names are selected. However, a criterion of 60% allows only the composer s name "Oomachi" to be selected.
The central processing unit 21 repeats the access to the index table TBL1 or TBL2, the formation of the matrix and the calculation of the similarity for all of the composer's names or the phrases. The selected composer's names or the phrases are memorized in the data memory unit 22 in the order of the similarity, and, then, the central processing unit 21 proceeds to a displaying sub-routine program SR5 as shown in FIG. 7.
In the displaying sub-routine program, the central processing unit requests the display controlling unit 25 to produce character images of the selected words or phrases together with messages on the display unit 24 as shown in FIG. 9. With the messages, the user notices that the key word is incorrect, and is prompted for selecting one from the selected words, or phases. The relative differences allow the user to remember the correct key word, and, accordingly, accelerate access to the correct musical information. In the instance shown in FIG. 9, the message includes the similarity. The similarity may disappear from the display if the value thereof is less than a predetermined value. The predetermined value may be variable and given by the user. The calculated values of similarity are indicative of the relative differences between the candidates and the key word.
When a correct composer's name is supplied from the character keyboard 16, the central processing unit accesses the musical data file MDB, and the pieces of musical data information are indicated on the display unit 24.
Although one particular embodiment of the present invention have been shown and described, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the present invention. In the information retrieval system hereinbefore described, the pieces of musical data information are provided in the form of musical scores, however, the pieces of musical data information may be provided in various forms such as, for example, a history, a player or a singer. Moreover, of the candidates selected in the preliminary analytic sub-routine program may be classified in terms of similarity thereby indicating a relative difference between the candidates and the key word. In another implementation, a printer unit associated with a driver unit may be coupled to the multi-bit bus system, and the related differences may be printed on a proper paper. The above described relative difference analyzer carries out the preliminary analysis using reference bit strings, however, the key word may be directly compared with the composer's names or the phrases, and this implementation is conducive to simplicity of the data base under the sacrifice of the execution time period.
A phrase given by a user may be different in key from the actual phrase. In order to cope with such an incorrect input phrase, the data base may have a plurality of phrases arranged in twelve keys for each candidate, however, another data base allows the given phrase to be compared with the twelve phrases which are different in key and sequentially produced upon comparison. The latter approach is advantageous over the former approach in memory space consumed by the data base. | A musical information retrieval system, for providing pieces of musical information to a user, is equipped with a relative difference analyzer for improvement of an average access time period even if the user is not familiar with an electronic processing system, and the relative difference analyzer comprises an input unit for providing a key word representative of a piece of identifying information indicative of an attribute of a musical composition, a data file including a plurality of books respectively having index records for storing respective pieces of musical attributive catalog information and detail data records for storing respective pieces of detailed musical data information associated with the pieces of detailed musical data information, respectively, an analyzer for searching the index records for candidates each partially identical with the piece of identifying information but partially different from the piece of identifying information, and a displaying unit for indicating the relative differences, if any. | 8 |
[0001] The present application claims priority under 35 U.S.C. 119 and 35 U.S.C. 365 to Korean Patent Application No. 10-2005-0129663 (filed on Dec. 26, 2005), which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] As the scale of semiconductor device integration increases, the width of metal interconnections used in the semiconductor device decreases, resulting in an increase of resistance and signal transmission delay in the metal interconnections. To solve the problem of signal transmission delay, a multi-layered interconnection structure may be substituted for single-layered interconnection structures.
[0003] However, as distances between metal interconnection layers decrease in the multi-layered interconnection structure, parasitic capacitance and parasitic resistance (impedence) between adjacent metal interconnections in the same layer increase, and therefore, the operational speed of the semiconductor device is reduced. With very fine interconnections in the device, signal transmission delays caused by parasitic capacitance in the interconnections significantly affects the operational characteristics (for example, speed, power consumption, and reliability, among others) of the semiconductor device. In order to reduce the parasitic capacitance between the interconnections, the widths of the interconnections may be reduced and the thickness of interlayer insulating layers may be enlarged. Accordingly, to form interconnections of metal having low resistivity and interlayer insulating films of material having a low dielectric constant, a material such as copper (Cu) may be used as the interconnection material. However, since the vapor pressure of the reactant generated while etching copper is low, dry etching copper is difficult.
[0004] Accordingly, a damascene or dual damascene process may be used in forming copper interconnections by forming via holes and/or trenches in an interlayer insulating layer, filling the via holes and/or the trenches with copper and then planarizing the copper with the insulating layer.
[0005] Particularly, the dual damascene process includes the steps of forming an etch stop layer over a semiconductor substrate, forming a first silane layer, an insulating layer and a second silane layer thereon, and etching selectively the layers to form via holes therein. Then, the via holes are filled with a photoresist film, and a trench pattern is formed over the second silane layer. Subsequently, using the trench pattern as a mask, an RIE (reactive ion etching) is performed on the second silane layer and the insulating layer to form trenches therein. A barrier metal film is formed over inside walls of the via holes and the trenches, which are then filled with a metal thin film. The metal thin film is then patterned to form metal interconnections to connect to electrodes and pads of the device.
[0006] In some instances, individual metal interconnections need to have a resistance different from the others depending on their function. The widths of the metal interconnections may be adjusted individually. When forming metal interconnections having a relatively lower resistance in a single layer, the widths of the interconnections may be adjusted to be wider.
[0007] FIGS. 1 and 2 illustrate plan and cross-sectional views of metal interconnections that are fabricated using a dual damascene process.
[0008] As shown in FIGS. 1 and 2 , metal interconnections 10 and 20 are formed to have different widths, and therefore different resistances. For example, metal interconnection 10 has a width W and a relatively higher resistance while metal interconnection 20 has a width W′ (greater than width W) and a relatively a lower resistance. The metal interconnections are spaced by a minimum distance S.
[0009] In general, a minimum design rule is used in forming metal interconnections in semiconductor devices. However, metal interconnections having a lower resistance often need to be formed. These metal interconnections should have a relatively greater width. This also means that the size of the semiconductor device is increased as much as the size for the metal interconnections. For example, when metal interconnections having a lower resistance need to be formed, but without increasing trench depths (see FIG. 2 ), the widths of those metal interconnections may be enlarged.
[0010] However, the chip size of semiconductor devices needs to be minimized to achieve large scale integration, a high yield per wafer, and other advantages. However, it is difficult to increase the integration level, and minimize chip size using a dual damascene process in which the widths of interconnections need to be enlarged.
SUMMARY
[0011] Embodiments are directed to a semiconductor device; and particularly to a method for fabricating a metal interconnection using a dual damascene process, and a semiconductor device made by the process.
[0012] Embodiments relate to a method for using a dual damascene process to form a metal interconnection with a relatively lower resistance and without an enlarged width.
[0013] Embodiments relate to a method for forming a metal interconnection using a dual damascene process, thereby fabricating a highly integrated semiconductor device.
[0014] Embodiments relate to a semiconductor device having a metal interconnection with a relatively lower resistance without enlarging the width thereof.
[0015] Embodiments relate to a method for forming a metal interconnection using a dual damascene process, including the steps of: forming sequentially an etch stop layer, a first silane layer, an insulating layer and a second silane layer over a semiconductor substrate; etching selectively the first silane layer, the insulating layer and the second silane layer to form one or more via holes; filling the via holes with a filler; forming a first etching mask for forming a first trench connecting to the via holes on the second silane layer; and, using the first etching mask, etching the second silane layer, the insulating layer and the filler to form the first trench having a predetermined depth connecting to one of the via holes; forming a second etching mask for forming a second trench on an entire surface of the semiconductor substrate, and using the second etching mask, etching the second silane layer, the insulating layer and the filler to form a second trench connecting to one of the via holes other than the via hole connecting to the first trench, wherein a depth of the second trench is different from that of the first trench; removing the filler in the via holes; removing a part of the etch stop layer exposed at the bottom of the via holes; and forming metal interconnections to fill the via holes and the trenches.
[0016] Embodiments relate to a semiconductor device including: an interlayer insulating layer including a plurality of trenches connecting to a number of via holes formed on a semiconductor substrate including lower interconnections, wherein widths of the trenches are greater than widths of the via holes; and metal interconnections formed by filling the via holes and the trenches with a metal film, wherein depths of the trenches vary depending on required resistances of the metal interconnections.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 illustrates a plan view of metal interconnections that are fabricated using a dual damascene process;
[0018] FIG. 2 depicts a cross-sectional view taken along a line X-X′; and
[0019] Example FIGS. 3 to 8 show cross-sectional views for explaining a method for forming a metal interconnection using a dual damascene process in accordance with embodiments.
DETAILED DESCRIPTION
[0020] In the drawings, in order to represent various layers and regions in a clear manner, their thicknesses are represented to be enlarged. Through the entire specification, like elements are designated by the same reference numerals. If a portion such as a layer, a film, a region or a plate is referred to be positioned on another portion, such an expression may incorporate a case in which there exists still another portion therebetween as well as a case in which the portion is positioned right on said another portion. On the contrary, if a portion is referred to be positioned right on another portion, it means that there is no still another portion therebetween.
[0021] Referring to FIG. 3 , an etch stop layer 120 , a first silane layer 140 , an insulating layer 150 and a second silane layer 160 are sequentially formed over a semiconductor substrate 100 . In one embodiment, the etch stop layer 120 includes SiN, and the insulating layer 150 includes insulating material of low dielectric constant such as FSG (Fluorine Silicate Glass), PSG (phosphorous silicate glass), BPSG (boron phosphorous silicate glass) and USG (un-doped silicate glass), or their equivalents. Further, the first and second silane layers 140 , 150 may include a material such as SiH 4 . In this embodiment, the first silane layer 140 , the insulating layer 150 and the second silane layer 160 form an interlayer insulating layer.
[0022] A lower interconnection structure may be formed under the etch stop layer 120 , for example, lower contacts and/or interconnections 80 formed in the semiconductor substrate 100 . In certain embodiments, such interconnections 80 may include contact structures that are fabricated using a damascene process.
[0023] Referring to FIG. 4 , the second silane layer 160 , the insulating layer 150 and the first silane layer 140 are selectively etched, to thereby form via holes 180 extending to the lower interconnections 80 . The etch stop layer 120 positioned below the first silane layer 140 serves as a barrier for stopping the etching of the via hole 180 .
[0024] Thereafter, in order to prevent the via holes 180 from being eroded during a subsequent process of forming trenches, a filler 200 such as Novolac photoresist, is deposited in and buries the via hole 180 . Other equivalent materials may be used to serve this function.
[0025] Referring to FIG. 5 , an anti-reflection film (not illustrated) is formed over the second silane layer 160 , and an etching mask 220 is formed thereon using a photoresist pattern. Using the etching mask 220 , first trenches 240 having a depth d are formed to connect to the via holes, and then the etching mask 220 is removed. It should be noted that trenches are not yet formed above the vias designated for metal interconnections of low resistance.
[0026] Referring to FIG. 6 , in order to form low resistance metal interconnections, a second etching mask 260 is formed, for example, using a photoresist pattern.
[0027] Referring to FIG. 7 , using the second etching mask 260 , second trenches 280 having a depth d′ (d′>d) are formed to connect to the via holes, and then the etching mask is removed. Thereafter, the filler 200 remaining in the via holes is removed. Then, the first and second trenches 240 and 280 and the via holes 180 are buried with a conductive film such as Cu film.
[0028] Subsequently, as shown in FIG. 8 , metal interconnections 300 including contacts are formed by performing chemical-mechanical polishing (CMP) on the resultant structure. As shown in FIG. 8 , since the depth d′ of the second trenches 280 is greater than that (d) of the first trenches 240 , the resistance of metal interconnections filling the second trenches 280 is lower than that of metal interconnections filling the first trenches 240 .
[0029] In the above-described embodiments, the depth of the second trenches 280 may be adjusted depending on required resistance of metal interconnections filled therein. Also, by adjusting the depths of one or more of the trenches differently, metal interconnections having various resistances can be implemented. Furthermore, by setting the widths of metal interconnections filling the trenches to be uniform, characteristics of a CMP process performed on the metal layers can be improved.
[0030] Accordingly, by adjusting the depths of trenches for metal interconnections, metal interconnections having low resistances can be fabricated without having to enlarging the widths of the metal interconnections, thereby producing highly integrated semiconductor devices.
[0031] In accordance with the embodiments, since metal interconnections with the low resistance can be used without enlarging the chip size by forming the trenches to have different depths from each other, a high integration of the semiconductor device can be achieved. Further, it is possible to improve the characteristics of the CMP for the metal film by forming the metal interconnections to have an identical width.
[0032] It will be obvious and apparent to those skilled in the art that various modifications and variations can be made in the embodiments disclosed. Thus, it is intended that the disclosed embodiments cover the obvious and apparent modifications and variations, provided that they are within the scope of the appended claims and their equivalents. | A semiconductor device includes an interlayer insulating layer including a plurality of trenches connecting to a number of via holes formed on a semiconductor substrate including lower interconnections, wherein widths of the trenches are greater than widths of the via holes, and metal interconnections formed by burying metal thin films in the via holes and the trenches. Depths of the trenches are adjusted differently from each other depending on required resistances of the metal interconnections. | 7 |
This is a continuation of U.S. patent application Ser. No. 08/487,141, filed Jun. 7, 1995, now U.S. Pat. No. 5,683,987 which is a continuation-in-part of U.S. patent application Ser. No. 08/379,180, filed Jul. 12, 1994, now abandoned, both of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to novel compositions and methods useful in cancer therapy for inhibiting the multidrug resistance phenotype, which is responsible for the failure of existing chemotherapeutic regimens to induce enduring remissions in the majority of cancer patients (Clarke et al., J. Natl. Cancer Inst. 84: 1506-1512, 1992). Specifically, the invention provides selected oligonucleotides (hereinafter "oligos"), and methods of use thereof, for inhibiting expression of genes responsible for the MDR phenotype, and for exerting aptameric inhibition of the MDR phenotype.
BACKGROUND OF THE INVENTION
The multidrug resistance phenotype is dependent upon the expression of molecular pumps that are capable of expelling chemotherapeutic agents from their site of action in cancer cells. These molecular pumps include, for example, the P-glycoprotein (hereinafter: P-gp) pump, and the multidrug resistance-associated protein (hereinafter: MRP) pump, which are encoded by the MDR1 and MRP genes, respectively.
The discussion set forth below illustrates the problems faced by clinical investigators seeking to improve cancer treatments. A number of references have been included to describe the general state of the art. Inclusion of these references is not an admission that such references represent prior art with respect to the present invention.
Multidrug resistance (hereinafter "MDR") is largely dependent on the expression of one or the other or both of two different genes. These genes encode transmembrane energy-dependent molecular "pumps" that expel a wide variety of anticancer agents from their site of action in tumors (Grant et al., Cancer Res. 54: 357-361, 1994; Riordan and Ling, Pharmacol. Ther. 28: 51-75, 1985). The normal functions of these molecular pumps is not well defined, but both are expressed by hematopoietic cells and P-gp has been shown to have a causal role in immunofunctioning (Gupta et al., J. Clin. Immunol. 12: 451-458, 1992). The MRP is a molecular pump initially found to be involved in multidrug resistance in lung cancer, and then later found to be expressed in other cancer types, while P-gp is a molecular pump long known to be involved in producing multidrug resistance in many tumor types (Chin et al., Adv. Cancer Res. 60: 157-180, 1993; Cole et al., Science 258: 1650-1654, 1992; Grant et al., Cancer Res. 54: 357-361, 1994; Krishnamachary and Center, Cancer Res. 53: 3658-3661, 1993; Zaman et al., Cancer Res. 53: 1747-1750, 1993).
Clinical studies in which P-gp inhibitors were administered prior to chemotherapy showed that such competitive inhibitors could increase the response of the tumors to the anticancer agents without causing an equivalent increase in toxicity to normal tissues (Marie et al., Leukemia 7: 821-824, 1993; Miller et al., J. Clin. Oncol. 9: 17-24, 1991; Pastan and Gottesman, Annu. Rev. Med. 42: 277-286, 1991; Raderer and Scheithauer, Cancer 72: 3553-3563, 1993; Sonneveld et al., Lancet 340: 255-259, 1992). Oligos designed to block the expression of MRP or P-gp have several features which should make them more clinically effective than any of the existing competitive inhibitors of P-gp or to any comparable inhibitors for MRP.
First, most chemical inhibitors used clinically to combat multidrug resistance have serious side effects unrelated to their ability to inhibit P-gp. In contrast, the phosphorothioate oligo, OL(1)p53, has been found to be essentially devoid of any toxicity when administered to patients (Bayever et al., Antisense Res. Dev. 2: 109-110, 1992; Antisense Res. Dev., in press, 1994). Similarly, this and other phosphorothioates have been shown to be nontoxic to a variety of animal species, even when given at high doses (Cornish et al., Pharmacol. Com. 3: 239-247, 1993; Crooke, Ann. Rev. Pharm. Toxicol. 32: 329-376, 1992; Iversen, Anti-Cancer Drug Design 6: 531-538, 1991). These findings show that at least some types of oligo have no acute toxicity per se when given systemically to animals or patients.
Second, some oligos, including phosphorothioates, have been shown often to have an RNAse-H dependent mechanism of action (Crooke, Ann. Rev. Pharm. Toxicol. 32: 329-376, 1992). RNAse-H enzyme activity is often expressed in clonogenic cells, while little or no activity is found in differentiated (non-proliferative) cells (Papaphilis et al., Anticancer Res. 10: 1201-1212, 1990; Crooke, Ann. Rev. Pharm. Toxicol. 32: 329-376, 1992). Because of this, blocking MRP or P-gp synthesis with oligos (as opposed to blocking their function by competitive inhibitors) should be relatively more effective in proliferating than in non-proliferating cells. Most normal cells that express P-gp or MRP are non-proliferating. For example, gastrointestinal crypt cells (stem cells) do not express P-gp, whereas the endstage (non-proliferating) luminal cells do (Chin et al., Adv. Cancer Res. 60: 157-180, 1993). Furthermore, once MRP or P-gp synthesis is blocked, the remaining membrane-associated drug-efflux pump of the parent cell would then be divided between the two daughter cells, reducing the effective amount of the molecular pump in the proliferating tumor cell population by one-half for each population doubling.
In addition, several recent papers report that ODNs not only are capable of blocking the expression of particular genes in vitro, but also are able to produce this effect in vivo. Some groups have successfully inhibited HIV gene expression (including tax) in human cells in xenogeneic transplant models (Kitajima et al., J. Biol. Chem. 267:25881-25888, 1992). Others have targeted genes in cancer cells, including c-myc, c-Ha-ras, NF-kB, c-myb, c-kit and bcr-abl. In each of these instances involving the administration of ODNs to treat animals with xenogeneic human cancers, the transplanted malignant cells were found to regress (Agrawal et al., Proc. Natl. Acad. Sci. 86:7790-7794, 1989; Proc. Natl. Acad. Sci. 88:7595-7599, 1991; Biro et al., Proc. Natl. Acad. Sci. 90:654-658, 1993; Gray et al., Cancer Res. 53:577-580, 1993; Higgins et al., Proc. Natl. Acad. Sci. 90:9901-9905, 1993; Ratajczak et al., Proc. Natl. Acad. Sci. 89:11823-11827, 1992; Wickstrom et al., Cancer Res. 52:6741-6745, 1992).
Furthermore, the Food and Drug Administration has approved several phosphorothioate antisense oligonucleotides for systemic administration to patients and for ex vivo treatment of hematopoietic stem cell grafts. These approvals include the now-completed OL(1)p53 phase I clinical trials (both systemic and ex vivo administered) which targeted transcripts of the p53 gene in patients with acute myeloid leukemia (Bayever et al., Antisense Res. Develop. 2: 109-110, 1992; Karp and Broder, Cancer Res. 54: 653-665, 1994). Thus, antisense oligonucleotides have the pharmacologic properties necessary for use as drugs.
There are six reports claiming reduced drug resistance in cultured cell lines following treatment with oligos targeting MDR-1 mRNA. Three of these (Vasanthakumar & Ahmed, Cancer Com. 1: 225-232, 1989; Rivoltini et al., Int. J. Cancer 46: 727-732, 1990; Efferth & Volm, Oncology 50:303-308, 1993) are totally unconvincing because they used oligos directed against mouse MDR-1 to treat human cells; in the corresponding human MDR-1 sequence, the longest matching nucleotide sequence was only 6 bases long. The paper by Thierry et al. (Biochem. Biophys. Res. Comm. 190: 952-960, 1993) reports no oligo with a sequence which matches the human MDR-1 gene, but this problem is apparently due to typing errors (personal communication from A. Thierry). Thierry's 15-mer that gave 95% inhibition of MDR-1 expression did so only when encapsulated in liposomes; this was associated with a 4-fold increase in sensitivity of the tumor cells to doxorubicin (Thierry et al., Biochem. Biophys. Res. Comm. 190: 952-960, 1993); when administered without liposomes, inhibition of MDR1 expression was 40% of control values. Furthermore, the calculated melting temperature for Thierry's 15-mer is less than 28° C., suggesting that at body temperature the amount of oligo bound is very low.
The most compelling papers in this group are by Jaroszewski et al. (Cancer Comm. 2: 287-294, 1990) and Corrias and Tonini (Anticancer Res. 12: 1431-1438, 1992). Both teams found inhibition with only one out of five oligos. Jaroszewski et al. (Cancer Comm. 2: 287-294, 1990) describe one phosphorothioate (which is being designated "Cohen(1)mdr" herein) that gave 25% reduction in P-gp expression at 15 μM and 33% reduction at 30 μM when incubated with MCF-7/ADR breast cancer cells for 5 days. This reduction in P-gp expression was associated with a small increase in the doxorubicin sensitivity of the cells (20% increase in cell death when 10 μM of the oligo was used. Corrias & Tonini (Anticancer Res. 12: 1431-1438, 1992) report a phosphodiester oligo that gave only a slight reduction in P-gp (data not shown herein) at 30 μM when incubated with doxorubicin-resistant colon adenocarcinoma cells for 36 hours. The reduction in P-gp expression was associated with a significant increase in the in vitro sensitivity of the cells to the cytotoxic effects of doxorubicin (80% and 53% dose reductions in IC 50 , respectively; the IC 50 being the inhibitory concentration of a chemotherapeutic agent (e.g., doxorubicin) which causes a 50% inhibition in cellular proliferation).
It is, therefore, a principal object of the present invention to provide MDR-oligos or MRP-oligos that target the genes encoding P-gp or MRP, respectively, or their RNA transcripts, in order to specifically and effectively sensitize clonogenic multidrug-resistant tumor cells to chemotherapeutic agents. It is another object of the present invention to provide oligos which will sensitize tumor cells much more efficiently than they do normal cells which express these same molecular pumps. As the foregoing discussion highlights, oligonucleotides effective for these purposes heretofore have been unavailable.
There is growing evidence that certain protein kinases, such as protein kinase A (PKA), and protein kinase C (PKC) in particular, are involved in the activation of the forms of drug resistance which depend on the expression of molecules producing multidrug resistance, such as, for example, P-glycoprotein, MRP, pi-class glutathione S-transferase, gamma-glutamylcysteine (Gekeler et al., Biochem. Biophys. Res. Comm. 205: 119, 1995; Grunicke et al., Ann. Hematol. 69 (Suppl 1): S1-6, 1994; Gupta et al., Cancer Lett. 76: 139, 1994), or the transmembrane pump capable of expelling glutathione conjugates from their site of action in cells (such as the GS-X pump (Ishikawa et al., J. Biol. Chem. 269: 29085, 1994).
These second-messenger pathways typically appear to be more active in drug resistant cancer cells compared to their drug sensitive counterparts. These pathways promote the expression of various drug resistance phenotypes by causing the up-regulation of a very small number of specific transcriptional regulators, including AP-1, that presumably control the activation of molecules involved in producing drug resistance in cancer cells (Grunicke et al., Ann. Hematol. 69(Suppl 1): S1-6, 1994). For example, activation of the ras oncogene in malignant cells is one of the ways that PKC and, in turn, multidrug resistance, can be up-regulated in tumor cells. Hence, the realization that what has been considered to be multiple discrete mechanisms for drug resistance share common activation pathways opens a new set of possibilities for broad spectrum therapeutic interventions.
Thus, if inhibitors of these second messenger pathways could be found, they should be of use for treating a wider variety of multidrug resistance phenotypes in cancer than agents designed to inhibit the function or expression of a single molecular species involved in drug resistance (Grunicke et al., Ann. Hematol. 69(Suppl 1): S1-6, 1994; Christen et al., Cancer Metastasis Rev. 13: 175, 1994). In addition, inhibitors of particular PKC isoenzymes, or of PKA, or molecular regulators up- or down-stream of these enzymes, should find a variety of other applications where these protein kinases are known to play an important role, including the treatment of viral infections, AIDS, Alzheimer's Disease, and conditions where immunosuppression is important such as in autoimmune diseases, transplantation-related reactions and inflammatory reactions.
Stein et al. (Biochemistry 32: 4855, 1993) discovered that both a 15-mer phosphodiester homopolymer of thymidine and a 28-mer phosphorothioate homopolymer of cytidine could inhibit the B1 isoenzyme of PKC, with the result that pinocytosis and cellular uptake of macromolecules was inhibited. For the 28-mer phosphorothioate, the IC 50 for directly inhibiting purified PKC-β1 activity was 1 μM; complete suppression required nearly 40 μM.
Conrad et al (J. Biol. Chem. 269: 32051, 1994) have shown that certain RNA aptamers can inhibit the βII isoenzyme of PKC. These RNA aptamers were selected from a pool of RNA molecules that contained a 120-nucleotide randomized region. PKC-βI is an alternatively-spliced variant of PKC-βII.
Schuttze et al (J. Mol. Biol. 235: 1532, 1994) have analyzed in detail the three-dimensional solution structure of the thrombin-binding DNA aptamer d(GGTTGGTGTGGTTGG). This aptamer binds to thrombin and inhibits its activity in the chain of reactions that lead to blood clotting. The authors conclude that "knowledge of the three-dimensional structure of this thrombin aptamer may be relevant for the design of improved thrombin-inhibiting anti-coagulants with similar structural motifs."
Using the human KM12L4a colon cancer cell line, Gravitt et al. (Biochem. Pharmacol. 48: 375, 1994) discovered that the agent thymeleatoxin (which stimulates the phorbol ester-responsive PKC isoenzymes -α, -βI, -βII and -gamma) induces multidrug resistance. Since this cell line expresses only the PKC-α isoenzyme, it is clear that PKC-α lies in a second messenger pathway that can up-regulate multidrug resistance.
Fan et al (Anticancer Res. 12: 661, 1992) presented data showing that the expression of rat brain PKC-βI confers a multidrug resistance phenotype on rat fibroblasts.
Thus, it is another object of the present invention to provide oligonucleotides that inhibit various MDR phenotypes in cancer cells by exerting an aptameric effect.
SUMMARY OF THE INVENTION
In accordance with the present invention, there are provided novel oligonucleotides targeting the human MDR1 gene or the human MRP gene or their transcripts which are uniquely effective in inhibiting multidrug resistance in human cancer cells. Administration of these oligos to patients having multidrug resistant cancer is done for the purpose of increasing sensitivity of the cancer(s) to the cytotoxic effects of therapeutic agents that would normally be expelled from their site of action in the tumor cells by the MRP or P-gp molecular pumps. In addition, the oligos may be administered to a patient with cancer or a premalignant syndrome to prevent the development of multidrug resistance in the patient's tumor. The oligos may be used alone or in combination with certain chemical inhibitors which exhibit an inhibitory effect on the MRP or P-gp pumps. The oligos may also be used in combination with chemotherapeutic drugs to purge bone marrow or peripheral stem cell grafts of malignant cells or non-malignant mononuclear cytotoxic effector cells. The oligos may be administered to patients receiving an organ transplant, or patients with autoimmune diseases, as an immunosuppressive agent alone or with other MRP or P-gp inhibitors or with cytotoxic or cytostatic drugs. The oligos to MDR1 herein described are much more effective than other oligos presently known. Oligos directed toward inhibiting expression of the MRP gene have not been described previously, insofar as is known.
Furthermore, the present inventor has found that MRP-oligos have activity for reversing multidrug resistance phenotype in non-lung cancer.
"Prototype oligos" have been designed, synthesized and used to confirm in in vitro experiments that indeed the nucleotide target sequences for oligo binding indicated in Tables 1 through 3 ("hotspots") within the MRP and MDR1 gene sequences or transcript sequences are particularly suitable for the practice of the present invention. Variant oligos with suitable physical properties have also been designed which target the same general areas of the MDR1 or MRP sequences as the prototype oligos. Such variant oligos, described herein in Tables 4 and 5 are expected to also have utility for the same therapeutic purposes as the prototype oligos.
Also disclosed are a set of oligonucleotide sequences which can dramatically reverse the multidrug resistance phenotype exhibited by cancer cells, even though the oligo sequences are such that they are not complementary to any known human gene. They must act, therefore, by interfering with the function of some key molecule needed for the production of the multidrug resistance phenotype. This type of phenomenon is generally known as an "aptameric effect." The oligonucleotides exhibiting this specific aptameric effect (hereinafter "MDR-aptamer" oligos) are highly active in vitro at concentrations below 1 μM. The degree to which these MDR-aptamers reverse the multidrug resistance phenotype is positively correlated with the degree to which, by themselves, they inhibit the in vitro proliferation of drug-resistant cancer cells. These MDR-aptamers do not have a major drug sensitizing effect on drug sensitive cells and they do not significantly inhibit the proliferation of such cells. Similarly, some MDR- and MRP-Oligos exhibit both an antisense effect on MDR1 or MRP expression and (to verying degrees) an MDR-aptameric effect. These MDR-aptamers can serve a variety of purposes, including being used: (1) to treat cancer patients, particularly those with multidrug resistant cancer, in order to sensitize the tumor to chemotherapeutic agents; (2) as probes to discover the critical molecular target in cells (to which they bind) required for the maintenance of the multidrug resistance phenotype; and (3) as prototype MDR-aptamers in structural studies for the further development of oligos of this type for clinical use as therapeutic agents.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1. Graph of predicted 3 H-TdR uptake count (Y-axis) as a function of Log 10 (dose of drug) (X-axis) for selected mdr oligonucleotides. The graph plots the estimated functions (curved lines) associating Log 10 (Vincristine dose) with expected " 3 H-TdR counts" for each oligo shown in the figure.
DETAILED DESCRIPTION OF THE INVENTION
In preferred embodiments of the invention, the oligos are administered systemically to cancer patients, either in combination with chemotherapeutic agents, in order to potentiate the elimination of multidrug resistant tumor cells from the body of the host; or alone, to prevent development of multidrug resistant phenotype, or with chemotherapeutic agents to purge malignant cells from bone marrow or peripheral stem cell grafts. The oligos also may be administered as an immunosuppressive agent.
The list of chemotherapeutic agents to be used in association with the prototype or variant oligos of the present invention is selected from but not limited to a list that comprises: (1) the vinca alkaloids: including vincristine, vinblastine, vindesine; (2) the anthracyclines, including daunorubicin, doxorubicin, idarubicin; (3) the epipodophyllotoxins, including VP-16 (etoposide) and VM-26 (teniposide); and (4) miscellaneous: steroids, mitomycin C, taxol, actinomycin D, melphalan.
The prototype or variant oligos may be used alone to inhibit P-gp or MRP function, or in combination with non-oligo inhibitors of these molecular pumps, selected from but not limited to a list comprising: PSC-833 (cyclosporin D analog), verapamil, cyclosporin A, FK506, tamoxifen, megestol, and novobiocin and its analogs.
The prototype or variant oligos may be used alone or in combination with the aforementioned agents to treat any human cancer which expresses a multidrug resistant phenotype, or to prevent the development of a multidrug resistance phenotype, including those types of human cancer selected from but not limited to a list comprising: breast cancer, lung cancer, colon cancer, liver cancer, renal cancer, pancreatic cancer, prostate cancer, ovarian cancer, cervical cancer, uterine cancer, bladder cancer, brain cancer, adrenal cancer, multiple myeloma, ear-nose-throat cancers (including esophageal, laryngeal, pharynx), leukemia, lymphoma, sarcoma and carcinoid tumors. This listing is included for the purpose of illustration only, and is not meant to limit the practice of the present invention.
The present invention encompasses oligonucleotides and oligonucleotide analogs which are complementary to selected target sites of MDR1 or MRP, and transcripts thereof. These target sites are sometimes referred to herein as "hotspots." Using a computer program, such as "Oligo" (Richik & Rhoades, Nucl. Acids Res. 17: 8543, 1989) and a reference such a Genbank, these hotspots were selected on the basis of their unique sequence (i.e., having high sequence homology with members of the gene family, but less than 85% homology with genes and RNA transcripts outside the gene family) and various physical parameters desirable for the antisense oligonucleotides to be produced. In preferred embodiments of the invention, oligos which are targeted to these "hotspots" possess the following characteristics: (1) length between about 10 and 40 bases, with a preferred range of about 15-30 and a particularly preferred range of 17-26; (2) negligible self-interaction (self-dimers and hairpins) under physiological conditions; (3) melting temperature ≧40° C. under physiological conditions; and (4) no more than 40% of the oligo composed of run of guanines or cytosines.
Preferred hotspots, prototype oligonucleotides and size variants thereof are set forth herein. These hotspots and oligos are disclosed with reference to specific MDR1 or MRP nucleotide sequences from the Genbank library. It will be appreciated by persons skilled in the art that variants (e.g., allelic variants) of these sequences exist in the human population, and must be taken into account when designing and/or utilizing oligos of the invention. Accordingly, it is within the scope of the present invention to encompass such variants, either with respect to the preferred hotspot disclosed herein or the oligos targeted to specific locations on the respective genes or RNA transcripts. With respect to the inclusion of such variants, the term "substantially the same as" is used herein to refer to various specific nucleotide sequences and variants thereof that would occur in a human population. Additionally, the term "substantially the same as" refers to oligo sequences that may not be perfectly matched to a target sequence, but the mismatches do not materially affect the ability of the oligo to hybridize with its target sequence under the conditions described.
The subject of the present invention is the nucleotide sequence of the disclosed oligos (listed in Tables 1 through 5) in association with a chemical backbone, the backbone selected from, but not limited to, a list consisting of the following types (reviewed in Neckers et al., Crit. Rev. Oncogen. 3: 175-231, 1992): phosphorothioates, dithioates, methylphosphonates, phosphodiesters, morpholino backbones, polyamide backbones, and any combination of the aforementioned backbone types, including, for example, phosphorothioate-capped phosphodiesters. The backbones may be unmodified, or they may be modified to incorporate a ribozyme structure, or a pendant group. Additionally, 2'-O-methyl (ribose-modified) oligos are suitable for the practice of the invention. The 2'-o-methyl sugar modification can be associated with any of the backbone linkages, including phosphorothioates, and the modification can be limited to the ends of the oligonucleotide. The oligos may also be associated with a carrier or vehicle such as liposomes or micelles, although other carriers could be used, as would be appreciated by one skilled in the art. Such carriers are used to facilitate the cellular uptake and/or targeting of the oligo, and/or improve the oligo's pharmacokinetic and/or toxicologic properties.
TABLE 1__________________________________________________________________________Preferred 20-mer, 22-mer and 26-mer MDR-oligo nucleotide sequenceswithin targeting hotspotsSEQ ID Nucleotide OLIGO (TrivialID HOT- Staiting Name) and variants OLIGO SEQUENCENO. SPOT Position* of same length (5'--->3')__________________________________________________________________________1 1 488 OL(6)mdr prototype CCCACGCCCC GGCGCTGTTC2 496 OL(6A)mdr GTGCTCAGCC CACGCCCCGG3 2 517 OL(16)mdr prototype GGCAAAGAGA GCGAAGCGGC4 518 OL(16A)mdr TGGCAAAGAG AGCGAAGCGG5 540 SJ(34)mdr prototype TCGAATGAGC TCAGGCTTCC6 542 SJ(34A)mdr TCGAATGAGC TCAGGCTT7 540 SJ(34B)mdr ACTCGAATGA GCTCAGGCTT CC8 533 SJ(34C)mdr AGCTCAGGCT TCCTGTGGCA9 543 SJ(34D)mdr CGAATGAGCT CAGGCT10 3 664 5(1)mdr prototype CCCTACCTCG CGCTCCTTGG AACGGC11 688 OL(10)mdr GCTCCCAGCT TTGCGTGCCC12 4 884 OL(12)mdr prototype GCGCGCTCCG GGCAACATGG13 881 OL(12A)mdr CGCGCTCCGG GCAACATGGT CC14 885 OL(12B)mdr CGCGCTCCGG GCAACATG15 881 OL(12C)mdr CTCCGGGCAA CATGGTCC16 941 OL(15)mdr prototype TGCTTCCTCC CACCCACCGC17 937 OL(15A)mdr TCCTCCCACC CACCGCCCGC18 938 OL(15B)mdr TTCCTCCCAC CCACCGCCCG19 939 OL(15C)mdr CTTCCTCCCA CCCACCGCCC20 940 OL(15D)mdr GCTTCCTCCC ACCCACCGCC21 5 1000 OL(5)mdr prototype TCTGGACTTT GCCCGCCGCC22 1001 OL(5A)mdr TTCTGGACTT TGCCCGCCGC23 1002 OL(5B)mdr GTTCTGGACT TTGCCCGCCG24 1003 OL(5C)mdr CGTTCTGGAC TTTGCCCGCC25 6 1125 OL(1)mdr prototype GCTCCTCCAT TGCGGTCCCC26 1123 OL(1B)indr GCTCCTCCAT TGCGGTCCCC TT27 1125 OL(1C)mdr TCTTTGGTCC TCCATTGCGG TCCCC28 1125 OL(1Q)mdr TTTGCTCCTC CATTGCGGTC CCC29 1125 OL(1W)mdr TCCTCCATTG CGGTCCCC30 1123 OL(1Wa)mdr CTCCATTGCG GTCCCCTT31 1125 OL(1Wb)mdr CTCCATTGCG GTCCCC32 1121 OL(1Wc)mdr CCATTGCGGT CCCCTTCA33 1127 OL(1X)mdr GCTCCTCCAT TGCGGTCC34 1122 OL(1A)mdr CCTCCATTGC GGTCCCCTTC35 7 1688 OL(2)mdr prototype GCAACCAGCA CCCCAGCACC36 1691 OL(2A)mdr GCAGCAACCA GCACCCCAGC37 8 5996 OL(3)mdr prototype TGCCCACCAG AGCCAGCGTC38 6278 OL(15)mdr prototype GCCTCCTTTG CTGCCCTCAC GA39 9 6551 SJ(36)mdr prototype CCAGGGCTTC TTGGACAACC TA__________________________________________________________________________ *The nucleotide starting position for targeting MDR1gene transcripts is based on the GenBank entries HUMMDR1A01 through HUMMDR1A26, considered as a single linear sequence, with Number 1 position being the most 5prime nucleotide of the HUMMDR1A01 GenBank entry. The Nucleotide Starting Positions in this Table represent the most 5prime nucleotide of the corresponding sense sequence.
Particularly preferred for practice of the invention are oligos that hybridize to the hotspots listed below (or substantially equivalent variants) for MDR-1, Genbank reference No. HUMMDR1-AO1 through -AO26, taken consecutively (Chin et al., Mol. Cell. Biol. 9: 3808, 1989; Chen et al., J. Cell. Biochem. 265: 506, 1990).
Hot-spot 6: Range of bases includes positions 1121-1158
(bases numbered as per footnote to Table 1);
sequence below (Sequence I.D. No. 102) is coding strand:
5'-TGAAGGGGACCGCAATGGAGGAGCAAAGAAGAAGAACT-3'
Hot-spot 2: Range of bases includes positions 540-564;
sequence below (Sequence I.D. No. 103) is coding strand:
5'-GGAAGCCTGAGCTCATTCGAGTAGC-3'
Hot-spot 3: Range of bases includes positions 685-708;
sequence below (Sequence I.D. No. 104) is coding strand:
5'-AGGGGCACGCAAAGCTGGGAGCT-3'
Hot-spot 4: Range of bases includes positions 881-904:
sequence below (Sequence I.D. No. 105) is coding strand:
5'-GGACCATGTTGCCCGGAGCGCGCA-3'
Table 1A describes several sequence variants of antisense oligos in Hotspot 3 of the MDR1 gene. Table 1B describes very similar oligos that bind near the translational start site of the mRNA. Oligo "5(1C)mdr" (SEQ ID NO:94) binds to an upstream splice junction site, while oligo "5(1G)mdr" (SEQ ID NO:98) binds to a site just upstream of the start codon. Interestingly, nearly identical sequences (only 1 base difference in 22) exist in both the genomic and the spliced cDNA versions of the gene (starting positions #666 and #405, respectively). The fourth position guanine in SEQ ID NO:98 makes a perfect match with the "AUG" start site region, while a fourth-position thymidine in SEQ ID NO:94 makes a perfect match precisely with the upstream exon 1B/intron 1 splice junction. A variant of these oligos, synthesized with a fourth position inosine base (such as, for example, oligo "5(1J)mdr", SEQ ID NO:101) should be able, therefore, to bind equally to transcripts from either site.
TABLE 1A__________________________________________________________________________Additional sequence variants in the Hotspot 3 region of the mdr1 geneSEQ Nucleotide OligoID HOT- Starting Trivial Oligo SequenceNO. SPOT Position.sup.1 Name (5'-->3')__________________________________________________________________________92 3 673 5(1A)mdr CGTGCCCCTA CCTCGCGCTC CT93 3 666 5(1B)mdr CCCTACCTCG CGCTCCTTGG AACG94 3 666 5(1C)mdr CCCT.sup.2 ACCTCG CGCTCCTTGG AA95 3 671 5(1D)mdr CGTGCCCCTA CCTCGCGCTC CTTG96 3 677 5(1E)mdr CGTGCCCCTA CCTCGCGC__________________________________________________________________________
TABLE 1B__________________________________________________________________________Additional sequence variants in the upstream splice junction siteSEQ Nucleotide OligoID HOT- Starting Trivial Oligo SequenceNO. SPOT Position.sup.4 Name (5'-->3')__________________________________________________________________________97 -- 408 5(1F)mdr TCCCGACCTC GCGCTCCT98 -- 403 5(1G)mdr CCCG.sup.2 ACCTCG CGCTCCTTGG AA99 -- 405 5(1H)mdr CCATCCCGAC CTCGCGCTCC TTGG100 -- 403 5(1I)mdr CCATCCCGAC CTCGCGCTCC TTGGAA101 -- 405 5(1J)mdr CCCI.sup.3 ACCTCG CGCTCCTTGG__________________________________________________________________________ .sup.1 The nucleotide starting position for targeting MDR1gene transcript is based on the GenBank entries HUMMDR1A01 through HUMMDR1A26, considered as a single linear sequence, with Number 1 position being the most 5prime nucleotide of the HUMMDR1A01 GenBank entry. The Nucleotide Starting Positions in this Table represent the most 5prime nucleotide of the corresponding sense sequence. .sup.2 If an inosine base is placed in this fourth base position, then th resulting ODN would effectively be a perfect match with both binding sites. .sup.3 This variant sequence contains an inosine base substituted at the fourth position where the singlebase variation between SEQ ID NO: 94 and SEQ ID NO: 98 exits. .sup.4 The nucleotide starting position for targeting mdr1 mRNA is based on GenBank entry HUMMDR1/M14758.
TABLE 2__________________________________________________________________________Preferred 23-mer MDR-oligo nucleotide sequences within targetinghotspots.SEQ Nucleotide OLIGO (TrivialID HOT- Starting Name) and variants OLIGO SEQUENCENO. SPOT Position* of same length (5'--->3')__________________________________________________________________________40 10 670 PA(1)mdr prototype GCGGGAGGTG AGTCACTGTC TCC41 670 AP(1)mdr GGAGACAGTG ACTCACCTCC CGC__________________________________________________________________________ *The nucleotide starting position for targeting the MDR1gene is based on the GenBank Entry 105674 "Hummdr1B", and represents the most 5prime nucleotide of the corresponding sense sequence.
TABLE 3__________________________________________________________________________Preferred 20-mer and 26-mer MRP-oligo nucleotide sequences withintargeting hotspotsSEQ Nucleotide OLIGO (TrivialID HOT- Starting Name) and variants OLIGO SEQUENCENO. SPOT Position* of same length (5'--->3')__________________________________________________________________________42 1 24 5(3)MRP prototype CGGCGGCGGC GGCGCAGGGA GCCGGG43 2 169 5(2)MRP prototype CGGTGGCGCG GGCGGCGGCG GGCACC44 3 220 OL(14)MRP prototype GCGGGTCGGA GCCATCGGCG45 222 OL(14A)MRP GAGCGGGTCG GAGCCATCGG46 223 OL(14B)MRP AGAGCGGGTC GGAGCCATCG47 225 OL(14C)MRP CCAGAGCGGG TCGGAGCCAT48 4 1210 OL(5)MRP prototype CTGCGGCCCG GAAAACATCA49 5 2114 OL(2)MRP prototype CGGTGATGCT GTTCGTGCCC50 2101 OL(2A)MRP CGTGCCCCCG CCGTCTTTGA51 2102 OL(2B)MRP TCGTGCCCCC GCCGTCTTTG52 2103 OL(2C)MRP TTCGTGCCCC CGCCGTCTTT53 2104 OL(2D)MRP GTTCGTGCCC CCGCCGTCTT54 2105 OL(2E)MRP TGTTCGTGCC CCCGCCGTCT55 2106 OL(2F)MRP CTGTTCGTGC CCCCGCCGTC56 2107 OL(2G)MRP GCTGTTCGTG CCCCCGCCGT57 2108 OL(2H)MRP TGCTGTTCGT GCCCCCGCCG58 2109 OL(2I)MRP ATGCTGTTCG TGCCCCCGCC59 2110 OL(2J)MRP GATGCTGTTC GTGCCCCCGC60 6 2516 OL(6)MRP prototype GGGCCAGGCT CACGCGCTGC61 2519 OL(6A)MRP GCCCGGGCCA GGCTCACGCG62 7 2848 OL(3)MRP prototype CCCTGGACCG CTGACGCCCG63 2834 OL(3A)MRP CGCCCGTGAC CCCGTTCTCC64 8 3539 OL(8)MRP prototype GCGGGATGAT GATGGCGGCG65 3538 OL(8A)MRP CGGGATGATG ATGGCGGCGA66 3540 OL(8B)MRP GGCGGGATGA TGATGGCGGC67 3541 OL(8C)MRP GGGCGGGATG ATGATGGCGG68 3542 OL(8D)MRP GGGGCGGGAT GATGATGGCG69 3543 OL(8E)MRP AGGGGCGGGA TGATGATGGC70 3528 OL(8F)MRP ATGGCGGCGA TGGGCGTGGC71 3529 OL(8G)MRP GATGGCGGCG ATGGGCGTGG72 3530 OL(8H)MRP TGATGGCGGC GATGGGCGTG73 3531 OL(8I)MRP ATGATGGCGG CGATGGGCGT74 3532 OL(8J)MRP GATGATGGCG GCGATGGGCG75 3533 OL(8K)MRP TGATGATGGC GGCGATGGGC76 9 4154 OL(4)MRP prototype CGATGCCGAC CTTTTCTCC77 4160 OL(4A)MRP GCCCCACGAT GCCGACCTTT78 4161 OL(4B)MRP CGCCCCACGA TGCCGACCTT79 4162 OL(4C)MRP CCGCCCCACG ATGCCGACCT80 4163 OL(4D)MRP TCCGCCCCAC GATGCCGACC81 10 4933 3(3)MRP prototype TGGCGGTGGC TGCTGCTTTG82 4936 3(3A)MRP GGATGGCGGT GGCTGCTGCT83 4937 3(3B)MRP CGGATGGCGG TGGCTGCTGC84 11 4637 OL(15)MRP prototype CCGGTGGGCG ATGGTGAGGA CG__________________________________________________________________________ *The nucleotide starting position for targeting MRPgene trancripts is based on the GenBank Entry #L05628: HUMMRPX", and represents the most 5prime nucleotide of the corresponding sense sequence.
Particularly preferred for practice of the invention are oligos that hybridize to the hotspots listed below (or substantially equivalent variants thereof) for MRP, Genbank reference No. HUMMRPX/L05628 (Cole et al., Science 258: 1650, 1992).
Hot-spot 1: Range of bases includes postions 3528-3566
(numbered as per footnote to Table 3);
Sequence below (Sequence I.D. No. 106) is coding strand:
5'-GCCACGCCCATCGCCGCCATCATCATCCCGCCCCTTGGC-3'
Hot-spot 2: Range of bases includes positions 2469-2538;
sequence below (Sequence I.D. No. 107) is coding strand:
5'-CGGACAGAGATTGGCGAGAAGGGCGTGAACCTGTCT-GGGGGCCAGAAGCAGCGCGTGAGCCTGGCCCGGG-3'
Hot-spot 3: Range of bases includes positions 1198-1242;
sequence below (Sequence I.D. No. 108) is coding strand:
5'-TCCACGACCTGATGATGTTTTCCGGGCCGCAGATCTTAAAGTTGC-3'
Hot-spot 4: Range of bases includes positions 2805-2896;
sequence below (Sequence I.D. No. 109) is coding strand:
5'-GCCAGCACAGAGCAGGAGCAGGATGCAGAGGAGAACGGGGTCACGGGCGTCA-GCGGTCCAGGGAAGGAAGCAAAGCAAATGGAGAATGGGAT-3'
TABLE 4______________________________________Preferred Size Variants of MDR-Oligos at different starting positionsin the MDR1 gene sequence hotspotsHOT- Nucleotide Oligo Size VariantsSPOT starting position (nucleotide length)*______________________________________1 460 25.24.23.22 461 25.24.23.22 462 25.24.23.22 463 25.24.23.22.21 464 25.24.23.22.21 465 25.22.21.19 466 25.21.19 467 25.19.18 468 25.19.18.17 469 25.18.17 470 17 486 17 488 20 496 20.17 497 17 498 172 517 25.24.23.22.21.20.19.18.17 518 25.24.23.22.21.20.19.18 519 24.23.22.21.19.18 520 24.23.22.21 521 22.21 522 21 523 212 540 25,24,23,22,21,20,19,18 541 23,22,21,20,19,18 542 22,21,20,19,183 663 25.24.23.22.21.19 664 26.25.24.23.22.21.19.18 665 25.24.23.22.21.17 666 25.24.23 667 25.24.23 668 25.24.23.22 669 25.24.23.22 670 25.24.23.22.21 671 23.21 672 23.21 673 21 674 21 676 19 677 18 678 17 680 21.19.18.17 681 19.18.17 682 19.18.17 683 21.18.17 684 21.17 685 21 686 21.17 687 21.19.17 688 174 879 25,24,23,22 880 24,23,22 881 23,22 882 22 883 21 884 20 885 19 912 21.19.18 913 19.18 914 19.18 915 18 937 25.24.23.22.21.20.19.18.17 938 25.24.23.22.21.20.19.18.17 939 25.24.23.22.21.20.19.18.17 940 25.24.23.22.21.20.19.18.17 941 25.24.23.22.21.20.19.18.17 942 24.23.22.21.19.18.17 943 24.23.22.21.19.18.17 944 22.21 945 21.19.18 946 19.18 947 19.175 981 22.21.19.18.17 982 21.19 983 19 984 19 985 18 986 17 995 23.22.19.18.17 996 22.18.17 997 17 998 19.18.17 999 24.23.22.18.17 1000 24.23.22.21.20.19.18.17 1001 22.21.20.19.18.17 1002 21.20.19.18.17 1003 20.19.18.17 1004 19.18.17 1005 24.23.19.18 1006 23.18 1008 25.24.23 1009 25.24.23 1010 25.24.23 1011 25.24.23 1012 25.24.23 1013 25.24.23 1014 25.24.23 1015 25.23 1031 22.21 1032 21.19 1033 19.18.17 1034 19.17 1055 17 1088 25 1089 25 1090 25 1091 25 1092 25 1093 25 1094 256 1121 25.24.23.22.21.19.18.17 1122 25.24.23.22.21.20.19.18.17 1123 25.24.23.22.21.20.19.18.17 1124 25.24.23.22.21.19.18.17 1125 25.24.23.22.21.20.19.18.17 1126 25.24.23.22.21.20.19.18.17 1127 25.24.23.22.21.19.18.17 1128 25.24.23.22.21.19.18.17 1129 25.24.23.22.21.19.18.17 1130 25.24.23.22.21.19.18.17 1131 25.24.23.22.21.19 1132 25.24.23.22 1133 25.24.23 1134 25.24.23 1135 24.23 1136 24.237 1685 25.24.23.22.21.19.18 1686 25.24.23.22.21.19.18.17 1687 25.24.23.22.21.19.18.17 1688 25.24.23.22.21.20.19.18.17 1689 25.24.23.22.21.18 1690 25.24.23.22.21.19.18.17 1691 25.24.23.22.21.20.19.18.17 1692 25.24.23.22.21.19.18.17 1693 25.24.23.22.19.15.17 1694 25.24.23.22.19.18.17 1695 25.24.23.22.18.17 1696 24.23.22 1697 24.238 5932 17 5995 22.21 5996 21.20.19.18 5997 19.18.17 5998 18.17 5999 17 6004 21 6007 17 .sup. 8A 6277 23 6278 22,21 6279 21,20 6280 209 6548 24.23.22 6549 23.22 6550 22 6551 22 6560 21 6562 19 6563 18 6564 17______________________________________ *The numbers indicate the 26mers, 25mers, 24mers, etc., down to 17mers that are contained within the oligo sequence shown. Size reduction in individual oligo is limited to removal of nucleotides from the 5prime end only of the oligo shown at each nucleotide starting position.
TABLE 5______________________________________Preferred Size Variants of MRP-Oligos at different starting positionsin the MRP gene sequence hotspotsHOT- NucleotideSPOTS starting position Oligo Size Variants______________________________________1 20 17 21 17 22 17 24 26 36,39,42,45,48,51,54 25.24.23.22.21.19.18.17 37,40,43,46,49,52 25.24.23.22.21.19.18.17 38,41,44,47,50,53 25.24.23.22.21.19.18.17 55 25 56 25 57 252 169 26.19.18.17 170 18.17 171 173 219 19 220 25.24.23.22.21.20.19 221 24.23.22.21.19 222 23.22.21.20.19.18.17 223 22.21.20.19.18.17 224 21.19.18 225 20.19.18 226 19.18 227 18 236 19 263 25.24 264 25.244 1198 24 1199 24.23 1200 24.23 1201 24.23 1202 25.24.23.22 1203 24.23.22 1204 25.24.23.22 1205 25.24.23.22.21 1206 25.24.23.22.21 1207 25.24.23.22.21 1208 25.24.23.22.21 1209 25.23.22.21 1210 25.22.21.20.19.17 1211 25.21.17 1212 25.21.17 1213 24.21.18.17 1214 25.17 1215 25.17 1216 25.17 1217 25.175 2101 25.24.23.21.20.19.18.17 2102 25.24.23.21.20.19.18.17 2103 25.24.23.21.20.19.18.17 2104 25.24.23.21.20.19.18.17 2105 25.24.23.21.20.19.18.17 2106 25.24.23.21.20.19.18.17 2107 25.24.23.22.21.20.19.18.17 2108 25.24.23.22.21.20.19.18.17 2109 24.23.22.21.20.19.18.17 2110 23.22.21.20.19.18.17 2111 22.21.19.18 2112 22.21.19 2113 21 2114 20 2115 196 2469 25.24.23 2470 25.24.23 2471 25.24.23 2472 25.24.23.22 2473 25.24.23.22.21 2474 25.24.23.22.21 2475 25.24.23.22.21 2476 24.23.22.21 2477 23.22.21 2478 22.21 2479 21 2489 22.21 2490 21 2516 20.17 2517 17 2518 19.18.17 2519 20.19.18.17 2520 18.17 2521 177 2805 25 2829 25.24.23.22.21 2830 24.23.22.21 2831 23.22.21 2832 22.21.19 2833 21.19 2834 20.19 2835 19.18 2836 18 2837 18.17 2848 20.19.18.17 2849 19.18 2850 18 2862 24.23.22.21.19 2863 25.24.23.22 2864 25.24.23.22 2865 25.24.23.22 2866 24.23.22 2867 24.23 2868 24.23 2869 24.23 2870 25.24.23 2871 25.24.23 2872 24.23 2873 238 3528 25.24.23.22.21.20.19.18.17 3529 25.24.23.22.21.20.19.18.17 3530 25.24.23.22.21.20.19.18.17 3531 25.24.23.22.21.20.19.18.17 3532 25.24.23.22.21.20.19.18.17 3533 25.24.23.22.21.20.19.18.17 3534 25.24.23.22.21.19.18 3535 25.24.23.22.21.19.18 3536 25.24.23.22.21.19.18 3537 25.24.23.21.19 3538 25.24.23.22.21.20.19.18 3539 25.24.23.22.21.20.19.18 3540 25.24.23.22.21.20.19.18 3541 24.23.22.21.20.19.18 3542 23.22.21.20.19.18 3543 22.21.20.19.18 3544 21.19.18 3545 21.19 3546 19 3547 19.18 3548 189 4146 25.24.23.22 4147 24.23.22 4148 23.22.21 4149 22.21.19 4150 21.19 4151 25.24.23.22.21.19.18 4152 25.24.23.22.21.19.18 4153 25.24.23.22.21.19.18 4154 25.24.23.22.21.20.19 4155 25.24.23.22.19 4156 25.24.23.22 4157 25.24.23.22.21 4158 25.24.23.22.21.19 4159 24.23.22.21.19 4160 23.22.21.20.19.18 4161 22.21.20.19.18 4162 21.20.19.18 4163 20.19.18.17 4164 19.18.17 4165 19.18.17 4166 18.17 4167 17 4173 1710 4873 25 4929 25.24.23.22 4930 25.24.23.22.21 4931 25.24.23.22.21.19 4932 25.24.23.22.21.19 4933 24.23.22.21.20.19.18 4934 23.22.21.19.18 4935 22.21.19.18 4936 21.20.19.18 4937 20.19.18 4938 19.18 4939 18 4940 17 4633 25,24,23,22,21 4634 24,23 4635 23 4636 22,21,20,19,18 4637 21 4639 19 4640 19,18______________________________________
Use of Selected Oligonucleotides for Systemic Treatment of Patients
Pursuant to the invention, oligos designed to inhibit the expression of the MDR1 or MRP genes are administered to patients in accordance with any of a number of standard routes of drug administration. For example, the oligo may be administered to a patient by continuous intravenous administration for a period of time such as ten days. An infusion rate of 0.05-0.5 mg/kg/hr should be suitable for the practice of the invention. Alternatively, the oligo may be injected daily, given orally or be released into the patient's body from an implanted depot or be given by some other route of administration as deemed appropriate according to the criteria of standard clinical practice.
Other inhibitors of P-gp or MRP function may be given in conjunction with the administration of the oligonucleotide in accordance with the best mode of use for the given agent. If a patient has cancer or a premalignant syndrome and the purpose of administering the oligo to the patient is to improve chemotherapy response, then chemotherapeutic agents will be given either during or at about the same time as the oligo administration. A period of about one week prior to or following the administration of the oligo should be a period of time during which chemotherapeutic drugs should be given to the patient. If the patient has cancer or a premalignant syndrome and the purpose of administering the oligo is to prevent the development of multidrug resistance in the diseased cells, then the oligos will be administered to patients at times when the patient does not have active levels of chemotherapeutic drugs in the patient's body. If a patient has an autoimmune disease, such as arthritis, is experiencing graft rejection or graft-versus-host disease, then the oligos may be administered to the patient alone or in combination with other agents including inhibitors of P-gp or MRP as an immunosuppressive therapy. Oligo doses and schedules suitable for cancer patients also should be suitable for patients with autoimmune disease or who are experiencing graft rejection. Drugs cytotoxic or cytostatic to cells of the patient's immune system may also be given in conjunction with the oligo to bring about an immunosuppressed state in the patient for the purpose of reversing the pathological conditions.
Use of Selected oligonucleotides for Depleting Malignant Cells or Cytotoxic Mononuclear Cells From Bone Marrow or From Peripheral Stem Cell Harvests
Pursuant to the invention, one first obtains a sample of bone marrow or peripheral stem cells in accordance with any of a number of standard techniques. The patient to receive an autologous transplant may then be treated with an optimal dose of radiation and/or chemotherapy according to standard clinical procedures.
The bone marrow or peripheral stem cell sample may be cryopreserved and stored until needed, or immediately treated with the oligo.
In order for the tumor cell or normal mononuclear cell targets to be affected by the oligo, the cells must be exposed to the oligos under conditions that facilitate their uptake by the malignant cells. This may be accomplished by a number of procedures, including, for example, simple incubation of the cells with an optimal concentration of the oligo in a suitable nutrient medium for a period of time suitable to achieve a significant reduction in P-gp or MRP expression. Four days should be sufficient incubation period, but time may need to be extended, e.g., for slow growing tumors. At this time, a chemotherapeutic drug may be added that will kill any cancer cells present in the graft in the case of an autologous transplant or non-malignant mononuclear cells that can produce graft-versus-host disease in the case of an allogeneic transplant. After the bone marrow or peripheral stem cells have been cultured as just described, they are then infused into the transplant recipient to restore hemopoiesis.
Aptameric Oligonucleotides Capable of Reversing Multidrug Resistance Phenotype
The MDR-aptameric oligonucleotides shown in Table 14 (Example 7) are very active in reversing the multidrug resistance phenotype, and in inhibiting the growth of multidrug resistant cancer cells. They have little or no drug sensitizing or proliferation-inhibiting activity on drug sensitive cells. This aptameric effect also is shared by the OL(1C)mdr oligo and, to a lesser extent, by the OL(1Q)mdr and SJ(34)mdr oligos. It has been found, using a previously described technique involving purified rat brain protein kinase C isoenzymes (Ward et al., J. Biol. Chem . 270: 8056, 1995) that these aptameric oligonucleotides do not significantly alter the activity of PKC-α, -β or -gamma. The existing data support the concept of developing these aptamers for clinical use, using basically the same strategy described herein for oligonucleotides targeting MDR1 or MRP. Using methodology of the type described by Schultze et al (J. Mol. Biol. 235: 1532, 1994), common structural features in these aptamers can be uncovered that would provide a basis for designing additional (and perhaps more specific and more active) aptamers for reversing multidrug resistance. In addition, using standard molecular biological techniques such as those described in standard texts such as, for example, Current Protocols in Molecular Biology (FM Ausubel et al., eds, New York: John Wiley & Sons, Inc., 1994), these MDR-aptameric oligonucleotides can be used to identify the target molecule to which they bind and produce the effect seen on multidrug resistance.
For example, these MDR-aptamers can be radiolabeled and incubated in vitro with cells which are then lysed; or, the MDR-aptamers can be used to treat cell lysates, and fractionation studies can then be carried out to isolate molecules to which the radiolabeled MDR-aptamer binds. Studies would then be carried out to confirm that a particular molecule to which the MDR-aptamer had been tightly bound has a functional role in multidrug resistance. For example, it might be shown that the molecule to which the MDR-aptamer binds is more active, or is expressed at higher levels, in multidrug resistant cells than in the drug-sensitive counterparts.
Purification of the protein to which the aptamers bind would allow microsequencing. The protein sequence can be used to generate a set of oligonucleotide probes that can be used to identify the cDNA and/or gene sequence that encodes the said protein. If it is a known protein or gene, then this information will identify the target of the MDR-aptamers. If it is not a known gene, then the gene can be cloned and characterized. Antisense oligos against this gene would be expected to have activity in reversing multidrug resistance. Even if the gene encoding the protein to which the MDR-aptamers bind is not novel, then observation that targeting this protein with aptameric oligos leads to a reversal of the multidrug resistance phenotype is a novel observation, and it provides the basis for a new therapeutic strategy for the treatment of cancer.
In sum, preferred embodiments of the present invention relate to the systemic administration of an oligonucleotide capable of inhibiting the expression of one or more of these pumps in the tumors of patients with cancer; or administering two oligos, one capable of inhibiting, for example, P-gp expression and the other inhibiting, for example, MRP expression, thereby rendering the patient's tumor more susceptible to the cytotoxic effects of chemotherapeutic agents administered together with the oligo. Also, these oligos may be administered to patients prophylactically to prevent the development of multidrug resistance in a tumor. These oligos may be used alone to inhibit multidrug resistance, or in combination with other inhibitors of P-gp or MRP. The invention also includes procedures and compositions for ex vivo administration to purge malignant cells from bone marrow grafts. Said oligos may also be administered to transplant or autoimmune patients as immunosuppressive agents.
In another application, these oligos may be used to interrupt the blood brain barrier, thus allowing therapeutic agents to pass from the general circulation into the central nervous system.
In yet another application, MRP oligos may be of use in inhibiting the transport of leukotrienes across cell membranes, and may be of clinical use in situations where this class of compounds is involved, for example, in inflammatory/allergic responses.
Also revealed are prototype oligos that can inhibit various multidrug resistance phenotypes in cancer cells by an aptameric effect.
The following examples are provided to describe the invention in further detail. These examples are intended to illustrate, and not to limit, the invention.
EXAMPLE 1
Sensitization of Multidrug-Resistant (MDR+) Cancer Cell Lines to Doxorubicin by MDR-Oligos
Multidrug resistant tumor cells were incubated with 15μM of OL(6)mdr oligo, Cohen(1)mdr oligo or a negative-control (HIV-2) oligo for 4 days at 37° C. in a humidified incubation chamber. Varying doses (5-fold serial dilutions) of doxorubicin (from 1×10 -5 M to 1×10 -8 M) were then added to the culture wells after the cells had been subcultured into media without oligos; cells were then incubated in the same culture environment for an additional three days. Radiolabeled (tritiated) thymidine was added to all cultures for 24 hr before harvest. Each data point is the mean of 4 replicates. The data (Table 6) demonstrate that OL(6)mdr is able to sensitize multidrug-resistant cancer cells to chemotherapeutic agents, nearly three times better than the best MDR-oligo reported in the literature (Jarozewski et al.: Cancer Comm. 2: 287-294, 1990.).
TABLE 6______________________________________Sensitization of 8226/Dox cells to killing by doxorubicin followingincubation with OL(6)mdr MDR-oligo. Relative SEQ IC.sub.50 SensitizationTreatment ID NO. dose (× 10-.sup.7 M) (fold increase)______________________________________Medium only -- 6.5 --HIV-2 control oligo* 85 7.0 --Cohen(1)mdr oligo** 86 5.0 1.3OL(6)mdr oligo 1 1.8 3.6______________________________________ *HIV-2 nucleotide sequence (20mer): 5TGTCTCCGCT TCTTCCTGCC3' (SEQ ID NO: 85); **Cohen(1)mdr nucleotide sequence (15mer): 5GCTCCTCCAT TGCGG3' (SEQ ID NO 86)
EXAMPLE 2
Sensitization of Multidrug-Resistant 8226/Dox Human Myeloma Cells and CEM/VBL10 Human Leukemia Cells to Vincristine Following Incubation with MDR-Oligos Under Low Oxygen Levels
As shown in this example, several oligos which target the MDR1 gene are able to sensitize multidrug-resistant cell lines to the cytotoxic effects of the chemotherapeutic agent Vincristine. Tumor cells were treated in vitro with 10 μM of the indicated oligo for 4 days at 37° C., then counted, dispensed into individual tubes, and pulsed with Vincristine at various doses (serial 5-fold dilutions) for 3 hrs. The cells were then washed and seeded into 96-well plates (quadruplicate replicates) for pulsing with tritiated thymidine 3 days later. Cells were harvested the next day (=4th day after drug treatment). Tritiated thymidine uptake was analyzed by liquid scintillation.
The Prototype MDR-oligos shown in Tables 1 and 2 represent the most potent of the MDR-oligos screened on the tumor cell line in these studies. In experiments not shown, most of the other phosphorothioate MDR-oligos evaluated in vitro (sequences not listed) had little-to-no capacity to sensitize targeted tumor cells to cytotoxic drugs at concentrations at which the prototype oligos had substantial activity, confirming that the dramatic antisense effects noted above were not merely a cellular response to exposure to phosphorothioate molecules, but appear to be sequence dependent.
The OL(1)mdr oligo (Table 7) is clearly much more potent than OL(6)mdr in sensitizing 8226/Dox cells to chemotherapeutic agents. Given the data in Tables 6 and 7, it is also evident that OL(1)mdr is much more potent than the Cohen(1)mdr oligo, even though the OL(1)mdr and Cohen(1)mdr oligos have overlapping sequences:
OL(1)mdr 5'-GCTCCTCCAT TGCGGTCCCC-3'
(SEQ ID NO. 25)
Cohen(1)mdr 5'-GCTCCTCCAT TGCGG-3'
(SEQ ID NO. 86)
The present inventor, therefore, has made the unobvious discovery that the inclusion of the sequence ("TCCCC") to the oligos that bind in the same general area as the Cohen(1)mdr oligo greatly increases the potency of the oligos in terns of sensitizing cells that express MDR1 to chemotherapeutic agents.
TABLE 7______________________________________Sensitization or multidrug-resistant tumor cells to killing byVincristinefollowing incubation with several MDR-oligos in 5% oxygen Relative Oligo IC.sub.50 dose sensitizationCell Type Used SEQ ID NO. (× 10-.sup.7 M)* (fold increase)______________________________________8226/Dox Control -- 4.5 -- OL(1)mdr 25 0.027 167 PA(1)mdr 40 0.28 16 5(1)mdr 10 1.80 2.5 OL(6)mdr 1 2.20 2.5CEM/ Control -- 100.0 --VLB10 5(1)mdr 10 0.9 111 OL(6)mdr 1 1.2 83 OL(5)mdr 21 1.5 67 OL(1)mdr 25 1.6 62 SJ(36)mdr 39 1.6 62 OL(2)mdr 35 1.6 62 PA(1)mdr 40 1.9 53 OL(3)mdr 37 2.0 50______________________________________ *IC.sub.50 = inhibitory concentration which gives 50% reduction in tritiated thymidine uptake into DNA
EXAMPLE 3
As shown in this example, it was determined that there was an increase in sensitivity of multidrug-resistant 8226/Dox human myeloma cells to Vincristine with increasing time of incubation following initial exposure to Vincristine. The experimental conditions were identical to those ustilized in obtaining the data shown in Table 7, except that the present experiment had two additional time points.
TABLE 8______________________________________Increase in sensitivity of multidrug-resistant 8226/Dox humanmyeloma cells to Vincristine with increasing time of incubationfollowing initial exposure to Vincristine SEQ Oligo Relative SensitizationOligo Used ID Concentration (fold increase)(Trivial Name) NO. (μM) Day 5* Day 7 Day 9______________________________________5(1)mdr 10 2 3.4 26.9 724 10 2.1 20.5 423OL(1)mdr 25 2 18.3 412 5500 10 75.8 389 5729PA(1)mdr 40 2 2.3 27 1309 10 6.3 28 550OL(6)mdr 1 2 1.6 3.5 61 10 1.8 15.9 550Control Oligo** 87 2 1.0 0.9 0 10 0.8 7.0 26.2 IC.sub.50 Value on: Day 5 Day 7 Day 9Media Control 4.4 × 10.sup.-7 M 7 × 10.sup.-6 M 5.5 × 10.sup.-4 M______________________________________ *Days after initial treatment exposure with Vincristine **Control oligo sequence: 5CCTCGGTCCC CCCTCGTCCC C3' (SEQ ID NO. 87)
EXAMPLE 4
In Vitro Sensitization of MRP-Expressing Lung Cancer Cells to Etoposide by MRP-Oligos
The Prototype MRP-ODN shown in Table 3 represent the most potent of the MRP-ODNs screened on the tumor cell line in these studies. The human non-small-cell lung adenocarcinoma cell line A427 was treated with oligos at various concentrations for 4 days in vitro. The cells then were pulsed with various concentrations of etoposide (range 1.6×10 -4 to 1×10 -6 M) for 3 hrs. Next, cells were trypsinized and seeded by volume into 96-well plates with 12 replicates per treatment condition. Three days later, tritiated thymidine was added and the cells harvested the next day.
The OL(8)MRP antisense oligo specific to an MRP gene-related sequence made the A427 lung cancer cell line 18-times more sensitive in vitro to the cytotoxic effects of etoposide (VP-16). The data (Table 9) confirm the specificity of this activity. OL(6)mdr, which targets transcripts of the MDR1 gene, was used as a negative control with this MRP-expressing cell line. When novobiocin, a putative MRP inhibitor, was used at the same time as VP-16, it increased the A427 drug sensitivity by about 5 fold.
TABLE 9______________________________________A427 Lung Cancer Cell Line Treated with MRP-oligos SEQ Oligo Etoposide (VP-16) ID Level Relative SensitizationTreatment NO. (μM) IC.sub.50 (fold increase)______________________________________Experiment 1Media-Control -- -- 3.6 × 10.sup.-5 M* --Novobiocin -- -- 0.72 × 10.sup.-5 M 5.0OL(6)mdr control 1 10.0 2.2 × 10.sup.-5 M 1.6OL(6)mdr control 1 5.0 3.0 × 10.sup.-5 M 1.2OL(6)mdr control 1 2.5 4.8 × 10.sup.-5 M 0OL(8)MRP 64 10.0 2 × 10.sup.-6 M 18.0OL(8)MRP 64 5.0 1.0 × 10.sup.-5 M 3.6OL(8)MRP 64 2.5 1.8 × 10.sup.-5 M 2.0Experiment 2Media Control -- -- 5 × 10.sup.-5 M --OL(6)MRP 60 10.0 6 × 10.sup.-6 M 85(2)MRP 43 10.0 8 × 10.sup.-6 M 6OL(3)MRP 62 10.0 9 × 10.sup.-6 M 55(3)MRP 42 10.0 1 × 10.sup.-5 M 5Experiment 3Media Control -- -- 6.0 × 10.sup.-5 M --OL(5)MRP 48 10 1.0 × 10.sup.-5 M 6OL(14)MRP 44 10 1.9 × 10.sup.-5 M 3OL(2)MRP 49 10 2.5 × 10.sup.-5 M 2.4Experiment 4OL(6)mdr control 1 1 5.0 × 10.sup.-5 M 0OL(4)MRP 76 1 1.6 × 10.sup.-5 M 3______________________________________ *IC.sub.50 = inhibitory concentration which gives 50% reduction in tritiated thymidine uptake
EXAMPLE 5
In this example, experimental conditions were identical to those utilized in obtaining the data in Example 2. These data show that the MRP-oligo, OL(8)MRP, can substantially sensitize non-lung cancer cells to chemotherapeutic agents, as determined in in vitro assays.
TABLE 10______________________________________In vitro sensitization of 8226/Dox cells to Vincristine by an MRP-oligoand comparison to several MDR-ODNs for relative potency. IC.sub.50 Relative SensitizationTreatment SEQ ID NO. dose (× 10-.sup.7 M) (fold increase)______________________________________Medium only -- 11 --OL(8)MRP 60 0.55 20OL(1)mdr 25 0.2 55OL(6A)mdr 2 0.88 12.5OL(3)mdr 37 1.0 11OL(2)mdr 35 3.0 3.7______________________________________
EXAMPLE 6
In vitro testing of MDR-Oligonucleotides was done on the multidrug-resistant (MDR+) RPMI-8226/Dox4 human multiple myeloma cell line (gift of Dr. William Dalton, Univ. Arizona Cancer Ctr., Tucson). Cells were incubated in vitro for 4 days at 37° C. with MDR-oligos at 0.2 μM final concentration; pulsed 18 hr with serial 5-fold dilutions of chemotherapeutic drug (vincristine) from 1×10 -4 M to 2×10 -10 M. Cells were then washed, and incubated for an additional 4 days. Tritiated thymidine ( 3 H-TdR) was added for last 18 hr to measure status of cellular proliferation. Controls included MDR+8226 cells similarly treated with vincristine but pretreated either with (a) control ODNs, or (b) culture medium only.
TABLE 11a______________________________________MDR--ODNs Oligo SEQ 5'-end length Why the siteOligo ID target (No. of was selected RelativeName No. site.sup.1 bases) (Footnote #) Activity______________________________________OL(1)mdr 25 1125.sup.1 20 +++OL(1A)mdr 34 1122 20 variant ++OL(1B)mdr 26 1123 22 variant ++++++OL(1C)mdr 27 1125 25 variant +++++++OL(1Q)mdr 28 1125 23 variant ++++++OL(1W)mdr 29 1125 18 variant +++++OL(1Wa)mdr 30 1123 18 variant ++++OL(1Wb)mdr 31 1125 16 variant ++++OL(1Wc)mdr 32 1121 18 variant ++++OL(1X)mdr 33 1127 18 variant +++OL(2)mdr 35 1688 20 +OL(3)mdr 37 5996 20 +OL(5)mdr 21 1000 20 +++OL(6)mdr 1 488 20 +OL(6A)mdr 2 496 20 variant --OL(7)mdr 110 2199 20 +OL(8)mdr 111 5722 20 --OL(9)mdr 112 3881 20 --OL(10)mdr 11 688 20 +++OL(11)mdr 851 20 +OL(12)mdr 12 884 20 +++OL(12A)mdr 13 881 22 variant +++++OL(12B)mdr 14 885 18 variant +++OL(12C)mdr 15 881 18 variant ++OL(13)mdr 958 20 --OL(14)mdr 5713 20 --OL(15)mdr 16 941 20 --OL(16)mdr 3 517 20 +SJ(1)mdr 113 85 20 splice junction --SJ(2)mdr 114 673 20 splice junction ++SJ(6)mdr 2559 20 splice junction +SJ(18)mdr 6074 20 splice junction +SJ(30)mdr 4867 20 splice junction --SJ(33)mdr 349 20 splice junction --SJ(34)mdr 5 540 20 splice junction +++SJ(34A)mdr 6 542 18 variant +++++SJ(34B)mdr 7 540 22 variant ++SJ(34C)mdr 8 533 20 varianl +SJ(34D)mdr 9 543 16 variant +SJ(35)mdr 1097 20 splice junction --SJ(36)mdr 39 6551 22 splice junction +3(1)mdr 7051 20 3'-end --5(1)mdr 10 664 26 2, AUG start ++5(2)mdr 640 28 2 --AP(1)mdr 41 670 23 3; TR binding +AP(4)mdr 636 22 3; TR binding +PA(1)mdr 40 -- 23 reverse of AP(1) +TH(2)mdr 2954 20 published +CAP(2)mdr 556 22 cap site +LOW(3)mdr 11 20 low Tm +Cohen(1)mdr 86 1130 15 published +NF-kB(1)mdr 296 22 3; TR binding --CAT(L)mdr 432 20 TR binding --Y-box-mdr 464 22 TR binding --______________________________________ Reactivity: -- = no effect; + = weak positive effect; +++++++ = very strong positve effect. The relative reactivity indicated for each MDR--ODN summarizes results obtained with 8226/Dox4, 8226/Dox6 and CEM/VLB10 multidrugresistant cell lines. .sup.1 The numbering for the 5end target site is based on Genbank entry HUMMDR1A01through-HUMMDR1A26 (Chin et. al., Mol. Cell. Biol. 9: 3808, 1989; Chen et al., J. Biol. Chem. 265: 506, 1990), considered as a continuous sequence with the nucleotide at the extreme 5end of the sequence being given the nucleotide base number 1. .sup.2 These ODNs were designed to have sufficient binding affinity to th 5untranslated portion of the cDNA to potentially block the movement of th ribosome toward the AUG start site. .sup.3 Binding sites of these oligos are within an enhancer for the MDR1 gene, the sequence of which is reported by Kohno et al, J. Biol. Chem. 265: 19690, 1990. (GenBank entry # HUMMDR1B/J05674). .sup.4 OL(7)mdr Sequence ID No. 110 TAGCCACATGGCCCCAGGAA OL(8)mdr Sequence ID No. 111 ACTGACTTGCCCCACGGCCA OL(9)mdr Sequence ID No. 112 CCAAAGGGCAAAGGGCAAGG SJ(1)mdr Sequence ID No. 113 GTACCTTACCTTTTATCTGG SJ(2)mdr Sequence ID No. 114 TGCCCCTACCTCGCGCTCCT
TABLE 11b______________________________________MRP-ODNs ODN 5'-end length Why the siteOligo SEQ target (No. of was selected RelativeName ID NO. site.sup.1 bases) (Footnote #) Activity______________________________________A(1)MRP 194.sup.1 20 AUG start site -OL(2)MRP 49 2114 20 -OL(3)MRP 62 2848 20 +++OL(4)MRP 76 4154 20 -OL(5)MRP 48 1210 20 +OL(6)MRP 60 2516 20 +OL(7)MRP 3155 20 -OL(8)MRP 64 3539 20 +++++OL(9)MRP 3800 20 +OL(10)MRP 4484 20 ++OL(11)MRP 4715 20 -OL(12)MRP 89 20 -OL(13)MRP 129 20 -OL(14)MRP 44 220 20 +OL(15)MRP 84 3312 20 -OL(16)MRP 1580 20 -3(2)MRP 4836 20 3'-end -3(3)MRP 81 4933 20 3'-end -5(2)MRP 43 164 26 2 +++5(3)MRP 42 24 26 2 ++LOW(1)MRP 351 20 low T.sub.m -LOW(2)MRP 714 20 low T.sub.m +CAP(2)MRP 1 19 Cap site +______________________________________ Reactivity: - = no effect; + = weak positive effect; +++++ = strong positive effect .sup.1 The numbering for the 5end target site is based on Genbank entry HUMMRPX/L05628 (Cole et al., Science 258: 1650, 1992) with the nucleotide at the extreme 5end of the sequence being given the nucleotide base numbe 1. .sup.2 These ODNs were designed to have sufficient binding affinity to th 5untranslated portion of the cDNA to potentially block the movement of th ribosome toward the AUG start site.
TABLE 12__________________________________________________________________________IC.sub.50 SUMMARY(based on 8226/Dox4 human myeloma cells) Fold-Increase inOligos* Sequence Oligo Vincristine sensitivity(trivial name) SEQ ID NO. Position Length IC.sub.50 to drug treatment**__________________________________________________________________________Media Control -- -- -- 1.2 × 10.sup.-5 M --OL(1)mdr 25 1125 20 1.4 × 10.sup.-7 M 86OL(1B)mdr 26 1123 22 1.6 × 10.sup.-9 M 7500OL(1C)mdr 27 1125 25 <<1.6 × 10.sup.-9 M >>7500OL(1Q)mdr 28 1125 23 <1.6 × 10.sup.-9 M >7500OL(1W)mdr 29 1125 18 2.1 × 10.sup.-9 M 5714OL(10)mdr 11 688 20 3.0 × 10.sup.-7 M 40OL(12)mdr 12 884 20 6.0 × 10.sup.-8 M 200OL(12A)mdr 13 881 22 3.2 × 10.sup.-8 M 375OL(12B)mdr 14 885 18 3.0 × 10.sup.-7 M 40SJ(34)mdr 5 540 20 4.1 × 10.sup.-8 M 293SJ(34A)mdr 6 542 18 <1.6 × 10.sup.-9 M >7500SJ(34C)mdr 8 533 20 5.5 × 10.sup.-9 M 2182__________________________________________________________________________ *All oligonucleotides were tested at a final concentration of 0.2 μM **Fold increase in drug sensitivity compared to media control (no oligo o drug).
EXAMPLE 7
Mathematical/Statistical Model Used to Analyze ODN- and Drug-Testing Data
The following mathematical/statistical model was used to analyze the effects of oligos and various drug treatments on targeted tumor cells in these studies. The model is based on experiments which generally involve treatment of tumor cells with one of several ODNs or media only, and with several dose levels of an anti-cancer agent (such as, for example, vincristine (VCR)) or media only. Analysis goals were to model the relationship of cell kill to the dose of VCR (for example), and to compare the effects of the various ODNs.
Investigation of the data indicate that the logarithm of counts can be modelled as a function of the dose of drug for each ODN; i.e.:
ln(count)=f(dose)+error
A "full model" that fits for each ODN and drug dose in a given experiment is as follows:
ln(count)=α+β.sub.1 (drug)+β2(dose) +β.sub.3 (square root of dose) +β.sub.4 (fourth root of dose)+error
Thus, the natural log (count) is modelled as a linear function of powers of drug dose in the assay. For a fixed ODN, i, the expected count for media-only (no drug) is
E(count).sub.media =exp(α.sub.i)
For the drug dose, d*, on the other hand, the expected count is
E(count)d*=exp(α.sub.i +β.sub.2i d*+β.sub.3i square root of d*!+β.sub.4i {fourth root of d*}).
Using standard linear regression techniques, the "full" model (19 regressor variables) was fitted to the data from all serial-dilution drug dose levels together; from this, a more parsimonious model was developed by removing regressor variables which did not contribute to the model fit. This final model contained 10 regressor variables.
From this most parsimonious model, with its 10 predictor variables, graphs of the data are prepared, in which Predicted 3 H-TdR uptake Counts (on the Y-axis) are plotted against Log 10 (dose of drug) (X-axis); this most parsimonious model fits the data with an excellent correlation coefficient of R 2 =0.98. The estimated functions (curved lines) associating Log 10 (Vincristine dose) with expected " 3 H-TdR Counts" for each oligo can be calculated, and are shown in the following FIGURE, where the "Media only" control counts are placed on the left-hand Y-axis.
Various estimates of parameters from the parsimonious model are shown in TABLE 13, which contains the model estimate of the count for each ODN with media only; differences here (when compared to "media only" no ODN!) reflect the cell kill associated with the ODN alone. TABLE 13 also contains an estimate of IC 50 values, the dose of vincristine (VCR) which is estimated to produce an expected count which is exactly half that expected with "media only" no VCR!. While formal statistical comparisons of the IC 50 values of the various ODNs is not possible, an ordering of the ODNs by estimated IC 50 values is possible.
TABLE 13__________________________________________________________________________Estimated Mean Count at VCR Dose = 0 and IC.sub.50 for Oligonucleotidesused totreat 8226/Dox4 cells: Results from most parsimonious modelOligonucleotide Estimated Mean Fold Increase in(trivial name) SEQ ID NO. Count (cpm) Estimated IC.sub.50 drug sensitivity**__________________________________________________________________________Medla oniy -- 159,500 1.28 × 10 - 5M --OL(12)mdr 12 159,500 5.50 × 10 - 8M 233OL(12B)mdr 14 159,500 7.39 × 10 - 7M 17.3OL(12A)mdr 13 159,500 2.97 × 10 - 8M 414OL(1B)mdr 26 120,800 1.79 × 10 - 8M 715OL(1C)mdr 27 40,200 1.33 × 10 - 7M 96.2OL(1Q)mdr 28 76,200 1.92 × 10 - 8M 667SJ(34A)mdr 6 100,300 6.81 × 10 - 8M 188__________________________________________________________________________ **fold increase in drug sensitivity compared to corresponding oligo control (no drug)
TABLE 14__________________________________________________________________________Sensitization of 8226/Dox Cells to Killing by VCRFollowing Incubation with MDR-aptameric oligonucleotides SEQ ID Sequence Fold Increase inTreatment No. (5'-->3') IC.sub.50 Drug Sensitization**__________________________________________________________________________Media -- -- 4 × 10.sup.-5 M --MDR-APT-1 88 CCCCTGGCGT TACCTCCTCG TTTCT 1 × 10.sup.-9 M 40,000MDR-APT-2 89 TTCGCCTGAT TTCCGCCTCC CGTCT 2 × 10.sup.-9 M 20,000MDR-APT-3 90 CGGTCCGTTA TGTTCCTG 7 × 10.sup.-9 M 5,714MDR-APT-4 91 ACTCGCCTCC CACGTAGTGC TT <1 × 10.sup.-9 M >40,000__________________________________________________________________________ **Fold increase in drug sensitivity compared to media control
It will be appreciated that changes may be made in the nature, composition, operation and arrangement of the various elements described herein without departing from the spirit and scope of the invention as set forth in the following claims.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 114(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:CCCACGCCCCGGCGCTGTTC20(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:GTGCTCAGCCCACGCCCCGG20(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:GGCAAAGAGAGCGAAGCGGC20(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:TGGCAAAGAGAGCGAAGCGG20(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:TCGAATGAGCTCAGGCTTCC20(2) INFORMATION FOR SEQ ID NO:6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 18 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:TCGAATGAGCTCAGGCTT18(2) INFORMATION FOR SEQ ID NO:7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:ACTCGAATGAGCTCAGGCTTCC22(2) INFORMATION FOR SEQ ID NO:8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:8:AGCTCAGGCTTCCTGTGGCA20(2) INFORMATION FOR SEQ ID NO:9:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 16 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:9:CGAATGAGCTCAGGCT16(2) INFORMATION FOR SEQ ID NO:10:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 26 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:10:CCCTACCTCGCGCTCCTTGGAACGGC26(2) INFORMATION FOR SEQ ID NO:11:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:11:GCTCCCAGCTTTGCGTGCCC20(2) INFORMATION FOR SEQ ID NO:12:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:12:GCGCGCTCCGGGCAACATGG20(2) INFORMATION FOR SEQ ID NO:13:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:13:CGCGCTCCGGGCAACATGGTCC22(2) INFORMATION FOR SEQ ID NO:14:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 18 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:14:CGCGCTCCGGGCAACATG18(2) INFORMATION FOR SEQ ID NO:15:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 18 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:15:CTCCGGGCAACATGGTCC18(2) INFORMATION FOR SEQ ID NO:16:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:16:TGCTTCCTCCCACCCACCGC20(2) INFORMATION FOR SEQ ID NO:17:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:17:TCCTCCCACCCACCGCCCGC20(2) INFORMATION FOR SEQ ID NO:18:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:18:TTCCTCCCACCCACCGCCCG20(2) INFORMATION FOR SEQ ID NO:19:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:19:CTTCCTCCCACCCACCGCCC20(2) INFORMATION FOR SEQ ID NO:20:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:20:GCTTCCTCCCACCCACCGCC20(2) INFORMATION FOR SEQ ID NO:21:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:21:TCTGGACTTTGCCCGCCGCC20(2) INFORMATION FOR SEQ ID NO:22:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:22:TTCTGGACTTTGCCCGCCGC20(2) INFORMATION FOR SEQ ID NO:23:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:23:GTTCTGGACTTTGCCCGCCG20(2) INFORMATION FOR SEQ ID NO:24:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:24:CGTTCTGGACTTTGCCCGCC20(2) INFORMATION FOR SEQ ID NO:25:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:25:GCTCCTCCATTGCGGTCCCC20(2) INFORMATION FOR SEQ ID NO:26:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:26:GCTCCTCCATTGCGGTCCCCTT22(2) INFORMATION FOR SEQ ID NO:27:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 25 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:27:TCTTTGCTCCTCCATTGCGGTCCCC25(2) INFORMATION FOR SEQ ID NO:28:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 23 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:28:TTTGCTCCTCCATTGCGGTCCCC23(2) INFORMATION FOR SEQ ID NO:29:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 18 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:29:TCCTCCATTGCGGTCCCC18(2) INFORMATION FOR SEQ ID NO:30:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 18 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:30:CTCCATTGCGGTCCCCTT18(2) INFORMATION FOR SEQ ID NO:31:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 16 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:31:CTCCATTGCGGTCCCC16(2) INFORMATION FOR SEQ ID NO:32:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 18 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:32:CCATTGCGGTCCCCTTCA18(2) INFORMATION FOR SEQ ID NO:33:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 18 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:33:GCTCCTCCATTGCGGTCC18(2) INFORMATION FOR SEQ ID NO:34:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:34:CCTCCATTGCGGTCCCCTTC20(2) INFORMATION FOR SEQ ID NO:35:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:35:GCAACCAGCACCCCAGCACC20(2) INFORMATION FOR SEQ ID NO:36:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:36:GCAGCAACCAGCACCCCAGC20(2) INFORMATION FOR SEQ ID NO:37:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:37:TGCCCACCAGAGCCAGCGTC20(2) INFORMATION FOR SEQ ID NO:38:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:38:GCCTCCTTTGCTGCCCTCACGA22(2) INFORMATION FOR SEQ ID NO:39:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:39:CCAGGGCTTCTTGGACAACCTA22(2) INFORMATION FOR SEQ ID NO:40:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 23 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:40:GCGGGAGGTGAGTCACTGTCTCC23(2) INFORMATION FOR SEQ ID NO:41:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 23 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:41:GGAGACAGTGACTCACCTCCCGC23(2) INFORMATION FOR SEQ ID NO:42:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 26 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:42:CGGCGGCGGCGGCGCAGGGAGCCGGG26(2) INFORMATION FOR SEQ ID NO:43:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 26 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:43:CGGTGGCGCGGGCGGCGGCGGGCACC26(2) INFORMATION FOR SEQ ID NO:44:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:44:GCGGGTCGGAGCCATCGGCG20(2) INFORMATION FOR SEQ ID NO:45:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:45:GAGCGGGTCGGAGCCATCGG20(2) INFORMATION FOR SEQ ID NO:46:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:46:AGAGCGGGTCGGAGCCATCG20(2) INFORMATION FOR SEQ ID NO:47:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:47:CCAGAGCGGGTCGGAGCCAT20(2) INFORMATION FOR SEQ ID NO:48:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:48:CTGCGGCCCGGAAAACATCA20(2) INFORMATION FOR SEQ ID NO:49:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:49:CGGTGATGCTGTTCGTGCCC20(2) INFORMATION FOR SEQ ID NO:50:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:50:CGTGCCCCCGCCGTCTTTGA20(2) INFORMATION FOR SEQ ID NO:51:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:51:TCGTGCCCCCGCCGTCTTTG20(2) INFORMATION FOR SEQ ID NO:52:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:52:TTCGTGCCCCCGCCGTCTTT20(2) INFORMATION FOR SEQ ID NO:53:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:53:GTTCGTGCCCCCGCCGTCTT20(2) INFORMATION FOR SEQ ID NO:54:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:54:TGTTCGTGCCCCCGCCGTCT20(2) INFORMATION FOR SEQ ID NO:55:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:55:CTGTTCGTGCCCCCGCCGTC20(2) INFORMATION FOR SEQ ID NO:56:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:56:GCTGTTCGTGCCCCCGCCGT20(2) INFORMATION FOR SEQ ID NO:57:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:57:TGCTGTTCGTGCCCCCGCCG20(2) INFORMATION FOR SEQ ID NO:58:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:58:ATGCTGTTCGTGCCCCCGCC20(2) INFORMATION FOR SEQ ID NO:59:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:59:GATGCTGTTCGTGCCCCCGC20(2) INFORMATION FOR SEQ ID NO:60:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:60:GGGCCAGGCTCACGCGCTGC20(2) INFORMATION FOR SEQ ID NO:61:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:61:GCCCGGGCCAGGCTCACGCG20(2) INFORMATION FOR SEQ ID NO:62:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:62:CCCTGGACCGCTGACGCCCG20(2) INFORMATION FOR SEQ ID NO:63:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:63:CGCCCGTGACCCCGTTCTCC20(2) INFORMATION FOR SEQ ID NO:64:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:64:GCGGGATGATGATGGCGGCG20(2) INFORMATION FOR SEQ ID NO:65:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:65:CGGGATGATGATGGCGGCGA20(2) INFORMATION FOR SEQ ID NO:66:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:66:GGCGGGATGATGATGGCGGC20(2) INFORMATION FOR SEQ ID NO:67:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:67:GGGCGGGATGATGATGGCGG20(2) INFORMATION FOR SEQ ID NO:68:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:68:GGGGCGGGATGATGATGGCG20(2) INFORMATION FOR SEQ ID NO:69:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:69:AGGGGCGGGATGATGATGGC20(2) INFORMATION FOR SEQ ID NO:70:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:70:ATGGCGGCGATGGGCGTGGC20(2) INFORMATION FOR SEQ ID NO:71:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:71:GATGGCGGCGATGGGCGTGG20(2) INFORMATION FOR SEQ ID NO:72:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:72:TGATGGCGGCGATGGGCGTG20(2) INFORMATION FOR SEQ ID NO:73:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:73:ATGATGGCGGCGATGGGCGT20(2) INFORMATION FOR SEQ ID NO:74:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:74:GATGATGGCGGCGATGGGCG20(2) INFORMATION FOR SEQ ID NO:75:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:75:TGATGATGGCGGCGATGGGC20(2) INFORMATION FOR SEQ ID NO:76:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 19 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:76:CGATGCCGACCTTTTCTCC19(2) INFORMATION FOR SEQ ID NO:77:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:77:GCCCCACGATGCCGACCTTT20(2) INFORMATION FOR SEQ ID NO:78:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:78:CGCCCCACGATGCCGACCTT20(2) INFORMATION FOR SEQ ID NO:79:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:79:CCGCCCCACGATGCCGACCT20(2) INFORMATION FOR SEQ ID NO:80:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:80:TCCGCCCCACGATGCCGACC20(2) INFORMATION FOR SEQ ID NO:81:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:81:TGGCGGTGGCTGCTGCTTTG20(2) INFORMATION FOR SEQ ID NO:82:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:82:GGATGGCGGTGGCTGCTGCT20(2) INFORMATION FOR SEQ ID NO:83:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:83:CGGATGGCGGTGGCTGCTGC20(2) INFORMATION FOR SEQ ID NO:84:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:84:CCGGTGGGCGATGGTGAGGACG22(2) INFORMATION FOR SEQ ID NO:85:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:85:TGTCTCCGCTTCTTCCTGCC20(2) INFORMATION FOR SEQ ID NO:86:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 15 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:86:GCTCCTCCATTGCGG15(2) INFORMATION FOR SEQ ID NO:87:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:87:CCTCGGTCCCCCCTCGTCCC20(2) INFORMATION FOR SEQ ID NO:88:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 25 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:88:CCCCTGGCGTTACCTCCTCGTTTCT25(2) INFORMATION FOR SEQ ID NO:89:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 25 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:89:TTCGCCTGATTTCCGCCTCCCGTCT25(2) INFORMATION FOR SEQ ID NO:90:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 18 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:90:CGGTCCGTTATGTTCCTG18(2) INFORMATION FOR SEQ ID NO:91:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:91:ACTCGCCTCCCACGTAGTGCTT22(2) INFORMATION FOR SEQ ID NO:92:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:92:CGTGCCCCTACCTCGCGCTCCT22(2) INFORMATION FOR SEQ ID NO:93:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 24 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:93:CCCTACCTCGCGCTCCTTGGAACG24(2) INFORMATION FOR SEQ ID NO:94:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 4TH POSITION(D) OTHER INFORMATION: "oligonucleotide"Inosine substitution for thymidine gives perfectmatch with both bindi(xi) SEQUENCE DESCRIPTION: SEQ ID NO:94:CCCNACCTCGCGCTCCTTGGAA22(2) INFORMATION FOR SEQ ID NO:95:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 24 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:95:CGTGCCCCTACCTCGCGCTCCTTG24(2) INFORMATION FOR SEQ ID NO:96:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 18 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:96:CGTGCCCCTACCTCGCGC18(2) INFORMATION FOR SEQ ID NO:97:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 18 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:97:TCCCGACCTCGCGCTCCT18(2) INFORMATION FOR SEQ ID NO:98:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 4TH POSITION(D) OTHER INFORMATION: Substitution of guanine withinosine gives a perfect match with both binding sites.(xi) SEQUENCE DESCRIPTION: SEQ ID NO:98:CCCNACCTCGCGCTCCTTGGAA22(2) INFORMATION FOR SEQ ID NO:99:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 24 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:99:CCATCCCGACCTCGCGCTCCTTGG24(2) INFORMATION FOR SEQ ID NO:100:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 26 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(xi) SEQUENCE DESCRIPTION: SEQ ID NO:100:CCATCCCGACCTCGCGCTCCTTGGAA26(2) INFORMATION FOR SEQ ID NO:101:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 4TH POSITION(D) OTHER INFORMATION: This variant sequence contains aninosine base substituted at the fourth position wherethe single base variation between SEQ ID:94 and SEQ IDNO:98 exists.(xi) SEQUENCE DESCRIPTION: SEQ ID NO:101:CCCNACCTCGCGCTCCTTGG20(2) INFORMATION FOR SEQ ID NO:102:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 38 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(xi) SEQUENCE DESCRIPTION: SEQ ID NO:102:TGAAGGGGCAAGCAATGGAGGAGCAAAGAAGAAGAACT38(2) INFORMATION FOR SEQ ID NO:103:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 25 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(xi) SEQUENCE DESCRIPTION: SEQ ID NO:103:GGAAGCCTGAGCTCATTCGAGTAGC25(2) INFORMATION FOR SEQ ID NO:104:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 23 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(xi) SEQUENCE DESCRIPTION: SEQ ID NO:104:AGGGGCACGCAAAGCTGGGAGCT23(2) INFORMATION FOR SEQ ID NO:105:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 24 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(xi) SEQUENCE DESCRIPTION: SEQ ID NO:105:GGACCATGTTGCCCGGAGCGCGCA24(2) INFORMATION FOR SEQ ID NO:106:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 39 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(xi) SEQUENCE DESCRIPTION: SEQ ID NO:106:GCCACGCCCATCGCCGCCATCATCATCCCGCCCCTTGGC39(2) INFORMATION FOR SEQ ID NO:107:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 70 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(xi) SEQUENCE DESCRIPTION: SEQ ID NO:107:CGGACAGAGATTGGCGAGAAGGGCGTGAACCTGTCTGGGGGCCAGAAGCA50GCGCGTGAGCCTGGCCCGGG70(2) INFORMATION FOR SEQ ID NO:108:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 45 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(xi) SEQUENCE DESCRIPTION: SEQ ID NO:108:TCCACGACCTGATGATGTTTTCCGGGCCGCAGATCTTAAAGTTGC45(2) INFORMATION FOR SEQ ID NO:109:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 90 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(xi) SEQUENCE DESCRIPTION: SEQ ID NO:109:GCCAGCACAGAGCAGGAGCAGGATGCAGAGGAAAGGGGTCACGGGCGTCA50GCGGTCCAGGGAAGGAAGCAAAGCAAATGGAGAATGGGAT90(2) INFORMATION FOR SEQ ID NO:110:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(ix) SEQUENCE DESCRIPTION: SEQ ID NO:110:TAGCCACATGGCCCCAGGAA20(2) INFORMATION FOR SEQ ID NO: 111:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(ix) SEQUENCE DESCRIPTION: SEQ ID NO: 111:ACTGACTTGCCCCACGGCCA20(2) INFORMATION FOR SEQ ID NO: 112:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(ix) SEQUENCE DESCRIPTION: SEQ ID NO:112:CCAAAGGGCAAAGGGCAAGG20(2) INFORMATION FOR SEQ ID NO: 113:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(ix) SEQUENCE DESCRIPTION: SEQ ID NO: 113:GTACCTTACCTTTTATCTGG20(2) INFORMATION FOR SEQ ID NO: 114:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: DNA (genomic)(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: YES(ix) SEQUENCE DESCRIPTION: SEQ ID NO: 114:TGCCCCTACCTCGCGCTCCT20__________________________________________________________________________ | The present invention provides novel compositions and methods useful in cancer therapy for inhibiting the multidrug resistance phenotype, which often thwarts long-term chemotherapeutic regimens. The novel compositions of matter comprise oligonucleotides targeted to the human MDR1 and MRP genes, which inhibit expression of these genes, thereby rendering tumors and other forms of cancer more susceptible to the cytotoxic effects of chemotherapeutic agents. Oligonucleotides are also provided that inhibit the multidrug resistance phenotype by exerting an aptameric effect. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates, in general, to a method and apparatus for tracking and guiding the drilling of a borehole, and more particularly to tracking a borehole being drilled generally horizontally under an obstacle such as a river, stream, lake, swampy area, or the like where access to the ground above the borehole is difficult or perhaps even restricted.
Various well-known drilling techniques have been used in the placement of underground transmission lines, communication lines, pipelines or the like through or beneath obstacles of various types. In order to traverse the obstacle, the borehole must be tunnelled underneath the obstacle from an above-ground entry point to a desired exit point, with the borehole then serving to receive a casing, for example, for use as a pipeline or for receiving cables for use as power transmission lines, communication lines, or the like. In the drilling of such boreholes, it is important to maintain them on a carefully controlled track, for often the borehole must remain within a right of way as it passes under the obstacle, and its entry and exit points on opposite sides of the obstacle must often be within precisely defined areas.
Prior systems for providing guidance in the drilling of boreholes have presented problems to the user, since they require access to the earth's surface above the location of the borehole to permit placement of grids or other guidance systems on the surface of the earth, above the paths to be followed by the borehole. Often, however, access to this region is not available. Furthermore, the placement of guide cables of this kind can be extremely time consuming, and thus expensive, and accordingly an improved method of guidance has been actively sought in the art.
SUMMARY OF THE INVENTION
In accordance with the present invention, a conventional drilling tool incorporating conventional steering apparatus is utilized to drill a borehole under an obstacle such as a river, or the like. The steering apparatus in the drilling tool is responsive to control signals to direct the drill as it progresses through the earth during a boring operation. The drill tool includes a sensor which incorporates a three-axis magnetometer for detecting vector components of magnetic fields in the region of the tool and a three-axis inclinometer for detecting vector components of the earth's gravity in the region of the tool. These magnetic field components and gravity components are used to determine the location and direction of the drill with respect to a target field source. The location and direction measurements are then used to provide appropriate control signals for directing the drill as it progresses in the borehole.
The target field for guiding the directional drilling is produced by a large solenoid which incorporates a coil surrounding a large ferromagnetic core. The solenoid core may be 15 feet long and 3 inches in diameter, for example, surrounded by a coil being connected to a reversible source of direct current of sufficient magnitude to provide a direct current magnetic field in the region of the drilling tool. In a preferred form of the invention, the solenoid and power source are mounted on a vehicle such as a truck for easy transportation to a drilling site, for use in guiding the drill.
In operation, the borehole drilling equipment is placed at a location where a borehole is to be started; i.e., at the borehole entrance, or head, which may be, for example, at one side of an obstacle. The vehicle containing the target solenoid is positioned at or near the area where the borehole is to exit the ground, for example, at a side of the obstacle opposite to that of the borehole entrance. Typically, the entrance may be at or near one bank of a river, with the exit being at or near the opposite bank and the borehole passing beneath the river. Drilling the borehole is begun at the entrance site and conventional survey methods are used to guide the drill for a major part of the distance toward the exit location. As the borehole nears the desired exit site; for example, within about 100 meters, further guidance is by way of the solenoid field.
When using target field guidance, the drilling is periodically stopped and the solenoid is energized in a first direction to produce a first direct current magnetic field for a first period of time and thereafter is energized in a second direction to produce a second direct current magnetic field for second period of time. The currents are of the same magnitude and produce direct current magnetic fields in opposite directions. The solenoid magnetic field is superimposed on the Earth's magnetic field, to produce a total magnetic field which may be referred to as the apparent Earth field. The vectors of the apparent Earth field are measured by the sensor during the first and second periods. At the same time, the earth's gravity is measured to determine the orientation of the drilling assembly and the measured gravity and magnetic field vectors are then used to locate the tool with respect .to the solenoid so that control signals can be produced to direct the drill toward the exit location with greater accuracy than is available with conventional borehole directional drilling techniques. The target solenoid does not have to be at the exit location, but may be nearby, and permits guidance of the drilling tool to a selected exit location with respect to the solenoid location.
The solenoid may have a guidance range of, for example, 100 meters with a current of 5 amps producing, for example, a magnetic field of 30 nanotesla at the drilling tool sensor at this distance. Such a field is sufficient to provide accurate guidance for the drilling process. Thus, for example, when a survey is required, the drill is stopped and the sensor system in the drilling tool is activated. The direct current is caused to flow in one direction in the solenoid coil for approximately 10 seconds, and then for approximately 10 seconds in the other direction. The sensor in the drilling tool measures the x, y and z components of the total magnetic field in the region of the sensor. The electromagnetic field data for the required location determination is found by simply taking the difference between the two total magnetic field measurements with the current positive and with the current reverse. These measurements, together with down hole tool orientation measurements, are then used to determine the distance and direction from the drilling tool to the solenoid, thereby permitting accurate determination of the location of the drill with respect to the solenoid and thus of the direction in which further drilling is to be done.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and additional objects, features and advantages of the present invention will be apparent to those of skill in the art from a consideration of the following detailed description of a preferred embodiment thereof, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagrammatic illustration of a drill guidance system utilizing a direct current solenoid for guiding the drilling of a horizontal borehole under an obstacle;
FIG. 2 is a diagrammatic illustration of the control system utilized in the system of FIG. 1; and
FIG. 3 is a diagrammatic illustration of the relationship of the solenoid to the location of a drill within the borehole being drilled.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 illustrates in diagrammatic form a directional drill assembly 10 which may be utilized to drill a borehole 12 through the earth under an obstacle such as a river or stream 14. As illustrated, the borehole enters the earth at an entry 16 on one bank of the river, and is directed to exit the earth in an exit region generally indicated by dotted lines at 18 on the opposite side of the river. It will be understood, of course, that the obstacle need not be a river, but may be a lake, a swamp, or other waterway, may be a restricted area, may be a mountain, or other area where access to the surface of the earth above the intended location of the borehole may be difficult. The borehole 12 is produced by means of a motor-driven drill 20 mounted on a drill string 22 carried by conventional surface drilling equipment generally indicated at 24. Connected between the drill 20 and the drill string 22 is a steering tool 26 which incorporates suitable instrumentation for controlling the operation of the drill motor and the direction of drill 20 in response to control signals from a directional controller 28 at the surface. The steering tool 26 preferably incorporates a three-axis magnetic field sensor 29 such as a Fluxgate magnetometer for detecting x, y and z vector components of magnetic fields in the region of the steering tool instrumentation. The magnetometer is responsive to the total magnetic field which includes not only the earth's apparent magnetic field, but magnetic fields due to anomalies in the earth, to material on the surface of the earth which might affect the magnetic field, and to a target field produced by a solenoid 30.
In accordance with the present invention, solenoid 30 incorporates a ferromagnetic core 32 (see FIG. 2) surrounded by a coil 34 connected to a reversible direct current source 36. The source 36 may be a battery pack, a DC generator driven by a gasoline engine, or the like. In accordance with the invention, the solenoid 32 is mounted on a vehicle 40 for easy portability so that the system of the invention may be transported easily to any desired location. As illustrated, the solenoid core may weigh in the neighborhood of 1000 lbs., with the reversible source supplying a current of, for example, 5 amps in order to produce a point source magnetic field generally indicated at 42 in FIG. 2.
The drilling assembly 10 may also include an inclinometer 46 for measuring the x, y and z components of the earth's gravity with respect to the drilling tool. The values of the measured quantities from the magnetometer 29 and the inclinometer 46 are communicated to the drilling equipment 24 and then to the directional controller 28 by, for example, a conventional drilling fluid pressure pulse technique, the pulses being detected by the drilling equipment 24 and converted to corresponding electrical signals for use by the controller 28. These signals communicate borehole survey data to drill operators, for example by way of a computer, who may then provide directional controlling data to the drill motor for regulating the direction of drilling. The outputs from the inclinometer 46 represent the earth's gravity vector along the coordinate axes 48 illustrated for borehole 12, wherein the z-axis lies along the axis of the borehole and the y and x coordinates lie in a plane perpendicular thereto. In similar manner, the vector components of the total magnetic field measured by the magnetometer 28 are obtained for the same vector coordinates.
Whenever a measurement is made to locate the drill 20 and the direction of the borehole 12, the drilling operation is stopped and the inclinometer 46, is used to make a measurement of the gravity vector. The magnetometer is used to make two measurements of the total magnetic field, one with the current in solenoid 30 in a positive sense and the other with the current flowing in a negative sense. The earth's field components are recovered by averaging the two magnetometer measurements and the solenoid field is found by taking the difference between the two measurements.
The solenoid 30 is located at a known position with respect to the exit region 18 toward which the borehole is being drilled, and the borehole is then directed with respect to the location of the solenoid. The solenoid does not have to be located in the area 18, but may be located to one side or the other, may be located between the area 18 and the obstacle, or may be located further away from the obstacle than the area 18. In any of these cases, the direction of drilling of the borehole 12 is controlled with respect to the known location of the area 18 with respect to the solenoid so that the borehole can be directed to exit the earth at area 18.
To make a determination of the location of drill 20, the drilling motor is stopped so that the control system is stationary with its inclinometer and magnetometer at a known depth from the entry 16 and at a known angle with respect to the vertical. Before the solenoid is activated, a standard sequence of survey data measurements of the earth and gravity field is made by the sensors 29 and 46, and this data is communicated to the surface directional controller and computer 28. Thereafter, the solenoid 30 is switched on to generate a DC magnetic field 42 in one direction for a predetermined period of time and measurements are made. Thereafter the measurements are repeated with the magnetic field in the opposite direction for a predetermined period of time. If the source strength of the solenoid is known, these two data sets provide all of the necessary information to determine both distance and direction from the drill to the solenoid, and thus to the exit area 18.
Both the inclinometer 46 and the magnetometer 29 in the steering tool 26 are used for determining the direction of the borehole 12 for surveying purposes and the orientation of the tool face; i.e., the direction of the axis 50 of the drill assembly 20, for use in controlling the direction of drilling. The solenoid field vector S (FIG. 3) at the magnetometer 29 is computed in the directional controller 28 by taking the difference in the apparent Earth's field measured with positive and with negative current flow in the solenoid 30. Subtraction of these measurements gives the Earth's field, and from these measurements and the inclinometer measurements the solenoid field strength and field direction with respect to x'y'z' coordinate system 52 (FIG. 3) defined by magnetic north (x'), magnetic east (y') and the downwards vertical direction (z') can be calculated. The direction of the source solenoid m is also determined with respect to the coordinate system 52 at the same time.
The field vector S is then naturally resolved into two parts, a first part parallel to the solenoid axis m and a second part defined by a unit vector r, which is a line perpendicular to the solenoid axis 42 and extending to the solenoid axis at a point P, which is the observation point. The unit vector r is formed from the measurement of the solenoid field S and the known direction of m by the vector relationship using dot products, as follows: ##EQU1## This r unit vector gives the radial direction from the solenoid axis 42 to the observation point P.
To find the radial distance r from the solenoid axis 42 to the observation point P, and to find the distance d along the solenoid axis to where the observation point P on the steering tool is located, it is convenient to decompose the solenoid field S into a part along m, S m and a part along r, S r , as follows:
S.sub.m =m.S (Eq. 4)
S.sub.r =r.S (Eq. 5)
These quantities are used to determine a quantity A as follows: ##EQU2## When the steering tool is far away; i.e., when (d/r)>0.707, the + sign is used in the foregoing equation, and when the steering tool is near; i.e., when (d/r)<0.707, the minus sign is used. Normally it will be obvious which value to use since one is constantly updating the location of the steering tool location as the drilling progresses. In addition, the normal surveying computer programs, which integrate the borehole direction during the course of drilling, give an approximate determination of the steering tool location, which is effectively at the drill bit.
The perpendicular radial distance r is found from the equation ##EQU3## where μ 0 =4π10 -7 , and m is the solenoid source strength in amp (meters) 2 . All distances are measured in meters. The axial distance d is found from the relationship
d=Ar (Eq. 8)
The solenoid 30 may also be located at a known position close to the entry region of the borehole to precisely guide the direction of drilling as well as determining the precise drill bit location for drilling the near side of the obstacle. This may be done when the near side would be out of range for a solenoid located on the far side.
Although the present invention has been described in terms of a preferred embodiment, variations and modifications may be made without departing from the true spirit and scope thereof, as defined in the following claims: | A method and apparatus for drilling a borehole under an obstacle including placing a solenoid on the surface of the earth at the far side of the obstacle, near a preselected borehole exit location. A drilling assembly at an entry location on the near side of the obstacle is driven to produce a borehole which is directed under the obstacle toward the exit location. Initially, guidance of the drilling assembly is by conventional survey techniques, but when the borehole moves to within about 100 meters of the solenoid, the solenoid magnetic field is used to guide the drilling operation. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a divisional of U.S. patent application Ser. No. 09/223,510, which was filed on Dec. 30, 1998 is now U.S. Pat. No. 6,312,865.
BACKGROUND OF THE INVENTION
The present invention relates to semiconductor devices using a photoresist, and to processes for manufacturing the same.
Various types of photoresists have been used or proposed. These resists should have a variety of desirable characteristics or properties. In general, all or most of these resists generally demand etching resistance, adhesiveness with low light absorption at 193 nm wavelength for ArF. Additionally, the resists should be developable by using 2.38 wt % aqueous tetramethylammonium hydroxide (TMAH) solution. It is, however, difficult to synthesize a polymer satisfying one or all these properties.
Many researches have focused on studies on norbolac type resin as a resin to increase transparency at 193 nm wavelength and increase etching resistance. As merely an example, “Bell Labs” tried to introduce alicyclic unit to the backbone chain of a copolymer in order to enhance etching resistance. A copolymer resin in which the backbone chain has norbornene, acrylate and maleic anhydride substituent, as represented by chemical formula I has been suggested:
[Formula I] See Appendix A
In the polymer resin of formula I, the maleic anhydride portion (portion A) was used for polymerizing alicyclic olefin group.
The maleic anhydride portion is soluble in 2.38% aqueous TMAH solution even it is not exposed, and thus a y-portion having tert-butyl substituent should be highly increased in order to prevent dissolution. But increase of the y-portion causes relative decrease of z portion, which enhances sensitivity and adhesiveness with substrate, to cause disadvantage in that photoresist is removed from the wafer in practical patterning.
Thus, an effective pattern cannot be formed without separately using a solubility controlling agent, and even if a pattern is formed by using a solubility controlling agent, the adhesiveness is too poor to be applied to practical patterning.
Under such circumstances, Bell Labs tried to solve the above-mentioned problems by using a solubility controlling agent of cholesterol type and by employing two-component resist comprising a polymer of cyclo-olefin and maleic anhydride.
However, in this case, very large amount (about 30% by weight based on the polymer) of the solubility controlling agent should be used, and thus the polymer of the above molecular structure basically has too low reproducibility and too high cost to be used as a polymer for a photoresist. From the above, it is seen that an improved photoresist resin that is cost effective, easy to manufacture, and has desirable other properties is clearly desired.
SUMMARY OF THE INVENTION
The present inventors have performed intensive studies to overcome the above limitations encountered in conventional resins, and as a result, they could synthesize novel norbornene derivatives having hydrophilic group(s). In a specific embodiment, the present invention provides a method using a step of introducing the monomer to the backbone chain of the polymer to develop a polymer having excellent resolution due to prominent enhancement of adhesive strength by introducing a hydrophilic group (—OH). The present method yields a photoresist having excellent etching resistance and heat resistance which are the characteristics of alicyclic olefins.
Numerous benefits or advantages are achieved by way of the present invention over conventional techniques. In a specific embodiment, the present invention provides a monomer comprising a novel norbornene derivative represented by following formula II:
[Formula II] See Appendix A
wherein, R′ and R″ independently represent hydrogen, or linear or branched C 1 -C 4 alkyl group with or without substituent(s), m represents number of 1 to 8, and n represents number of 1 to 6, and a process for preparing the same.
In an alternative embodiment, the present invention provides a polymer for a photoresist comprising bicycloalkene compounds represented by chemical formulas II and V, and maleic anhydride of chemical formula VI, and a process for preparing the same.
In a further embodiment, the present invention provides a polymer for photoresist represented by formula III or IV, which comprises bicycloalkene compound(s) and maleic anhydride, and process for preparing the same.
[Formula III] See Appendix A
[Formula IV] See Appendix A
In the formula, R′ and R″ independently represent hydrogen, or linear or branched C 1 -C 4 alkyl group with or without substituent(s), R 1 and R 2 independently represent hydrogen, or linear or branched alkyl, cycloalkyl, alkoxyalkyl or cycloalkoxyalkyl having 1 to 10 carbon atoms with or without substituent(s), m is an integer from 1 to 8, and the molar ratio w:x:y:z is (0-99%):(0-99%):(0-99%) (0-99%) [provided that w and x are independently 0.005-0.9 part by mole, and y and z are independently 0.001-0.9 part by mole in case of formula IV].
In still a further embodiment, the present invention provides a polymer for photoresist which comprises bicycloalkene compounds represented by formulas II and V, and maleic anhydride represented by formula VI, and a photoresist formed by using a polymer represented by formula III, IV, VII, VIII or IX, and a process for manufacturing the photoresist.
[Formula V] See Appendix A
[Formula VI] See Appendix A
Still further, the present invention provides a polymer for photoresist. The polymer includes a variety of elements such as bicycloalkene compounds represented by formulas II and V, and maleic anhydride represented by formula VI, and a process for forming a photoresist pattern by the use of the photoresist formed with the polymer represented by formula III, IV, VII, VIII or IX.
Moreover, the present invention provides a polymer for photoresist. The present polymer includes a variety of elements such as bicycloalkene compounds represented by formulas II and V, and maleic anhydride represented by formula VI, and a semiconductor device using the photoresist formed with the polymer represented by formula III, IV, VII, VIII or IX.
[Formula VII] See Appendix A
[Formula VIII] See Appendix A
[Formula IX] See Appendix A
BRIEF DESCRIPTION OF DRAWING
FIG. 1 illustrates NMR data of the polymer prepared in Example 9.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is embodied in a polymer usable for lithography process using ultra-short wavelength light source such as KrF (248 nm), ArF (193 nm), X-ray, ion beam and E-beam which is expected to be applied in 1 G or 4 G DRAM or other highly integrated circuits, and having a novel norbornene monomer introduced to the backbone chain of the polymer. The invention is further embodied in a process for manufacturing the same, and a photoresist containing the same polymer.
Among the bicycloalkene compounds represented by formula II, preferable compounds are 3-hydroxypropyl 5-norbornen-2-carboxylate, 4-hydroxybutyl 5-norbornen-2-carboxylate, 5-hydroxypentyl 5-norbornen-2-carboxylate, 6-hydroxyhexyl 5-norbornen-2-carboxylate, 7-hydroxyheptyl 5-norbornen-2-carboxylate, 8-hydroxyoctyl 5-norbornen-2-carboxylate, or the like.
The bicycloalkene derivatives (formula II) according to the present invention can be prepared by reacting hydroxyalkyl acrylate with cyclopentadiene in the presence of tetrahydrofuran.
The hydroxyalkyl acrylate is preferably selected from a group consisting of 3-hydroxypropyl acrylate, 4-hydroxybutyl acrylate, 5-hydroxypentyl acrylate, 6-hydroxyhexyl acrylate, 7-hydroxyheptyl acrylate and 8-hydroxyoctyl acrylate.
The polymer according to the present invention (formula III or IV) can be prepared by polymerizing the bicycloalkene compounds represented by chemical formulas II and V and maleic anhydride represented by formula VI in the presence of polymerization initiator.
Preferable bicycloalkenes to be used for the polymers for photoresist according to the present invention may be one or more compounds selected from a group consisting of bicycloalkenes represented by formula V wherein R is hydrogen or tert-butyl group, and bicycloalkenes represented by formula II wherein m is 3 and R′ and R″ are hydrogen.
More preferably, bicycloalkenes for the polymers according to the present invention are selected from a group consisting of 3-hydroxypropyl 5-norbornen-2-carboxylate, tert-butyl 5-norbornen-2-carboxylate, 5-norbornen-2-carboxylic acid, 3-hydroxypropyl bicyclo[2,2,2]-oct-5-en-3-carboxylate, tert-butyl bicyclo[2,2,2-oct-2-en-carboxylate and bicyclo[2,2,2]oct-5-en-2-carboxylic acid.
Among the polymers according to the present invention, the polymers prepared from the bicycloalkene represented by formula V wherein R is hydrogen or tert-butyl and n is 1, the bicycloalkene represented by formula II wherein R′ and R″ are hydrogen and m is 3 [i.e., one or more bicycloalkenes selected from a group consisting of 3-hydroxypropyl 5-norbornen-2-carboxylate, tert-butyl 5-norbornen-2-carboxylate and 5-norbornen-2-carboxylic acid], and maleic anhydride represented by formula VI are particularly preferable.
The polymers according to the present invention can be prepared by a conventional polymerization process such as bulk polymerization or solution polymerization. Polymerization initiators usable in the present invention include benzoyl peroxide, 2,2′-azobisisobutyronitrile (AIBN), acetyl peroxide, lauryl peroxide, tert-butyl peracetate, di-tert-butyl peroxide, or the like.
As a solvent, cyclohexanone, methyl ethyl ketone, benzene, toluene, dioxane, dimethylformamide and/or tetrahydrofuran may be used individually, or in a mixture.
In the process for preparing the polymers according to the present invention, general polymerization condition including temperature and pressure of radical polymerization may be controlled dependent upon the property of the reactants, but it is preferable to carry out the polymerization reaction at a temperature between 60 and 200° C. for 4 to 24 hours.
The polymers represented by formula III or IV according to the present invention have molecular weight of 3,000-100,000, and can be used in lithography process using ultra-short wavelength light such as KrF or ArF light source, X-ray, ion beam or E beam, which is expected to be applied to 1G or 4G DRAM.
The polymers according to the present invention may be used in the formation of a positive micro-image by preparing a photoresist solution in which the polymer is mixed with an organic solvent and a conventional photo acid generator according to a conventional process for preparing a photoresist composition.
In the process for forming photoresist pattern of semiconductor element, the amount of the polymer according to the present invention depends on the organic solvent or photo acid generator used, and the condition of lithography, but conventionally it is about 10 to 30% by weight on the basis of the organic solvent used in the preparation of the photoresist.
The process for forming a photoresist pattern of a semiconductor element by using the polymer according to the present invention is described in detail here-in-below:
The polymer according to the present invention is dissolved in cyclohexanone, methyl 3-methoxypropionate, ethyl 3-ethoxypropionate, ethyl lactate or propylene glycol methyl ether acetate at a concentration of 10 to 30% by weight. Onium salt or organic sulfonic acid as inorganic acid generator (0.01-10% by weight based on the polymer) is incorporated to the solution, and the mixture is then filtered through an ultra-micro filter to prepare photoresist solution.
As the photo acid generator, triphenylsulfonium triplate, dibutylnaphthylsulfonium triplate, 2,6-dimethylphenylsulfonate, bis(arylsulfonyl)-diazomethane, oxime sulfonate and 1,2-diazonaphthoquinon-4-sulfonate can be mentioned.
Then, the photoresist solution is spin-coated on a silicon wafer to form a thin film, which is then pre-baked in an oven at 80-150° C. or on a hot plate for 1-5 minutes, exposed to light by using far ultraviolet exposer or an eximer laser exposer, and post-baked in an oven at a temperature between 100° C. and 200° C. or on a hot plate for 1 second to 5 minutes.
The exposed wafer is impregnated in 2.38% aqueous TMAH solution for 30 seconds to 1.5 minutes to obtain an ultra-micro positive photoresist pattern.
The syntheses of novel norbornene derivatives according to the present invention, the syntheses of polymers using the derivatives, manufacturing the photoresist comprising the polymers, and process for forming micro-patterns in a semiconductor device are described in detail by referring to Examples.
A better understanding of the present invention may be obtained in light of following examples which are set forth to illustrate, but are not to be construed to limit, the present invention.
Syntheses of Norbonren Derivatives
EXAMPLE I
Synthesis of 3-hydroxypropyl 5-norbornene-2-carboxylate
In a reactor, cyclopentadiene (66 g) and tetrahydrofuran solvent (500 g) were charged, and the mixture was stirred homogeneously. To the reaction mixture, 3-hydroxypropyl acrylate (130 g) was added, and the resultant mixture was stirred at a temperature between −30° C. and 60° C. for about 10 hours to carry out the reaction.
When the reaction was completed, the solvent was removed by using a rotary evaporator, and the residue was distilled under reduced pressure to obtain 168 g (yield: 86%) of 3-hydroxypropyl 5-norbornene-2-carboxylate.
EXAMPLE II
Synthesis of 4-hydroxybutyl 5-norbornen-2-carboxylate
The same procedure described in Example I was repeated but 4-hydroxybutyl acrylate (144 g) was used instead of 3-hydroxypropyl acrylate to give 178 g (yield: 85%) of 4-hydroxybutyl 5-norbornen-2-carboxylate.
EXAMPLE III
Synthesis of 5-hydroxypentyl 5-norbornen-2-carboxylate
The same procedure described in Example I was repeated but 5-hydroxypentyl acrylate (158 g) was used instead of 3-hydroxypropyl acrylate to give 190 g (yield: 85%) of 5-hydroxypentyl 5-norbornen-2-carboxylate.
EXAMPLE IV
Synthesis of 6-hydroxyhexyl 5-norbornen-2-carboxylate
The same procedure described in Example I was repeated but 6-hydroxyhexyl acrylate (172 g) was used instead of 3-hydroxypropyl acrylate to give 205 g (yield: 86%) of 6-hydroxyhexyl 5-norbornen-2-carboxylate.
EXAMPLE V
Synthesis of 7-hydroxyheptyl 5-norbornen-2-carboxylate
The same procedure described in Example I was repeated but 7-hydroxyheptyl acrylate (186 g) was used instead of 3-hydroxypropyl acrylate to give 204 g (yield: 81%) of 7-hydroxyheptyl 5-norbornen-2-carboxylate.
EXAMPLE VI
Synthesis of 8-hydroxyoctyl 5-norbornen-2-carboxylate
The same procedure described in Example I was repeated but 8-hydroxyoctyl acrylate (200 g) was used instead of 3-hydroxypropyl acrylate to give 207 g (yield: 78%) of 8-hydroxyoctyl 5-norbornen-2-carboxylate.
Syntheses of Bicycloalkene Compounds
EXAMPLE VII
Synthesis of tert-butyl 5-norbornen-2-carboxylate
In a reactor, cyclopentadiene (66 g) and tetrahydrofuran solvent (500 g) were charged, and the mixture was stirred homogeneously. To the reaction mixture, tert-butyl acrylate (128 g) was added, and the resultant mixture was stirred at a temperature between −30° C. and 60° C. for about 10 hours to carry out the reaction.
When the reaction was completed, the solvent was removed by using a rotary evaporator, and the residue was distilled under reduced pressure to obtain 175 g (yield: 90%) of tert-butyl 5-norbornene-2-carboxylate.
EXAMPLE VIII
Synthesis of 5-norbornen-2-carboxylic Acid
In a reactor, cyclopentadiene (66 g) and tetrahydrofuran solvent (500 g) were charged, and the mixture was stirred homogeneously.
To the reaction mixture, acrylic acid (72 g) was added, and the resultant mixture was stirred at a temperature between −30° C. and 60° C. for about 10 hours to carry out the reaction.
When the reaction was completed, the solvent was removed by using a rotary evaporator, and the residue was distilled under reduced pressure to obtain 124 g (yield: 90%) of 5-norbornen-2-carboxylic acid.
Syntheses of Polymers
EXAMPLE IX
Synthesis of poly[3-hydroxypropyl 5-norbornen-2-carboxylate/tert-butyl 5-norbornen-2-carboxylate/5-norbornen-2-carboxylic acid/maleic anhydride]polymer (Formula VII)
In tetrahydrofuran, benzene or toluene, dissolved were 3-hydroxypropyl 5-norbornen-2-carboxylate (0.05-0.8 mol), tert-butyl 5-norbornen-2-carboxylate (0.5-0.95 mol), 5-norbornen-2-carboxylic acid (0.01-0.3 mol) and maleic anhydride (1 mol).
Then, 2,2′-azobisisobutyronitrile (AIBN) (0.01-10 g), as a polymerization initiator, was added thereto, and the reaction was performed at a temperature between 60° C. and 70° C. for 4-24 hours.
Crude product thus obtained was precipitated from ethyl ether or hexane, and the precipitate was filtered and dried under reduced pressure to give poly[3-hydroxypropyl 5-norbornen-2-carboxylate/tert-butyl 5-norbornen-2-carboxylate/5-norbornen-2-carboxylic acid/maleic anhydride]polymer represented by formula VII, of which the NMR data is shown in FIG. 1 . (yield: ≧70%)
EXAMPLE X
Synthesis of poly[4-hydroxybutyl 5-norbornen-2-carboxylate/tert-butyl 5-norbornen-2-carboxylate/5-norbornen-2-carboxylic acid/maleic anhydride]polymer (Formula VIII)
In tetrahydrofuran, benzene or toluene, dissolved were 4-hydroxybutyl 5-norbornen-2-carboxylate (0.05-0.8 mol), tert-butyl 5-norbornen-2-carboxylate (0.5-0.95 mol), 5-norbornen-2-carboxylic acid (0.01-0.3 mol) and maleic anhydride (1 mol).
Then, 2,2′-azobisisobutyronitrile (AIBN) (0.01-10 g), as a polymerization initiator, was added thereto, and the reaction was performed at a temperature between 60° C. and 70° C. for 4-24 hours.
Crude product thus obtained was precipitated from ethyl ether or hexane, and the precipitate was filtered and dried under reduced pressure to give poly[4-hydroxybutyl 5-norbornen-2-carboxylate/tert-butyl 5-norbornen-2-carboxylate/5-norbornen-2-carboxylic acid/maleic anhydride]polymer represented by formula VIII (yield: ≧70%).
EXAMPLE XI
Synthesis of poly[3-hydroxypropyl 5-norbornen-2-carboxylate/tert-butyl 5-norbornen-2-carboxylate/mono-methyl cis-5-norbornen-endo-2,3-dicarboxylate/maleic anhydride]polymer (Formula IX)
In tetrahydrofuran, benzene or toluene, dissolved were 3-hydroxypropyl 5-norbornen-2-carboxylate (0.05-0.8 mol), tert-butyl 5-norbornen-2-carboxylate (0.5-0.95 mol), mono-methyl cis-5-norbornen-endo-2,3-dicarboxylate (0.01-0.3 mol) and maleic anhydride (1 mol).
Then, 2,2′-azobisisobutyronitrile (AIBN) (0.01-10 g), as a polymerization initiator, was added thereto, and the reaction was performed at a temperature between 60° C. and 70° C. for 4-24 hours.
Crude product thus obtained was precipitated from ethyl ether or hexane, and the precipitate was filtered and dried under reduced pressure to give poly[3-hydroxypropyl 5-norbornen-2-carboxylate/tert-butyl 5-norbornen-2-carboxylate/mono-methyl cis-5-norbornen-endo-2,3-dicarboxylate/maleic anhydride]polymer represented by formula IX (yield: 74%).
Preparation of Photoresist and Pattern Formation
EXAMPLE XII
Poly[3-hydroxypropyl 5-norbornen-2-carboxylate/tert-butyl 5-norbornen-2-carboxylate/5-norbornen-2-carboxylic acid/maleic anhydride]polymer (formula VII) (10 g) was dissolved in 3-methoxymethyl propionate (40 g, solvent), and triphenylsulfonium triplate or dibutylnaphthylsulfonium triplate (about 0.01-1 g) as a photo acid generator, was added thereto. After stirring, the mixture was filtered through a 0.1 μm filter to give a photoresist. Then the photoresist was coated on a surface of a wafer. After heat treatment, the photoresist was developed by a photo-developing process to form a pattern. Thus, a semiconductor element having perpendicular L/S pattern with thickness of the polymer 0.6 μm and the width of 0.13 μm was obtained.
EXAMPLE XIII
Poly[3-hydroxypropyl 5-norbornen-2-carboxylate/tert-butyl 5-norbornen-2-carboxylate/mono-methyl cis-5-norbornen-2-endo-2,3-dicarboxylate/maleic anhydride]polymer (formula IX) (10 g) was dissolved in 3-methoxymethyl propionate (40 g, solvent), and triphenylsulfonium triplate or dibutylnaphthylsulfonium triplate (about 0.01-1 g) as a photo acid generator, was added thereto. After stirring, the mixture was filtered through a 0.1 μm filter to give a photoresist. Then the photoresist was coated on a surface of a wafer. After heat treatment, the photoresist was developed by a photo-developing process to form a pattern. Thus, a semiconductor element having perpendicular L/S pattern with thickness of the polymer 0.6 μm and the width of 0.13 μm was obtained.
As described above, the photoresist formed by using the polymers for KrF or ArF according to the present invention has excellent etching resistance, heat resistance and adhesiveness, and is developable with 2.38 wt % aqueous TMAH solution, so that satisfactory results can be obtained in view of resolution of perpendicular L/S pattern of 0.13 μm with resist thickness of 0.6 μm, and the depth of a focus.
Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, it is to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
APPENDIX A
FORMULA I
FORMULA II
FORMULA III
FORMULA IV
FORMULA V
FORMULA VI
FORMULA VII
FORMULA VIII
FORMULA IX | The present invention relates to a semiconductor device using a copolymer-containing photoresist, and a process for manufacturing the same. As a norbornene derivative (monomer) having a hydrophilic group is synthesized and introduced to the backbone chain of a polymer, the polymer according to the present invention has excellent etching resistance and heat resistance, which are the characteristic points of alicyclic olefin structure, and provide excellent resolution due to prominent enhancement of adhesiveness resulted from introducing a hydrophilic group (—OH). | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a securement device for securing a steering spindle bearing unit on a bracket unit of an adjustable steering column for a motor vehicle. The securement device comprises at least one clamping device and at least one locking element, activatable by the clamping device, as well as at least one counterlocking element. The locking element and the counterlocking element, in a closed position of the clamping device, are disposed in an engagement position, and the securement device comprises at least one resilient reset element for resetting the locking element in an open position of the clamping device.
In adjustable steering columns for motor vehicles, securement devices are employed in order to secure or lock the adjustable steering column in the set position for normal operation of the motor vehicle. When the securement device or its clamping device are in an open state, the steering wheel attached on the adjustable steering column can be adjusted by the driver of the motor vehicle into the desired position in the height and/or length direction. In the prior art, such securement devices are also referred to as clamping systems. There are securement devices that are based on the engagement of locking and counterlocking element under form closure. However, there are also securement devices in which by means of a clamping locking element and counterlocking element in the closed position of the clamping device are exclusively in operational connection under friction closure. Friction closure is disclosed in prior art for example in EP 0 802 104 A1.
The problem encountered in the case of clamping under friction closure is attaining sufficient fixedness and resistance of the connection against a dislocation of the steering column during the operation of the motor vehicle. In many cases, in particular high fixedness of the connection is to be ensured even in the event of a crash. However, simultaneously the capability of simple adjustments is also to be given in the open position of the clamping device. In general, it is herein preferred for the adjustability of the steering column in the height and/or length direction to be an infinite one.
EP 0 802 104 A1 proposes the use of several frictional faces in order to increase the frictional force correspondingly. DE 196 43 203 A1 shows an example of the connection under form closure by means of teeth engagement known in the prior art. However, this technology also entails various problems. On the one hand, not every adjustment position can be set and, on the other hand, there is always the risk that when closing the securement device the tips of the toothings corresponding to one another impact one another and, accordingly, no secure engagement takes place. A further disadvantage of such form-closure solutions involving toothing engagement is that in the open position of the clamping device a free-moving friction closure clamping of the steering column must be achieved using special means such that the column does not rattle and is smoothly adjustable.
A generic securement device is shown in DE 10 2007 003 091 B3. In this implementation according to the prior art, the form-closure engagement of locking element and counterlocking element is again achieved by means of toothing when the clamping device is in the closed position. In the open position of the clamping device, the locking element is lifted out of the toothing of the counterlocking element by spring arm-like resilient reset elements. This is intended to ensure that relatively high holding forces can be provided. On the other hand, for the case of very high forces occurring, for example in the event of a motor vehicle crash, a form-closure connection between locking and counterlocking element is to be effected via the edge-side toothing. The implementation shown in DE 10 2007 003 091 B3 entails the above listed disadvantages of engagement by toothing. Especially with frequent adjustments of the steering column, the toothings can become only half engaged. A disadvantage of this solution according to the prior art between locking and counterlocking element accordingly consists in damage to the edge-side teeth with frequent and strong strain. With these implementations, further, the form-closure snap-in-locking between locking and counterlocking element potentially occurs only after a certain displacement path. This occurs if during the closure of the clamping device, the teeth do not mesh with one another but come to lie one on the other. If this displacement path is to be kept short, the tooth must also be kept small which increases the loading of the tooth material.
SUMMARY OF THE INVENTION
The invention addresses the problem of improving a generic securement device to the extent that, on the one hand, it enables infinite adjustability and, on the other hand, provides high resistance against dislocation of the steering column in the closed state of the clamping device.
To attain this, the invention proposes a securement device.
Consequently, the invention provides that the securement device comprises at least one engagement element which, in the closed position of the clamping device, by means of preferably plastic reforming of at least one surface of the locking element and/or of the counterlocking element, is in engagement with this surface under form closure.
It is consequently a fundamental concept of the invention to equip the securement device with at least one engagement element which, during the closing of the clamping device, carves itself into at least one surface of the locking element and/or of the counterlocking element and thus ensures, by means of preferably plastic reforming, an engagement under form closure. This leads to the desired high resistance forces against a dislocation of the steering column or the steering spindle in the closed position of the clamping device. Yet, this realization of the form closure by reforming of the surface also has the advantage that form-closure engagement of the engagement element is possible at any of the desired sites since with each closing of the clamping device a new, preferably plastic, reforming takes place with which the engagement element carves into the surface at any of the set or desired sites. It is herein also insignificant if in the immediate vicinity of this site there is still a hole or a recess from a preceding engagement of the engagement element into the surface. Through the reforming during the closing of the clamping device, the engagement element generates a new recess in the surface, whereby an older recess, disposed originally perhaps directly adjacently, can also be closed again through the reforming process. It becomes hereby feasible to adjust the adjustable steering column often and infinitely, wherein after the adjustment the desired high resistance force against a dislocation of the steering column in the closed position of the clamping device is attained again. The surface into which the engagement element engages is consequently specifically provided or laid out for the purpose of becoming reformed multiple times by the engagement element. Before the first engagement of the engagement element into the surface, this surface can be implemented planar or smooth.
The term “at least one engagement element” means that it is feasible to provide, in fact, only one single engagement element. However, as a rule, the securement device will comprise several relevant engagement elements which subsequently advantageously carve simultaneously into the surface during the closing of the clamping device. The universal use throughout of the formulation ‘at least one engagement element’ in the patent claims and the description is a purely linguistic simplification. The same applies also to the other structural components which are listed as ‘at least one structural component’.
The engagement element can be disposed at several different structural components of the securement device. It is, for example, feasible for the engagement element to be disposed on an additional support between the locking element and the counterlocking element, and the surface, with which the engagement element is in engagement in the closed position of the clamping device, is a portion of the locking element or of the counterlocking element. However, it is also feasible for engagement elements to project on both sides of this support, which, in this case, engage into a surface of the locking element as well as also into such a surface of the counterlocking element when the clamping device is brought into the closed position. However, it is also feasible for the engagement element to be a portion of the locking element or a portion of the counterlocking element and the surface, into which the engagement element engages, is associated with the, in each case, other structural component. Preferred embodiments of the invention in this context provide for the engagement element to be preferably integrally implemented on the locking element. Stated differently, the engagement element can consequently be a permanent or fixed structural component of the locking element. It is understood that the same applies conversely also to the counterlocking element. It is preferably provided for the locking element to comprise a plate-like base body. This can also be realized at the counterlocking element.
The engagement element projects advantageously beyond or from the plate-like base body. Especially preferred embodiments provide for the clamping device in its closed position to prestress the locking element in a clamping direction against the counterlocking element and for the engagement element to project in the direction parallel to the clamping direction from a surface, facing the counterlocking element, of the locking element.
In terms of the above described reforming of the surface during the engagement of the engagement element, it is advantageous for the engagement element to be harder than the surface with which it is in engagement in the closed position of the clamping device. This can be attained, for example, through the selection of different materials or through appropriate tempering of the engagement element.
In the opened position of the clamping device, it is advantageously provided for the resilient reset element to effect an abrogation of the form-closure engagement of the engagement element into the surface with which it is in engagement in the closed position of the clamping device. For this purpose, the appropriate lifting of the engagement element from the surface can be achieved by the resilient reset element. Herein, the complete lifting or bringing out of contact is preferred. At least one contact element is advantageously provided, which can also be realized as a spacer, which, after lifting the at least one engagement element from the surface of the locking part or the counterlocking element, is in contact with a surface of the locking element or counterlocking element. Hereby, even in the open position of the clamping device, an additional friction closure between the contact element, which can also be a spacer, and the surface can be provided which through the friction force counteracts an undesirable displacement of the adjustable steering column in the open position of the clamping device and thereby facilitates the selective adjustment by the driver of the motor vehicle. Through this measure the rattling in the open position of the clamping device can also be prevented. It is of advantage for the contact element to be connected with the locking element or with the counterlocking element.
The resilient reset element can fundamentally be a separate structural component acting between the locking element and the counterlocking element, such as, for example, one or several springs or the like. Especially for this case, it is conceivable and feasible for the contact element to be connected with the resilient reset element and/or be formed by it. However, preferred embodiments provide that the resilient reset element is realized in the form of an elastic deformability of the locking element. Stated differently, the locking element or a region thereof herein forms itself the resilient reset element. In particular in the case of locking elements with a plate-like base body these resilient properties for providing the resilient reset element can be attained through the appropriate material selection and setting of the thicknesses. It is understood that the counterlocking element can also be correspondingly realized for the realization of the resilient reset element.
Independently of the type of realization of the resilient reset element or of the resilient reset elements, the invention advantageously provides that the resilient reset element during the movement of the clamping device into its open position automatically abrogates the form-closure engagement of the engagement element into the surface with which it is in engagement in the closed position of the clamping device. Therewith is ensured that no scoring of the material or the like can occur during an adjustment activation. Abrogating the engagement form closure in the open position of the clamping device or a corresponding separation of the structural components, however, can alternatively also take place via an additional element or through the installation of another element that ensures the requisite separation.
The layout of the engagement element or of the engagement elements and of the locking element and of the counterlocking element is advantageously performed such that the clamping device during its movement between the closed and open position (and conversely) only needs to generate the smallest possible excursion. In these terms, it is advantageous if the engagement element is realized such that it is relatively flat-angled. A few tenths millimeter can here already suffice. The extent of the engagement element in the clamping direction is advantageously between 0.1 and 0.4 mm, preferably only 0.2 mm. Stated differently, the engagement elements consequently projects maximally between 0.1 and 0.4 mm, preferably only 0.2 mm. The engagement element can in principle have the most diverse geometric forms. The element can be a straight or angled cleat or the like. However, especially preferred embodiments provide for the engagement element to be realized as a nub. In the case of several engagement elements, a corresponding nub field results. It is preferred to select as irregular an arrangement as possible in order to prevent that at different settings different nubs can carve themselves in at one and the same point of the surface of the counterlocking element or of the locking element in the case of locking.
The engagement element, and in particular corresponding nubs, can be formed for example using a stamping process. The type of stamping and the number of nubs or engagement elements can be laid out such that the tips of the nubs or engagement elements under the clamping force of the clamping device carve or form themselves by at least half the height, preferably by the entire height, into the surface when the clamping device is brought into the closed position. The engagement elements or nubs are advantageously distributed. They are preferably spaced apart from one another.
Preferred embodiments of the invention provide for at least one spacer to be disposed between the locking element and the counterlocking element and to be spaced apart from the engagement element. This spacer also contributes to the engagement element being automatically lifted from said surface by the resilient reset element in the open position of the clamping device. The spacer can be disposed or fixed on the locking element but also on the counterlocking element or on both of the elements or also be retained by other means between the locking element and counterlocking element.
Preferred embodiments of the invention provide in this context that the clamping device comprises one clamp bolt preferably penetrating through the locking element and/or the counterlocking element, with the spacer being further removed from the clamp bolt than the engagement element. This does not absolutely need to be the case, however, it is advantageous in terms of spatial forces distribution. Especially preferred is the use of several engagement elements implemented as nubs which are distributed in the proximal vicinity of the clamp bolt. The proximal vicinity in terms of the invention is that region within a radius about the clamping axis that has a magnitude of approximately one third to maximally one half of the distance from one of the contact elements or spacers to the clamping axis. When in doubt, the clamping axis is formed by the center longitudinal axis of the clamp bolt.
In order to enable as high a force as possible to be applied in the region of the engagement element(s) by means of the clamping device, preferred embodiments of the invention provide that the clamping device in its closed position tightens the locking device in a clamping direction against the counterlocking element and that it includes a press pad, wherein the press pad acts, preferably only in the proximity of the engagement element, upon the locking element in the closed position in the clamping direction. Stated differently, the press pad or the pressure piece acts as directly as possible on the rear side of the locking element or potentially the counterlocking element or the other supports where, on the opposite front side, the engagement element or elements are located. The press pad or the pressure piece can act, for example, directly onto the locking element and/or counterlocking element on that side that is opposite the engagement element.
Apart from the securement device per se, the invention also relates to an adjustable steering column for a motor vehicle, wherein the adjustable steering column comprises a steering spindle bearing unit for the rotatable bearing of a steering spindle and a bracket unit provided for securing the adjustable steering column on the body of the motor vehicle. The adjustable steering column comprises a securement device according to the invention for securing the steering spindle bearing unit on the bracket unit. In especially preferred embodiments of such adjustable steering columns, the counterlocking element is a component, preferably a side jaw adjacent to the steering spindle bearing unit, of the bracket unit.
The steering spindle bearing unit is consequently that structural component of the adjustable steering column in which the steering spindle is rotatably bearing supported. The bracket unit is that part of the adjustable steering column which serves for securing the adjustable steering column on the body of the motor vehicle. To adjust the position of the steering spindle, and therewith the steering wheel to be secured thereon, the steering spindle bearing unit is displaced relative to the bracket unit that is body-stationary or that is securable on the body. Adjustable steering columns according to the invention can herein provide the adjustment in the longitudinal direction of the steering spindle or in a height direction orthogonal thereto or in both of the directions.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and details of preferred embodiments of the invention are evident based on the following description of the Figures, in which:
FIGS. 1 and 2 show of an adjustable steering column implemented according to the invention;
FIGS. 3 and 4 show a first embodiment variant according to the invention in a detail depiction in a section plane normal to the longitudinal direction of the steering spindle;
FIG. 5 shows a part of the clamping device with a press pad disposed thereon, in a first embodiment;
FIG. 6 shows the locking element associated with the embodiment according to FIG. 5 ;
FIG. 7 shows an alternative embodiment of a corresponding part of the clamping device;
FIG. 8 show an embodiment of the locking element which is combinable with the clamping element according to FIG. 7 ;
FIGS. 9 and 10 show a second embodiment according to the invention in a type of depiction analogous to FIGS. 3 and 4 ; and
FIG. 11 shows a locking element associated with FIGS. 9 and 10 .
DETAILED DESCRIPTION OF THE INVENTION
Similar elements or elements having the same effect are denoted in the Figures by the same reference numbers.
FIGS. 1 and 2 show in perspective depiction an adjustable steering column 4 with a securement device 1 implemented in the form of a first embodiment of the invention. First, the features known per se of this adjustable steering column 4 will be discussed. It comprises a steering spindle bearing unit 2 in which the steering spindle 18 is bearing supported such that it is rotatable about its longitudinal axis. On the steering wheel adapter 32 of the steering spindle 18 can be connected the steering wheel, not shown here. To implement the depicted steering column as an adjustable steering column 4 , the steering spindle bearing unit 2 is supported on the bracket unit 3 such that it is displaceable. The bracket unit 3 is that structural component of the adjustable steering column 4 that is or becomes fixed on the body of the motor vehicle. In the depicted embodiment, securement plates 21 are provided for this purpose. It is understood that the bracket unit 3 can also be secured fixedly or detachably in a different manner on the body of the motor vehicle. In the depicted embodiment, between bracket unit 3 and steering spindle bearing unit 2 is located an intermediate part 20 known per se which is secured via a swivel joint 29 on the bracket unit 3 such that it is swivellable. With the securement device 1 open, the steering spindle bearing unit 2 in the depicted embodiment, can be displaced relative to the bracket unit 3 in the length directions 27 as well as also in the height directions 28 . In the depicted embodiment, the length adjustment takes place through the corresponding shifting of the steering spindle bearing unit in one of the length directions 27 in the intermediate part 20 and the height adjustment in one of the height directions 28 takes place by swiveling steering spindle bearing unit 2 together with the intermediate part 20 about the swivel joint 29 relative to the bracket unit 3 . In the closed state of the securement device 1 the holding forces are of such magnitude that at least during normal operation a displacement in the length direction 27 or in the height direction 28 is not possible. In the closed position, the securement device 1 presses the two side jaws 19 of the bracket unit 3 so firmly against the intermediate part 20 and the steering spindle bearing unit 2 that the desired locking is achieved. For the event of a crash, even with the securement device 1 closed, a dislocation, especially in the length direction 27 and preferably with the intermediate placement of special energy absorption elements, can be possible. This can be realized as is known in prior art per se and does not need further explanation here. The side jaws 19 are in any case implemented elastically resilient such that, with the securement device 1 open, they enable the adjustment feasibilities of the adjustable steering column 4 .
The securement device 1 of the depicted embodiment is implemented in multiple parts. It comprises the clamping device 5 , here also implemented in multiple parts, as well as in the depicted embodiment also the two side jaws 19 of the bracket unit 3 . The clamping device 5 realized here also comprises several structural components. These are a manual operating lever 22 , a clamp bolt 15 , a first and second cam arrangement 25 and 26 as well as nuts 23 and a compression bearing 24 . In addition, the clamping device 5 comprises according to the invention also pairwise cooperating locking elements 6 and counterlocking elements 7 , which, in the depicted embodiment, are implemented or disposed on both sides, thus in the proximity of both side jaws 19 . The cooperation according to the invention of the locking elements 6 and counterlocking elements 7 will be described further down. First is emphasized that the clamping device 5 can be brought from its open position into its closed position and conversely by swivelling the manual operating lever 22 about the longitudinal axis of the clamp bolt 15 . As is known per se, for this purpose one of the two cam arrangements 25 or 26 can be connected torsion-tight with the manual operating lever 22 and the other of the two cam arrangements 25 or 26 can be connected torsion-tight with the bracket unit 3 . By turning the two cam arrangements 25 and 26 with respect to one another about the longitudinal axis of the clamp bolt 15 , an excursion is generated which in the closing direction leads to an interlocking of the side jaws 19 . The clamping directions 12 , thus the directions in which, during the closing of the clamping device 5 , pressure is built up, are drawn in FIG. 2 and extend parallel to the longitudinal axis of the clamp bolt 15 .
In the depicted embodiment, the clamp bolt 15 penetrates through elongated holes 33 in side jaws 19 whereby the height adjustment in the height directions 28 is enabled.
Before discussing the cooperation according to the invention of locking element 6 and counterlocking element 7 , reference is made to the fact that the securement device 1 is in its open position when the clamping device 5 is in its open position. The same applies to the closed position, here also the securement device 1 is in its closed position when the clamping device 5 is also in its closed position. Reference is further made to the fact that the depicted embodiment is only one of many possible variants of an adjustable steering column 4 . All implementation features known in prior art can be replaced by other implementation features known in prior art, provided a functional adjustable steering column results herefrom. For example, the intermediate part 20 can be omitted or it can be suitably replaced. The adjustable steering column 4 can be one that is only adjustable in the length directions 27 or only in the height directions 28 . Steering spindle bearing unit 2 and bracket unit 3 can be realized differently. The same applies to the features known per se of securement device 1 and clamping device 5 . For example the manual operating lever 22 can be replaced by an electric motor or the like. The same applies to the realization and torsion-tight fixing of the cam arrangements 25 and 26 , to name only a few examples of divergent implementation variants.
As explained in the introduction, the invention addresses the problem of implementing the securement device 1 or the clamping device 5 such that an unintentional displacement of steering spindle bearing unit 2 relative to the bracket unit 3 in the closed position of the clamping device 5 is effectively prevented. However, on the other hand, every position within the system-dependent displacement limits can also be set, thus an infinite adjustment is enabled.
The measure according to the invention already described in the introduction is provided for this purpose. In the depicted embodiment, several engagement elements 9 are provided which in this variant of the invention are a component of the locking element 6 . The locking element 6 comprises a plate-like base body 11 from which the engagement elements 9 project in the direction toward the counterlocking element 7 and parallel to the clamping direction 12 . In the depicted embodiment, the engagement elements 9 are realized in the form of embossed nubs. The counterlocking element 7 in the depicted embodiment is in each case a component of the side jaw 19 . The surface 10 of the counterlocking element 7 into which the engagement elements 9 engage or carve are the surface regions next to the elongated holes 33 . It should be understood that this is only an example. Converse dispositions are also conceivable. The engagement elements 9 could also be disposed on the counterlocking element 7 , thus here on the side jaws 19 . In this case the surface 10 would, for example, be located on the locking element 6 . In contrast hereto, it is even conceivable for the engagement elements 9 to be disposed on a separate support between locking element 6 and counterlocking element 7 , and locking element 6 as well as counterlocking element 7 to comprise corresponding surfaces 10 into which the engagement elements 9 carve during the closing of the clamping device 5 . It is an essential fundamental concept of the invention for the engagement elements 9 to carve into the surface 10 by reforming it. While the engagement elements 9 are impressed into the corresponding sites of the surface 10 , an indentation is created thereby that material of the surface 10 generated from this region is pressed into side regions. This type of reforming can take place at any site of the surface 10 . If this reforming strikes a reforming that has occurred previously at this location, the old reforming is punched over. This has two advantages. For one, through the carving of the engagement elements 9 into the surface 10 and the reforming carried out thereby a form closure, and therewith a highly stable securement or locking, is attained. Yet, for another, in terms of an infinite adjustment any desired position can be set. Even if at this site a surface structuring from an older reforming of the surface 10 is still located, this older forming is punched over by the renewed carving of the engagement elements 9 and the reforming entailed therein, such that the form closure is realized at the new desired site. In the open position of the clamping device 5 , in contrast, the form closure is to be abolished again. To this end it is advantageous if a resilient reset element 8 is provided which, in the open position of the clamping device 5 , lifts the engagement element 9 or the engagement elements 9 from the surface 10 . The resilient reset element or elements 8 can be separate structural components such as springs or the like. However, preferred embodiments, such as those shown here, provide for the resilient reset element 8 to be realized in the form of an elastic deformability of the locking element 6 . Especially in the case of the last-mentioned variants, spacers 14 , spaced apart from the engagement elements 9 , can be provided. In the variants, depicted in FIGS. 1 to 8 , of the invention these spacers 14 are components of the locking element 6 , however here they are disposed at the margin.
FIG. 3 shows the open position of the clamping device 5 in a section normal to the longitudinal axis of the steering spindle 18 . In this position, the engagement elements 9 fixed on the locking element 6 are not carved into the surface 10 of the region of the side jaw 19 utilized here as the counterlocking element 7 . In the open position of the clamping device 5 , the engagement elements 9 are herein completely lifted from the surface 10 such that there is no longer any friction closure.
FIG. 4 shows the clamping device 5 in its closed position. The engagement elements 9 in this position have carved themselves into the surface 10 reforming the latter such that the desired form closure has been attained. For the sake of completeness, reference is made to the fact that the engagement elements 9 are, in fact, not located in the sectional plane shown in FIGS. 3 and 4 but rather in front and/or behind it. In the section plane they would engage into the elongated hole 33 and therewith into void. For the sake of depicting them, they are drawn in FIG. 4 even if in this position they are carved into the surface 10 and are thereby bent. The same applies also to the FIGS. 9 and 10 shown later. During the opening of the clamping device 5 in the depicted embodiment, the plate-like base body 11 resiliently resets the locking element 6 back into its position according to FIG. 3 . FIG. 6 shows the locking element 6 utilized in this embodiment. The plate-like base body 11 includes a receiving cutout 30 and a torsional protection 31 . The clamp bolt 15 is guided through the receiving cutout 30 . The engagement elements 9 , implemented here in the form of nubs, project parallel to the clamping direction 12 from the plate-like base body 11 and are disposed in the immediate vicinity of the receiving cutout 30 and therewith of the clamp bolt 15 . The spacers, in this embodiment also disposed on the plate-like base body 11 , are in comparison further removed from the receiving cutout 30 and therewith from the clamp bolt 15 . It is in general advantageous if in embodiments such as those shown the engagement elements 9 are disposed as close as possible to the clamp bolt 15 since here constructionally simply the highest forces can be transmitted. However, in view of the overall system, the disposition of the engagements 9 should be such that they engage into the surface 10 with laterally sufficient spacing next to the elongated hole 33 since otherwise there is a risk of damage to the guide way. It is understood that, instead of the depicted nubs, geometrically differently formed-out projections can be provided as engagement elements 9 . These can be, for example, cleats, sawteeth or the like. The surface 13 , from which project the engagement elements 9 , should in the assembled state advantageously be disposed opposite the surface 10 into which the engagement elements 9 penetrate. The one or the several torsional protection(s) 31 engage into the elongated hole 33 such that during the displacement of the steering spindle bearing unit in the adjustment direction, given by the elongated hole 33 , guidance under torsional protection of the locking element 6 is given. A minimal torsional play can herein be intentionally provided. In the depicted embodiments the torsional protections 31 are simultaneously, through a collar-draw operation, implemented as a receiving cutout for receiving a guide pin 16 of the second cam arrangement 26 facing the locking element 6 . In this simple manner a torsional protection is formed for the locking element as well as also for the second cam arrangement 26 . However, it is conceivable and feasible to implement the technical solution without torsional protections 31 also. The elongated hole 33 can be realized linearly or in the form of an arc. Independently of whether the elongated hole 33 is linear or in the form of an arc, an identical or identically realized locking element 6 can be employed.
It is, however, preferred to provide a torsional protection. Alternatively to the depicted solutions, guide pin 16 could also be disposed on the locking element 6 , and a corresponding torsional protection 31 could be disposed on the corresponding counter piece. Moreover, there are still many other options conceivable for torsional protection. Other connection or torsional protection means are also conceivable and feasible, such as a recurved metal sheet tab which engages into a recess of the cam arrangement 26 or encompasses it. The guide pin 16 effecting the torsional protection can also be of such length that it projects in terms of torsional protection into the elongated hole 33 . If for the compression bearing 24 a torsional protection is to be also prepared, this can be implemented analogously to that for the cam arrangement 26 . The compression bearing 24 can also be realized simply as a washer. FIGS. 3 and 4 as well as 9 and 10 illustrate that the compression bearings 24 do not absolutely need to be equipped with guide pins 16 .
FIG. 5 shows the backside of the second cam arrangement 26 on which the guide pin 16 of the torsional protection is fixed. The guidance geometry is disposed opposite the receiving cutout 30 for the clamp bolt 15 such that the locking element 6 can move in straight-line as well as curved guide ways without a redevelopment being required for this purpose. This enables similar locking elements 6 and cam arrangements 25 and 26 to be employed in different adjustable steering columns 4 . The receiving cutout 30 for the clamp bolt 15 is surrounded in the second cam arrangement 26 by a convex region which forms the press pad 17 or the pressure piece. This press pad presses onto the backside of the locking element 6 in that region in which on the other side the engagement elements 9 are disposed such that these, as already described, carve into the surface 10 of the counterlocking element 7 during the closing of the clamping device 5 . The locking element 6 or its plate-like base body 11 are herein, as described, elastically deformed. On the opposite side or in the proximity of the opposite side jaw 19 , a press pad 7 is correspondingly disposed on the compression bearing 24 . FIGS. 7 and 8 show divergent implementations of locking element 6 and second cam arrangement 26 or compression bearing 24 . Yet the difference between them consists only therein that in the embodiment according to FIGS. 7 and 8 two guide pins 16 are disposed instead of one guide pin 16 .
As already explained in the introduction, it is advantageously provided that the engagement elements 9 and/or also the entire locking element 6 is or are realized of a harder material than the surface 10 into which carve the engagement elements 9 .
An alternative embodiment of the invention is shown in FIGS. 9 to 11 . In contrast to the first embodiment, the spacers 14 are here not implemented on the locking element 6 , but rather as a component of the counterlocking element 7 . The spacers 14 in this embodiment according to FIGS. 9 to 11 are formed by a margin region of the counterlocking element 7 which encompasses that region (=the surface 10 ) into which the engagement elements 9 engage when the securement device is closed. Between these spacers 14 or the margin regions is located a recessed region in which is located the surface 10 . FIG. 9 shows in a depiction analogous to FIG. 3 the clamping device 5 in the open position. In this open position, the engagement elements 9 of the locking element 6 are not carved into the surface 10 of the counterlocking element 7 . FIG. 10 shows the closed position of the clamping device 5 . In the closed position, the locking element 6 has been deformed to such an extent that the engagement elements 9 have carved into the surface 10 and consequently the desired form closure has been attained. Due to the elastic properties and the conditional resilience due thereto of the plate-like base body 11 , during the opening of the clamping device 5 the state according to FIG. 9 is reached again. For the reasons mentioned, in this embodiment is also advantageously provided that the spacers 14 in the open position of the clamping device 5 are still in contact on the locking element 6 under friction closure. It is understood that here also the complete lifting in the open state of the clamping device 5 can be realized. FIG. 11 shows a feasible variant of the locking element 6 according to this embodiment. It differs from FIG. 6 only by the omission of the spacers 14 .
In conclusion, reference is made to the fact that the invention can also be realized with clamping devices differing from those shown. Instead of the cam arrangements 25 and 26 , for example, an axial pressure plate, movable in the direction parallel to the clamp bolt 15 , can be provided. For example, between the cam contours rolling bodies can also be disposed. Other solutions are also conceivable and feasible.
According to the embodiments, through the fixing under form closure of the steering spindle bearing unit 2 with respect to the bracket unit 3 , a high fixing force is provided in the height direction 28 . In particular in the event of a crash in this way obliquely acting forces acting onto the steering spindle bearing unit in the event of a crash are braced and the torsioning of the steering column can be prevented. If an especially high resistance force against a displacement of the steering spindle bearing unit 2 with respect to the bracket unit 3 in the length direction is required, the invention can in this case also be employed.
To the extent it is technically feasible, different features of the above described embodiments can also be combined with one another and replaced without leaving the scope of the invention.
LEGEND TO THE REFERENCE NUMBERS
1 Securement device
2 Steering spindle bearing unit
3 Bracket unit
4 Adjustable steering column
5 Clamping device
6 Locking element
7 Counterlocking element
8 Resilient reset element
9 Engagement element
10 Surface
11 Plate-like base body
12 Clamping direction
13 Surface
14 Spacer
15 Clamp bolt
16 Guide pin
17 Press pad
18 Steering spindle
19 Side jaw
20 Intermediate part
21 Securement plate
22 Manual operating lever
23 Nut
24 Compression bearing
25 First cam arrangement
26 Second cam arrangement
27 Length direction
28 Height direction
29 Swivel joint
30 Receiving cutout
31 Torsional protection
32 Steering wheel adapter
33 Elongated hole | A fixing device has at least one clamping device and at least one locking element which can be acted upon by the clamping device, and at least one counter locking element. In a closed position of the clamping device, the locking element and the counter locking element are arranged in an engagement position, and the fixing device has at least one elastic resetting element for resetting the locking element in an open position of the clamping device. The fixing device has at least one engagement element which, in the closed position of the clamping device, is in engagement by preferably plastic deformation of at least one surface of the locking element and/or of the counter locking element in a form-fitting manner with the surface. | 8 |
TECHNICAL FIELD
The present invention relates to electronics, and, in particular, to the electronic switches, such as complementary metal-oxide semiconductor (CMOS) switches.
BACKGROUND
A conventional CMOS switch comprises one or more CMOS transistors, each with its bulk (e.g., substrate or well) connected to one of the power supply rails (i.e., Vdd or Vss). For example, a single N-type CMOS (NMOS) transistor, with its drain connected to the input node Vin, its source connected to the output node Vout, its gate connected to receive a switch-control signal, and its bulk connected to Vss, can function as a CMOS switch that selectively presents an input voltage appearing at node Vin as an output voltage at node Vout, where the value of the switch-control signal applied to the transistor gate determines whether the switch passes or holds off the input signal.
Another example of a conventional CMOS switch is formed from an NMOS transistor connected in parallel to a P-type CMOS (i.e., PMOS) transistor, where the NMOS transistor is configured as before, and the PMOS transistor has its source connected to node Vin, its drain connected to node Vout, its gate connected to receive an inverted version of the switch-control signal, and its bulk connected to Vdd.
The ranges of voltages that can be applied to such conventional CMOS switches are often limited due to finite N-channel and/or P-channel thresholds. In some situations, the allowable input range spans only a portion of the available supply voltage range (e.g., Vdd-Vss). Moreover, any voltage beyond the supply voltage range is usually not allowed, since it may interfere with the proper operation of the switch in its open (i.e., off) mode.
To accommodate an input voltage range beyond the supply voltage range, some prior-art implementations rely on a boosted supply. This more-positive and/or more-negative supply is often locally generated and used instead of the PC board power supply, in effect operating the switch from a new power supply that now includes the desired expanded range.
Another prior-art implementation relies on attenuation of all input voltages to ensure that the input voltage levels remain within the allowable range.
SUMMARY
In one embodiment, the present invention includes a switch circuit for selectively presenting an input signal appearing at an input node of the switch circuit as an output signal at an output node of the switch circuit. The switch circuit comprises a switch block and switch-control circuitry. The switch-control circuitry is adapted to selectively open and close the switch block based on a switch-control signal. The switch block is connected between the input node and the output node and comprises one or more interconnected transistors, wherein a bulk of at least one transistor in the switch block is connected to one of the input node and the output node.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings in which like reference numerals identify similar or identical elements.
FIG. 1 shows a schematic circuit diagram of a switch circuit, according to one embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 shows a schematic circuit diagram of a switch circuit 100 , according to one embodiment of the present invention. Based on a switch-control signal applied at node Select, switch circuit 100 selectively presents an input voltage applied at node Vin as an output voltage at node Vout.
Switch circuit 100 comprises control-signal buffer 102 , switch block 104 , and first and second level shifters 106 and 108 . Control-signal buffer 102 buffers the switch-control signal applied at the Select node and provides buffered (inverted and non-inverted) versions of the switch-control signal to switch block 104 and level shifters 106 and 108 . Level shifters 106 and 108 shift the levels of the buffered switch-control signals from buffer 102 (from the range (Vss,Vdd) to the ranges (Vss,Vin/Vout)) and apply level-shifted versions of the buffered switch-control signals to switch block 104 . The buffered switch-control signal from buffer 102 and the level-shifted switch-control signals from level shifters 106 and 108 determine whether switch block 104 in an open (i.e., off) mode or a closed (i.e., on) mode.
If switch block 104 is in its open mode, then switch block 104 holds off the input voltage applied at node Vin (i.e., the input voltage is not presented as an output voltage at node Vout). In its open mode, switch block 104 also holds off the high voltages applied at node Vout from reaching node Vin. If switch block 104 is in its closed mode, then switch block 104 passes the input voltage applied at node Vin to the node Vout (i.e., the input voltage is presented as an output voltage at node Vout). Together, control-signal buffer 102 and level shifters 106 and 108 form switch-control circuitry for switch circuit 100 .
Physical Description
Switch block 104 comprises two sets of one or more transistors connected in parallel, where the first set has PMOS transistor P 23 connected in series with PMOS transistor P 2 (i.e., at their drains) and the second set has just NMOS transistor N 2 . As shown in FIG. 1 , the source and bulk of P 23 and the drain of N 2 are all connected to node Vin. Similarly, the source and bulk of P 2 and the source of N 2 are all connected to node Vout. The bulk of N 2 is connected to Vss (e.g., ground).
Control-signal buffer 102 comprises inverters I 4 and I 2 connected in series, such that the output of I 4 is connected to the input of I 2 . The output of I 2 is connected to the gate of N 2 .
First level shifter 106 comprises a pair of cross-connected (i.e., gate to drain) PMOS transistors P 0 and P 1 connected in series with a pair of NMOS transistors N 3 and N 1 , respectively (at their drains). Similarly, second level shifter 108 comprises a pair of cross-connected PMOS transistors P 4 and P 5 connected in series with a pair of NMOS transistors N 5 and N 6 , respectively (at their drains). The output of inverter I 4 is connected to the gates of N 1 and N 6 , while the output of inverter I 2 is connected to the gates of N 3 and N 5 . The sources and bulks of P 0 and P 1 are both connected to node Vin, and the sources and bulks of P 4 and P 5 are both connected to node Vout. The sources and bulks of N 1 , N 3 , N 5 , and N 6 are all connected to Vss.
Functional Description
Low Switch-Control Signal
Functionally, if the switch-control signal applied at the Select node is low (e.g., Vss), then the output of inverter I 4 is high (i.e., Vdd) and the output of inverter I 2 is low (i.e., Vss).
If the output of I 2 is low, then N 2 is off and N 2 prevents the input voltage applied to node Vin from reaching Vout and also prevents a voltage applied at node Vout from reaching Vin.
If (i) the output of I 4 is high and (ii) the output of I 2 is low, then (a) N 1 and N 6 are both on and (b) N 3 and N 5 are both off.
In first level shifter 106 , if N 1 is on, then the gate of P 0 is driven towards Vss, which turns P 0 on. If P 0 is on and N 3 is off, then the gate of P 23 tracks the input voltage applied to node Vin. If the input voltage at Vin is low, then P 23 is on. If the input voltage at Vin is high, then P 23 is off.
Similarly, in second level shifter 108 , if N 6 is on, then the gate of P 4 is driven towards Vss, which turns P 4 on. If P 4 is on and N 5 is off, then the gate of P 2 tracks the voltage applied to node Vout. If the voltage at Vout is low, then P 2 is on. If the voltage at Vout is high, then P 2 is off.
Thus, if the voltages at Vin and Vout are both low, then P 23 and P 2 are both on, but, since, Vin and Vout are both low, it is functionally the same as if Vin and Vout were held off from each other. If (i) the input voltage at Vin is low and (ii) the voltage at Vout is high, then (a) P 23 is on and (b) P 2 is off, and the voltages at Vin and Vout are held off from each other. Similarly, if (i) the input voltage at Vin is high and (ii) the output voltage at Vout is low, then (a) P 23 is off and (b) P 2 is on, and the voltages at Vin and Vout are held off from each other. Lastly, if the voltages at nodes Vin and Vout are both high, then P 23 and P 2 are both off and the voltages at Vin and Vout are held off from each other.
As such, if the switch-control signal is low, then switch block 104 is functionally open (i.e., off), no matter whether the voltages applied at Vin and Vout are high or low.
High Switch-Control Signal
If, on the other hand, the switch-control signal applied at the Select node is high (e.g., Vdd), then the output of inverter I 4 is low (i.e., Vss) and the output of inverter I 2 is high (i.e., Vdd).
If the output of I 2 is high, then N 2 is on and N 2 enables the input voltage applied to node Vin to reach Vout.
If (i) the output of I 4 is low and (ii) the output of I 2 is high, then (a) N 1 and N 6 are both off and (b) N 3 and N 5 are both on.
In first level shifter 106 , if N 3 is on, then the gate of P 1 is driven towards Vss, which turns P 1 on. If P 1 is on and N 1 is off, then the gate of P 0 tracks the input voltage applied to node Vin. If the input voltage at Vin is low, then P 0 is on. If P 0 and N 3 are both on, then the gate of P 23 also tracks the low input voltage applied to node Vin and P 23 is on. If the input voltage at Vin is high, then P 0 is off. If P 0 is off and N 3 is on, then the gate of P 23 is driven towards Vss, which turns P 23 on.
Similarly, in second level shifter 108 , if N 5 is on, then the gate of P 5 is driven towards Vss, which turns P 5 on. If P 5 is on and N 6 is off, then the gate of P 4 tracks the voltage applied to node Vout. If the voltage at Vout is low, then P 4 is on. If P 4 and N 5 are both on, then the gate of P 2 also tracks the low voltage applied to node Vout and P 2 is on. If the voltage at Vout is high, then P 4 is off. If P 4 is off and N 5 is on, then the gate of P 2 is driven towards Vss, which turns P 2 on.
Thus, if the switch-control signal is high, then the P 23 and P 2 are both on, no matter whether the voltages applied at Vin and Vout are high or low. As such, if the switch-control signal is high, then switch block 104 is functionally closed (i.e., on).
Application of High Input/Output Voltages
The two sets of transistors in switch block 104 form two switch paths: one path containing P 23 and P 2 and the other path containing N 2 . Each path, when selected, passes signals over a portion of the supply range (Vdd-Vss).
Moreover, since the bulk of P 23 is connected to Vin, if an input voltage greater than Vdd is applied to Vin, then the bulk voltage and the source voltage of P 23 will both track the input voltage at Vin. This reduces the chances of breakdown or other adverse effects at P 23 due to high input voltages compared to a prior-art configuration in which the bulk of a PMOS transistor would be connected to Vdd. Moreover, first level shifter 106 ensures that the gate of P 23 also tracks the input voltage at Vin, which further reduces the chances of problems at P 23 due to input voltages greater than Vdd.
Similarly, since the bulk of P 2 is connected to Vout, if a voltage greater than Vdd is applied to Vout, then the bulk voltage and the source voltage of P 2 will both track the voltage at Vout. This reduces the chances of breakdown or other adverse effects at P 2 due to high voltages at Vout compared to a prior-art configuration in which the bulk of a PMOS transistor would be connected to Vdd. Moreover, second level shifter 108 ensures that the gate of P 2 also tracks the voltage at Vout, which further reduces the chances of problems at P 2 due to voltages at Vout greater than Vdd.
Thus, switch circuit 100 is capable of passing or holding off in either direction (i.e., Vout to Vin as well as Vin to Vout). The input signal range includes the entire power supply range. The input signal range also includes signals within one threshold voltage below the negative supply. On the positive side, the input signal can be substantially higher than the positive supply so long as no device breakdown level is exceeded. This extended input signal range is achieved without requiring either a boosted power supply or attenuation of the input signals. Also switch drivers require no stand-by DC current from either input or output.
ALTERNATIVE EMBODIMENTS
The present invention has been described in the context of switch circuit 100 in which switch block 104 has two transistor sets connected in parallel, where the first set has two PMOS transistors (P 23 and P 2 ) and the second set has only one NMOS transistor (N 2 ). The present invention is not necessarily limited to this embodiment. For example, in an alternative embodiment, the first set could have a single PMOS transistor and the second set could have two NMOS transistors, where the bulk of the PMOS transistor is connected to Vdd and the bulk of each NMOS transistor is appropriately connected to either the input node or the output node. Such an embodiment would have a negative voltage range. In another alternative embodiment, the first set could have two PMOS transistors and the second set could have two NMOS transistors, where the bulk of each NMOS and PMOS transistor is appropriately connected to either the input node or the output node. Such an embodiment would have a voltage range that spans beyond both positive and negative supply voltages.
The present invention can be implemented in the context of any CMOS technology, such as N-well, P-well, or multiple-well technologies. As used in the following claims, the term “channel terminal” refers generically to either the source or the drain of a CMOS transistor.
The present invention may, but does not have to, be implemented in a single integrated circuit, such as application-specific integrated circuit (ASIC) or a programmable device such as a field-programmable gate array (FPGA).
Unless explicitly stated otherwise, each numerical value and range should be interpreted as being approximate as if the word “about” or “approximately” preceded the value of the value or range.
It will be further understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated in order to explain the nature of this invention may be made by those skilled in the art without departing from the scope of the invention as expressed in the following claims.
The use of FIGURE numbers and/or FIGURE reference labels in the claims is intended to identify one or more possible embodiments of the claimed subject matter in order to facilitate the interpretation of the claims. Such use is not to be construed as necessarily limiting the scope of those claims to the embodiments shown in the corresponding figures. | In one embodiment, an electronic switch selectively passes an input signal from an input node to an output node based on a switch-control signal. The bulk of at least one transistor in the switch is connected to either the input node or the output node. The switch has two series-connected PMOS transistors connected in parallel with an NMOS transistor. The bulk and source of the first PMOS transistor are connected to the input node, while the bulk and source of the second PMOS transistor are connected to the output node. First and second level shifters ensure that the gates of the first and second PMOS transistors track the voltages at the input and output nodes, respectively. This configuration improves the ability of the switch to receive input voltages outside of the switch's power supply range without adversely affecting operations of the switch. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a broadly modulated radiant gas burner that yields minimal emissions of air-pollutants, especially nitrogen oxides (NOx). More particularly, the burner face of this invention is a porous mat of metal and/or ceramic fibers which is divided into segments that can be individually fired.
Radiant, surface-combustion gas burners are fed fuel gas admixed with enough air to ensure complete combustion of the fuel gas. Because these burners function without secondary air, their modulation of heat output is limited. Yet, there are important uses of surface-combustion gas burners in tight spaces, such as in the casings of gas turbines, where adding spare burners to increase heat delivery is not a practical solution to broad heating modulation.
Assignee's U.S. Pat. No. 6,199,364 to Kendall et al discloses compact surface-stabilized gas burners that are well suited for use with gas turbines. Surface-stabilized gas burners are therein defined as having burner faces with dual porosities so that surface combustion from the lower porosity areas serves to keep the blue flames from the higher porosity areas attached to the burner face when fired at rates of at least about 500,000 BTU/hr/sf (British Thermal Units per hour per square foot) of burner face.
A principal object of this invention is to provide compact surface-stabilized gas burners featuring a broad range of heat delivery.
Another important object is to provide such surface-stabilized gas burners with internal walls that divide each burner into two or more segments that can be individually and independently fired to vary the thermal output, while maintaining the adiabatic flame temperature of the fired segments in a range yielding low emissions.
Still another object is to provide segmented surface-stabilized gas burners that are simple in construction as well as operation.
These and other features and advantages of the invention will be apparent from the description which follows.
SUMMARY OF THE INVENTION
Basically, the segmented surface-stabilized gas burner of this invention which has a combustion surface formed of metal and/or ceramic fibers may have a unitary body with internal partitions to provide independent burner segments, or it may have two or more burner modules that are compactly fitted together.
U.S. Pat. No. 4,543,940 to Krill et al describes a segmented radiant surface burner formed of large cylindrical segments that are bolted together in axial alignment. This arrangement of large burner segments was conceived to fit the peculiar shape of combustion chambers of fire tube boilers. The serial alignment involves sealing between the abutted ends of contiguous burner sections and requires an individual duct to supply fuel gas and air to each burner segment. The complex ducting of fuel gas and air to each burner segment is antithetical to this invention's objective of burner compactness that is essential to burners used with gas turbines.
The combustion surface may be formed of ceramic fibers as taught by U.S. Pat. No. 4,746,287 to Lannutti, of metal fibers as set forth in U.S. Pat. No. 4,597,734 to McCausland, or of mixed metal and ceramic fibers according to U.S. Pat. No. 5,326,631 to Carswell et al. For high surface firing rates, say, at least about 500,000 BTU/hr/sf of burner face, a rigid but porous mat of sintered metal fibers with interspersed bands or areas of perforations is preferred. Such a burner face is shown in FIG. 1 of U.S. Pat. No. 5,439,372 to Duret et al. Still another form of porous metal fiber mat sold by N.V. Acotech S.A. of Zwevegem, Belgium, is a knitted fabric made with a yarn formed of metal fibers. In the rigid porous and perforated burner of Duret et al, radiant surface combustion is interspersed with blue flame combustion from the perforations. Similarly, the yarn of the knitted metal fiber fabric provides radiant surface combustion and the interstices of the knitted fabric naturally provide interspersed spots of increased porosity that yield blue flames.
At the aforesaid high surface firing rates, the flames from the areas of increased porosity produce such intense non-surface radiation that the normal surface radiation from the areas of lower porosity disappears. However, the dual porosities make it possible to maintain surface-stabilized combustion, i.e., surface combustion stabilizing blue flames attached to the burner face. Burner faces with dual porosities are referred to as surface-stabilized burners. With such burners, flaming is so compact that visually a zone of strong infrared radiation appears suspended close to the burner face. It is noteworthy that with at least about 40% excess air, surface-stabilized combustion yields combustion products containing low emissions as little as 2 ppm (parts per million) NOx and not more than 10 ppm CO and UHC (unburned hydrocarbons), combined.
In as much as the segmented burner of this invention is particularly valuable in uses where the combustion zone is spatially limited, it is seldom a flat burner. Cylindrical burner faces and variations thereof, e.g., tapered or conical, are the usual forms of the segmented burner.
The burner segments which fit together may be designed to deliver equal quantities of heat, but it is usually advantageous to have segments of unequal heat delivery capacities. For example, a two-segment burner, can have one segment with 60% and the other segment with 40% of the total heat delivery capacity of the burner. Such unequal segments permit greater heat delivery modulation than if the burner had two equal segments. The same is true of three-segment burners. Three segments of 55%, 35% and 10% of heat delivery capacity permit greater modulation of heat delivery than is possible with three segments of equal heat delivery capacity.
BRIEF DESCRIPTION OF THE DRAWINGS
To facilitate further description and understanding of the invention, reference will be made to the accompanying drawings of which:
FIG. 1 is a schematic representation of a simple two-segment cylindrical burner shown in axial section;
FIG. 2 is a similar representation of a three-segment cylindrical burner shown in axial section;
FIG. 3 is a left end view of the burner of FIG. 2;
FIG. 4 is a left end view of the burner of FIG. 1 modified to provide three burner segments;
FIG. 5 schematically represents a hemispherical burner having two burner segments;
FIG. 6 is a schematic axial section of a three-segment conical burner adapted for use with a gas turbine; and
FIG. 7 shows an alternate form of an element of the burner of FIG. 6 .
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 schematically depicts a two-segment cylindrical burner 10 having a porous fiber combustion surface 11 which is divided into two separate burning segments by a funnel-like baffle 12 . Tube 13 connected to frusto-conical portion 14 of funnel 12 is fitted co-axially in cylinder 15 to create core plenum 16 and annular plenum 17 . Core plenum 16 expands beyond tapered baffle 14 into plenum 18 which supplies fuel gas and air to segment A of combustion surface 11 . Segment A of surface 11 is the portion to the right of the line where baffle 14 meets an inner support screen (not shown) of fiber surface 11 . Porous fiber combustion surface 11 surrounding annular plenum 17 is segment B contiguous to segment A.
It is obvious that fuel gas and air can be supplied to tube 13 for surface combustion on only segment A of porous fiber layer 11 . For increased thermal output, fuel gas and air can be introduced via cylinder 15 to annular plenum 17 for combustion on segment B of fiber layer 11 . Of course, the reverse order of firing can be carried by feeding fuel gas and air to plenum 17 and feeding fuel gas and air to core plenum 16 when increased heat output is desired.
The simplicity and compactness of burner 10 of FIG. 1 demonstrates that it can be made with a unitary cylindrical body having a hemispherical closed end and a funnel-like baffle inserted through the opposite open end of the cylindrical body. In fact, that is the construction that has been described in relation to FIG. 1 . However, if each of lines 13 , 14 in FIG. 1, which form funnel 12 , are considered as two contiguous metal sheets and segments A, B of fiber layer 11 are not united at circumferential line S, burner 10 becomes one having two telescoped burner modules. The module with plenum 16 , 18 has its tube 13 inserted into a central, similar tube of annular plenum 17 . The insertion is made from the right end of cylinder 15 that supports segment B of porous fiber layer 11 . When tapered wall 14 of plenum 18 is brought into contact with similar tapered wall of annular plenum 17 , the insertion is completed and segment A of combustion surface 11 meets segment B to function essentially as if surface 11 had been pressure or vacuum molded or knitted as a continuous porous fiber layer 11 spanning both plenums 17 , 18 .
FIG. 2 shows an axial section of cylindrical burner 20 that is sealed by metal disk 21 at its right end and open at its opposite end.
FIG. 3 is a left end view of burner 20 revealing three radial baffles 22 , 23 , 24 which form three plenums 25 , 26 , 27 in burner 20 . Plenums 25 , 26 , 27 feed three equal segments of porous fiber combustion surface 28 on cylinder 29 . However, it is usually preferable to make the angles between baffles 22 , 23 , 24 unequal so that the areas of the three segments of combustion surface 28 are also unequal. Moreover, baffles need not be radial. For example, two baffles at right angles to each other within cylinder 29 can provide three plenums of unequal size. A single baffle that is not a diametrical divider will form two plenums of unequal size in burner 20 with porous fiber layer 28 divided into two segments of unequal areas.
FIG. 4, like FIG. 3, is an open end view of a cylindrical burner 30 that, like burner 10 of FIG. 1, has a funnel-like plenum surrounded by an annular plenum. Burner 30 differs from burner 10 in that the annular plenum is divided into two unequal parts by baffles 31 , 32 extending from tube 33 outwardly to the cylindrical screen (not shown) that supports porous fiber layer 34 . Thus, baffles 31 , 32 have converted the two-segment burner 10 of FIG. 1 into three-segment burner 30 .
FIG. 5 is a diametrical sectional view of hemispherical burner 40 that has a pan plenum 41 with inlet opening 42 . A hemispherical screen which supports a porous layer 43 of metal and/or ceramic fibers is attached to pan 41 . Funnel-like baffle 44 with its tube 45 extending through pan 41 divides combustion surface 43 into two segments, A, B that can be fired separately or together. Fuel gas and air supplied to tube 45 will yield radiant surface combustion on segment A of porous fiber layer 43 . When increased heating is desired, fuel gas and air introduced through inlet 42 to pan 41 will combust on segment B of porous fiber layer 43 . Of course, combustion can be carried out with only segment B of burner 40 . When greater heating is desired, fuel gas and air can be fed to tube 45 for combustion on segment A of porous fiber layer 43 .
FIG. 6 demonstrates a three-segment burner 50 of the invention adapted for use with a gas turbine. FIG. 6 is presented as an improved (provides greater thermal modulation) burner for replacement of burner 62 in FIG. 6 of assignee's U.S. Pat. No. 6,199,364. Whereas prior burner 62 has a single plenum 63 , new burner 50 has three plenums, 51 , 52 , 53 which supply fuel gas and air to three segments A, B, C of porous combustion surface 54 . Tubular baffle 55 separates plenum 51 from plenum 52 which is separated from plenum 53 by tubular baffle 56 . Burner 50 of this invention, like burner 62 of assignee's patent, is surrounded by metal liner 57 that has multiple louvers 58 . Liner 57 spaced from combustion surface 54 serves to confine the combustion zone.
Housing 59 is a metal cylinder attached to the casing of a gas turbine (not shown). Three-segment burner 50 is attached to housing cap 63 by spacer bolts (not shown). Inasmuch as prior burner 62 was made with a dual porosity burner face 64 , the new three-segment burner 50 can also have burner face 54 with dual porosity. The tapered cylindrical support of burner face 54 has an impervious cylindrical extension 54 A welded to a circular opening in metal disk 60 . Similarly, baffle 56 is welded to an opening in disk 61 and baffle 55 is connected to an opening in disk 62 . Spacer bolts (not shown) hold disks 60 , 61 , 62 in the desired spaced arrangement and spacer bolts between disk 62 and housing cap 63 support the entire assembly of disks 60 , 61 , 62 which are components of burner 50 . Cylindrical band 65 is welded to disk 60 and is dimensioned for a slip-fit with collar 64 of liner 57 . Thus, when cap 63 is lifted away from housing 59 , all of burner 50 is withdrawn from housing 59 .
Plenums 51 , 52 , 53 are each supplied with fuel gas by valved tubes 66 , 67 , 68 , respectively. Pipe 69 feeds tubes 66 , 67 , 68 which are connected to ring manifolds 70 , 71 , 72 , respectively, each manifold having multiple holes positioned to inject fuel gas above disks 62 , 61 , 60 , respectively. Compressed air from the compressor section of a gas turbine (not shown) flows into and fills housing 59 which is part of the casing of the turbine. Compressed air in housing 59 flows over disks 60 , 61 , 62 and into plenums 53 , 52 , 51 , respectively. Compressed air discharges from plenums 51 , 52 , 53 through segments A, B, C, respectively, of porous fiber burner face 54 into combustion zone 75 . Compressed air also passes through the multiple louvers 58 of liner 57 into combustion zone 75 . By opening the valve of tube 68 , fuel gas is injected upward as multiple jets from holes in ring manifold 72 into the compressed air flowing over disk 60 and the resulting gas-air mixture flows into plenum 53 from which it exits through segment C of porous burner face 54 and, upon ignition, undergoes radiant surface combustion. Any known igniter 76 positioned below disk 60 near segment C will ignite the gas-air mixture exiting segment C of porous burner face 54 .
When greater thermal delivery is required, fuel gas may similarly be fed through valved tube 67 to ring manifold 71 , and injected by manifold 71 as multiple jets into compressed air flowing between disks 61 , 62 . Thence, the mixture flows through plenum 52 and segment B of burner face 54 to produce more surface-stabilized combustion. For maximum heating, fuel gas is admitted through valved tube 66 to manifold 70 from which it escapes as multiple jets into compressed air passing between disks 62 and housing cap 63 . The gas-air mixture fills plenum 51 and combusts upon exiting segment A of porous burner face 54 . The products of combustion from segments A, B, C mix with compressed air entering combustion zone 75 through louvers 58 of liner 57 . The total hot gases flow from combustion zone 75 through curved duct 77 (partially shown) which channels the hot gases to the turbine (not shown) as the driving force thereof.
The great range of thermal modulation made possible by the invention is best appreciated if the area of combustion surface 54 of segmented burner 50 and the area of combustion surface 64 of prior burner 62 (U.S. Pat. No. 6,199,364) are made equal. Burner 62 can be thermally modulated over a range that is characteristic for the selected type of combustion surface. If the same type of combustion surface is used on segmented burner 50 , then all three segments A, B, C can be individually and independently modulated to the same extent as combustion surface 64 of prior burner 62 . But segmented burner 50 can have any one or two of segments A, B, C turned off by closing valved tubes 66 , 67 , 68 , respectively, to achieve a great turn-down of heat output to a small fraction of the lowest turn-down possible with prior burner 62 .
A two-segment burner that still permits substantially broader thermal modulation than prior burner 62 can be visualized by eliminating either tubular baffle 55 along with disk 62 , ring manifold 70 and valved tube 66 , or tubular baffle 56 along with disk 61 , manifold 71 and valved tube 67 . Segmented burner 50 is shown in FIG. 6 in a preferred cone-like shape, i.e., a conical form with a convex end in lieu of a pointed apex. This term, cone-like shape, as herein used, shall also include truncated conical forms. Of course, other forms of segmented burners, such as those shown in FIGS. 1, 2 , 4 , 5 may be adapted for use with gas turbines.
The unique feature of segmented burners of this invention for gas turbines is that compressed air from the compressor of a gas turbine flows into and around the segmented burner continuously whether one or all the segments are being fed fuel gas. The percentage of compressed air going into each segment and around the burner being fixed by the dimensions given the various parts of the burner. For example, if the space between disks 61 , 62 is reduced, less compressed air will flow into plenum 52 . In short, while a burner is in operation, at any rate of compressed air flow, the flow of compressed air into any plenum cannot be varied. Only the flow of fuel gas can be varied to each plenum.
While burner 50 is shown in FIG. 6 with a louvered liner 57 , an alternate liner is known as a backside-cooled liner (ASME Paper 99—GT-239). FIG. 7 is a schematic representation of backside-cooled liner 57 A as a substitute for louvered liner 57 of FIG. 6 . FIG. 7 shows only the right profile of liner 57 A inasmuch as the left profile is only a mirror image of FIG. 7 . Liner 57 A is without louvers or other openings except for a few louvers 58 A in the end portion of liner 57 A which is connected to curved duct 77 . A cylindrical metal shell 57 B, called convector in the ASME Paper, surrounds liner 57 A and is spaced therefrom to provide a narrow annular gap. Convector 57 B extends over substantially the full length of liner 57 A and is connected and sealed to liner 57 A at 57 C where liner 57 A meets curved duct 77 .
Thus, compressed air flowing between housing 59 and convector 57 B will, besides entering the spaces between disks 60 , 61 , 62 and housing cap 63 , flow through the gap between convector 57 B and liner 57 A exiting through a few rows of openings or louvers 58 A in the portion of liner 57 A adjacent to curved duct 77 . Accordingly, any liner that serves to confine the combustion zone close to the burner surface and to moderate the combustion temperature can be used with the segmented burner.
Moreover, each burner need not have an individual liner. U.S. Pat. No. 6,199,364 shows a circular array of five burners in FIG. 3 which have a pair of metal liners that confine the combustion of all five burners in an annular zone. Such a collective liner may be used for several burners of this invention. Inasmuch as the collective liner is in two concentric parts, it is possible to cool each part with compressed air in a different way. For example, the inner liner may be louvered and the outer liner may be backside-cooled, or vice versa.
As known, the metal screen which supports the porous fiber layer of surface combustion burners usually has a perforated back-up plate that helps to ensure uniform flow of the fuel gas-air mixture though all of the porous fiber burner face. In a unitary (not modular) segmented burner of this invention, each internal baffle can be held in place by welding to a back-up plate. In the absence of a back-up plate, a baffle can be welded to the screen that supports the porous fiber layer.
While natural gas is a fuel commonly used with gas turbines, the burner of this invention may be fired with higher hydrocarbons, such as propane. Liquid fuels, such as alcohols and gasoline, may be used with the burner of the invention, if the liquid fuel is completely vaporized before it passes through the porous burner face. The term, gaseous fuel, has been used to include fuels that are normally gases as well as those that are liquid but completely vaporized prior to passage through the burner face. Another feature of the invention is that the burner is effective even with low BTU gases, such as landfill gas that often is only about 40% methane.
The term, excess air, has been used herein in its conventional way to mean the amount of air that is in excess of the stoichiometric requirement of the fuel with which it is mixed.
Those skilled in the art will visualize variations and modifications of the invention in light of the foregoing teachings without departing from the spirit or scope of the invention. For example, circular manifold 70 in FIG. 6 can be eliminated if valved fuel tube 66 is extended so that it discharges through a mixing nozzle into the opening where baffle 55 is joined to disk 62 . Accordingly, only such limitations should be imposed on the invention as are set forth in the appended claims. | A segmented surface-stabilized gas burner features wide modulation of thermal output simply by the independent control of fuel gas flow to each burner segment. The burner also features a porous fiber burner face, preferably having dual porosities, and a metal liner positioned to provide a compact combustion zone adjacent the burner face. The segmented surface-stabilized burner is ideally suited for use with gas turbines not only because of its compactness and broad thermal modulation but also because only the flow of fuel gas to each burner segment requires control while the relative flow of compressed air into the segments of the burner remains unchanged. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to a mechanism for regulating a wiper motor in a vehicle.
In the traditional wiper regulators, the electrical circuit for the wiper motor is coupled to a wiper switch in series with the ignition switch so that the wipers are automatically turned off when the ignition is turned off. A feature of the commonly used circuit is that when the ignition is turned on again the wipers begin to wipe once again if the wiper switch was not turned off beforehand. This also is the case for wiper regulators with an automatic return to the final position because the wipers are immediately deactivated when the ignition is switched off (normally not in the final position) and when the ignition is switched on again, even when the ON/OFF switch is turned off, it strives to reach its final (resting) position. Very often, the wipers are not turned off but rather are switched into the interval wiping position. This type of interval switch only makes the wipers activate during specified time intervals by means of a time switch so that when the driver turns off the vehicle motor he is not reminded to switch off the wipers even if the wipers are running. If the wiper electrical circuit is only interrupted by turning off the ignition switch, then when the ignition is turned on again the interval circuit is activated again. All these familiar circuits have the idiosyncrasy that the wipers can only be turned on when the ignition switch is turned on, which can lead to destruction of the wiper blades in the case of wipers frozen solid to the window when they are jolted away from the window, or if the windshield wipers do not budge, it can lead to an excessive strain and destruction of the motor or of the wipers themselves. In particular, with a regulator with automatic switching off of the wipers at its end positions, the driver will suffer these consequences if the wipers are coincidentally frozen out of the resting position because the wipers, even upon subsequent turning off with the ON/OFF switch on the dashboard, will strive to reach their resting position when the ignition is switched on.
An object of the present invention is to create a mechanism for regulating a wiper motor in a vehicle, which prevents the wipers from starting up unintentionally when the ignition is turned on. This objection is fulfilled with the circuit having the features of the present invention.
BRIEF SUMMARY OF THE INVENTION
With the mechanism provided by the invention, the result achieved is that after the wipers have been turned off by turning off the ignition switch, the wiper switch (ON/OFF switch) has to be activated again to get the windshield wipers going again. In this way wipers that are frozen onto the windshield will not be automatically jolted into activity when the ignition is turned on but rather must be consciously activated by the driver after the windshield ice has melted. In this way, any destruction of or damage to the sensitive wiper blades due to their being ripped away from the windshield can be prevented. For windshield wipers that are frozen solid to the windshield and which cannot be moved even when the motor is turned on, any excess strain and possible destruction of the motor or of the wiper rods is eliminated.
In a first embodiment, a simple model of an ON/OFF switch with two contacts for a simple wiper regulator system not having an automatic resting position switch is demonstrated.
In accordance with a second embodiment of the invention which may be utilized in wiper systems which include an automatic resting position switch for the wipers, mandatory startup of the wipers which cannot be controlled by the driver should they be in an intermediate position is avoided when the ignition switch is turned on.
A simple and inexpensive design of an ON/OFF switch with wiper contacts for use in the arrangement according to the second embodiment is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in an exemplary way and further details are provided with the aid of the drawings in which:
FIG. 1 shows a regulator switch with an ignition switch, an ON/OFF switch and a holding (latching) switch in accordance with a first embodiment of the present invention;
FIG. 2 shows a regulator switch in accordance with a second embodiment of the invention for use in a vehicle having an additional automatic wiper resting position turn-off switch; and
FIG. 3 shows the scheme of the wiper contact and ON/OFF switch used in the embodiment shown in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to FIG. 1, an ON touch contact (5), a holder (latching) relay (7), and an ignition switch (9) are in series in the electrical circuit of a wiper motor (3). The ON touch contact (5) is bridged by a holder circuit (latching circuit) (10) in which a contact (11) of the holder relay (7) and an OFF button (13) are located.
The circuit has the following effect:
When the driver wants to turn on the wipers when the ignition has been turned on, the ignition switch (9) is closed. The ON touch contact (5) is closed for a short period of time so that electricity flows through the winding of the holder relay (7) and attracts the contact (self-maintenance switch) (11). In this way, the holder circuit (10) is closed (the contact of the OFF button (13) is closed when not activated) and the ON button (5) is bridged. The circuit therefore maintains itself and the flow of electricity to the wiper motor (3) continues until either the OFF button (13) is activated for a short period of time by the driver or is interrupted by the ignition switch (9) upon turning off the vehicle. Upon activation of OFF button (13) or opening of ignition switch (9) current ceases in holder relay 7 and holder circuit (10). Thus, if the ignition switch is again, closed, no power wll be delivered to the wiper motor (3) because there is no closed current path. Only when the ON button (5) closes again does current re-enter the wiper motor through ON switch (5) and then holder circuit (10).
The ON button (5) and the OFF button (13) can be put together in a ON/OFF bascule which can be activated from both sides with a spring between them which either bias a contact open or closes it.
In FIG. 2, an ON/OFF switch (15) is located in the electricity circuit (1) of the wiper motor (3) the two way contacts of which in the ON position connects point (17) with point (19) and in the OFF position, connects point (17) with point (23). From point (23) a wire (25) leads to the terminal switch (27) which switches from point (29) to the adhesively connected point (31) when the wiper reaches its resting position. A bridging wire (21) goes from point (19) to point (29) of the terminal switch (27). Another wired section (33), similar to the circuitry shown in FIG. 1, is connected to the bridging wire (21) and connected to the wire (25) through switch 27. Section (33) includes the holder relay (7) with its contact (11) and attached holding circuit (19), the ignition switch (9), and a mutual wiper contact (35) which is activated with the ON/OFF switch (15). By turning on the ON/OFF switch (15) (connecting points (17) and (19)), the wiper contact (35) closes for a short period of time. A more exact description of the switch is provided further below.
The circuit shown in FIG. 2 has the following effect:
(a) If the driver turns on the wiper by using the ON/OFF switch (15) with the ignition switch closed and later turns the wiper off again, the circuit will operate in the following manner:
The ignition switch (9) is closed and the ON/OFF switch (15) is turned on by connecting point (17) with point (19). Simultaneously, the wiper contact (35) is closed for a short period of time. The electrical circuit to the wiper motor is therefore closed across the bridging wire (21), the wiper contact (35), and the ignition switch (9). Electricity then flows through holder relay (7) causng switch (11) to close thereby bridging the reopening wiper contact (35) so that the flow of electricity to the wiper motor (3) can be maintained. The terminal switch (27) moves with each complete cycle of the wipers from its point (29) to point (31) but is ineffective to effect the conduction electricity to the wiper motion because of the interruption between point (17) and point (23). When the wipers are turned off, point (17) is connected with point (23), and with that, the bridging of the terminal switch (23) is discontinued. If the wipers do not coincidentally come to their resting position when they are switched off, then the terminal switch 27, as demonstrated, connects with point (29). The wipers then continue to move until they assume their resting position and thereby causing terminal switch (27) to switch from point (29) to point (31) and the motor stops. In order to achieve this, the self-maintenance switch 11 of the holding relay (7) is not allowed to open (current is maintained in holding relay 7) when the ON/OFF switch is reswitched from point (19) to point (23). During the reswitching process, then, point (19) and point (23) must be connected for a short period of time with point (17) (see switch in FIG. 3). When the wipers have achieved their resting position, the electrical circuit to the wiper motor (3) is interrupted and switch 11 is opened.
(b) If the driver has turned off the vehicle (ignition switch (9) is open) and the ON/OFF switch (15) is left in the ON position (connection from (17) to (19)), whereby the wipers have been turned off in an intermediate position (terminal switch (27) is connected to point (29)), then the circuitry will operate in the following manner:
When the ignition is turned on again and with that, the ignition switch is closed, then the electrical circuit remains open circuited because the holding relay (7) is inoperative (switch (11) is open and wiper contact (35) is open). Now, for example, if the wiper blades are frozen to the windshield in an intermediate position, the driver can wait until the windshield wipers have separated somewhat as a result of the effects of the windshield defroster and thereupon he can activate the ON/OFF switch (15) to the OFF position. In this case, for the short period of time of the switching process, point (17) is connected with point (19) and point (23) and simultaneously the wiper contact (35) is closed for a short period of time. The holding switch is then activated again, the wipers are directed to their resting position and the holding switch is once again broken off as a result of the open circuiting of the electrical circuit across the terminal switch (27), thereby causing the wiper motor (3) to be turned off.
In FIG. 3, a push switch with contact strips (37, 39, 41) and with a push part (43) with friction contacts (45 and 47) is demonstrated schematically. The contact strips overlap in a central switching area. The demonstrated (full line) position of the push part (43) in connection with the reference illustration corresponds to the demonstrated (full line) positions of the ON/OFF switch (15) and of the wiper contact (35) in FIG. 2, whereby the friction contact 47 and the contact strip (41) correspond to the wiper contact (35). In the motion of the push part (43) from the full line illustrated ON position to the dashed line illustrated OFF position (shown in FIG. 3), an area is passed through in which, on the one hand, the wiper contact (friction contact (47) and contact strip (41)) is closed and, on the other hand, point (17) is connected to both point (19) (ON position) and point (23) (OFF position).
The switch can also be designed as a rotating switch whereby the contact strip (41) is on a second switch level. | An electrical, vehicle wiper, motor regulator which prevents the wiper motor from automatically starting up when the vehicle ignition is turned on. The regulation includes a holder circuit which prevents the wiper motor from being driven when the ignition is turned on, even when the wiper ON/OFF switch had previously been left on, in those wiper systems which include a terminal switch for automatically returning the wipers to normal resting position. | 8 |
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